Cementitious-filler/coating repair system for commercial and residential panelized roofs

Abstract

The Invention is a filler/coating system with multiple formulations and mixtures designed to profile roof substrates in optimizing water shed drainage characteristics. These mixtures have a weight that is 50% of the weight of water. This weight reduction reduces the load on the existing roofing elements and allows for the optimized profiling of the slope of a roof without increasing the weight on the existing roof elements/members, this objective is met by the displacement of the water that normally fills and sits in the sagging ponding areas of a weakened and deteriorated roofing structure. The existing roofing elements need not be removed, torn off or repaired, as this system is designed to be an overlay filler/coating system that provides an ideal profiling slope of the roofs substrate for the application of a new water tight roofing membrane system to then be applied.

Claims

1. These formulated filler coating mixtures are the only roofing systems on the market that utilize a cement based ultra lightweight mixture that is formulated with absolutely no sand or gravel aggregates in which the said mixtures are used to fill and or coat an existing roofing to profile the roof to correct improper water shed drainage characteristics, which then allows a new water tight roofing membrane system to be installed.

2. These formulated filler coating mixtures are the only roofing systems on the market that utilize a urethane rubber based ultra lightweight mixture that is formulated with lightweight aggregates in which the said mixtures are used to fill and or coat an existing roofing to profile the roof to correct improper water shed drainage characteristics, which then allows a new water tight roofing membrane system to be installed.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 shows top-down overview of the structural framing elements of a low slope (flat) commercial panelized roof composition.

[0019] FIG. 2 shows side view cut away of a section of the elements of a repaired roof.

[0020] FIG. 3 top-down overview of a roof in various phases of completion.

DETAILED DESCRIPTION OF THE INVENTION

[0021] The Invention is a coating/filler system with multiple formulations and mixtures designed to profile roof substrates in optimizing water shed drainage characteristics.

[0022] The Invention teaches two types of base formulations/mixtures: [0023] (a) A cement-based coating that utilizes light weight aggregates (perlite, vermiculite, or poly-styrofoam) each of these aggregates can be used separately; one in place of another and or they can be combined and blended together as desired. The invention teaches the use of four basic types of these cement-based formulations/mixtures: (1) Fine aggregate mixes for thin skimmed applications. (2) Medium aggregate mixes. (3) Course aggregate mixes for thicker or deeper applications and (4) Blended mix formulations of the three aggregate sizes optimizing performance characteristics. [0024] These mixtures are formulated with the Portland cement that is utilized as the binding agent of the mixtures. The cement is mixed with an acrylic polymer to make a cement paste creating the consistency of a thin milkshake, to which the lightweight aggregate is added into and mixed thoroughly. There is no sand or gravel aggregates being utilized in these mixtures, instead the invention teaches the isolated use of lightweight aggregates of perlite, vermiculite, or poly-styrofoam. The volume measured ratios between the cement and the lightweight aggregate is taught by the invention to be adjustable to increase the strength and or the performance characteristics of a mixture formulation as needed or in contrast to be able to make lighter weight mixtures as may be required. The options of cement to the lightweight aggregate ratios are: [0025] 1-Part cement to 2-parts aggregate. [0026] 1-Part cement to 3-parts aggregate. [0027] 1-Part cement to 4-parts aggregate. [0028] 1-Part cement to 5-parts aggregate. [0029] 1-Part cement to 6-parts aggregate. [0030] (b) A urethane rubber-based coating that can that utilizes light weight aggregates (perlite, vermiculite, or poly-styrofoam) each of these aggregates can be used separately one in place of another and or they can be combined and blended together as desired. The invention teaches the use of four basic types of these cement-based formulations/mixtures: (1) Fine aggregate mixes for thin skimmed applications. (2) Medium aggregate mixes. (3) Course aggregate mixes for thicker or deeper applications and (4) Blended mix formulations of the three aggregate sizes optimizing performance characteristics. [0031] These mixtures are formulated with a two-part urethane rubber that is utilized as the binding agent of the mixtures. The rubber is mixed creating the consistency of a thin milkshake, to which the lightweight aggregate is added into and mixed thoroughly. There is no sand or gravel aggregates being utilized in these mixtures, instead the invention teaches the use of lightweight aggregates of perlite, vermiculite, or poly-styrofoam. The volume measured ratios between the rubber and the lightweight aggregate is taught by the invention to be adjustable to increase the strength and or the performance characteristics of a mixture formulation as needed or in contrast to be able to make lighter-weight mixtures as may be required. The ratios are: [0032] 1-Part rubber to 2-parts aggregate. [0033] 1-Part rubber to 3-parts aggregate. [0034] 1-Part rubber to 4-parts aggregate. [0035] 1-Part rubber to 5-parts aggregate. [0036] 1-Part rubber to 6-parts aggregate.

[0037] The process for addressing the renewing or restoration of an existing roofing project is as follows: [0038] 1. Remove any debris and presser wash the entire roof. Vacuum or blow off any standing water and let roof fully dry. [0039] 2. Apply the proprietary Acrylic Bonding/Primer Agent of the invention to pretreat the roof. Don't apply the Acrylic Bonding Agent to the roof if the urethane rubber-based filler coating mixture is used, as it is an incompatible mix combination. [0040] 3. Mix the filler coating mixture with the proprietary Acrylic Admixture to a consistency of a thin milkshake and apply to screed/level out any low-lying areas of the project and let dry. If the cement-based filler coating mixture is used allow an overnight dry time. If the urethane rubber-based filler coating mixture is used allow one hour to dry. [0041] 4. Apply the water tight roofing system of your choice providing that it is a textile membrane reinforced based system.

[0042] FIG. 1 shows top-down overview of the structural framing elements 10 of a commercial panelized roof composition. The roof is first constructed with the placement of the glulams 4 which typically have the dimensions of (63350-ft) and are placed on 20-ft centers, which run the length of the building 6. The purlins 2 which have the typical dimensions of (4820-ft) are installed next between the glulams 4 and are placed on eight ft centers. Then installed between the purlins 2 there are sub-purlins 8 which have the typical dimensions of (248-ft) and are installed on a two ft center between the purlins 2. Once the roof framing 10 is built it is then decked with 4-ft8-ft sheet of OSB plywood 14.

[0043] FIG. 2 shows side view cut away of a section of a 2-ft8-ft bay 12 that is decked with sheet of OSB plywood 14. The sub-purlins 8A and 8B are shown to be at a span of 2 feet and the sheet of OSB plywood 14 is sagging as is the typical condition/problem experienced in the field. The existing sheet of OSB plywood 14 has the old existing water tight roofing membrane system 16 installed and it also is sagging the same as the sheet of OSB plywood 14. The filler coating 18 is applied to level the void to which the new water tight roofing membrane system 20 is now applied and the roof repair/renewal are complete.

[0044] FIG. 3. Top-down overview of the corner section of the building 6 and the roof in various materials layered in staged phases of completion. The glulams 4, purlins 2, sub-purlins 8, the plywoodl4 and the old existing water tight roofing membrane system 16.

[0045] FIG. 3. A further illustration of existing ponding 22b and 22c that are confined to the 2 ft by 8 ft bays 12, whereas the existing pond 22A is confined to two of the 2 ft by 8 ft baysl2 because the 24 sub-purlin 8 that separate the two bays 12 is also sagging along with the plywood 14.

[0046] FIG. 3. A further illustration of the pond 26 covers three of the 2 ft by 8 ft bays 12 because two of the 24 sub-purlins 8 that separate the three bays 12 are also sagging along with the plywood14.

[0047] FIG. 3. A further illustration of filler coating being applied to level the ponds 24a, 24b and 24c with the new water tight roofing membrane system 20 being installed