Device for building concrete roofs and method

Abstract

An apparatus used in roof construction wherein insulation material is held flush within the channels formed by the apparatus. The flush engagement between the insulation material and the walls defining the channels of the apparatus leads to a greater surface area securing the insulating material in place. The apparatus includes attachment means on its top flanges to mount rebar members to the apparatus holding the rebar grid in place. The vertically disposed flanges of the apparatus include openings that allow concrete to pass through the apparatus preventing fatigue points caused by the interruption of concrete. The apparatus can be employed in a method that allows a roof to be transported to a job site with the rebar grid already secured to an apparatus.

Claims

1. An apparatus used in concrete roof construction, comprising: A) two C-channel beams each having an elongated bottom wall and an elongated coextensive top wall kept at a parallel and spaced apart relationship with respect to each other and each beam further including a side wall perpendicularly mounted to their respective bottom and top walls, said side walls being abuttingly disposed with respect to each other and defining a channel for each beam, whereby each of said channels have cooperative dimensions to partially house the edges of an insulating board, substantially flush with the bottom flange; B) a rebar attachment assembly having two elongated attachment walls continuous through the entire length of the beam and mounted substantially perpendicular to said top walls and kept at a substantially parallel and spaced apart relationship with respect to each other further including each an inwardly disposed attachment flange extending along the entire length of said beam and substantially perpendicularly from said attachments walls, said inwardly disposed attachment flanges being uninterrupted and extending towards each other a predetermined distance to define a longitudinally extending cavity between said attachment flanges, attachments walls and top walls for receiving a predetermined amount of concrete or cement, and said attachment flanges having a width and include a plurality of through holes at predetermined distances from each other, said through holes are centrally located with respect to said width of said attachment flanges so that part of the attachment flanges longitudinally extend along both sides of said through holes; and C) a plurality of rebar members defining a rebar grid mounted to said rebar attachment assembly with a corresponding plurality of tie wraps cooperatively mounted to said attachment flanges through said through holes to secure said rebar members in place, said cavity extending along the entire length of the beam to receive said cement or concrete to further secure said rebar members to said rebar attachment assembly with a slab of concrete or cement poured over said insulating boards and over the top of said attachment flanges, thereby securing the rebar members in the cavity.

2. An apparatus used in concrete roof construction, comprising: A) two C-channel beams each having an elongated bottom wall and an elongated coextensive top wall kept at a parallel and spaced apart relationship with respect to each other an each beam further including a side wall perpendicularly mounted to their respective bottom and top walls, said side walls being abuttingly disposed with respect to each other and defining a channel for each beam, whereby each of said channels have cooperative dimensions to partially house the edges of an insulating board, substantially flush with the bottom flange; B) a rebar attachment assembly having two elongated attachment wall continuous through the entire length of the beam and mounted substantially perpendicular to said top walls and kept at a substantially parallel and spaced apart relationship with respect to each other further including each an inwardly disposed attachment flange extending along the entire length of said beam and substantially perpendicularly from said attachments walls, said inwardly disposed attachment flanges being uninterrupted and extending towards each other a predetermined distance to define a longitudinally extending cavity between said attachment flanges, attachments walls and top walls for receiving a predetermined amount of concrete or cement, and said attachment walls include a plurality of through holes at predetermined distances from each other; and C) a plurality of rebar members defining a rebar grid mounted to said rebar attachment assembly and a plurality of said rebar members passing through said through holes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which:

(2) FIG. 1 represents an isometric view of an embodiment of the present device wherein transportation rebar TR is mounted to Z-channel device 10 using throughholes 142.

(3) FIG. 1A displays an isometric view of an alternate embodiment of the present invention wherein rebar R is mounted to rebar attachment assembly 40 using tie wraps 47.

(4) FIG. 1B shows an isometric view of an alternate embodiment of the present invention wherein rebar R is mounted to rebar attachment assembly 40 using clips 45.

(5) FIG. 1C illustrates a front elevational view of the present invention securing insulating boards I between two Z-channels 10 while rebar R is mounted to rebar attachment flange 44 and concrete is poured over it to create a secure engagement.

(6) FIG. 2 is an isometric view of a roof with forms showing a grid made of rebar R mounted to a plurality of Z-channels 10 before concrete has been poured. Steel plates 46 can be seen securing the distal ends of insulating boards I.

(7) FIG. 2A illustrates an alternate embodiment showing a partial isometric view of a roof showing the grid made of rebars R mounted to a plurality of Z-channels 10 before concrete has been poured. Plates 46 can be seen further securing the insulation boards I within the roof.

(8) FIG. 2B is a cross-sectional elevation of a portion of the roof after being poured engaging rebar member R and insulating boards I in place.

(9) FIG. 3 is an isometric view of a roof with a partial cross-section showing the grid made of rebar R secured to the present invention. A partial view of insulation boards I can also be seen secured by Z-channel devices 10.

(10) FIG. 4 shows an isometric view of the present invention as part of a pre-assembled roof section being transported by crane using transportation rebar TR.

(11) FIG. 5 shows an isometric top partial view of a roof showing the concrete layer poured over rebar member R

(12) FIG. 6 shows an isometric view of device 10 securing one insulation board I on both longitudinal sides. The shorter sides of insulation board I is being secured by plates 46.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

(13) Referring now to the drawings, where the apparatus, a Z-channel member, is generally referred to with numeral 10, it can be observed that it basically includes a insulation engagement assembly 20 and rebar attachment assembly 40.

(14) As seen in FIGS. 1-1B, insulation engagement assembly 20 includes bottom channel flange 22, side wall 24, and top channel flange 26. Bottom channel flange 22 and top channel flange 26 are kept at a spaced apart and parallel relationship with respect to each other by side wall 24. Bottom channel flange 22, side wall 24, and top channel flange 26 are mounted together to define the space wherein channel 23 travels.

(15) Insulating material I is inserted into channel 23 and are flush with bottom channel flange 22, side wall 24, and top channel flange 26. This flush relationship securely holds insulating material I in place within channel 23.

(16) FIGS. 1-1B show rebar attachment assembly 40. Rebar attachment assembly 40 includes vertically disposed flange 42 that is perpendicularly mounted above top channel flange 26. Rebar attachment assembly 40 further includes rebar attachment flange 44 that inwardly extends from vertically disposed flange 42 and is perpendicularly mounted thereon. Rebar attachment flange 44 includes a plurality of throughopenings 144 that are used to allow tie wraps 47 to pass through and attach rebar member R to rebar attachment flange 44 as seen in FIG. 1A. In an alternate embodiment shown in FIG. 1B, rebar members R can be secured to rebar attachment flange 44 using clips 45. In another alternate embodiment shown in FIG. 1, vertically disposed flanges 42 include throughholes 142 wherein transportation rebar members TR are inserted and used to transport Z-channel apparatus 10, as shown in FIG. 4.

(17) Additionally, as seen in FIGS. 1-1B, Z-channel 10 includes cavity 48 between vertically disposed flange 42. Cavity 48 is filled with concrete further securing rebar members R to Z-channel member 10. In an alternate embodiment, as seen in FIG. 1 vertically disposed flange 42 includes throughholes 143 which allow concrete to pass into cavity 48 and connect with concrete on opposite sides of vertically disposed flanges 42, thereby creating a more secure engagement by preventing fatigue prone areas caused by the interruption of the concrete.

(18) The method of assembling the concrete roof using the apparatus or Z-channel includes the following steps. a) pre-cut the insulating boards to a desired length depending on the size of the roof; b) pre-cut the apparatus or Z-channel depending on the size of the roof; c) position one Z-channel on one side of the insulating board I so that an edge of the insulating board is partially housed within channel 23 and flush against bottom channel flange 22, side wall 24, and top channel flange 26. Position a second Z-channel in the same way on the opposite side of insulating material I d) as seen in FIG. 6, steel plates 46 are then used to cover the shorter ends of insulating board I perpendicular to the longer ends that were covered by the Z-channels in the previous step; e) repeat the above steps for each insulating board I to be placed in the roof (in a preferred embodiment, shown in FIG. 2A, each steel plate 46 can be used to cover the shorter ends of multiple insulating boards I put together).

(19) The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense.