Roof system

Abstract

A roofing system provides a stronger bond than conventional roof systems to withstand greater uplift pressures in hurricane force winds, while also providing a sound fire rating. The system includes a non-corrosive metal blocking structure, including a perimeter edge closure that has an anchoring flange for attachment to the roof deck, a parallel upper flange and an intermediate flange extending perpendicularly between the upper and lower flanges. The system further includes lightweight insulating concrete applied to the roof deck and filled between the upper and lower flanges of the edge closure, an inter-ply sheet applied by torch or self-adhesive directly to the insulating lightweight concrete, and a torch applied cap membrane over the inter-ply sheet. Direct attachment of the inter-ply sheet to the lightweight insulating concrete without the use of hardware fasteners preserves the integrity of the underlying lightweight insulating concrete for future re-roofing.

1 . A roof system for installation on a roof deck of a building structure comprising:
 a slurry coat of lightweight insulating concrete applied on a top surface of the roof deck;   a layer of insulation applied on top of said slurry coat;   a top coat of lightweight insulating concrete applied over said layer of insulation;   an inter-ply sheet applied and bonded to said top coat; and   a cap membrane applied on top of said inter-ply sheet and bonded to said inter-ply sheet.   
   
   
       2 . The roof system as recited in  claim 1  wherein said layer of insulation is EPS Holly board. 
   
   
       3 . The roof system as recited in  claim 1  wherein said inter-ply sheet is bonded to said top coat by torch weld. 
   
   
       4 . The roof system as recited in  claim 1  wherein said inter-ply sheet is bonded to said top coat with an adhesive. 
   
   
       5 . The roof system as recited in  claim 1  wherein said cap membrane is bonded to said inter-ply sheet by torch weld. 
   
   
       6 . The roof system as recited in  claim 1  further comprising a metal edge closure attached to the roof deck and extending about a perimeter of the roof deck. 
   
   
       7 . The roof system as recited in  claim 6  wherein said metal edge closure comprises:
 an anchoring flange structured and disposed for attachment to the roof deck;   an upper flange extending parallel to said anchoring flange and spaced above said anchoring flange;   an intermediate flange extending perpendicularly between said anchoring flange and said upper flange; and   said anchoring flange and said upper flange being spaced apart to form a gap for receipt of the slurry coat, the layer of insulation and the top coat between said anchoring flange and said upper flange.   
   
   
       8 . A roof system for installation on a roof deck of a building structure comprising:
 a metal edge closure including an anchoring flange structured and disposed for attachment to the roof deck along a perimeter of the roof deck, an upper flange extending in spaced relation above the anchoring flange to form a gap between the anchoring flange and the upper flange, and an intermediate flange extending perpendicularly between said anchoring flange and said upper flange;   a lightweight insulating concrete deck applied on a top surface of the roof deck and within the gap between the anchoring flange and the upper flange of the metal edge closure;   an inter-ply sheet applied to the lightweight insulating concrete deck and bonded to a top surface of the lightweight insulating concrete deck; and   a cap membrane applied on top of the inter-ply sheet and bonded to the inter-ply sheet.   
   
   
       9 . The roof system as recited in  claim 8  wherein the lightweight insulating concrete deck comprises:
 a slurry coat of lightweight insulating concrete applied on a top surface of the roof deck;   a layer of insulation applied on top of said slurry coat; and   a top coat of lightweight insulating concrete applied over said layer of insulation.   
   
   
       10 . The roof system as recited in  claim 9  wherein said layer of insulation is EPS Holly board. 
   
   
       11 . The roof system as recited in  claim 9  wherein said inter-ply sheet is bonded to the top coat by torch weld. 
   
   
       12 . The roof system as recited in  claim 9  wherein said inter-ply sheet is bonded to said top coat with an adhesive. 
   
   
       13 . The roof system as recited in  claim 9  wherein said cap membrane is bonded to the inter-ply sheet by torch weld. 
   
   
       14 . The roof system as recited in  claim 8  wherein the roof deck is a metal deck having flutes.