Fiber-Reinforced Deck Panel for Waterproof Stone Surfacing
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Solution Overview
Problem
Existing outdoor flooring systems struggle to accommodate stone or stone-like materials on sloped or waterproofed surfaces without compromising structural integrity or aesthetics, particularly on decks and rooftops, as they require mechanical penetrations that breach waterproofing and lack suitable structural support for thin-gauged stones.
Innovation Solution
A deck, rooftop terrace, and patio surface system utilizing a fiber-reinforced structural panel with a mounting fastener and interconnecting system, allowing for the use of stone or stone-like surfaces of varying shapes and sizes, bonded with a flexible adhesive to create a stable and aesthetically pleasing planar array without grouted spaces, enabling drainage and support over waterproofed areas without penetrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners are used to secure stones to deck surfaces, then structural stability is improved, but waterproofing integrity is compromised due to penetrations
Solution Approach 1:
A fiber-reinforced structural panel serves as an intermediary layer between the deck surface and the stone surfacing material. This panel provides mechanical attachment points for fasteners while maintaining the waterproofing membrane's integrity by preventing direct penetrations through it. The panel acts as a mediator that distributes loads and enables stone installation without compromising the underlying waterproofing system.
2Shape
If thin-gauged stones are used for aesthetic purposes, then visual appeal is improved, but structural support requirements increase
Solution Approach 1:
The system employs a composite construction consisting of a fiber-reinforced structural panel combined with thin-gauged stone surfacing material. The fiber-reinforced panel provides the necessary structural strength and load-bearing capacity, while the thin stone layer contributes aesthetic appearance. This composite approach allows the use of thinner, more visually appealing stones without sacrificing structural integrity, as the reinforcement panel compensates for the reduced thickness of the stone material.
3Strength
If traditional grouted stone installations are used, then structural stability is improved, but drainage capability is reduced due to grouted spaces
Solution Approach 1:
The fiber-reinforced structural panel features a porous or open-cell structure that allows water to pass through it vertically. This porosity enables drainage functionality while the panel's engineered structure maintains sufficient load-bearing capacity. The porous design eliminates the need for grouted spaces between stones, as the panel itself provides both structural support and drainage pathways, allowing water to flow through the system without obstruction.
4Adaptability or versatility
If stone surfaces are installed on sloped or uneven substrates, then adaptability to various deck types is improved, but achieving a planar array becomes difficult
Solution Approach 1:
The fiber-reinforced structural panel is installed first as a preliminary layer over the sloped or uneven substrate, creating a stable, level base surface. This panel can be configured to accommodate various deck types and slopes, and once installed, it provides a planar reference surface. The stone surfacing material is then installed on top of this pre-established planar base, ensuring that the final stone array achieves proper planarity even when the underlying substrate is irregular or sloped.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides a stable, aesthetically appealing, and water-permeable outdoor flooring solution that supports thin-gauged stones, allowing for easy installation and removal of panels, accommodating uneven surfaces, and maintaining structural integrity while avoiding the need for traditional grouting or penetrations, thus enhancing durability and flexibility.
Implementation Method 1
a surfacing material bonding agent for attachment to the structural panel
Data Source
AI summary
A system and method for providing an outdoor flooring such as a lightweight deck surface, employs a fiber reinforced polymer structural panel with internally tapered plural grid openings therein. A connector is driven into selected openings to enable the panel to be secured to a deck frame, or in the case of an impenetrable deck frame, a series of plates are used with or without pipe stanchions to make a floating or raised floating planar surface. A surfacing material, such as a quarried stone, is attached to the top of the panel, providing a stone deck surface without requiring substantial structural support.