US6604330B2
Expired / Lapsed
US
⏱️ 0.0 years remaining
Ballast block deck system and pedestal assembly therefor
Assignee: Individual
•
Filing: 2001-05-22
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Granted: 2003-08-12
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Expires: 2021-05-22
Abstract
Abstract A ballast block deck system includes a plurality of ballast blocks ( 12 ) laterally positioned to form an elevated deck ( 14 ) on an existing roof structure. Each block ( 12 ) has a predetermined thickness and multiple corner portions ( 22 ). A pedestal assembly ( 30 ) is located directly beneath the corner portions ( 22 ) of adjacent ballast blocks ( 12 ) to space and support the blocks ( 12 ) a spaced distance above the existing roof surface. The pedestal assembly ( 30 ) includes a support plate ( 34 ) having a support surface ( 40 ) for supporting the corner portions ( 22 ) thereon, a cornercap ( 42 ) which overlies the corner portions ( 22 ), and a fastener ( 44 ) which removably attaches the cornercap ( 42 ) to the support plate ( 34 ). When installed, the corner portions ( 22 ) of adjacent ballast blocks ( 12 ) are captured between the support plate ( 34 ) and cornercap ( 42 ) of the pedestal ( 30 ). Preferably, the corner portions ( 22 ) of the ballast blocks ( 12 ) include a recessed area ( 18 ) so that the cornercap ( 42 ) lies flush with the top surface ( 16 ) of the ballast blocks ( 12 ), and preferably, the corner portions ( 22 ) have a groove ( 20 ) for cooperatively engaging a flange ( 56 ) depending from the cornercap ( 42 ) so that lateral movement of the blocks ( 12 ) relative to the pedestal ( 30 ) and to other blocks ( 12 ) is prevented.
Inventors
- 👤 John Repasky
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 15:07
CPC Classifications
E; E04; E04F; E04F19/00; E04F19/02; E04F19/06; E04F19/062; E04D; E04D11/00; E04D11/005; E04F15/00; E04F15/02; E04F15/02005; E04F15/02022; E04F15/02044; E04F2015/02105; E04F2015/02111; E04F2201/00; E04F2201/05
Claims Analysis
Total Claims: 22
Claim 1
Independent Claim
298 words
A ballast block deck system for forming an elevated surface ( 14 ) on an existing roof structure, comprising: a plurality of ballast blocks ( 12 ) laterally positioned in a pattern to form a deck, each of said ballast blocks ( 12 ) having a predetermined thickness (T 1 ) and multiple corner portions ( 22 ), said pattern including intersection areas ( 32 ) in which corner portions ( 22 ) of adjacent ballast blocks ( 12 ) extend, said corner portions ( 22 ) of said ballast blocks ( 12 ) each having a top surface ( 16 ) with an upwardly open groove ( 20 ) and a recessed area ( 18 ), said groove ( 20 ) extending to a greater depth within the ballast block ( 12 ) than said recessed area ( 18 ); a pedestal assembly ( 30 ) located directly beneath one of said intersection areas ( 32 ) for supporting said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ) a spaced distance above the existing roof surface; said pedestal assembly ( 30 ) including a support plate ( 34 ) having a support surface for supporting said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ) thereon, and said pedestal assembly ( 30 ) including a removable cap ( 42 ) which overlies said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ) and a fastener ( 44 ) which removably attaches said cap ( 42 ) to said support plate ( 34 ) so that said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ) are captured between said support plate ( 34 ) and said cap ( 42 ).
Claim 2
Dependent Claim
298 words
A ballast block deck system for forming an elevated surface ( 14 ) on an existing roof structure, comprising: a plurality of ballast blocks ( 12 ) laterally positioned in a pattern to form a deck, each of said ballast blocks ( 12 ) having a predetermined thickness (T 1 ) and multiple corner portions ( 22 ), said pattern including intersection areas ( 32 ) in which corner portions ( 22 ) of adjacent ballast blocks ( 12 ) extend, said corner portions ( 22 ) of said ballast blocks ( 12 ) each having a top surface ( 16 ) with an upwardly open groove ( 20 ) and a recessed area ( 18 ), said groove ( 20 ) extending to a greater depth within the ballast block ( 12 ) than said recessed area ( 18 ); a pedestal assembly ( 30 ) located directly beneath one of said intersection areas ( 32 ) for supporting said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ) a spaced distance above the existing roof surface; said pedestal assembly ( 30 ) including a support plate ( 34 ) having a support surface for supporting said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ) thereon, and said pedestal assembly ( 30 ) including a removable cap ( 42 ) which overlies said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ) and a fastener ( 44 ) which removably attaches said cap ( 42 ) to said support plate ( 34 ) so that said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ) are captured between said support plate ( 34 ) and said cap ( 42 ).
Claim 3
Dependent Claim
26 words
A ballast block deck system according to claim 1 , wherein said cap( 42 ) and said corner portions ( 22 ) have complementary locking means.
Claim 4
Dependent Claim
56 words
A ballast block deck system according to claim 2 , wherein said complementary locking means of said cap ( 42 ) is a flange ( 56 ) which depends from said cap ( 42 ), and wherein said complementary locking means of said corner portions ( 22 ) is said upwardly opened groove ( 20 ).
Claim 5
Dependent Claim
63 words
A ballast block system according to claim 2 , wherein said support plate ( 34 ) has a plurality of radially extending upstanding walls ( 38 ) which define quadrants ( 40 ) on said support surface, and wherein each of said quadrants ( 40 ) supports one of said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ).
Claim 6
Dependent Claim
68 words
A ballast block deck system according to claim 3 , wherein said cap ( 42 ) has a top surface ( 54 ), and wherein said recessed areas ( 18 ) of said corner portions ( 22 ) permit said top surface ( 54 ) of said cap ( 42 ) to lie flush with said top surface ( 16 ) of said ballast blocks ( 12 ).
Claim 7
Dependent Claim
44 words
A ballast block deck system according to claim 3 , wherein said cap ( 42 ) has a peripheral edge ( 60 ), and wherein said flange ( 56 ) depends from said cap ( 42 ) adjacent said peripheral edge ( 60 ).
Claim 8
Dependent Claim
31 words
A ballast block deck system according to claim 6 , wherein said flange ( 56 ) extends continuously along said peripheral edge ( 60 ) of said cap ( 42 ).
Claim 9
Dependent Claim
62 words
A ballast block deck system according to claim 4 , wherein said upstanding walls ( 38 ) on said support plate ( 34 ) have a thickness (T 2 ) which is substantially equal to and defines a laterally spacing between said adjacent ballast blocks ( 12 ) to permit drainage of fluid through said deck to the underlying existing roof surface.
Claim 10
Dependent Claim
75 words
A ballast block deck system according to claim 8 , wherein said fastener ( 44 ) is a screw having a head ( 48 ) and a threaded shaft ( 50 ), said cap ( 42 ) has a central aperture ( 46 ) for engaging said head ( 48 ), and said support plate ( 34 ) has a centrally located threaded aperture ( 52 ) for engaging said threaded shaft ( 50 ).
Claim 11
Dependent Claim
45 words
A ballast block system according to claim 8 , wherein said support plate ( 34 ) is stackably received on said pedestal assembly ( 30 ) and wherein said pedestal assembly ( 30 ) includes at least two stackable members ( 34 , 68 ).
Claim 12
Dependent Claim
23 words
A ballast block system according to claim 8 , wherein said pedestal assembly ( 30 ) is made of a moldable plastic material.
Claim 13
Dependent Claim
28 words
A ballast block system according to claim 9 , wherein said screw has a length which is greater than said thickness of said ballast blocks ( 12 ).
Claim 14
Dependent Claim
28 words
A ballast block system according to claim 9 , wherein said screw has a central channel ( 70 ) extending axially therethrough to provide a drainage path therethrough.
Claim 15
Dependent Claim
302 words
A ballast block deck system for forming an elevated surface ( 14 ) on an existing roof structure, comprising: a plurality of ballast blocks ( 12 ) each having top and bottom surfaces ( 16 , 24 ) and each having corner portions ( 22 ), said top surfaces ( 16 ) in said corner portions ( 22 ) each having an upwardly open groove ( 20 ) and a recessed area ( 18 ), said groove ( 20 ) having a greater depth than said recessed area ( 18 ); a pedestal assembly ( 30 ) extending from the existing roof surface and supporting multiple corner portions ( 22 ) of adjacent ballast blocks ( 12 ) a spaced distance above the existing roof surface; said pedestal assembly ( 30 ) having a support plate ( 34 ) with a plurality of upstanding walls ( 38 ) defining separate support surfaces ( 40 ) on said support plate ( 34 ), each of said support surfaces ( 40 ) engaging said bottom surface ( 24 ) of one said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ); said pedestal assembly ( 30 ) having a cap ( 42 ) overlying said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ), said cap ( 42 ) being seated in said recessed areas ( 18 ) so that said cap ( 42 ) lies substantially flush with said top surfaces ( 16 ) of said adjacent ballast blocks ( 12 ) and having a flange ( 56 ) depending into said grooves ( 20 ); and said pedestal assembly ( 30 ) having a hold-down fastener ( 44 ) which removably attaches said cap ( 42 ) to said support plate ( 34 ).
Claim 16
Dependent Claim
302 words
A ballast block deck system for forming an elevated surface ( 14 ) on an existing roof structure, comprising: a plurality of ballast blocks ( 12 ) each having top and bottom surfaces ( 16 , 24 ) and each having corner portions ( 22 ), said top surfaces ( 16 ) in said corner portions ( 22 ) each having an upwardly open groove ( 20 ) and a recessed area ( 18 ), said groove ( 20 ) having a greater depth than said recessed area ( 18 ); a pedestal assembly ( 30 ) extending from the existing roof surface and supporting multiple corner portions ( 22 ) of adjacent ballast blocks ( 12 ) a spaced distance above the existing roof surface; said pedestal assembly ( 30 ) having a support plate ( 34 ) with a plurality of upstanding walls ( 38 ) defining separate support surfaces ( 40 ) on said support plate ( 34 ), each of said support surfaces ( 40 ) engaging said bottom surface ( 24 ) of one said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ); said pedestal assembly ( 30 ) having a cap ( 42 ) overlying said corner portions ( 22 ) of said adjacent ballast blocks ( 12 ), said cap ( 42 ) being seated in said recessed areas ( 18 ) so that said cap ( 42 ) lies substantially flush with said top surfaces ( 16 ) of said adjacent ballast blocks ( 12 ) and having a flange ( 56 ) depending into said grooves ( 20 ); and said pedestal assembly ( 30 ) having a hold-down fastener ( 44 ) which removably attaches said cap ( 42 ) to said support plate ( 34 ).
Claim 17
Dependent Claim
62 words
A ballast block deck system according to claim 14 , wherein said upstanding walls ( 38 ) on said support plate ( 34 ) have a thickness (T 2 ) which is substantially equal to and defines a laterally spacing between said adjacent ballast blocks ( 12 ) to permit drainage of fluid through said deck to the underlying existing roof surface.
Claim 18
Dependent Claim
74 words
A ballast block ( 12 ) for use in forming an elevated deck on an existing roof structure, comprising at least four corner portions ( 22 ) having a top surface ( 16 ) each having an upwardly open groove ( 20 ) and a recessed area ( 18 ), said grooves ( 20 ) extending to a greater depth within the ballast block ( 12 ) than said recessed areas ( 18 ).
Claim 19
Dependent Claim
74 words
A ballast block ( 12 ) for use in forming an elevated deck on an existing roof structure, comprising at least four corner portions ( 22 ) having a top surface ( 16 ) each having an upwardly open groove ( 20 ) and a recessed area ( 18 ), said grooves ( 20 ) extending to a greater depth within the ballast block ( 12 ) than said recessed areas ( 18 ).
Claim 20
Dependent Claim
34 words
A ballast block ( 12 ) according to claim 16 , wherein said corner portions ( 22 ) of the ballast block ( 12 ) are truncated forming a vertical endwall ( 28 ).
Claim 21
Dependent Claim
55 words
A ballast block ( 12 ) according to claim 17 , wherein in each of said corner portions ( 22 ) said groove ( 20 ) extends substantially parallel to said endwell ( 28 ), and said recessed area ( 18 ) extends between said endwell ( 28 ) and said groove ( 20 ).
Claim 22
Dependent Claim
24 words
A ballast block ( 12 ) according to claim 18 , wherein each of said recessed areas ( 18 ) is trapezoidal in shape.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2006-08-11 | 2007-02-10 | 2007-08-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2010-08-11 | 2011-02-10 | 2011-08-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2014-08-11 | 2015-02-10 | 2015-08-12 | $7700.00 | Window Closed / Lapsed |