US20070144080A1

US20070144080A1 - Cementitious roofing systems and methods

Info

Publication number: US20070144080A1
Application number: US11/318,239
Authority: US
Inventors: Randy Berner
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-12-23
Filing date: 2005-12-23
Publication date: 2007-06-28

Abstract

A roofing system constructed from cementitious materials that may be provided with various desired cosmetic appearances, some of which may resemble conventional roofing shingle patterns and the like. Methods for constructing roofing systems from cementitious materials shot under pressure through a hose are also disclosed.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention
The invention relates to roofing systems and methods and, more particularly, to systems and methods for constructing roofs for residential and commercial structures from cementitious materials that are capable of being applied through a hose under pressure and stamped, cut or carved to achieve a desired cosmetic appearance.
2. Description of the Invention Background
Over the years, a variety of different materials have been employed by the construction industry to construct roofs for residential and commercial buildings. One typical roof arrangement consists of a series of roof trusses that are erected on the walls of the structure. Roof trusses are a pre-built series of structural members designed to carry the load of the roof to the outside walls. In most residential applications, the structural members comprise wooden 2×4's or 2×6's. In many commercial applications, such structural members comprise metal C-shaped beams and the like. Sheathing material such as plywood, particle board, wafer board, etc. is then attached to the trusses and serves to form the roof surface. The sheathing is then commonly covered with a commercially available roofing or “felt” paper and shingles, tiles, wooden shakes or other commercial roofing materials are applied over the roofing paper and sheathing to provide the roof with a desired cosmetic appearance.
Although the trusses are designed to withstand anticipated wind and weight loads, the sheathing and shingles that are attached to the trusses are vulnerable to damage from high winds and severe weather. For example, these commonly used materials are very vulnerable to wind damage when used on structures located in areas that encounter hurricanes, tornadoes and/or other severe storms. In addition, various types of conventional roofing materials are susceptible to damage caused by walking on them when performing simple maintenance tasks on the roof. Moreover, the waterproofing qualities of such roofing materials decline with age and generally have to be replaced every few years (in many cases, less than 15 years) after they have been installed.
In an effort to construct roofs that are less susceptible to damage from severe weather conditions and high winds and to reduce the amount of maintenance and repair and replacement work associated with convention shingle-type roofing systems, cement materials have been employed. One such approach involved the use of reinforced concrete poured onto sheets of steel decking material supported on frames constructed from steel beams and support members. The installation costs associated with such approaches generally prevent their use in residential construction applications. Furthermore, such poured-in-place concrete/steel decking roof arrangements lack the aesthetic appearance that can be attained when utilizing conventional trusses, sheathing and shingles.
Other concrete or cement roofing systems suffer from similar problems. For example, another concrete roofing system involves the use of precast concrete or cement panels that are formed offsite and then transported to the building location. The costs associated with transporting the panels to the building site can be significant. In addition, a crane must be used to lift and maneuver the panels onto the trusses or other framing structures. These panels are heavy and difficult to handle. Thus, these types of roofing systems are expensive, difficult to install and also lack the aesthetic appearance that can be attained when using conventional shingles, tiles, etc.
Thus, as can be appreciated from the forgoing discussion, there is a need for a roofing system that can withstand high winds and other severe weather conditions without experiencing the damage often encountered when employing conventional shingles, tiles, etc., and yet maintain the cosmetic appearance of such tiles, shingles, etc.
There is yet another need for a roofing system fabricated utilizing cementitious materials without the need for cranes and the like that are commonly employed when utilizing precast concrete roofing panels, etc.
There is another need for a roofing system that can be constructed with desired cosmetic appearances that resemble various types of roofs constructed utilizing conventional shingles, shakes, tiles, etc. but is more durable than roofs constructed utilizing such conventional materials.

SUMMARY

In accordance with one embodiment of the present invention, there is provided a roofing system that comprises sheathing material that is attached to a roof framing support structure. A waterproof barrier is applied to an outer surface of the sheathing material and a rail system is attached to the sheathing material. Cementitious material is applied under pressure onto the rail system and sheathing material such that the rail system is embedded in the cementitious material. A cosmetic pattern is formed into an outer surface of the cementitious material.
In accordance with another embodiment of the present invention there is provided a roofing system that includes sheathing materials that are supported on a roof framing support structure. Peel and stick material is applied to the sheathing materials to form a waterproof barrier thereon. A plurality of elongated metal angles that each have a lower leg and an upper leg are applied to the peel and stick material such that they are substantially parallel to each other and spaced from each other at predetermined intervals. Each upper leg protrudes away from the peel and stick material and has a plurality of cross-supports attached thereto. The cross-supports extend transversely relative to the upper leg to which they are attached. A plurality of fasteners serve to attach the lower leg of each elongated metal angle to the sheathing material. A gunite material is applied under pressure onto the plurality of metal angles and the peel and stick material on the sheathing material such that each of the metal angles is embedded in the gunite material. The gunite material has a cosmetic pattern formed into an outer surface thereof.
In accordance with another embodiment of the present invention, there is provided a method of forming a roof surface that includes attaching sheathing material onto a support structure. The method also includes waterproofing an exposed surface of the sheathing material and forming a roofing material support structure on the sheathing material. The method further includes applying cementitious material under pressure onto the waterproofed surface of the sheathing material and embedding the roofing material support structure in the cementitious material. The method also includes forming a shingle pattern in an outer surface of the cementitious material.
In accordance with yet another embodiment of the present invention there is provided a method for constructing a roof on the walls of a building that includes mounting a plurality of roof trusses on the walls and attaching sheathing material onto the plurality of roof trusses. The method also includes applying a waterproof barrier on an exposed surface of the sheathing material and attaching a plurality of rails to the sheathing material on top of the waterproof barrier. The method further includes shooting gunite material under pneumatic pressure out of a hose onto the sheathing material and plurality of rails and forming shingle patterns in outer surfaces of the gunite material.
Accordingly, various embodiments of the invention provide solutions to the shortcomings of other roofing systems and roof construction methods. Those of ordinary skill in the art will readily appreciate, however, that these and other details, features and advantages will become further apparent as the following detailed description proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying Figures, there are shown present embodiments of the invention wherein like reference numerals are employed to designate like parts and wherein:
FIG. 1 is a side elevational view of a portion of a roof constructed according to an embodiment of the present invention;
FIG. 2 is a partial cross-sectional view of the roof of FIG. 1 taken along line 2-2 in FIG. 1;
FIG. 3 is a cross-sectional exploded assembly view of a portion of a roof constructed according to an embodiment of the present invention;
FIG. 4 is a cross-sectional view of a portion of a rail system of the present invention attached to a section of sheathing material;
FIG. 5 is an end view of a roof with an embodiment of a rail system of the present invention attached thereto;
FIG. 6 is a side elevational view illustrating one method of applying cementitious material to a roof constructed in accordance with an embodiment of the present invention;
FIG. 7 is a partial cross-sectional view of portion of a roof constructed in accordance with an embodiment of the present invention;
FIG. 8 is a plan view of a roof illustrating various steps of constructing a roof in accordance with an embodiment of the present invention; and
FIG. 9 is a top view of a stamp arrangement that may be used to form a portion of a shingle pattern into the outer surface of the cementitious material.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings for the purposes of illustrating the present embodiments of the invention only and not for the purposes of limiting the same, FIG. 1 is a front elevational view of a side 13 of a roof 10 constructed according to an embodiment of the present invention. FIG. 2 is a partial cross-sectional elevational view of the roof 10 taken along line 2-2 in FIG. 1. In the embodiment depicted in these Figures, the roof 10 includes a roof framing support structure 10′ that, in various embodiments, may comprise a series of conventional trusses 12 that may be installed utilizing known construction methods and techniques. See FIG. 2. Trusses 12 may be fabricated from wood, metal, etc. and be designed in accordance with the appropriate building codes to accommodate the anticipated loading and environmental conditions.
In one embodiment, the roof 10 further includes sheathing material 14 such as ¾″ plywood, particle board, waffle board, etc. Such sheathing material is commonly provided in 4′×8′ sheets 15 (FIG. 8) and is attached to the trusses 12 using appropriate fasteners such as nails, screws, etc. However, other sheathing materials and fasteners may be used.
After the sheathing material 14 has been fastened to the trusses 12 or other roof framing support structure, conventional “peel and stick” roofing material 16 is applied over the outer or “upward facing” surface 14′ of sheathing 14 to form a substantially weatherproof barrier over the outer surface 14′. See FIG. 3. Such peel and stick roofing material 16 may be supplied in rolls that are 4′ wide and may be applied by removing a paper backing from the material to expose its adhesive backing for application onto the outer surface 14′ of the sheathing material 14. In one embodiment, the peel and stick roofing material such as that peel and stick roofing material manufactured by Polyglass U.S.A., Inc., of 150 Lyon Drive, Fernley, Nev. 89408 under the trademark POLYSTICK™ may be employed. However other conventional waterproofing roofing materials may be used to form a substantially waterproof barrier on the outer surface 14′ of the sheathing 14.
In one embodiment, the peel and stick roofing material 16 may be applied to the outer surface 14′ of the sheathing 14 in a conventional manner that is somewhat similar to the method employed when installing roofer's felt paper. That is, one strip 17 of peel and stick roofing material 16 is applied on the outer surface 14′ adjacent the along the lower edge 11 of the roof structure 10. The next strip 17′ of roofing material 16 is applied adjacent to the first strip 17 of roofing material 16 and may be arranged to overlap the upper edge of the first strip 17 a slight amount, e.g., approximately 6 inches (distance “A” in FIG. 3). Subsequent additional strips 17″, 17′″, etc. of the roofing material 16 are applied to the sheathing material 14 in this manner until the outer surface 14′ of the sheathing materials 14 forming an entire side 13 of the roof structure 10 is covered by the roofing material 16. The reader will appreciate that such method of overlapping the strips 17, 17′, 17″, 17′″, etc. of roofing material 16 prevents water from infiltrating under the roofing material 16 at the seams between the respective strips of roofing material 16. Thus, at this point, the outer surface of the roof 10 is substantially waterproof.
Various embodiments of the present invention also employ a unique and novel roofing material support structure generally designated as 20. More specifically and with reference to FIGS. 1-5, in one embodiment, the support structure 20 comprises a plurality of rails 22 attached to the sheathing 14 in a predetermined spacing arrangement as will be discussed in further detail below. In one embodiment, the rails 22 comprise 2″×2½″ galvanized metal angles 23 (i.e., distance “B” is approximately 2 ½″ and distance “C” is approximately 2″). See FIG. 4. The reader will understand, however, that rails 22 could conceivably comprise other sizes of angle or other shaped members without departing from the spirit and scope of the present invention. Rails 22 may also be fabricated from other suitable materials such as stainless steel, or other structural members fabricated from, for example, vinyl or other polymeric materials. As can be seen in FIGS. 1 and 6, each length of angle 23 has a series of cross-supports 30 attached thereto at predetermined intervals. In one embodiment, for example, the cross-supports 30 comprise ¼″ diameter galvanized metal dowels or rods. In other embodiments, the cross-supports 30 may be fabricated from other suitable members. The cross-supports 30 may be transversely attached to the upper leg 24 of the corresponding angle member 23 by inserting each cross-support 30 through a corresponding hole 25 in the upper leg 24. See FIG. 4. The cross-supports 30 may be retained in position by virtue of an interference fit between the cross-support 30 and the hole 25 or it may be retained in position by welding or other suitable fastening means.
As can be seen in FIG. 4, the cross-supports 30 may be located above the lower leg 26 a distance “D”. In one embodiment, distance “D” is approximately 1⅛ inches (the centerline of the cross-support is approximately half way up the leg 24). However, the cross-supports could be located at other distances above the lower leg 26 without departing from the spirit and scope of the present invention. The cross-supports 30 may also protrude out from each side of the upper leg a distance “E”. In one embodiment, for example, distance “E” may be approximately 2″ when the angles 23 are spaced from each other a distance “F”. See FIG. 3. However, other lengths of cross-supports could be used. In one embodiment, the angles 23 are attached to the sheathing material 14 and roofing material 16) such that each angle 23 is located on a corresponding seam 19 between adjacent strips 17,17′, 17″,17′″, etc. of roofing material 16. Thus, for applications wherein the roofing material 16 is approximately 4′ wide, the angles 23 will be spaced approximately 4′ from each other going up a side 13 of the roof structure 10. That is, in that application, distance “F” would be approximately 4′. See FIG. 3. However, other spacing arrangements could be employed.
As can be seen in FIGS. 3 and 4, the lower legs 26 of the angles 23 may be attached to the sheathing material 14 by conventional fasteners such as ½″×¾″ galvanized lag screws 28 arranged at, for example, 3′ “on center”. However, other fasteners and fastener arrangements could be used to attached the angles 23 to the sheathing 14. To assist with the installation of the angles 23, an adhesive material 29 such as conventional mastic adhesive materials may be applied to the lower leg 26 of each angle 23 to adhere the angle 23 to the roofing material 16 in the desired location during installation of fasteners 28. The reader will understand that the angles 23 on the lower edges of the sheathing 14 forming the bottom edge 11 of the roof are only provided with the one half of the cross-supports 30 that extend upward. See FIGS. 1, 2 and 5.
After the desired number of angles 23 have been attached to the sheathing 14 as shown in FIGS. 1-5, a cementitious material 40 may be applied to the roof. As used herein, the term “cementitious material” refers to flowable concrete, cement or mortar material that can be conveyed (“shot”) through a hose under pressure and includes, but is not limited to, material commonly referred to in the industry as “gunite” or “shotcrete” that is commonly pneumatically projected through a hose. The gunite material 40 may be projected at pressures from approximately 125 to 150 psi, depending upon the application. Unlike conventional concrete which is commonly poured in place and then compacted in a second operation, gunite undergoes the placement and compaction actions simultaneously due to the force with which it is projected from the hose nozzle. Such material tends to be more dense, homogeneous, strong and waterproof that other concrete materials and results in a very dense and impervious mass with significant compressive strength. For example, after the gunite material 40 has cured, it may be have a 4500 PSI compressive strength depending upon the particular application. In one embodiment, a commercially available waterproofing additive may be added to the gunite material 40 prior to application to improve waterproof qualities thereof. Gunite is a product of the guniting process. Gunite, when applied under pressure, has no cold joint. This means that it can stop and start again without cracking at the joint.
In one embodiment, gunite material 40 is “shot” under pneumatic pressure onto the roof and rail arrangement at 125-150 PSI through a hose 42 attached to a conventional “through batch” truck 44. See FIG. 6. It is conceivable, however, that the gunite material 40 may also be applied at other pressures depending upon the jobsite specific needs. The use of such trucks enables the gunite material 40 to be shot onto the roof 10 under pressure thereby eliminating the need for a crane or other equipment for lifting heavy preformed concrete panels associated with other concrete roofing systems. In various methods of the present invention, an operator 46 remains at the truck 44 to add bags of Portland cement material to the truck wherein it is mixed with sterile sand and water. For example, in an embodiment of the present invention, 1 bag of Portland cement is mixed with 4 bags of sterile sand and an appropriate amount of water to achieve a final product that has a compressive strength of, for example, on the order of 4500 PSI. For steeper roof applications, less water may be used in the mixture.
In an embodiment, a hose operator 48 stands on the roof 10 and controls the hose nozzle to shoot the gunite material 40 under pressure onto the sheathing 14 and rail system 20 on each side 13 of the roof 10. The rail system 20 also provides the hose operator 48 with a convenient support structure to prevent the operator from slipping off the roof. In one application method, the operator 48 applies the gunite material 40 onto one side 13 of the roof 10, beginning at the top of that side 13 and working down to the bottom edge 11 of that side 13. The last amount of gunite material 40 may be shot onto the lower portion of the roof from the ground or scaffolding, depending upon the nature of the surrounding grade and landscape.
The gunite material 40 is applied to cover or embed the rail system 20 and is smoothed to provide it with a substantially constant thickness of approximately 2½″. In an embodiment, the gunite material 40 is smoothed to have a consistent thickness by a screed board. The screed board may be configured to carve a portion of the desired cosmetic pattern into the smoothed material. After the gunite material 40 has been applied to one side 13 of the roof 10, the operators move to another side 13 of the roof 10 and apply the gunite material 40 thereto in the same manner. This process is repeated until the entire roof has been completed. The gunite material 40 is also used to form a roof cap 49 between sections of roof as shown in FIG. 2. Each roof section, however, is of one-piece construction. In one embodiment, the gunite material 40 generally dries or hardens to a consistency that enables it to be cut or carved approximately two hours after it has been applied to the roof.
In one application, after the material 40 has dried, in one embodiment, it may be stamped, cut or carved to resemble an overlapping shingle pattern, generally designated as 50. As can be seen in FIG. 7, in one embodiment, the peak 54 or highest part of a single shingle pattern 52 may be approximately 2½″ (distance “G”) and the valley 56 (lowest part) may be approximately ¾″ (distance “H”). Each row 51 of shingle pattern 52 may be approximately 12″ wide (distance “I”) such that a total of 4 rows 51 of shingle patterns 52 extend between each angle 23. In one embodiment, the desired shingle pattern may be formed in the following manner.
During the screeding process, the screed board or screed tool may be configured to carve into the material 40 the horizontally extending peaks 54. Thus, the screed board or tool may be so configured that it removes the material between respective peak lines 54. This removed material is represented by the phantom lines 57 in FIG. 7. The vertically extending lines 58 of the shingle pattern and the lines 60 may be formed into the material 40 utilizing a stamping process.
FIG. 9 illustrates a stamp 200 that could be employed to stamp the vertical lines 58, 60 into the material 40. Such stamps 200 may be fabricated from, for example, rubber or other suitable material and may be sized so they may extend between adjacent rails 22. The stamp 200 may have a series of vertically protruding central portions 210 that are used to form the lines 58 in the material 40. The end portions 220 of the stamp are used to form the lines 60 in the material 40. In one embodiment, the end portions 220 protrude downward a distance that is longer than the distance in which the central portions 210 protrude such that, when the stamp 200 is placed onto the material such that the bottom portion 212 of the stamp 200 extends from a lower rail 22 and the upper portion 214 of the stamp 200 is received on the adjacent upper rail 22, and the central portion 216 of the stamp is pressed into the material 40, the lines 58 created by the central portions 212 are shallower than the lines 60 that are created by the end portions 220. For example, in one embodiment the lines 58 may have a depth (e.g., approximately ¼-⅜″ depth) that is approximately 10-15% of the greatest depth of the material 40 and the lines 60 may have a depth that is approximately one half of the greatest depth of the material (e.g., approximately 1¼″ deep). Such arrangement permits the lines 60 to accommodate expansion and contraction of the material 40. See FIG. 1. The stamp 200 may be configured such that the lines or expansion joints 60 may be provided every 4′ along the length of the roof (distance “J” in FIG. 1) and be staggered up the roof so that the expansion joints 60 extending between two angles 23 are not aligned with the expansion joints 60 in the adjacent sections of gunite material 40. See FIG. 1. However, other expansion joint spacing arrangements may be employed.
The conventional shingle pattern 50 depicted in FIGS. 1-3, 7, and 8 is just one cosmetic pattern that may be cut or carved into the gunite material 40. The reader will understand that other shingle arrangements, patterns, sizes and shapes may be stamped, cut or carved into the gunite material 40 without departing from the spirit and scope of the present invention. For example, shake-like patterns, scalloped shingle patterns, elongated shingles, narrow shingles, etc. may be stamped, cut or carved into the gunite material 40 to provide the roof structure with the desired cosmetic appearance. Also, in the embodiment depicted in FIG. 7, the upper leg 24 of each angle 23 is completely embedded in the gunite material 40. However, a different cosmetic appearance could be achieved by permitting the upper end of the upper leg 24 of one or more of the angles 23 to be uncoated with gunite material 40 to make it exposed. In various embodiments of the subject invention, concrete additives such as, for example, commercially available color dies, hardening agents, elastizers, etc. may be added to the gunite material 40 prior to being shot onto the roof to provide the gunite material 40 with desired attributes and/or color. In addition, a conventional sealant material such as a Xylene based sealant may be applied to the material after the pattern has been formed. Such sealant material may be applied by sprayers, rollers, etc.
In the unlikely event that a portion of the roof system is damaged, various embodiments of the present invention may be repaired, for example, by removing an area back to a stamped joint 60 or rail, then rebuild roof sheathing and reshooting new material into the area and restamping, cutting and/or carving the desired pattern.
FIG. 8 is a top view of a roof system of the present invention that illustrates one method for installing a roofing system embodiment of the present invention. As can be seen in that Figure, section 100 of the roof illustrates the application of 4′×8′ sheets 15 of sheathing materials 14. Section 110 of the roof illustrates the next step of applying strips 17, 17′, 17″, 17′″ of the roofing material 16 in an overlapping fashion. Section 120 illustrates the application of the rail system 20 on top of the strips 17, 17′, 17″, 17′″ of roofing material 16. Section 130 of the roof illustrates the gunite material 40 after a desired pattern 50 has been stamped, cut or carved therein.
The various embodiments of the subject invention represent vast improvements over prior roofing systems and most particularly over prior roofing systems that employ cement or concrete. The unique and novel aspects of the various embodiments of the roofing system of the present invention provide the advantages commonly associated with prior concrete roofing systems without the associated costs and without sacrificing cosmetic appearance. The essentially one-piece roof construction eliminates the problems associated with prior roofing arrangements that may employ thousands of separate shingles, shakes, etc. which can be blown off by high winds. Furthermore, a variety of different cosmetic appearances may be attained in the essentially one-piece roof structures without sacrificing durability and the roof's ability to withstand high winds, etc. Thus, various embodiments of the present invention will find particular utility in those geographic areas that commonly experience severe weather and high winds. In addition, the roofing systems of the present invention will last longer and require less maintenance than roofs manufactured utilizing conventional shingles, slate, shakes and other conventional roofing materials.
The invention which is intended to be protected is not to be construed as limited to the particular embodiments disclosed. The embodiments are therefore to be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the spirit of the present invention. Accordingly, it is expressly intended that all such equivalents, variations and changes which fall within the spirit and scope of the present invention as defined in the claims be embraced thereby.

Claims

1. A roofing system, comprising:

sheathing material attached to a roof framing support structure;

a waterproof barrier on said sheathing material;

a rail system attached to said sheathing material; and

cementitious material applied under pressure onto said rail system and sheathing material such that said rail system is embedded in said cementitious material, said cementitious material having a cosmetic pattern formed into an outer surface thereof.

2. The roofing system of claim 1 wherein said rail system comprises:

at least one elongated support member attached to said sheathing material such that a portion of said elongated support member protrudes away from said sheathing material; and

a plurality of cross-supports attached to said portion of said elongated support member and extending transversely relative thereto.

3. The roofing system of claim 2 wherein each said elongated support member comprises an angle.

4. The roofing system of claim 2 wherein each said elongated support member is attached to said sheathing material by a plurality of mechanical fasteners.

5. The roofing system of claim 4 wherein each said elongated support member is attached to the waterproof barrier by adhesive.

6. The roofing system of claim 1 wherein said cementitious material comprises gunite.

7. The roofing system of claim 6 further comprising a color additive material in said gunite to provide said gunite material with a desired color.

8. The roofing system of claim 1 wherein said waterproof barrier is formed from at least one strip of peel and stick roofing material applied to said sheathing material.

9. The roofing system of claim 1 wherein said cosmetic pattern comprises a pattern resembling patterns of conventional roofing shingle materials.

10. The roofing system of claim 3 wherein a portion of an upper leg of at least one said angle is not embedded in said cementitious material.

11. The roofing system of claim 1 wherein said roof framing support structure comprises a plurality of roof trusses supported on at least two spaced wall structures.

12. The roofing system of claim 11 wherein said roof trusses are fabricated from material selected from the group of materials consisting of metal and wood.

13. The roofing system of claim 1 further comprising at least one expansion joint in said cementitious material.

14. A roofing system comprising:

sheathing materials supported on a roof framing support structure;

peel and stick material applied to said sheathing materials to form a waterproof barrier thereon;

a plurality of elongated angles, each said angle having a lower leg applied to said peel and stick material such that said elongated angles are substantially parallel to each other and spaced from each other at predetermined intervals, each said angle having an upper leg protruding away from said peel and stick material and having a plurality of cross-supports attached thereto, said cross-supports extending transversely relative to said upper leg to which they are attached;

a plurality of fasteners attaching said lower leg of each said elongated angle to said sheathing material; and

a gunite material applied under pressure onto said plurality of angles and said peel and stick material on said sheathing material such that each said angle is embedded in said gunite material, said gunite material having a cosmetic pattern formed into an outer surface thereof.

15. A method of forming a roof surface, comprising:

attaching sheathing material onto a support structure;

waterproofing an exposed surface of the sheathing material;

forming a roofing material support structure on the sheathing material;

applying cementitious material under pressure onto the waterproofed surface of the sheathing material and embedding the roofing material support structure in the cementitious material; and

forming a shingle pattern in an outer surface of the cementitious material.

16. The method of claim 15 wherein said waterproofing an exposed surface of the sheathing material comprises applying a peel and stick roofing material to the exposed surface of the sheathing material.

17. The method of claim 15 wherein said forming a roofing material support structure on the sheathing material comprises attaching a plurality of angles on the sheathing material such that the angles are substantially parallel to each other and are spaced from each other a predetermined distance.

18. The method of claim 17 wherein said attaching a plurality of angles on the sheathing material comprises:

adhering each of the angles onto the waterproofed exposed surface of the sheathing material; and

affixing each of the angles to the sheathing material with a plurality of fasteners.

19. The method of claim 15 wherein said applying a cementitious material comprises shooting gunite material under pressure out of a hose onto the sheathing material and roofing material support structure.

20. The method of claim 19 further comprising leveling the gunite material to provide the gunite material on the sheathing material with a substantially consistent thickness.

21. The method of claim 20 further comprising permitting the leveled gunite to dry to a consistency wherein the shingle pattern can be formed in the outer surface thereof.

22. The method of claim 15 wherein said forming comprises stamping the shingle pattern into the outer surface.

23. The method of claim 21 wherein said forming comprises cutting the shingle pattern in the outer surface of the dried gunite.

24. The method of claim 15 further comprising providing at least one expansion joint in said cementitious material.

25. The method of claim 24 wherein said providing at least one expansion joint in said cementitious material comprises stamping the at least one expansion joint in the cementitious material.

26. The method of claim 15 wherein said forming a shingle pattern in an outer surface of the cementitious material comprises:

screeding at least one portion of the shingle pattern into the outer surface of the cementitious material; and

stamping at least one other portion of the shingle pattern into the outer surface,

27. The method of claim 17 further comprising forming expansion joints in the cementitious material located between the angles.

28. A method for constructing a roof on the walls of a building, said method comprising:

mounting a plurality of roof trusses on the walls;

attaching sheathing material onto the plurality of roof trusses;

applying a waterproof barrier on an exposed surface of the sheathing material;

attaching a plurality of rails to the sheathing material on top of the waterproof barrier;

shooting gunite material under pneumatic pressure out of a hose onto the sheathing material and plurality of rails; and

forming shingle patterns in outer surfaces of the gunite material.