US3364058A

US3364058A - Composite floor and deck covering structure

Info

Publication number: US3364058A
Application number: US343908A
Authority: US
Inventors: Herman B Wagner; David S Weiant
Original assignee: Selby Battersby and Co
Current assignee: SB Decking Inc
Priority date: 1964-01-16
Filing date: 1964-01-16
Publication date: 1968-01-16
Anticipated expiration: 1985-01-16

Description

Jan. 16, 1968 H. B. WAGNER ET AL 3,3

COMPOSITE FLOOR AND DECK COVERING STRUCTURE Filed Jan. 16. 1964 INVENTORS. HERMAN B. WAGNER DAVID s. WEIANT WxWV ATTYS United States Patent 3,364,658 COMPOSITE FLOOR AND DECK COVERING STRUCTURE Herman B. Wagner, Perlrasie, and David S. Weiant, Philadelphia, Pa, assignors to Selby, Battershy & Co., Philadelphia, Pa., a cnrporation of Delaware Filed Jan. 16, 1964, Ser. No. 343308 11 Claims. (Cl. 117-40) This invention relates to a traffic-bearing composite floor and deck covering, and more particularly to a completely monolithic and seamless permanent deck and floor covering which is not affected by snow and ice, and which permits normal movement of the substructure or base support without damage thereto.

A covering for sub-floor or base support is subjected to many stresses. For example, the sub-floor may shrink and expand with temperature changes. In the case of wood sub-floors, ordinarily there is additional shrinkage and expansion due to changes in humidity. Such shrinking and expansion subjects the covering to stresses of a magnitude which may produce cracks in the covering. If moisture can penetrate these cracks, additional damage may result, particularly where the covering is subject to freezing and thawing conditions.

Considerable effort has been made to provide a floor and deck covering which is not subject to damage by reason of movement of the subfloor. These efforts have resulted in systems where the covering is made somewhat elastic and is separated from the sub-floor so that the subfioor can move relative to the covering. One such means of separation comprises a felt under-layer which is attached to the sub-floor along the periphery of the floor and at spaced points within the interior floor area.

A major problem with the use of felt as the separating means between the sub-floor and covering has been cracking at the corners where the felt is bonded directly to the sub-floor as well as to the covering and where both the covering and the sub-floor are subjected to lateral as well as longitudinal movement.

A primary object of this invention is to provide a trafficbearing composite floor and deck covering which permits normal movement of the substructure supporting it to take place without harm to the covering.

Another object of this invention is to provide a seamless permanent deck and floor covering which is tough, durable and fire-retardant.

A further object of this invention is to provide a monolithic composite floor and deck covering which can be applied to a wide variety of areas, such as old leaking sundecks and useless roof areas, to provide an attractive and useful floor.

.Still another object of this invention is the provision of a composite floor and deck covering which is waterproof and free from costly maintenance such as caulking, etc.

Yet a further object of this invention is to provide a dry mix, which when combined with water, produces a construction material which is particularly useful in providing a release coating which permits relative movement between the wear surface of a floor and deck covering and a sub-floor, whereby the covering is not subjected to damaging stresses due to normal movement of the subfloor.

These and other objects of this invention will become further apparent for a consideration of this specification, claims and accompanying drawing.

The figure of the drawing is a diagrammatic perspective view, substantially enlarged, showing a composite floor and deck covering according to this invention.

In accordance with this invention there is provided a floor and deck covering for use on a sub-floor or base support comprising a relatively thin release coat applied as a plastic mass over the base support and which upon setting forms a substantially non-tacky, solid layer having an indentation characteristic of less than above 50% four hours after application and a shear strength of not more than about 2.5 p.s.i. seven days after application; and a relatively thicker wear coat over said release coat.

Referring now to the figure in the accompanying drawing, there is illustrated at 10 a base support or subfloor, which may be of plywood, wood, quarry tile, concrete slabs, steel or any other construction which is strong enough to support the anticipated load. The base support or sub-floor should be provided with a relatively smooth surface, free of pits, holes and loose materials. In addition to being sound, the base support should be free of such materials as oil, grease, paint, etc.

Superimposed on the base support 10 is a release coat, generally indicated at 12. The purpose of the release coat is to permit relative movement between the base support or portions thereof and the wear and waterproofing layers in the floor and deck covering construction of this invention. In this manner the wear and waterproofing layers are isolated from movement of the substructure and are not subject to stresses as would cause damage thereto, such as cracks, spalling, etc.

The release coat preferably comprises a composition which can be applied to the base support by unskilled workmen as a plastic mass, as by trowelling. Preferably, it may comprise a composition having as the major constituent an inorganic cementitious material, and also will contain inorganic filler and a release agent.

To permit application of the wear coat, and also a waterproofing coat if desired, over the release coat, without undue delay after application of the release coat, the release coat should solidify in a relatively short period of time, for example, in about 2 to 4 hours, and after becoming hard should have sufficient compressive, indentive and tensile strength to support workmen applying the overlayer or layers without any substantial rupture or cracking. For this purpose an indentation characteristic at the end of four hours of less than about 50% is desirable, an indentation characteristic of less than about 30% at the end of four hours being preferred. All values for indentation characteristic given in this specification and appended claims are based on the method of determination identified in the art as MIL-D-3134F Specification of Jan. 24, 1962. This specification is more fully described hereinafter in connection with the several specific examples. In addition to having sufficient strength to permit completion of the covering without damage, the release coat should be substantially non-tacky.

As stated previously, the release coat functions to isolate the movements of the sub-floor from the covering so that the former may expand and contract without damage to the latter. To provide for such isolation, the release coat should rupture at a relatively low shear stress, to release the wear and any waterproofing coats from the sub-floor. In other words rupture of the release coat takes place when the stresses created by movement of the subfloor and/ or covering exceed a given minimum value. It was found that to obtain the desired release, shear strength seven days after application should be less than about 2.5 p.s.i. as determined by the equation:

shear strength= 9 a ing (wear layer, moisture proof layer, etc.), 1 is the thickness of the covering layer or layers (release layer not included), and l is one-half the length of the sample being tested, the sample being one inch in width.

Shear strength as determined by the above Formula 1 may be derived from data obtained from apparatus comprising a surface having two separable halves. A test sample one inch in width comprising a release coat and wear coat (as well as other over-layers, e.g. a waterproofing coat) is placed in the apparatus so as to be equally divided on both halves of the separable surface areas. The halves are then separated and the distance between the two halves (the value of d in Formula I) is determined when the release coat permits separation of the wear layer from the test apparatus. The presence or absence of cracks in the wear layer at the time of release is also noted.

The modulus of elasticity (m in Formula I) of the release coat used in calculating shear strength, may be determined by measuring deformation vs. stress in a Scott tester using sample portions of the test sample. The method by which modulus of elasticity may be determined is more fully described in connection with the specific examples hereinafter set forth.

Although the release coat may vary considerably in the thickness, it should be of relatively uniform thickness throughout its entire extent, and preferably should range in thickness from about 0.025 to about 0.035 inch. If the release coat is substantially less than 0.025 inch it may be discontinuous in certain areas, and in these areas there may be a tendency for the immediate over-layer, e.g. a waterproofing layer, to adhere to the sub-flooring, thereby impairing the floating action of the floor covering. At such points of contact stresses which will damage the covering may be set up even under ordinary movement of the sub-flooring. If the release layer has a thickness which is substantially in excess of 0.035 inch, the time required for the release layer to set to permit application of the over-layers may be considerably increased and application costs may thereby be increased.

As stated above, the release coating preferably comprises as the major constituent an inorganic cementitious material which can be applied as a plastic mass. Preferably, the cementitious material will comprise such substances as calcined gypsum, lime and hydraulic cement. By the term hydraulic cement is meant any of the wellknown construction cements such as magnesium oxychloride cement, Kuhl cement, Portland cement, aluminous cement, pozzolanic cement, special activator cements, etc.

The release coat, in addition to inorganic cementitious material, may contain an organic release agent. The purpose of the release agent is to lower the shear strength of the release layer to such a level as will permit rupture thereof when subjected to movements of the sub-floor and/or floor covering. The organic release agent may comprise any material which obtains this result without adversely afiecting other properties of the release coat, such as compressive strength, indentation characteristic, etc., to such a level that the coating is too weak or fragile to permit the subsequent application of the wear and waterproofing layers.

Typical of the organic release agents which may be used in the release coat of this invention are anionic surface active agents, paraffin waxes, polymer emulsions such as polyethylene emulsions, and silicones. The anionic surface active agents, particularly the alkyl and alkyl aryl sulfonates, and metal salts of fatty acids, are preferred release agents according to this invention.

The alkyl and alkyl aryl sulfonates used in this invention have the formula or alkyl aryl containing from 12 to 20 carbon atoms. and X is hydrogen, alkali metal and alkaline earth metal.

Suitable alkyl sulfonates are: sodium and potassium octyl, nonyl, decyl, hendecyl, dodecyl, tridecyl, tetradecyl, hexadecyl, octadecyl sulfonate. A preferred alkyl sulfonate comprises sodium dodecyl sulfonate.

Alkyl aryl sulfonates which may be used are those derived from benzene, naphthalene, diphenyl and diphcnylmethane, and include among others: sodium and potassium hexyl, heptyl, octyl, nonyl, decyl, hendecyl, dedecyl, tridecyl, and tetra-decylbenzene sulfonate. As with the alkyl sulfonates, the alkyl group in the alkyl aryl sulfonates 'may comprise either a straight or branched chain. A preferred alkyl aryl sulfonate comprises sodium dodecylbenzene sulfonate.

The salts of fatty acid which may be used in this invention have the formula where R is alkyl containing from 8 to 18 carbon atoms and X is hydrogen, alkali or alkaline earth metal.

Typical compounds of this type are the sodium and potassium salts of such fatty acids and capric, undecylic, lauric, tridecoic, hydristic, pentadecanoic, palmitic, margaric, stearic, nondecyl, and arachidic acid.

The inorganic release agent may also comprise a waxy solid hydrocarbon of the paraffin series containing from 10 to about 30 carbon atoms.

The release coat or layer may also contain a linear silicon resin as a release agent. Such silicon resin preferably has a molecular weight in the range between about 250 and 2000.

The amount of release agent which may be incorporated in the release layer may vary considerably; however, ordinarily the weight ratio of inorganic cementitious material to release agent will be in the range between about 6:1 and about 20:1, a weight ratio in the range between about 8:1 and about 12:1 being particularly preferred.

In addition to inorganic cementitious material and release agent, the release coat may contain a finely divided inorganic filler having an average particle size in the range about 25 and about 325 Examples of suitable inorganic fillers are fine sand, silica flour, pow= dered calcium carbonate, powdered barium sulfate, ground cinders, and finely divided perlite or vermiculite. The inorganic filler may be present in the release coat in an amount up to about 50%, by weight, of the inorganic cementitious material. Preferably, the inorganic filler is present in an amount from about 10 to about 20%, by weight, of inorganic cementitious material.

Sufiicient water should be added to the solid con stituents to provide the mixture with a consistency per mitting relatively easy uniform application to the sub floor, as by trowelling. Ordinarily the amount of water used should be such as to provide the composition with a slump of from about 4 to about 11 inches, as determined by ASTM designation (3143-58 entitled Slump of Portland Cement Concrete. A preferred slump is one of approximately 10.25 inches.

For the purpose of providing the floor or deck coat ing with waterproofing characteristics where the con'' struction may be subjected to Water, as in exterior decks, there is applied over the release coat 12, a waterproofing coat generally indicated at 14 in the figure in the accompanying drawing. This layer essentially comprises a textile fabric, such as burlap, impregnated and coated with rubber.

In applying the waterproofing coat 14, preferably the release layer 12 is covered with a rubber latex to a thickness when wet of approximately inch. Application of the rubber latex may be by means of a trowel, a little at a time, so that while the latex is still wet a textile fabric may be embedded in and fully wetted by the latex.

The textile fabric may be composed of organic or inorganic fibers and may be either woven or non-woven. A preferred fabric for use in this invention which provides adequate strength at reasonable cost is burlap, a 7 /2 oz. burlap being a particularly suitable fabric. The burlap or other fabric should be applied as strips and should overlap each other, an overlap of two to four inches being generally satisfactory. To the excess amount of rubber latex that works through the fabric while it is being embedde, additional latex should be added, as by trowelling, into the fabric surface. The amount of latex used should be sufiicient to fill all pinholes so that the upper surface of the fabric comprises a continuous rubber film free of holes. In order to insure complete coverage of the fabric with latex, it is preferable to apply a second coat of rubber latex to the upper surface of the fabric after the first has dried. The thickness of the waterproofing layer may be from about 35 to about 100 mils. a thickness of about 60 mils being generally sufiicient for good waterproofing.

As stated above, the purpose of this layer comprising rubber coated and impregnated textile fabric is to provide waterproof characteristics to the composite floor and deck covering where the covering will be exposed to moisture. This waterproofing layer can, however, be omitted where the floor construction need not have waterproof properties.

In the present application the term rubber is used. This term as used herein is intended to include not only natural rubber, but also any artificial or synthetic rubber. For certain purposes some of the synthetic rubbers may be preferable to natural rubber by reason of their resistance to chemical attack, for example by oils and greases. Of these synthetic rubbers a polymerized chlorine derivative of 1,3-butadiene, which is sold under the trademark Neoprene is presently preferred. The term latex as used herein in connection with rubber is intended to mean an aqueous dispersion of any rubber as herein defined. As such, therefore, these terms are used in their broadest conventional sense throughout the present specification and claims. The rubber latex may, if desired, contain conventional vulcanizing agents and/or vulcanization accelerators.

The next layer above the waterproofing layer 14 is the wear coat and is indicated at 16. The composition of the wear layer comprises hydraulic cement and rubber latex. The hydraulic cement in the composition 16 is present in an amount sufficient to substantially dehydrate the latex used and thereby provide a relatively rigid composition as finally dried and cured. This composition also contains a suitable mineral filler as aggregate, preferably a hard igneous rock, such as andesite, having a grain a particle size of about 16 to about 60 mesh. This wear coat is applied over the entire floor or deck area and may have a thickness of about As" to about Depending upon the desired thickness of the wear coat, it may be applied as a single coat or a plurality of coats, the second being superimposed on the first after the first has dried.

The wear coat is initially plastic and has a consistency permitting relatively easy application as by trowelling.

For many purposes, the construction hereinabove described is satisfactory. However, the top surface may be enhanced in appearance by applying thereto a relatively thin coating of a resin composition. Suitable resins for this purpose are vinyl resins, such as polymers and copolymers of vinyl chloride and vinylidene chloride, epoxy resins, polyurethane resins, acrylic resins and the like. Such resin composition may contain pigments to provide the top coat With a pleasant color. The top coat also provides a smooth finish and acts as a seal.

The resin compositions employed as a top layer may also contain a plasticizer and a. filler, in addition to a coloring agent. The proportions of the ingredients may vary considerably depending upon the density and flexibility required and the ype of resin, plasticizer and filler used. In general the most satisfactory compositions for use as the wear resisting layer of floor coverings contain about 25% to 50% by Weight of resin and from about 6 10% to 30% of a plasticizer, the balance being filler and pigment.

Various advantages of this invention may be seen by reference to the following examples, which are merely illustrative of the invention and are not in any way intended to limit the scope of the invention.

In the examples of the shear stress data for the release layer was determined by means of extension apparatus comprising a surface 40" in length and 16" in width, divided into two halves. By means of a screw mechanism the two halves can be separated, In the examples each test sample comprised a strip 1" wide and 20" long. Each test sample was placed in the extension device perpendicular to the line of separation of the two halves, so that equal portions of the sample were disposed on each half.

Each test sample comprised the following layers:

(1) A release coat approximately & thick for providing relative movement between the surface of the extension apparatus and the superimposed waterproofing, wear and top coats.

(2) A waterproofing coat approximately 0.06" thick comprising a 7 /2 oz. burlap impregnated with a polychloroprene latex containing vulcanizing constituents.

(3) A wear coat approximately 0.125" thick comprising polychloroprene latex, vulcanizing constituents for the latex, cement and fine aggregate having an average particle size of between 30 and 250 mesh, and

(4) A top coat approximately .010 thick comprising plasticized polyvinylchloride.

The release coat, wear coat and top coat were applied by means of a trowel. The waterproof coat was applied to the release coat by trowelling polychloroprene latex over the release coat, applying the burlap thereto, and then trowelling addition polychloroprene latex over the burlap to insure that all of the interstices of the burlap were filled with latex. Approximately 3 hours were permitted to lapse subsequent to application of the release coat and prior to application of the waterproofing coat.

Seven days after application of the above-described coatings to the surface of the extension apparatus, it was opened at a rate of approximately mils per minute. The width of the opening between the two halves was measured when the release coat provided release, i.e. first permitted relative movement between the coats superimposed on the release coat and the supporting release coat applied on the surface of the extension apparatus. Shear strength for the release coat was then determined by means of Formula I, discussed above.

In determining shear strength according to Formula I, the modulus of elasticity (m) may be obtained using a Scott Tension Test machine. In determining modulus of elasticity for use in calculating shear strength for the release layer in the following specific examples, samples of floor covering comprising a Waterproofing layer, a wear layer and a top layer (see layers 14, 16 and 18, respectively of the drawing) eight inches long by two inches wide were placed in the jaws of the Scott tester. The distance between the jaws was 6 inches. The samples were subjected to a load of 70* lbs. and the increase in length under this load was measured using calipers. Modulus of elasticity was then calculated by means of the equation:

where m is themodulus of elasticity, l is the initial distance between clamps before application of load, L is the load applied to the specimen, d is the elongation in inches and A is the cross sectional area of the test specimen.

In the examples the modulus of elasticity obtained was the average of tests on several test specimens. In the examples the modulus of elasticity for each sample was determined to be approximately 8300 p.s.i.

In the below examples, initial and final set data are Gilmore Needle Set Times obtained according to ASTM Designation C 26658T. Indentation characteristics were determined according to the procedure described in MILD3134F Compressive strength data was obtained according to ASTM Designation C 109-58 entitled, Compressive Strength of Hydraulic Cement Mortars.

The method by which indentation characteristic for the several examples was determined is set forth in MILD 3134F dated Ian. 24, 1962. In this standard method for determining indentation an hydraulic press and an indentor are required. Three indentations were made on each sample and the results averaged. The center of each indentation was not less than 1% inches from the edge of the test specimen and not less than 2 /2 inches from the center of the adjoining indentation. A load of 2000 lbs. was applied for 30 minutes by a flat faced circular indentor having an area of one square inch and a perimeter rounded to a radius of inch.

The release coat was applied to a flat steel plate A thick and 6" x 6" in size so as to obtain a smooth flat surface. An Ames type thickness gauge was used to measme the thickness of the steel plate and the combined thickness of the steel plate and applied release coat. After the prescribed indentation for /2 hour, the amount of indentation was determined and percent indentation calculated.

In the below examples, no changes were made in the compositions of the several coats, with the exception of the release coat, which is noted in the examples. The several coats were applied in the same manner to approximately the same thickness in each of the examples.

Example I The release coat had the following composition:

Water-40 g. per 100 g. of solids.

An initial set of the release coat was obtained in 89 minutes and a final set was obtained in 145 minutes. The indentation characteristic of the release layer was 65% after 4 hours and 65% after 7 days. The compressive strength for the release coat (standard 2" x 2" blocks) was 288 p.s.i. after 15 days, and 345 p.s.i. after 30 days.

A release coat of the above composition was tro-welled onto the surface of the extension apparatus described above to a uniform thickness of approximately & The waterproofing, wear and top coats hereintofore described were then applied and the composite was permitted to set for a period of seven days. The extension apparatus was then activated, the rate of separation between the two halves being approximately 100 mils per minute. Release by the release coat was obtained when the two halves had been separated 0.5 in.

Shear strength after 7 days was determined to be 1.30 p.s.i. The coating system was free of cracks.

Example 11 Example I was repeated with a base coat having the following composition:

Water-40 g. per 100 g. of dry solids. The system had the following properties:

Set: Minutes Initial 95 Final 160 8 Indentation characteristics: Percent After 4 hours 18.2 After 6 hours 15.1 After 7 days 15.1 Compressive strength: P.s.i. After 15 days 240 After 30 days 320 Release:

0.625" after 7 days.

Shear strength:

After 7 days, 1.60 p.s.i.

Condition of top coat:

Free from cracks.

Example 111 Example I was repeated with a base coat having the following composition:

Constituent: Weight percent Sodium lauryl sulfate 8 Calcined calcium sulfate 52 Silica flour (125 mesh) 40 Water-40 g. per g. of dry solids.

The system had the following properties:

Shear strength:

After 7 days, 1.52 p.s.i.

Condition of top coat: Free from cracks.

Example IV Example I was repeated with a base coat having the following composition:

Constituent: Weight percent Sodium lauryl sulfate 10 Calcined calcium sulfate 82 Silica flour (125 mesh) 8 Water-40 g. per 100 g. of dry solids.

The system had the following properties:

Set: Minutes Initial 94 Final Indentation characteristics: Percent After 4 hours 26.4 After 6 hours 25.0 After 5 days 25.0

Compressive strength: P.s.i. After 15 days 200 After 30 days 325 Release:

0.594 after 7 days.

Shear strength:

After 7 days, 1.53 p.s.i.

Condition of top coat:

Free from cracks.

9 Example V Example I was repeated with a base coat having the following composition:

Constituent: Weight percent Sodium lauryl sulfate l2 Calcined calcium sulfate 72 Silica flour (125 mesh) 8 Water-40 g. per 100 g. of dry solids. The system had the following properties:

Release:

0.625" after 7 days.

Shear strength:

After 7 days, 1.6 p.s.i.

Condition of top coat: Free from cracks.

Example VI The procedure of Example I is repeated using the composition of that example, with the exception that the sodium lauryl sulfate is replaced by sodium octadecyl sulfonate, and similar release characteristics are observed.

Example VII The procedure of Example I is repeated using the composition of that example, with the exception that the sodium lauryl sulfate is replaced by sodium dodecyl benzene sulfonate, and similar release characteristics are observed.

Example VIII The procedure of Example I is repeated using the composition of that example, with the exception that the sodium lauryl sulfate is replaced by sodium laurate, and simi-. lar release characteristics are observed.

What is claimed is:

1. A traffic-bearing composite floor and deck covering which permits relative movement between the wear surface thereof and the supporting subfioor, whereby said wear surface is not subjected to damaging stresses due to movement of the sub-floor, comprising a relatively thin release layer capable of being ruptured when subjected to stresses created by relative movement between said subfioor and said wear surface to isolate said wear surface from the movement of said sub-floor applied as a plastic mass over a sub-floor so as to be substantially coextensive therewith and which upon setting forms a substantially non-tacky, solid layer having an indentation characteristic of less than about 50% four hours after application and a shear strength of not more than about 2.5 p.s.i., seven days after application, and a relatively thicker wear layer over said release layer which is applied as a plastic mass and upon setting comprises hydrated hydraulic cement, rubber, and solid mineral aggregate filler.

2. A floor and deck covering according to claim 1 in which said release layer comprises as the major constituent upon setting up a hydrated inorganic cementitious material selected from the group consisting of gypsum, lime and hydraulic cement.

3. A floor and deck covering according to claim 2 in wlhich said release coat contains a finely divided inorganic fi ler.

4. A floor and deck covering according to claim 1 in which there is a relatively thin waterproofing layer between said wear layer and said release layer, said waterproofing layer comprising a textile fabric impregnated with rubber.

5. A floor and deck covering according to claim 1 including as the top layer a composition having as its major constituent a vinyl resin.

6. A traffic-bearing composite floor and deck covering which permits relative movement between the wear surface thereof and the supporting sub-floor, whereby said Wear surface is not subjected to damaging stresses due to normal movement of the sub-floor, comprising a relatively thin release layer capable of being ruptured when subjected to stresses created by relative movement between said sub-fioor and said wear surface to isolate said wear surface from the movement of said sub-floor applied as a plastic mass over a sub-floor so as to be substantially coextensive therewith and which upon setting forms a substantially non-tacky, solid layer having an indentation characteristic of less than about 50% four hours after application and a shear strength of not more than about 2.5 p.s.i. seven days after application, said release layer comprising as the major constituent upon setting a hydrated inorganic cementitious material selected from the group consisting of gypsum, lime and hydraulic cement and containing an anionic surface active agent, the weight ratio of inorganic cementitious material prior to hydration to anionic surface active agent being in the range between about 6:1 and about 20:1, and a relatively thicker wear layer over said release layer which is applied as a plastic mass and upon setting comprises hydrated hydraulic ce ment, rubber, and solid mineral aggregate filler.

7. A floor and deck covering according to claim 6 in which said release layer contains finely divided inorganic filler.

8. A floor and deck covering according to claim 6 in which there is a relatively thin waterproofing layer between said Wear layer and said release layer, said waterproofing layer comprising a textile fabric impregnated with rubber.

9. A floor and deck covering according to claim 6 including as the top layer a composition having as its major constituent a vinyl resin.

10. A floor and deck covering according to claim 6, in which said surface active agent is selected from the group consisting of alkyl and alkyl aryl sulfonates of the formula RSO X where R is alkyl containing from 8 to 20 carbon atoms and alkyl aryl containing from 12 to 20 carbon atoms and X is hydrogen, alkali and alkaline earth metal; and salts of fatty acids of the formula R'COOX' where R is alkyl containing from 8 to 18 carbon atoms and X is hydrogen, alkali and alkaline earth metal 11. A floor and deck covering according to claim 10 wherein said anionic surface active agent comprises sodium lauryl sulfate.

References Cited UNITED STATES PATENTS 2,593,492 4/1952 Scripture 106-90 2,672,793 3/1954 Rowe et al. 106-90 2,793,129 5/1957 Klein 106-90 2,877,135 3/1959 Schwarzwalder et a1. 117-70 3,008,843 11/1961 Jolly 106-90 3,190,762 6/1965 Carlson et al 106-90 ALFRED L. LEAVITT, Primary Examiner.

A. H. ROSENSTEIN, Assistant Examiner.

Claims

1. A TRAFFIC-BEARING COMPOSITE FLOOR AND DECK COVERING WHICH PERMITS RELATIVE MOVEMENT BETWEEN THE WEAR SURFACE THEREOF AND THE SUPPORTING SUB-FLOOR, WHEREBY SAID WEAR SURFACE IS NOT SUBJECTED TO DAMAGING STRESSES DUE TO MOVEMENT OF THE SUB-FLOOR, COMPRISING A RELATIVELY THIN RELEASE LAYER CAPABLE OF BEING RUPTURED WHEN SUBJECTED TO STRESSES CREATED BY RELATIVE MOVEMENT BETWEEN SAID SUBFLOOR AND SAID WEAR SURFACE TO ISOLATE SAID WEAR SURFACE FROM THE MOVEMENT OF SAID SUB-FLOOR APPLIED AS A PLASTIC MASS OVER A SUB-FLOOR SO AS TO BE SUBSTANTIALLY COEXTENSIVE THEREWITH AND WHICH UPON SETTING FORMS A SUBSTANTIALLY NON-TACKY, SOLID LAYER HAVING AN INDENTATION CHARACTERISTIC OF LESS THAN ABOUT 50% FOUR HOURS AFTER APPLICATION AND A SHEAR STRENGTH OF NOT MORE THAN ABOUT 2.5 P.S.I., SEVEN DAYS AFTER APPLICATION, AND A RELATIVELY THICKER WEAR LAYER OVER SAID RELEASE LAYER WHICH IS APPLIED AS A PLASTIC MASS AND UPON SETTING COMPRISES HYDRATED HYDRAULIC CEMENT, RUBBER, AND SOLID MINERAL AGGREGATE FILLER.