material for roof deck

[H3Jim]

I suppose this request is primarily addresseed to Sean, since he's the only one I know with a roof deck.

Do you have any recommmendations for material / pattern?  I just got a materials catalog from my friendly neighborhood metal supplier.  It has all kinds of expanded metal, extruded metal, fiberglass, aluminum, steel, vinyl etc.  Having used your deck for sometime now, are you happy with the material and pattern you have, would  you do something different next time?

Do you have any comments on minimum load to provide for?  I was thinking it didn't have to be too much, I only expect a few people plus a table and chairs up there. NO to mention i don't want to put too much strain on the roof itself. 

I was thinking lightweight, non slip but still comforable with bare feet, corrosion reisistent, easy to bolt down, easy to mount hinged railings on it.

I suppose while I'm asking, any comments or suggestions on the railing?  Good for safetly, but if someone tripos and lunges toward it, most of what I'm thinking about putting up would not hold a 200 pounder doing a header.

Of all the ladders I've seen, I like the kind that fold in the middle the best.  I can store in in a bay, or even on top of the roof, and bring it down only when I want to use it.

[chazwood]

If you stored your ladder on the roof ...how would you get up on the roof to get it?

[Nick Badame Refrig/ACC]

Hi Jim,

Here is a couple pics of Jeff Horton's Newell. He has a race deck that is constructed with aluminum.

I'm not sure what the supports are made of but, maybe the pics will give you an idea.

Nick-

[PP]

If you stored your ladder on the roof ...how would you get up on the roof to get it?

You had to ask, but I'm waiting for the answer too LOL

[H3Jim]

Reach up and get it.  Just fasten it right near the opening.

[Sean]

I suppose this request is primarily addresseed to Sean, since he's the only one I know with a roof deck.

Now, see, as soon as you said that other decks came out of the woodwork...

Do you have any recommmendations for material / pattern? ...  Having used your deck for sometime now, are you happy with the material and pattern you have, would  you do something different next time?

We're quite happy with what we have.  But I'm sorry, I don't remember what it is.  I basically gave Infinity a footprint for the deck, and they came up with the design, including materials.  The deck is supported by four "feet" that have aluminum footpads to spread the load.  Those feet are positioned above the two heavy box beams that run the length of my roof.  The pads are bolted down (into riv-nuts), so the whole deck can be removed if necessary for maintenance or whatever (never, so far).

Welded to the footpads are aluminum risers made of square tube perhaps 6" long or so, which let the whole deck clear the curve of the roof.  Then there is a welded framework of aluminum square tubing, and above that the actual deck material.  This is an aluminum extrusion, with multiple "I-beam" cross-section topped by perforated deck with non-skid knurling.  It is made for the purpose.  If you called Infinity and asked Jim or Danny they might be able to give you a manufacturer and product name.  It's worked so well, I would not go looking for anything different.

In addition to being lightweight and sturdy, the perforations allow water to pass through, and the knurling makes for a non-slip surface.  As a bonus, we can get the hooks of rubber truck-style bungees into the perforations to hold the el-cheapo lawn chairs we keep up there tight to the deck when traveling.

Do you have any comments on minimum load to provide for?  I was thinking it didn't have to be too much, I only expect a few people plus a table and chairs up there. NO to mention i don't want to put too much strain on the roof itself.

Our deck is roughly 7' x 7'.  That's room for about four people, which I figure to be 250 lbs per each (a conservative number which allows for beefy guys, or jumping around, or more than four, etc.) for a total of say 1,000 lbs.  I would guess our deck could probably hold nearly twice that, though.  1,000 lbs over 50 square feet is 20 psf -- I would say that's a good overall figure.

I was thinking lightweight, non slip but still comforable with bare feet, corrosion reisistent, easy to bolt down, easy to mount hinged railings on it.

The stuff we used is all of the above, with the possible exception of the bare foot part.  I do go up in my bare feet, but I feel the knurls and the perfs.  The bare aluminum does stay quite cool though.

I suppose while I'm asking, any comments or suggestions on the railing?  Good for safetly, but if someone tripos and lunges toward it, most of what I'm thinking about putting up would not hold a 200 pounder doing a header.

We used Speed-Rail, I'm going to say 1" diameter.  Easy to work, goes together in a snap.

Using some aluminum round tubing just a hair larger than the Speed-Rail, Infinity made sleeves that the rails drop into, which are fastened to the deck frame.  The holders are chamfered, notched, beveled, and slotted so the rail uprights remain attached permanently and fold up. then drop in.  I would say the rail system would easily hold my theoretical 250-lb guy who's had one beer too many.

Perhaps we need to post a video on the blog of how the deck sets up.  In the meantime, the "overview" video clip in this post:
http://ourodyssey.blogspot.com/2008/03/video-tour-of-odyssey.html
has a short segment showing the deck.

I know I have some photos of the deck framing and the deck itself, which I can upload if need be.

Of all the ladders I've seen, I like the kind that fold in the middle the best.  I can store in in a bay, or even on top of the roof, and bring it down only when I want to use it.

We use this one:
http://www.campingworld.com/browse/skus/index.cfm/Outdoor-and-RV-Accessories/6-Compact-Folding-Step-Ladder/skunum=20318
(note that the photo shows a pair of back legs, but this model actually is a straight ladder with only one side).

It was too long to store under our couch where we wanted it, so we cut one rung's worth off the top end.

-Sean
http://ourodyssey.blogspot.com

[busguy01]

Eagle 01 here with a 6' x 24' roof deck. I built it 7 years ago, mostly for races. has worked very well. I did not want to ad much weight to the bus up high. Frame work is alum. Z sections formed to run the lenght with welded cross menbers on 18" centers. Z section rivited, full lenght, to the bus roof cross menbers to take all of the load. Used hallow plastic deck 2 x 6's  run for to aft - bolted to cross members. They are a little further apart than called for by manufacter but work good for this use. Welded for and aft trim to both z channels. Also  installed fishing chair bases that are inset into deck. Have had 12 people on the deck for races many times. For a rail - I welded formed poctes to the outside of the z channels and used 1" x 1" square alum tubs for pickets -- then had a two pices fabric side made that slips over the pickets. Very strong and blocks wind also. Don't forget the ad 120V and 12 V DC outlets to roof! I also inatalled a cable hookup so we can put a TV on the roof for the rave broadcast. Don't like ladders!!! I put a large marine style hatch over the bed - very water proof with 4 dogs. Has srceen so it also lets in air when you want ventalation. Mine is about 24" sq. and tinted. The whole thing, less body weights in at about 400 lbs.

Just my way - your mileage amay vary!
JimH

[H3Jim]

Wow, thanks for the great answers.  Yes, Sean, the others did come out, there had to be others.  Thats another testament as to why this board works so well.  Thanks again for those details.  You've sure been busy on the boards lately, answering all kinds of stuff for us. Thats a great idea about bungees for lawn chairs etc.  Do you ever wish the deck was larger?

Eagle01, I had not thought of electrical outlets up there, but you're right, as soon as I'd spend any time up there, I'd be wanting power.

[TomC]

Folding ladders are nice except when the ladder is rated at 225lbs and you weigh over 300lbs. 

If you don't like the diamond aluminum plate, you could use the same wood as flat bedders use which is called Apitong-a type of industrial Mahogany.  There are also man made products that are fashioned as planks of wood.  Good Luck, TomC

[Sean]

Found it!

Here's the stuff we used for the decking itself:
http://www.slipnot.com/index.php?main_page=index&cPath=1_6_125

I see from this page that it comes in many widths, ours is made from 6" sections ("planks") and it is 1" thick.  I seem to remember they got it in 10' or so lengths.

Do you ever wish the deck was larger?

Not really.  You know, it's usually just the two of us, and that's plenty of space for anything we want to do up there.  The couple of times we've had guests, it's been no problem to fit a couple more.  The size, of course, was dictated by the amount of real estate we had left on the roof. We've got roof airs, plus the DataStorm dish.  It did not make sense to extend it around the sides of an A/C.  Frankly, if I had more available clear space up there, I'd put more solar on it, not more deck.

-Sean
http://ourodyssey.blogspot.com

[Sean]

Here's the stuff we used for the decking itself:
http://www.slipnot.com/index.php?main_page=index&cPath=1_6_125

Oops,  wrong link.

That's the same stuff, but coated with non-skid texture material.  Our stuff is bare.  Here's the right link (complete with cross-section and load tables):
http://www.gratingpacific.com/aluminumgrating1.htm

BTW, the Google search is "punched plank" and will turn up several suppliers.

-Sean
http://ourodyssey.blogspot.com

[Sean]

OK, largely as a result of this discussion, Louise made a video clip of the deck and its railing system.  It's in this post:

http://ourodyssey.blogspot.com/2008/03/small-space-saturday-roof-deck.html

-Sean
http://ourodyssey.blogspot.com

[H3Jim]

Cool video, thanks a lot for doing that.  It helps me plan it out.

Oh well I'm getting distracted, I need to do some better interior  lights first.  But then the hard part and the fun part is designing what to do.  after the decisoins are made as to what, the doing is fast and anticlimatic.  So if I figure out the deck, I may have it done before I know it.

Anyway, thanks for sharing.

[JohnEd]

Jim,

Didn't somebody post recently that after they spray foamed the interior ceiling that the roof was solid enuf and didn't require a deck.  If that is true I would think white non skid would do the trick for safty and then a railing of sorts.  KISS! High heals would be a no no.  Treat it like a sailboat..."white sole soft rubber or barefoot....pic one of those" reads the sign at the gang plank.  Or ladder in you case.

John

John

[Sojourner]

About walking on bus's roof with cured hot sprayed foam underneath it.
Yes it true you can walk on it but not for everyday and any time. It only to show how much stiffer than without hot sprayed foam for sound deaden the interior as well insulation. If you stomp on it in between rib is will crack the foam and then it will be flexing like it before hot spray foam.
So you still need strong deck separate from roof's surface for extra strong trouble free everyday walking surface.

I might add is to include a vertically metal lip of 2" to avoid stair's leg from slipping off of outer edge.....yike, yike!

FWIW

Sojourn for Christ, Jerry