Patent Publication Number: US-8984832-B2

Title: Flooring, deck and patio surface system and method of use

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application incorporates by reference and is a continuation-in-part of U.S. patent application Ser. No. 12/416,002 filed Mar. 31, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 11/669,586 filed Mar. 31, 2007, which claims priority of U.S. provisional patent application 60/764,190 filed Mar. 31, 2006. 
    
    
     BACKGROUND OF THE INVENTION 
     This invention relates to outdoor flooring, surfaces for decks, rooftop terraces, patios and the like, and more particularly, to a decking system and method for enabling use of surface materials that would ordinarily lack suitable structural features to accommodate deck, rooftop terraces or patio applications. 
     Stone or stone-like walkways, terraces, patios and steps are frequently used at homes and businesses, as the appearance is attractive and enjoyed by many. Generally, these stones must be laid onto a level, on-grade, firm soil. Walkway and step stones are typically rather thick, to provide sufficient internal structural properties to support weight necessary in walkway and step use. In addition, thin-gauged stones used in this same manner, with no internal structural properties, require a thick concrete pad for support. 
     Many residential second floor decks are sloped for drainage or are above waterproofed lower decks or living spaces and as such cannot employ mechanical penetrations that would breech the integrity of the decks protective waterproofing. Common commercial roofs or decks have multiple slopes and numerous protrusions such as drains or vents and must have an elevated substrate system above the waterproofing to attach and or support the stones in order to present an aesthetically attractive and structurally stable planar array of stone. Common joist framed decks that would be finished with the same stone or stone-like material would require a solid, water resistant structural support spanning between multiple joist framing. 
     Henceforth, an outdoor flooring, deck, rooftop terrace and patio surface system would fulfill a long felt need in the construction industry. This new invention utilizes and combines known and new technologies in a unique and novel configuration to overcome the aforementioned problems and accomplish this. 
     SUMMARY OF THE INVENTION 
     In accordance with the invention, a deck, rooftop terrace and patio surface system comprises a fiber reinforced structural panel employed as a substrate underlayment, a mounting fastener for enabling the panel to be mechanically secured to a deck joist framing, patio, or the like, a panel elevation, interconnecting and spacing system and a surfacing material bonded agent for attachment to the structural panel. 
     Accordingly, it is an object of the present invention to provide an improved deck system to enable use of stone or stone-like surface, of varying non-uniform shapes and sizes, of varying thicknesses, in above-ground framed deck and rooftop terrace applications. 
     It is a further object of the present invention to provide an improved system for the use of stone in deck, rooftop or patio applications where the deck, rooftop or patio alone would not allow for the aesthetic use of stones. 
     It is yet another object of the present invention to provide an improved method for providing a truly planar deck surface utilizing connectors that reside below the plane of affixation for the surface adornment stone. 
     Another objective of the present invention is to provide a deck, rooftop terrace or patio system adapted to support a thin-gauged stone or stone-like surface by field-bonding two dissimilar materials with a flexible bonding agent causing the materials to inherit the strengths of each and forming a new solid and stable structural flooring. The deck, rooftop terrace or patio or patio system shall allow water to pass directly past the stones and the panels as there will be no grouted spaces between the stone surfaces and the structural panels beneath them. 
     Another object of the present invention is to provide a deck or patio system adapted for use over waterproofed living space without requiring penetration of the waterproof membrane. The deck or patio system shall allow water to pass directly past the stones and the panels. 
     Another object of the present invention is to provide a system of deck or patio panels adapted for easy subdivision into panels sized adapted for use with conventionally sized commercially available stones or to adapt to standard building dimensions. 
     It is still another object of the present invention to provide a system and method for providing a new floating or raised surface over an existing damaged patio surface or waterproofed rooftop terrace. The floating system is to be constructed with commercially available piping and connector disks that serve as the devices to establish and maintain the spacing of panels in the raised surface and the devices to distribute the weight of the decking system in situations where there are no points of attachment between the panels and the underlying rooftop, patio or deck and to interconnect all adjoining panels so as to allow panels to be individually removed at anytime during the life of the finished surface. 
     The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements. 
     It has many of the advantages mentioned heretofore and many novel features that result in a new outdoor flooring, deck, rooftop terrace and patio surface system which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art, either alone or in any combination thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view of a portion of the system according to the invention; 
         FIG. 2  is a top view of the connector of  FIG. 1 ; 
         FIG. 3  is a sectional view of the connector of  FIG. 1  taken along line A-A of  FIG. 2 ; 
         FIGS. 4-15  are illustrations of the steps of the method of installing a deck system in accordance with the invention; 
         FIG. 16  is a view of an alternate structural panel; 
         FIG. 17  is a close up view of an alternate structural panel; 
         FIG. 18  is a perspective view of a connector for connecting adjacent panels and/or mounting panels to an adjustable pedestal support for elevating the panel; 
         FIG. 19  is a top view of an installation of plural panels using plural connectors; 
         FIG. 20  is a side view of an installation where connectors are floating; 
         FIG. 21  is a perspective view of a panel for use in pedestal mounting configurations; 
         FIG. 22  is a view of underneath the corner of a panel; 
         FIG. 23  is a top view of an installation of plural panels using plural connectors; 
         FIG. 24  is a perspective view of two adjacent panels positioned on a connector disk; 
         FIG. 25  is a top perspective view of a spacer/aligner; 
         FIG. 26  is a top perspective view illustrating use of the connector disk and pipes to provide an elevated mounting for panels; 
         FIG. 27  provides an up close perspective view of a pipe mounted in a connector; 
         FIGS. 28 and 29  are side sectional views showing the mounting of connectors with pipes and panels, with stone/tile in  FIG. 28  and pavers in  FIG. 29 ; and 
         FIG. 30  is a top perspective view of a panel mounted on a connector disk, with a support pipe and bottom connector disk, providing a raised deck portion for mounting of pavers, stones or tiles for example. 
     
    
    
     DETAILED DESCRIPTION 
     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 
     Basically, the present invention supports an open celled structural panel that allows the placement of a variety of finished surfaces in any form and configuration and across adjoining interconnected structural panels, or within the panel dimension so that each finished structural panel is removable independently of others with the finished stone tile attached, the same being placed as glued surfaces or dry-laid floating surface materials and all with an open cell structure to allow moisture to drain through the structural panel. The structural panel may be installed directly atop the area to be floored or may be installed in a raised position above the area to compensate for any non horizontal or non planar anomalies in the area, such as may be found on the deck or rooftop of a commercial building. Further, the structural panels (raised or not) may be mechanically affixed to the area or may be installed as a floating sub floor, wherein the mass and friction of the entire sub floor assembly with the flooring installed maintains its horizontal position. The floating sub floor option is used where it is not desirable to have any penetrations into the underlying area to be floored, such as is the case when it forms the ceiling of another living space. This open celled structural floor panel can be mechanically secured to the underlying surface or framing members through the use of a connector that forms a biting, wedged friction against the angled walls of the open cells of the structural panel so as to provide a horizontal plate with a central orifice to receive a screw that passes through the connector and into the underlying surface. The connector with installed screw will rest in its final position no higher than flush with the top of the structural panel such that no machining is required to place a finished stone, tile, concrete surface directly over the structural panel. Prior art panels utilize connectors that span more than one of their open cells leaving a protuberance above the plane of the panel proper. The open cells of the structural floor panel taper inward from their top to bottom at approximately 2 degrees, with a minus 1 degree and plus 10 degree tolerance. The array of open cells in the structural panel is spaced and divided into standard 16″ and 24″ O.C. dimensions accommodating the cut down of a 48″×48″ panel to 16″×48″ or 24″×48″ panels with a full perimeter bar structure so as to meet USA dimensional building standards and accommodate commercially available flooring products. 
     The bonding of the finished stone, tile, concrete floor tile or the like to the open celled structural plastic panel is accomplished using a flexible adhesive without any cement based bonding or bedding materials. 
     To accommodate the raised positioning of the structural panel a standard ABS pipe with a support plate affixed on either end is used as a stanchion to raise the panels and to act as a support base to transmit the load on the panel array to the underlying surface. Recommended stanchion spacing will prevent sagging anywhere in the panel system. The top face of the support plate has a removable centering spacer that when used in conjunction with the structural panels will interlock and properly space all adjoining panels. It is to be noted that whether the sub flooring system is raised or not it will create an open drainage space under the structural panel. 
     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting. 
     Referring to  FIG. 1 , an exploded perspective view of a portion of the system  10 , a structural panel  12 , suitably comprising a fiber reinforced polymer panel having a grid pattern of openings (open cells)  14  in the illustrated embodiment, is adapted to be received on top of a deck base structure, which may suitably comprise wood deck framing timbers or other framing material such as metal  16 . A connector  18 , described  5  in further detail in connection with  FIGS. 2-5  herein, is adapted to be received in an open cell  14  so as to engage with the structural panel  12 , seating such that the side walls  29  of connector reside within an open cell, below the top surface of the panel  12 . The connector includes a central orifice  30  adapted to receive a mechanical fastener therethrough, preferably a screw  10  to secure the panel to the underlying deck base structure  16 . 
     A surfacing material  22 , which may comprise a cut stone having an aesthetically pleasing appearance, color and/or pattern, is suitably bonded to the structural panel, using a bonding material  24 , for example. The surfacing material may also comprise manufactured stone-like material, tile, dry laid brick, concrete or stone pavers, for example. 
     The structural panel is suitably provided in sheets having dimensions of 4 feet by 4 feet, with a 1.5 inch square open cell size, approximately 1 inch thick. The individual grid openings narrow from the top of the panel to the bottom, such that they are wider at the top face than at the bottom. In the particular embodiment, the open cell is 1 5/16th inch at the top measured from interior edge to the opposite edge of an individual open cell, but is 1¼th inch at the bottom face of the panel. This corresponds to an approximate two degree downward taper of the inside open cell walls  3 , although experimentally it has been shown that tapers from one degree to twelve degrees also work satisfactorily. 
     A suitable panel that is employed with the system and method may be a fiber reinforced general purpose polyester molded resin panel, although other materials may be used. The panel size is preferably 4 foot by 4 foot in the preferred embodiment, based on construction standards and practices, but may be otherwise re-sized to the desired dimensions, within a 1/16th inch tolerance, so as to provide a system that functions with 16 inch and 24 inch framing dimensions typically used in deck applications. Note, however the 48″×48″ square dimension meets the standard USA building dimension layout. The panel can be provided in other sizes than the illustrated example, chosen to have sufficient support while spanning the supporting elements supporting the panel. Preferably the panel is a pre-configured dimensional size suitable for compliance with customary building practices. 
     Referring now to  FIGS. 2-3 , which are views illustrating the connector  18  and explaining how it is manufactured, the connector in a preferred embodiment is made of a stainless steel material, stamped into the shape shown in  FIG. 2 . The connector is provided with a row series of twelve teeth  26  (serrated edge) on the edge of each its sides  29 . The four peripheral corners  27  of the connector are chamfered or radiused such that the adjacent sides  29  do not meet (share a common edge.) Teeth  26  are suitably 3/64th inch in height. A central orifice  30  is provided in the connector, with a depressed annular region  31  about the orifice  30  so as to provide a 17/32 inch inner diameter flat bottom countersink, for receiving a fastener head as discussed below. 
     After the fastener is formed, its sides  29  are then bent approximately 88 degrees to matingly conform to match the approximate 2 degree inside taper of the open cells (with a tolerance of plus or minus 5 degrees) with the edge of serrated teeth  26  then again bent at approximately 90 degrees, so as to extend normally from the side walls and provide the configuration visible in  FIG. 3 . There is a taper between opposing side walls of the connector that matingly conforms to the taper of opposing side walls of the open cells. With the teeth bent to extend normally from the side walls so as to form a peripheral toothed flange, a flexing frictional wedge is formed, that increases in frictional resistance as the connector is forced further down in the open cell, as would be the case when the mechanical connector placed therethrough is tightened. The connector is installed with its side walls facing upward so that they can flex slightly to accommodate variances in the in the physical dimensions of the open cell that they are placed in. This allows for two things to happen: first the connecter can always be fit down into a cell such that the top surface of all of its four sides can reside below the top planar surface of the structural panel, and the connector can always be tightly wedged in any cell, albeit at a different elevation than neighboring connectors. In this design if the contractor chooses to tighten down one specific region of a panel or series of panels, for an aesthetic or structural reason, this can be done. Such may be necessary when installing structural panels on rooftop applications over uneven rolled roofing. In employing the system to provide a deck or patio surface, the installation steps illustrated in  FIG. 4-15  are employed. The example shown in  FIGS. 4-15  is in a deck installation, where a wood frame deck is present and the system is installed thereon. 
     Generally, first an optional waterproof membrane such as a 40 mil bituminous based material, is placed over the deck to protect the framing from water damage over time. Next, in  FIG. 4 , plural structural panels are cut and positioned as necessary to fit over the area of the deck framing that the system is to be installed upon. Next, ( FIG. 5 ) connectors  18  are placed into openings  14  in the structural panel in locations where the panel is to be secured to the deck. The connectors are tapped with a hammer so as to have the top of the connectors be flush with the top surface of the structural panel. The open corner design of the connectors allow the sides  29  to flex to accommodate the frictional engagement especially when the connector is placed in the open cell slightly askew or when the cell walls have slight differences in their respective tapers. 
     Stainless steel screws are then screwed through the openings  30  in each fastener, to secure the structural panels to the deck frame  16 , as shown in  FIGS. 6 and 7 ,  FIG. 7  being a split view showing both a close up view of a single secured fastener/screw and a farther away view illustrating a wider area, with 5 connectors visible. 
     An edge trim  40  may now be applied to the peripheral edges of the assembled structural panel group, by cutting the trim to length and applying adhesive thereto (to the inside corners of the edge trim) and then mounting the edge trim to the edges of the panels ( FIGS. 8-10 ). The edge trim can be, for example, metal edge trim and may be provided in a variety of colors and finishes, as desired for the aesthetic taste of the user. 
     The surface material  22  is now prepared and applied to the structural panel, illustrated in  FIGS. 11-14 . In the illustrated embodiment, surfacing material  22  comprises quarried stone tiles having dimensions of 15¾ inch by 15¾ inch, and approximately 11/32nd inch thickness. The surface material tiles are first dry set and cut to fit around any obstacles  42  (a vertical post in  FIG. 13 ). Next, an adhesive is applied to the back of the stones and spread with a notched trowel in the particular embodiment shown. The adhesive suitably comprises an elastomeric polymer. The surface material is now placed adhesive side down onto the structural panel surface, positioned suitably with ⅛th inch spacing between the tiles. The joints between tiles are not grouted, but are left open, allowing drainage and room for expansion and providing an appearance that is visually appealing.  FIG. 15  illustrates a finished deck surface employing stone tiles as the surfacing material, with edge trim on the peripheral edges of the structural panel. 
     In an alternative embodiment, the bonding material  24  is provided in the form of a sheet membrane, not illustrated as it resides beneath the surfacing material shown in  FIG. 15 ) such as an EPDM rubber or similar material, which is flexible and soft. The sheet is suitably 1/16th inch thick, of dimensions corresponding to those of the surfacing material  22 , and is coated on both sides with a pressure sensitive contact adhesive. The sheet membrane is placed onto the surfacing material  22  and then the surfacing material is placed onto the structural panel  12 . This alternative manner of adhering the material to the panel results in a flexible bond. 
     NOTE: This method of bonding stone/tile in exterior applications is very unique and could have some significant long-term value!! 
       FIG. 16  is a diagram of an alternative structural panel  12 ′, while  FIG. 17  is a close-up perspective view of a portion of a panel  12 ′. Panel  12 ′ includes plural openings  14 ′, which are substantially square in the illustrated configuration, provided in a grid-like pattern. The panel  12 ′ is suitably 4 feet long in dimension of arrow  44  by 4 feet long in the dimension defined by arrow  46  illustrated embodiment. Approximately centrally of the panel spanning from edge to edge is a cut line  50 , defined by a double sidewall  58 ,  58 ′ between openings  14 ′ adjacent one another along the cut lines, with a central opening  60  defined therein. A solid portion  56  is provided across the cut line at regularly spaced intervals, the interval being the size of the spacing of the openings in the illustrated embodiment, The cut line  50  provides an easy to cut dividing line along the panel providing sub-dividable portions to easily cut the panel (or a portion thereof) into 2 parts or to cut out a standard size portion. Along the other direction of the panel, a pair of cut lines  52  and  54  are defined, suitably evenly spaced, to provide an easy to cut line defining 3 sub-dividable portions of the panel in that direction for sub-dividing the panel in to 3 sub-portions. In the illustrated embodiment, the cut lines enable easy cut lines with 24 inch and 16 inch spacing, which are typical joist spacing employed in deck construction, for example. Other dimension may be employed as desired to provide easy to cut lines along typically desired spacing. Note that cutting down between the double bars with a saw blade allows the panels to be cut down to 16″ and 24″ standard USA building dimensions a full perimeter bar. 
     In situations where the underlying surface is sloped, uneven, has protuberances or penetrations it is desirable to cheaply and securely raise the sub flooring system to a height that allows it to be horizontally planar or float just above a waterproofing deck surface.  FIGS. 18-30  illustrate embodiments utilizing pipe stanchions and support plates for use to provide a terrace surface, optionally in a pedestal configuration. 
       FIG. 18  is a perspective view of a stanchion support plate for connecting adjacent panels and/or for mounting panels to a stanchion under support. The stanchion support plate  62  is a disk-shaped member having 4 central raised members  64  suitably of substantially square profile when viewed from above. Centrally of the members  64  is a recessed portion  66 . Radially positioned about the edge of the stanchion support plate  62  are 8 raised members  68 . Member  64  and  68  are of size and shape so as to be receivable in openings  14  or  14 ′ of panels  12 ,  12 ′, and as discussed below, to engage with alternate panel  70 . In a particular embodiment, stanchion support plate  62  has a diameter of 6 inches. 
       FIG. 19  is a top view of an installation of plural panels  12 ′ using plural stanchion support plates  62 . In the illustration of  FIG. 19 , at the leftmost edge of the installation of panels  12 ′, the stanchion support plates  62  are moved inwardly slightly from the edge of the panel, illustrating the case where there is some obstruction, for example, that would prevent the stanchion support plate from extending beyond the left most edge of a panel, as contrasted with the rightmost portion of the drawing, where the stanchion support plates are able to extend beyond the edge of the panels, and are accordingly positioned. 
     There are 6 panels  12 ′ shown in  FIG. 19 , with a portion of one panel having illustrative pavers or bricks  64  placed thereon and dry-laid over optional construction fabric (nonwoven)  65  (perimeter pavers being secured with adhesive), and a portion of another panel  12 ′ having tiles or stones  67  placed thereon, either secured to the panels with adhesive applied to the tiles or stones or via sheet adhesive. A metal trim  69  may be applied to peripheral edges of the panels, a portion being illustrated in  FIG. 19 . The connectors may be floating or secured to the underlying layer. 
       FIG. 20  is a side view of an installation where stanchion support plates  62  are floating (i.e. not secured to any base or substrate) on a concrete base, for example. 
       FIG. 21  is a perspective view of a panel  70  for use in pedestal mounting configurations. The panel  70  is suitably 31⅝ inch by 31⅝ inch dimensions in a particular embodiment and 1.25 inch thickness. Panel  70  includes central portions  72 ,  74  that define thicker edges of the openings along portions  72 ,  74 , subdividing the panel into 4 equal size quadrants. The edges  76  of the panel are wider (as contrasted with panels  12 ,  12 ′ which have edges with substantially the same width as the portion between any 2 adjacent openings). 
       FIG. 22  is a view of underneath a corner of panel  70 , wherein a recessed region  80  is defined, of depth and shape profile so as to correspond to the height and shape of raised members  64  of stanchion support plate  62 . 
       FIG. 23  is a top view of an installation of plural panels  70  using plural stanchion support plates  62 . In the illustration of  FIG. 23 , at the leftmost edge of the installation of panels  12 ′, the stanchion support plates  62  are moved inwardly slightly from the edge of the panel, illustrating the case where there is some obstruction, for example, that would prevent the stanchion support plate from extending beyond the left most edge of a panel, as contrasted with the rightmost portion of the drawing, where the stanchion support plates are able to extend beyond the edge of the panels, and are accordingly positioned. The stanchion support plates  62  are suitably positioned to be 31¾ inches on center, placed so as to be positioned at intersection points of any adjacent panels and at the corners of any 4 adjacent panels. 
     Referring to  FIGS. 24 and 30 , a perspective view of two adjacent panels  70  positioned on a stanchion support plate  62 , a spacer/aligner member  82  is received in recessed portion  66  of the disk  62  and acts to space adjacent panels  70  with approximately ⅛ inch between. Portions  64  are received in recessed region  80  to secure the panels to the stanchion support plate. 
       FIG. 25  is a top perspective view of spacer/aligner  82 , wherein a lower portion  84  is of a shape and profile to be received within portion  66  of a stanchion support plate  62 , and upper arm portions  86  define the alignment and spacing of corners of adjacent panels  70 . 
     Referring again to  FIG. 23 , field pavers  88  may be dry-laid on the panels  70  over optional nonwoven construction fabric. Edge pavers  90  in this configuration would be glued to the panels  70  with adhesive. Stones or tiles  92  can be adhered to the panels  70  with adhesive applied to the panels individually or with sheet adhesive. The stone/tile  92  can be fit to the individual panels  70  edges so that the panes can be removed at a later time if desired,  FIG. 23  showing one panel  70 ′ being so fit with stone/tile. 
       FIG. 26  is a top perspective view illustrating use of the stanchion support plate  62  in connection with stanchions  94  (which are preferably four inch nominal schedule  40  ABS pipe sections) to provide an elevated mounting for panels  70 . The spacing and configuration of raised members  68  on stanchion support plate  62  are such that lower end of stanchion  94  is received on the support plate  62 , inwardly of the raised member  68 , for mounting of the support plate  62  to the pipe. The lower stanchion support plate provides a bottom mounting of the stanchion  94 . On the top of stanchion  94 , a second stanchion support plate  62  is mounted, to form a pedestal, whereby the top of the second stanchion support plate  62  is thereby positioned to receive panels  70 . Plural stanchions  94  and connectors are positioned to define a mounting field for plural panels  70 , providing a raised deck portion for mounting of pavers, stones, or tiles, for example, as shown in  FIG. 30 . 
       FIG. 27  provides an up close perspective view of stanchion  94  mounted in a stanchion support plate  62 . The support plates  62  are suitably secured to the stanchions by adhesive. 
       FIGS. 28 and 29  are side sectional views showing the mounting of stanchion support plates with stanchions and panels  70 , with stone/tile in  FIG. 28 , and pavers in  FIG. 29 . 
     Accordingly, with the herein described systems, gauged stone or tile may be employed in any outdoor living space (or indoor) in any climate and without the requirement of the use of traditional cement based mortars grouts or adhesives. Also, on grade pavers can be provided to surface the underlayment system with brick/concrete/stone pavers without the need for traditional sand beds. 
     The components of the systems described herein provide a strong yet light-weight underlayment assembly for a durable and secure exterior flooring surface for elevated decks and rooftop terraces, supplying strength, durability and creative flexibility. 
     In a particular embodiment, the outdoor floor system described herein weighs only 8-10 lbs. per square foot combined weight of the outdoor floor system underlayment and an average weight of a ¼″-½″ gauged stone or tile, which falls within the “10-15 lbs./sq′ of dead load” calculations for residential deck construction. Under these conditions the system can be placed over conventionally framed deck structures with joist spacing 16″-24″ O.C. A roof top terrace will also only need to be designed for standard load conditions. Paver deck applications will be 10-20 lbs./sq′ dead load and will require additional structural reinforcement and consultation with a licensed structural engineer. 
     The system can cover an existing cracked patio if the sub-grade is stable. The finished patio can be installed as a level surface with positive drainage, and no cracks will migrate through the new finished stone surface. It can also be placed over any solid bearing surface. Each panel is supported by the interlocking connectors  62 . 
     The high strength panel members have dimensional stability and minimal deflection under load conditions and require no additional surfacing material to achieve strength. This solid underlayment adds reinforcing strength to a stone/tile surface and bearing strength to a dry-laid paver surface. 
     The system further provides lateral strength or side-to-side stability, achieved in part by using adhesive to bond panel edges edge-to-edge. 
     In accordance with the above, a structural underlayment system used for outdoor floors is provided that can be placed over wood or metal joist framing or on a pedestal system. It supports natural gauged stone or tile, brick, concrete or stone pavers and can be used in place of other materials used for elevated decks or rooftop terraces. 
     Accordingly, as system and method are provided whereby a deck surface of quarried stone is feasible. The use of the fiber reinforced polymer structural panels, the connectors and the adhering of the stone tiles results in a lightweight high strength system weighing only 8 to 10 pounds per square foot in the preferred embodiment. The bonding of the surface material to the structural panel provides further strength to the overall system. As noted above, other surface materials may be employed, including but not limited to tile, brick, concrete and stone pavers. 
     Under an ASTM #E72-98 test, an exemplary system withstood 6282 lbs. of force with no failure, a maximum 1.47″ deflection and a maximum 0.35″ set deflection. 
     The preferred material for the surfacing material  22  is natural quarried stone, which includes slates, quartz and sandstone. All stones are suitably from deep cuts producing the highest quality and highest density stone for exterior applications. 
     In preferred embodiments, all stones have an ASTM #C121 Water Absorption of 0.10%-0.37%. and an ASTM #C1026 Freeze Thaw unaffected rating or a natural resistance to damage under these conditions. Generally all stones have an ASTM #1028 Coefficient of Friction equal to or greater than most wood or composite products, so as to not be overly slippery as a walking surface. In most cases sealing of the surface is not required due to the high density of this material. However, sealing can enhance the natural beauty if applied, but it is not required for long-term durability. 
     Although the illustrated embodiment details an outdoor flooring system for use over a wood frame deck surface other uses are also possible. For example, the system and method can be employed as ground level patios, either as new construction or to cover a cracked or otherwise undesirable patio, providing positive drainage. Application to steps is also another use. Further, the system and method can be employed over waterproofed living spaces, for example, by placing the structural panels over the top of the waterproof deck on sleepers (horizontal structural member on or near the ground that support weight) as a level, floating deck, without the use of the connectors so as to provide a floating sub floor that does not penetrate the underlying surface&#39;s waterproof membrane. 
     The above description will enable any person skilled in the art to make and use this invention. It also sets forth the best modes for carrying out this invention. There are numerous variations and modifications thereof that will also remain readily apparent to others skilled in the art, now that the general principles of the present invention have been disclosed. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.