Cowboy-hat shaped washer for a metal roof deck and method for fastening a roof deck

Abstract

Disclosed herein is a washer having a substantially planar annular area defining an opening for through passage of a fastener and a non-planar area radially outwardly disposed of the planar annular area. A method for fastening a roof deck comprising inserting a fastener through a washer having a substantially planar annular area and a non-planar area radially outwardly disposed of the planar annular area and driving the fastener through the roof deck or through an opening therein. A corrugated metal roof deck system comprising a subjacent support and a corrugated metal roof supported by the support. A waster having a substantially planar annular area defining an opening for through passage of a fastener and a second non-planar area radially outwardly disposed of said planar annular area with a fastener extending through said washer through said deck and into said subjacent support.

Description

BACKGROUND

Metal roof decking, usually but not exclusively corrugated, is employed in many commercial buildings and storage buildings as well as some residential buildings. Most metal decks are paddle welded to the underlying structure. Welding is inconsistent and weak. It is also subject to rust and corrosion because it bums the protective coating off both sides of the steel decking at its interface. Recently some metal roof decking material is affixed by fasteners such as screws. To spread to a larger surface area any load placed on the roof deck by the screw head during wind uplift or similar events, a flat washer has commonly been placed under the screw head. While this does indeed spread some of the load of the screw, it also causes a point stress especially in corrugated decking material. This point stress is created where the flat washer intersects the curved corrugation.

Roof failures have occurred due to penetration of the roof deck at these point stress points during wind uplift and consequent tearing of the roof decking from the penetration point around the fasteners. This of course leads to an easy undesired removal of the roof assembly after sufficient fastening points have been compromised causing extreme deck deflection in high winds.

SUMMARY

Disclosed herein is a unique and novel washer having parallel edges bent up like the edges of a cowboy hat brim. A washer having a substantially flat annular area defining an opening for through passage of a fastener and a bent radially outwardly disposed of the planar annular area.

A method for fastening a roof deck comprising inserting a fastener through a washer having a substantially flat area and a bent area radially outwardly disposed of the flat area such that the washer resembles a cowboy hat and driving the fastener through the cowboy hat washer, through an opening therein the roof deck and into the underlying structural support beam.

A corrugated metal roof deck system comprising a subjacent support and a corrugated metal roof supported by the support. A washer having a substantially flat area defining an opening for through passage of a fastener and a bent area radially outwardly disposed of said flat area with a fastener extending through the washer, through the deck and into the subjacent support.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alike in the several Figures:

FIG. 1 is a perspective view of a washer as disclosed herein;

FIG. 2 is a cross-sectional view;

FIG. 3 is a perspective view of a washer of FIG. 1 in a trough of a metal corrugated deck for a roof; and

FIG. 4 is a cross-sectional view similar to FIG. 2 with a fastener extended therethrough.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2 simultaneously, washer 10 comprises an expanse of material 12 of 1¼″ (in one embodiment) having a first section 14 and at least one second section 16. Material 12 defines an opening 18 for through passage of a separate structure. In one embodiment the separate structure is a fastener such as a nail or screw. Opening 18 may be dimensioned to closely approximate a nominal diameter of the shank 20 of the fastener 22 intended to pass therethrough such that a head 24 of such fastener (FIG. 4) cannot pass through. In one embodiment, the first section 14 includes a substantially flat area 18 of washer 10 which is sized sufficiently to be contacted in a substantially flush manner by undersurface 26 of head 24 of fastener 22. The second section 16 of which includes bent areas 30. The bent areas 30 of section 16 are in one embodiment bent in a parallel manner to one another and cause the washer 10 to resemble a cowboy hat brim. The shape advantageously closely approximates a shape of a trough 32 (FIG. 3) in a corrugated metal deck 34 (such as a type “B” corrugated metal deck or other corrugated material). Because of the bent configuration of the washer, there are no significant stress points created by the washer on a corrugated roof deck during a wind uplift condition. Without the stress points, the fastener/washer assembly is far less likely to pull through the roof deck or have the roof deck rip through the washer. Accordingly, failure is deferred to much higher wind uplift pressures and fatigue cycling. In testing of the device and method disclosed herein, the roof deck did not fail at maximum test criteria of 225 pounds per square foot and 280 pounds per square foot at two respective testing facilities. It is to be understood that although the term “bent” suggests a metallic structure of washer 10 and even though a metallic structure is indeed contemplated, other materials may be employed including plastics. In the case of metals or plastics, the washer may either be bent as described or may be molded as such.

The method for fastening a roof deck comprises producing a washer having characteristics described hereinabove. This can be accomplished by such means as stamping, rolling, hot forming, molding, casting, etc.

The formed washer is then deposited on a fastener of a type and shape capable of passing through the opening in washer 10 as described above. In this condition the fastener and washer combination is driven through the deck with the fastener extending into a subjacent support.

A roof deck secured with a plurality of the fastener/washer combination described herein is capable of withstanding extraordinarily high wind uplift forces without failure.

While preferred embodiments have been shown and described, modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustrations and not limitation.

Claims

1. A washer defining a first surface and a second surface, the first and second surfaces remaining equidistant from one another at all points of the washer, the washer being for a metal roof deck comprising: a substantially flat area defining an a single opening for through passage of a fastener; and a bent area radially outwardly disposed of said flat area configured to nest with a corrugation in the metal roof deck, the flat area and the bent area being of a single contiguous uninterrupted piece of material absent holes other than the opening for through passage of the fastener.

2. A washer for a metal roof deck as claimed in claim 1 wherein said washer is rolled in the bent area.

3. A washer for a metal roof deck as claimed in claim 1 wherein said bent area is rolled less than 90°.

4. A washer for a metal roof deck as claimed in claim 1 wherein said washer is metal.

5. A washer for a metal roof deck as claimed in claim 1 wherein said washer is plastic.

6. A washer for a metal roof deck as claimed in claim 1 wherein said washer is bent on two lateral sides thereon.

7. A washer for a metal roof deck as claimed in claim 6 herein said bent areas are in parallel to each other.

8. A washer for a metal roof deck as claimed in claim 1 wherein said bent areas is are ¼″ wide.

9. A method for fastening a corrugated metal roof deck comprising: depositing a washer having an area radially outwardly disposed; expanse of metal material having a circular outer periphery if rendered flat with a first surface and a second surface remaining substantially the same distance from each other throughout the expanse of the washer; a single opening in the expanse of material of the washer dimensioned to closely receive the fastener therethrough; a substantially flat area of the washer; a bent area radially outwardly disposed of the flat area, the bent area disposing both the first and second surface of the washer out of plane with the flat area of the washer, said bent area causing said washer to substantially nest with a corrugation of the corrugated metal roof deck; driving said fastener through a corrugated metal roof deck into a structural joist; orienting said washer complementarily to said roof deck; and securing said washer and roof deck by tightening said fastener against the structural underlying joist.

10. A roof assembly comprising: a subjacent support; a corrugated metal roof deck supported by the support; and a washer having the first surface and a second surface, the surfaces being consistently spaced from one another over the entirety of the washer, the washer having a substantially flat area defining an a single opening for through passage of a fastener and a bent area radially outwardly disposed of the flat area; a fastener extending through said washer, through said deck and into said subjacent support.

11. A roof assembly as claimed in claim 10 wherein said washer is rolled in the bent area.

12. A roof assembly as claimed in claim 10 wherein said washer is rolled parabolically.

13. A roof assembly as claimed in claim 10 wherein said washer is metal.

14. A roof assembly as claimed in claim 10 wherein said washer is plastic.

15. A roof assembly as claimed in claim 10 wherein said washer is thicker than the deck metal.

16. A roof assembly as claimed in claim 10 wherein the washer conforms to the shape of the corrugation resting on the sub-adjacent support.

17. A metal washer that conforms to the shape of a type B corrugated metal deck smaller low flute.

18. A washer for fastening corrugated metal decks to structural supports bent in the configuration of the metal deck, the washer being thicker than the metal decking and being greater than ¾″ of an inch in outside diameter.

19. A washer for corrugated metal roof deck, the washer comprising: an expanse of metal material having a circular outer periphery if rendered flat with a first surface and a second surface remaining substantially the same distance from each other throughout the expanse of the washer; a single opening in the expanse of material of the washer dimensioned to closely receive a fastener therethrough; a substantially flat area of the washer; a bent area radially outwardly disposed of the flat area, the bent area disposing both the first and second surface of the washer out of plane with the flat area of the washer, the bent area causing the washer to substantially nest with a corrugation of the corrugated metal roof deck.