The disclosures of U.S. patent application Ser. No. 17/207,860, filed Mar. 22, 2021, and U.S. Provisional Patent Application No. 62/993,336, filed Mar. 23, 2020, are specifically incorporated by reference herein as if set forth in their entireties.
This disclosure relates generally to roofing systems, and more specifically to roofing installation systems for attaching a fabric substrate to a roof deck or substrate to receive a subsequent liquid applied roof coating.
Mechanically bonded liquid applied roofing (LAR) systems require installation of an appropriate fabric, mesh or base-sheet (hereinafter referred to collectively as fabric) on a roof deck using mechanical fasteners. The fasteners usually include washer-like fastener plates that are positioned on top of the fabric and are attached with nails or screws driven through the fabric and into the underlying roof deck. Problems with such traditional fabric attachment techniques include such fastener plate edges cutting into and damaging the fabric, shadow areas around the fasteners that are not effectively sealed by a subsequently applied liquid roof coating, and unwanted penetrations of the fabric. A need exists for a roofing system that successfully addresses these and other problems and shortcomings. It is to the provision of such a system that the present disclosure is primarily directed.
Briefly described, example roofing systems including a plurality of fastening assemblies are disclosed for attaching a fabric to a roof deck prior to application of an LAR coating. The fastening assemblies may be installed on an uncleaned or unprimed roof deck prior to laying a fabric on the roof. In some embodiments, the fastening assemblies may reside underneath the fabric and may utilize mechanical binding or chemical bonding to secure the fabric without piercing the fabric. The disclosed fastening assemblies and roofing systems in which they are employed according to the principles of the present disclosure can provide various advantages including increased efficiency and reliability, elimination of shadow areas or dimples or bumps in the fabric, efficiencies in the number of fasteners, and ease of fabric installation.
Various aspects, features, and advantages of the present disclosure include, without limitation a fastening system for attaching overlying fabric to a roof deck. In embodiments, the fastening system comprises a plurality of first elements configured to be secured to the roof deck and a plurality of second elements for securing the overlying fabric to the plurality of first elements without piercing the fabric.
In some embodiments of the fastening system, each of the plurality of first elements comprises a base and each of the plurality of second elements comprises a binding material on the base, the binding material configured to soften when heated sufficient to bond with the fabric. In embodiments, the binding material resides on top of the base. In other embodiments, the binding material resides below the base; and the base comprises openings to allow the binding material to flow through the base when heated.
In additional embodiments of the fastening system, the plurality of second elements comprise locking tabs extending upwardly from each of the plurality of first elements, the locking tabs being configured to attach mechanically to the overlying fabric. In embodiments, each of the locking tabs comprises a cap configured to snap into an open area of the overlying fabric. In further embodiments, each cap is cone-shaped.
In other embodiments the fastening system, the plurality of second elements comprise attachment plates configured to reside atop the fabric, the attachment plates being securable to the plurality of first elements. In some embodiments, the plurality of first elements have upstanding alignment tabs and studs that extend through open areas of the overlying fabric, and the plurality of second elements include openings spaced and sized to receive the upstanding alignment tabs and studs; and with the fasteners comprising nuts threadable onto the studs to secure the attachment plates to the first elements.
In still other embodiments of the fastening system, the plurality of first elements comprise grommets mountable in pre-drilled holes in the roof deck. In embodiments, the grommets are internally threaded; and wherein the plurality of second elements comprise threaded fasteners with heads. In other embodiments, the plurality of second elements comprise attachment plates configured to be positioned between the threaded fasteners and the fabric.
In other aspects of the present disclosure, a roofing system is disclosed, comprising a roof deck; a plurality of first elements positioned along the roof deck; a fabric positioned over the roof deck and the plurality of first elements; a plurality of second elements configured for securing the fabric to the plurality of first elements without piercing the fabric; and at least one fastener inserted through the first and second elements, the roof deck, the fabric and so as to couple the first and second elements together; wherein the fabric is captured and held against the roof deck by the first and second elements.
In some embodiments of the roofing system each of the plurality of first elements comprises a base and each of the plurality of second elements comprises a cover plate adapted to seat upon the base, with the fabric engaged and held therebetween. In embodiments, each base further comprises at least one stud and plurality of alignment tabs projecting from a surface of each base, and wherein at least one stud and the alignment tabs are configured to extend at least partially through open areas of the fabric and the cover plate; with the at least one stud being engaged by one of the fasteners to secure each of the cover plates to a corresponding one of the bases.
In other embodiments of the roofing system, each base comprises a grommet having a barrel inserted into the roof deck and an attachment flange projecting radically from a first end of the barrel and adopted to seat upon a surface of the roof deck; and wherein each of the fasteners is configured to be received within a barrel of one of the grommets. In embodiments, the plurality of second elements comprise attachment plates configured to be positioned over the attachment flanges of the grommets; wherein the attachment plates are secured to the grommets by insertion of the fasteners therethrough.
In some embodiments of the roofing system, the fabric comprises at least one of a permeable mesh, woven fabric, non-woven fabric, plastic, foam material or combinations thereof; and includes a plurality of open areas configured to enable at least partial penetration of a liquid roof coating therein.
In other embodiments of the roofing system, the plurality of first elements each comprise a plurality of alignment tabs and studs that extend through open areas of the fabric; and wherein the plurality of second elements each comprise a plurality of openings configured to receive at least a portion of the alignment tabs and the studs of a corresponding one of the first elements, and wherein the fasteners comprise nuts threadable onto the studs to secure each of the second elements to the corresponding one of the first elements.
In some embodiments of the roofing system, the plurality of first elements comprise grommets received within pre-drilled holes in the roof deck and mounted to the roof deck; wherein the grommets are internally threaded, and wherein the fasteners each comprise threaded fasteners to engage internal threads of the grommets. In addition, the second elements comprise attachment plates configured to be positioned between the threaded fasteners and the fabric.
In embodiments, the roofing system further comprises a liquid applied roof coating (LAR) applied over the fabric; wherein the liquid applied roof coating at least partially penetrates the fabric to form a liquid applied roof.
In some embodiments of the roofing system, the roof deck comprises a plurality of panels, sheets, boards, or combinations thereof, including metal, isocyanurate board (ISO), modified bitumen, wood, oriented strand board, membrane materials, cement, or combinations thereof.
In another aspect of the present disclosure, a method is provided, comprising positioning a plurality of first elements at spaced locations along a roof deck; placing a fabric over the plurality of first elements and the roof deck; wherein the fabric includes a plurality of open areas defined therealong; positioning a plurality of second elements over the plurality of first elements, with at least one fastener extending through each of the first and second elements and into the roof deck; wherein the fabric is captured and held against the roof deck between the first and second elements; and applying a liquid applied roof (LAR) coating over the fabric and roof deck; wherein the liquid applied roof coating at least partially penetrates the fabric.
In embodiments, the LAR coating penetrates through open spaces defined in the fabric, and coats the fabric. In some embodiments, the LAR coating penetrates through the open spaces of the fabric and into fibers of the fabric, so as to be at least partially absorbed by the fabric as well as coating the fabric and passing through the open spaces thereof.
In other embodiments of the method, the first elements each comprise a base having a plurality of alignment tabs and studs configured to be received through a portion of the open areas of the fabric; the second elements each comprise a cover plate having a plurality of openings therein; and wherein positioning the second elements over the first elements comprises aligning the openings formed in one of the cover plates with the alignment tabs and at least one stud of a corresponding one of the bases; and fitting each of the cover plates over their corresponding bases with at least the studs projecting through the openings of the attachment plates and secured with nuts.
In other embodiments of the method, the first elements comprise grommets and the second elements comprise attachment plates; and further comprising inserting a barrel of each grommet into an opening in the roof deck; aligning an opening formed in each attachment plate with an opening formed in a corresponding one of the grommets, and inserting one of the fasteners therethrough.
Accordingly, embodiments of fastening systems and methods for attaching fabric materials to a roof deck prior to application of an LAR coating to form a roof structure that are directed to the above discussed and other needs are disclosed. The foregoing and other advantages and aspects of the embodiments of the present disclosure will become apparent and more readily appreciated from the following detailed description and the claims, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the present disclosure.
The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced.
Reference will now be made to the drawing figures wherein reference numerals indicate various elements throughout the several drawings.
In this embodiment, the fastening assembly includes a first element that can include a washer-shaped base 12 be positioned on the roof deck, and has a second element comprising a binding material 13 that is received atop the base 12. A fastener such as a nail or screw 16, is extendable through central openings 12A/13A of the base 12 and the binding material 13 and will be driven into a roof deck. In some embodiments, the base 12 further has a central depression 12B within which the head 14 of the nail or screw 16 resides so that it does not form a bump or dimple in the fabric 18. Other types of fasteners for mechanically attaching the fabric also can be used.
As illustrated in
In embodiments, the fabric 18 will have crisscrossing strands 19 forming open areas 21, and is applied over the roof deck covering the installed fastening assemblies 11. As indicated in
The binding material 13 can be heated or otherwise treated (such as with a solvent) until it melts or softens, flows through the open areas of the fabric, and binds to the strands 19. The fabric 18 is thus securely attached to the roof deck at a plurality of locations without penetrations, bumps, shadows, or dimples in the fabric. The LAR coating can then be applied atop the attached fabric. Examples of LAR coatings that can be used in various embodiments include, but are not limited to silicone, acrylate, polyurethane, polyurea, silane terminated polyurethane, silane terminated polyether, silane terminated polyethylene, polyvinylidene fluoride or polyvinylidene difluoride (PVDF), or combinations thereof.
As shown in
The binding material 13 may be, but is not limited to, a thermoset material with setting temperature that may be from 60° to 400° Centigrade, or a thermal plastic material with softening temperature that may range from 60° to 400° Centigrade. In some embodiments, a thermoset material with a setting temperature in a range from 60° to 200° Centigrade, 80° to 300° Centigrade, or 80° to 400° Centigrade; or a thermal plastic with a softening temperature in a range from 60° to 200° Centigrade also could be used. In other embodiments, a thermoset material with a setting temperature in a range from 80° to 200° Centigrade, 80° to 300° Centigrade, or 80° to 400° Centigrade; or a thermal plastic with a softening temperature in a range from 80° to 200° Centigrade, 80° to 300° Centigrade, or 80° to 400° Centigrade also could be used.
Other thermoset, thermo plastic, and/or other heat setting or binding materials, or combinations thereof, also can be used. Examples of such binding materials may include, without limitation, phenolic formaldehyde, epoxy, polyester, polyimide, phenolic neoprene, or combinations thereof.
The base 12 and binding material 13 may be delivered as separate pieces or pre-assembled. The fastening assemblies may be installed on roof decks or substrates that can include, but are not limited to, panels, sheets, boards, or combinations thereof, and which can be formed from metal, isocyanurate board (ISO), modified bitumen, wood, oriented strand board, membrane materials, cement, or combinations thereof, and can be provided with or without coating layers on top (collectively referred to herein as a roof deck).
The fastening assemblies may be secured to the roof deck 11 with fasteners such as nails or a screws 16. The fabric will be applied on the upper surface of the roof deck so that it covers over the attached fastening assemblies. The binding materials are then treated with direct or indirect heat to a temperature above their setting or softening temperature with the fabric pressed against the fastening assemblies. The binding materials are allowed to cool down and solidify to complete the bond between the fastening assemblies and the fabric. In some embodiments detailed herein, the binding materials can be chemically treated to complete the bond between the fastening assemblies and the fabric.
The installation sequence also can be modified by installing a plurality of metal or plastic bases and first applying or inserting a fastener, such as a nail or screw, through openings defined in each base and into the roof deck, as indicated in
The combined areas of the openings 32 in the base 31 of this embodiment may be between 50% and 90% of the total area of the base. In some embodiments, the combined areas of the openings 32 in the base can be between 50% and 80%. In some embodiments, such as for use of plastic and/or rubber materials, the combined areas of the openings 32 in the base can be between 50% and 70%; 50% and 60%; or 50% and 55%. In some embodiments, such as for use of metal and/or ceramic materials, the combined areas of the openings 32 in the base can be between 70% and 90%; 70% and 80%; 70% and 75%; or 60% and 70%. Other combinations also can be provided.
The binding material, once heated and allowed to cool and re-solidify, forms a bond both with the base 31 and the fabric for a secure attachment. If the base 31 is made of metal, induction heating can be used to heat the binding material without using direct heat and without contacting the binding material 29. The binding material may be chosen so that it may be softened with a chemical solvent and allowed to re-cure for form the bond without heating.
With continued reference to the embodiment shown in
Once received through the open areas 48, the peripheral edges of the caps 39 overlap a portion of the strands 47 bordering the openings as shown at 43 in
As illustrated in
As shown in
In some embodiments, the studs can comprise fasteners that further serve to fasten one or more components of the roof deck together and/or to a rafter or other support of the roof as well as attaching the base to the roof deck. For example, as discussed above, the roof deck can include panels or sheets of metal, isocyanurate boards (ISO), modified bitumen, wood, membranes, cement, or combinations thereof, as well as other types of sheets, panels or boards, with or without coating layers on top. In some non-limiting embodiments, such as where ISO boards or similar roof deck materials are used, a first end or portion of one or more of the studs can be inserted through each base and through the roof deck, securing both the base and the roof deck together and to an underlying support, without necessarily requiring separate and/or additional fasteners to first attach the roof deck to a support, then to attach the bases to the roof deck.
Each of the second elements of the fastening assembly can include a cover plate 66 that has openings 65 sized and configured to receive the alignment tabs 63 of the base 62 when the cover plate is aligned over and laid atop the base 62. The cover plate 66 also has holes 67 defined therein that will be positioned to receive the threaded studs 64 of the base 62. The cover plate 66 can be attached to the base 62 by lowering it onto the base until the threaded studs, and the alignment tabs of the base, extend through their respective holes in the cover plate 66. The cover plate 66 is then secured to the base with fasteners such as nuts 68 or other connectors threaded onto to the ends of the threaded studs, as shown in
In use, a plurality of bases 62 are secured to a roof deck 61 at spaced locations. The fabric 55 is then laid on the roof deck and positioned as desired. The upstanding alignment tabs 63 and threaded studs 64 extend through open areas of the fabric to hold the fabric in position until permanently secured, such as with an LAR coating. With the fabric held in place, cover plates 66 are installed on top of the fabric overlying each of the installed bases 62, and being secured with nuts 68. The fabric becomes securely fastened to each of the fasteners due to the alignment tabs 63 extending through open areas of the fabric and into their respective openings 67 in the overlying cover plate 66, with the fabric being captured and held between the first and second elements of the fastening assembly 56. An LAR coating will be applied, at least, partially penetrating or being absorbed into the fabric and thereafter curing to form an LAR coated roof structure.
As illustrated in
The fastening assembly 71 further will include a plurality of second elements, each of which can comprise a metal or plastic washer-shaped attachment plate 79 that is securable to a corresponding one of the installed grommets 72 using a threaded fastener 82 (e.g. a screw, bolt, or similar threaded fastener) having a head 81. The threads of the fastener 82 will engage with the internal threads 70 formed in the barrel of the grommet 72 to provide a mechanical connection therebetween. As with previously described embodiments, the attachment plate 82 has a central recess configured to receive the head of the fastener 82 in a substantially seated engagement to avoid bumps or dimples in the installed fabric.
In use, a plurality of grommets 72 are installed in spaced, pre-drilled holes in the roof deck 71 (
The fastening assemblies for use in roofing systems according to the present disclosure enable the formation of liquid applied roof structures that can be mechanically bonded to an underlying roof deck, providing protection against water and wind uplift effects, while further enabling a minimization of the number of fasteners required. In addition, a need for substantial cleaning and/or priming of the roof deck prior to installation of the fabric and LAR coating further can be substantially avoided or minimized.
The foregoing description generally illustrates and describes various embodiments of the present disclosure. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present disclosure without departing from the spirit and scope of the disclosure as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Moreover, while a variety of specific example roofing systems and fastening assemblies that embody principles and aspects thereof have been described in the present disclosure, it will be understood by the skilled artisan that a wide range of additions, deletions, and modifications, both subtle and gross, may well be made to the illustrated examples without departing from the spirit and scope of the present disclosure.
The present patent application is continuation of co-pending U.S. patent application Ser. No. 17/207,860, filed Mar. 22, 2021, which claims priority to and the benefit of U.S. Provisional Patent Application No. 62/993,336, filed Mar. 23, 2020.
Number | Date | Country | |
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62993336 | Mar 2020 | US |
Number | Date | Country | |
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Parent | 17207860 | Mar 2021 | US |
Child | 17901266 | US |