The present application relates generally to construction and insulation of roofs and more particularly to flat or low-slope roofs.
There are several types of roofing systems for low slope or flat roofs. As a general rule, however, all roofing systems including low slope and flat roofing systems, include at least three basic components: a substrate, thermal insulation and a water-proofing membrane. Four primary types of roofing systems are known: built-up roof (asphalt or cold tar pitch base), modified bitumen (asphalt based pre-manufactured sheets), single ply (EPDM, TPO and PVC and thermoplastic alloys) and spray foam polyurethane (polyurethane foam with silicone, acrylic, polyurethane and polyurea coatings).
Built-up roof and modified bitumen roofing systems are known to use two layers of ridged insulation board mechanically fastened to provide a substrate for the roof membrane. The first layer is used for insulation and to provide a flat surface. The second layer is used to provide increased insulation and to isolate the roof membrane from the wear/fatigue factor created by the fasteners and insulation board transitions.
On flat roofs, ridged insulation is typically fastened onto the roof deck using a fastener with a stress distribution plate. Panel members are secured to the secondary structure members by a workman who serially stands above one of the panel members and drives a fastener through the panel member to attach it to the underlying secondary structural members. Fastening the distribution plates is an unwieldy and time consuming process because the stress distribution plates must be correctly positioned on the insulation board and the plates must be placed right side up for proper attachment. The plates can be distributed onto the roof deck by machine; however, the plates still need to be aligned correctly on the insulation sheet.
An insulation board assembly is directed to ridged insulation boards that have additional structural elements pre-installed onto the surface. These additional structural elements may be introduced during the manufacturing process or in an operation that is separate from manufacture. According to one embodiment, the insulation sheet has a matrix of stress distribution plates pre-installed on its face. In another embodiment, the insulation board has a full-coverage, reinforced facer pre-installed on its face. In a third embodiment, the reinforced facer is pre-installed onto the insulation board in a lattice configuration. An insulation board that has the necessary structural elements pre-incorporated onto its surface eliminates the need for the installer to handle and correctly place and position the individual components. This saves considerable time and reduces component placement errors.
Either during the manufacturing process or as a separate operation, a matrix of stress distribution plates may be pre-installed in or onto the face of the insulation board in various patterns and densities.
Provisions of a ridged insulation board with pre-installed and pre-positioned stress distribution plates having sufficient strength eliminates the need for separate and additional stress distribution plates and thereby improves efficiency by reducing errors and labor costs.
A method of fastening the insulation board having pre-installed structural elements is adaptable for efficient installation on flat or low slope roofs.
Referring now to the drawings wherein like elements are numbered alike in the several Figures:
A ridged insulation board assembly is designated generally by the number 10. The ridged insulation board assembly 10 is preferably employed in roofing systems, which are flat or low pitch configurations and typically have a substantial expense. The ridged insulation board assembly 10 is comprised generally of a ridged insulation board 14 and an additional structural element, such as stress distribution plates 12, incorporated on or into the surface of board 14 as shown in
Alternatively, the stress distribution plates 12 can be introduced in an operation that is separate from manufacture but prior to installation of the assembly 10 onto the structural surface or roof deck. For this application, this process of introducing additional structural elements in or onto the surface of the ridged insulation board 14 will be referred to as “pre-installation” and the elements themselves as being “pre-installed.” Stress distribution plates 12 are pre-installed on or into the surface of insulation board 14 in various patterns and densities as shown in
It should also be understood that the insulation board assembly 10 meets all building code and approval requirements. The installer will place the assembly 10 onto the surface and drive a fastener directly through the each of the pre-installed (and therefore pre-positioned) stress distribution plates 12.
It should also to be understood that stress distribution plates 12 are not the only structural element that can be pre-installed onto insulation board 14. In another embodiment, as depicted in
It should be understood that it is not necessary for the reinforced facer layer to be a full coverage layer as shown in
While preferred embodiments have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and scope of the present invention.
This application claims the priority of U.S. Provisional Application 60/760,153 filed Jan. 18, 2006.
Number | Date | Country | |
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60760153 | Jan 2006 | US |