The present invention relates generally to roofing structures for buildings, especially commercial buildings, and more particularly relates to a system for blocking the edges of a roof structure to facilitate securement of roofing elements thereto, e.g., for border containment of a flowable cementitious roofing material, rigid insulation panels, and other roofing materials.
In the construction of buildings with flat roofs, especially commercial buildings, a blocking system of some type is typically provided about the perimeter edge of the roof structure to act as a border for and to facilitate securement of any of various roofing elements that may commonly be utilized. For example, many conventional commercial buildings are constructed with flat roofs on which a lightweight concrete or a comparable synthetic flowable cementitious roofing material may be cast in situ. Other commercial building roofs may utilize rigid insulation boards or panels which may be made of wood fiber, perlite, polyisocyanurate, polystyrene (expanded or extruded), cellular glass, gypsum board, and composites. A perimeter edge blocking system provides a containment border within which the roofing material is contained while being installed. The perimeter edge blocking system may also provide for the securement of other roofing elements, such as gravel stops, roof curbs, copings, fascia, etc.
Conventionally, roof blocking systems are fabricated of elongate wood boards nailed to the roof structure. However, wood roof blocking systems suffer several disadvantages. Wood is subject to deterioration and decay from exposure over time to the elements, particularly moisture, even when treated with preservatives. Wood also may be damaged by insects such as termites. In addition, variations commonly occur from one wood board to another due to natural physical differences in grain, knots, splintering and splitting, and wood boards are subject to warping, all of which may result in undesirable dimensional variations between differing wood boards.
All of these reasons as well as other factors make wood a less than optimal material from which to fabricate roof blocking systems. Accordingly, a need exists in the construction industry for a new form of roof blocking system made of material other than wood which will overcome the above-described problems. U.S. Pat. No. 6,237,293 proposes a roof blocking system which may be made of galvanized steel, other steel, aluminum or plastic. Alternative Roof Blocking System, located in Fort Lauderdale, Fla., produces a commercial embodiment of such roof blocking system identified by the designation “A.R.B.S.” which is intended as a substitute for wood blocking systems. While the “A.R.B.S.” system performs adequately for its intended purpose, the system is fabricated in a unitary one-piece configuration, which makes the system somewhat difficult to handle and to install.
It is accordingly an object of the present invention to provide an alternative system for blocking an edge of a roof structure of a building which overcomes the problems and disadvantages of roof edge blocking systems made of wood and which is easier to handle and install than the “A.R.B.S.” system. A further object of the present invention is to provide additional features and advantages not realized by either of these conventional systems.
Briefly summarized, the roof edge blocking system of the present invention provides a two-piece construction that simplifies the installation of the system. More specifically, the present roof edge blocking system comprises an elongate base member for affixation to the roof structure along the edge thereof, and an elongate cover member for affixation over the base member. The base member is of a generally U-shaped cross-sectional configuration having a lower transverse section for superposed resting abutment on and affixation to the roof structure and spaced-apart inner and outer leg sections generally upstanding from opposite lateral sides of the lower transverse section. The cover member is of an inverted generally U-shaped cross-sectional configuration having an upper transverse section for spanning across the leg sections of the base member and spaced-apart inner and outer leg sections depending from opposite lateral sides of the upper transverse section for respectively extending downwardly along outward sides of the upstanding inner and outer leg sections of the base member. Thus, the base and cover members, as assembled together, form an auxiliary perimeter structure on the roof structure for securement of roofing elements thereto.
In a preferred embodiment of the roof edge blocking system, the base and cover members, as assembled together, define an interior cavity and the respective inner leg sections of the base and cover members cooperatively define passageways into the cavity for disposition facing inwardly from the edge of the roof structure. For example, the inner leg section of the cover member may be formed therealong with a series of openings, while the inner leg section of the base member terminates adjacent the openings of the cover member as assembled together. In such an embodiment, the inner leg section of the cover member may include a lip for engagement with a terminal edge of the inner leg section of the base member. A cap member may be provided for affixation to the base and cover members as assembled together to form an end closure to the interior cavity.
According to another feature of the present roof edge blocking system, the cover member may include a spacer flange extending laterally from the inner leg section of the cover member for spacing of roofing elements on the roof structure a defined distance from the base and cover members as assembled. Another feature of the present blocking system is that the outer leg section of the cover member may include a cleat for affixation of a fascia element or coping cap. The cover member may also include a series of vents in the upper transverse section thereof.
The present roof edge blocking system is particularly adapted for use with a building wherein the roof structure has a corrugated roof deck for supporting a roofing material thereover, which may for example be a flowable cemetitious material or a rigid insulative material or a combination thereof. In such an embodiment of the present blocking system, the elongate base member is affixed to the roof deck along the edge of the roof structure. With the elongate cover member affixed over the base member, the thusly assembled base and cover members form an auxiliary perimeter structure on the roof structure for border containment of the roofing material. In turn, a portion of the roofing material may be contained within the interior cavity within the base and cover members. For example, the interior cavity within the base and cover members is adapted to receive flow of a cemetitious roofing material through the passageway openings and into the cavity with the cap member closing the end of the interior cavity to prevent escape of the material. The spacer flange extending laterally from the inner leg section of the cover member is effective for spacing of a rigid insulative roofing material a defined distance from the base and cover members as assembled. The vents in the upper transverse section of the cover member provide for escape of air as the cavity fills with the cementitious material and vents the material as it cures.
According to a further aspect of the invention, an elongate containment member is provided for affixation to the corrugated roof deck at the edge of the roof structure to dam a cementitious roofing material in the corrugations of the roof deck beneath the base member to prevent flow thereof off the edge of the roof structure.
Referring now to the accompanying drawings and initially to
Most basically, the roof edge blocking system 10 comprises an elongate base member 20 configured and adapted for affixation to the roof structure 12 along its perimeter edge 14, and a mating elongate cover member 22 configured and adapted for affixation over the base member 20. The elongate base member 20 is typically in the form of a series of plural linear base member segments, represented in
Each segment of the base member 20 is formed of a generally U-shaped cross-sectional configuration having a lower transverse section 26 with spaced-apart inner and outer leg sections 28, 30, respectively, extending in generally upstanding relation from the opposite lateral sides of the lower transverse section 26. In this manner, the lower transverse section 26 of each base member segment is adapted to be placed in superposed resting abutment on the deck 16 and affixed thereto by penetration of the screws 24 downwardly through the transverse section 26 and then through an abutting corrugation of the deck 16 at spacings along the length of each base member segment. Installation of the base member segments in this manner is easily accomplished as the U-shaped configuration of the base member segments permits clear access to the lower transverse section 26 for driving of the screws 24. Locations for the screws 24 may be pre-formed in the transverse section 26 at the same spacings as the corrugations of the deck 16 to further simplify the ease and simplicity of installation. Splice elements 25 are provided in a U-shape closely mated to that of the base member segments to be inserted at the abutting ends between adjacent base member segments to bridge over and thereby cover the abutted segment ends.
Each segment of the cover member 22 is formed of an inverted generally U-shaped cross-sectional configuration which mates with the configuration of the base member segments. Specifically, the cover member segments 22 have an upper transverse section 32 with spaced-apart inner and outer leg sections 34, 36, respectively, depending from opposite lateral sides of the upper transverse section 32. Each cover member segment is dimensioned such that its upper transverse section 32 is adapted to span across the leg sections 28, 30 of a base member segment with the inner and outer leg sections 34, 36 respectively extending downwardly along outward sides of the upstanding inner and outer leg sections 28, 30 of the base member segment.
To further facilitate secure mating of the base and cover members 20, 22, the outer leg section 30 of each base member segment is formed at its upper end with an inwardly extending flange 38 for providing a support surface on which the upper transverse section 32 of a mating cover member segment may seat in abutment when fully assembled together. The inner leg section 28 of each base member segment is of a lesser upstanding height than the outer leg section 30, terminating in an upper linear edge 40, which engages in an angled lip 42 formed on the inward surface of the inner leg section 34 of each cover member segment to similarly seat the respective inner leg sections 28, 34 of the base and cover member segments when fully assembled together. A series of recessed openings 44 are formed in the upper transverse section 32 of each cover member segment at spacings therealong to receive screws 46 which are sufficiently elongated to penetrate the mating base member segment and the corrugated roof deck 16 therebelow, to secure the base and cover members 20, 22 together as thusly assembled. The recessed character of the openings 44 allows the heads of the screws 46 to rest in countersunk manner within the recesses to be flush with the upper surface of the transverse section 32.
In this manner, the assembled base and cover members 20, 22 define a substantially open interior cavity 50 extending the full length of the blocking system 10. Each of the cover member segments is formed along its length with a series of enlarged spaced-apart openings 48 through the inner leg section 34 thereof at a location above the lip 42 to open into the cavity 50 in the assembled condition of the base and cover members 20, 22. The openings 48 are of sufficient size to permit the cementitious roofing material to flow relatively freely through the openings 48 into the interior cavity 50, as more fully described below. A cap member 35 is provided in a configuration mated to that of the interior cavity 50, for insertion of the cap member 35 into the open end of the assembled base and cover members 20, 22 to close the interior cavity thereat and thereby prevent escape of cementitious material received within the cavity 50. Vent holes are preferably formed in the upper transverse section 32 of the cover member 22 to facilitate curing of the cementitious material within the cavity 50.
Each of the cover member segments also includes a flange 52 laterally extending outwardly from the inner leg section 34 to be disposed in an essentially horizontal disposition at a spacing above the deck 16 in the installed and assembled condition of the roof edge blocking system 10. The flange 52 is formed along its length with a series of enlarged spaced-apart openings 54, similar to the openings 48, of sufficient size to permit the cementitious roofing material to flow relatively freely through the openings 54, as more fully described below.
As best seen in
The installation and use of the roof edge blocking system 10 may thus be understood with reference to
A quantity of cementitious material, typically a lightweight concrete material C, is poured and spread over the deck 16 to substantially fill the channels defined by the corrugations in the deck. Typically, a network of insulating panels 58, such as EPS (expanded polystyrene) boards, is to be embedded in the cementitious material, whereby the pouring of the material is temporarily stopped while the boards are placed across the deck 16. Importantly, the flanges 52 projecting from the cover member segments insure that the panels 58 are properly spaced from the blocking system 10. The pouring of the cementitious material is then resumed until the material covers the entirety of the panels 58 to the level of the transverse sections 32 of the cover member 22 of the blocking system 10. As the cementitious material spreads across the deck 16, the material passes through the openings 48 in the cover member segments, so as to substantially fill the interior cavity 50 defined within the base and cover members 20, 22. Likewise, the cementitious material also passes through the opening 54 in the flanges 52 of the cover member segments to fill the space beneath the flanges and adjacent the panels 58. Upon the curing of the cementitious material, the roof structure may then be finished in any desired conventional manner, e.g., by the installation of a rubber membrane M, a finishing coping or fascia, gravel, etc.
As will be understood, the blocking system 10 of the present invention is accordingly simple to handle and install. In particular, the two-piece construction of the base and cover members 20, 22 allows easy installation of fastening screws to secure the base member 20 in place to the deck 16 without the cover member 22 or any other elements obstructing access to the transverse section 26 of the base member. The cover member 22 easily and securely fits in place over the base member 20 and can then be separately secured in place via the screws 46. Advantageously, the blocking system 10 eliminates the conventional use of wood boards as part of the blocking system and thereby avoids issues of dealing with the warping or dimensional inconsistencies in wood boards as well as post-installation issues of potential decay and deterioration over time.
While the roof edge blocking system of the present invention has been illustrated and described in
Those persons skilled in the art will thus recognize and understand that the invention is susceptible of broader utility and application in various forms of roof structures. Many embodiments and adaptations of the present invention other than those herein described, as well as many variations, modifications and equivalent arrangements, will be apparent from or reasonably suggested by the present invention and the foregoing description thereof, without departing from the substance or scope of the present invention. Accordingly, it is to be understood that the foregoing disclosure is only illustrative and exemplary of the present invention and is made merely for purposes of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended or to be construed to limit the present invention or otherwise to exclude any such other embodiments, adaptations, variations, modifications and equivalent arrangements, the present invention being limited only by the claims appended hereto and the equivalents thereof.
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