This application is related to U.S. Pat. Nos. 8,661,760; 8,661,761 and 8,677,710 each of which is incorporated herein by reference in its entirety.
The installation of slate and tile roofs is labor intensive and typically requires skilled workers to properly set down overlapping courses of relatively brittle roofing tiles. When used herein, “tiles” refers to natural tiles such as slate tiles as well as artificial tiles such as those fabricated from ceramic materials.
Recent developments in slate roof installation systems have simplified the installation of roofing tiles while also reducing the amount of tiles required to cover a roof. One such improved system requires only a single overlap of one upper course or row of tiles over the top or upper portion of a lower course of tiles. This system requires the use of a layer of water resistant material such as a thin sheet of plastic, “tar paper” or similar construction material to provide adequate protection for the underlying roof decking.
That is, instead of using three rows of overlapping tiles to waterproof an underlying roof deck, a layer of waterproof or water resistant sheet material is placed beneath each row of tiles so as to provide a water repelling layer beneath the adjacent side edges of adjoining tiles. The sheet material thereby prevents water seeping between the cracks or openings formed between adjacent tiles from damaging the underlying roof deck.
While this system is easier to install than conventional “three layer” tile roofs, the underlying layers of water resistant material can degrade over time due to embrittlement from sunlight as well as from abrasion from sand, dust and grit particles blown by high winds. Moreover, the lowest course or row of tiles in “two layer” systems can be subject to damage from high winds due to the lighter weight of a single overlying row of tiles.
That is, conventional three layer tile roofs apply the weight and stability of two overlying courses or rows of tiles to the lowest or bottom row or course of tiles to secure each respective bottom row of tiles in position. This is particularly advantageous along the lowest row or course of tiles located along eave portions of each roof where exposure to high winds tends to lift or peel the exposed tile edges upwardly, allowing for the entry of wind-blown rain. In extreme conditions such as in hurricanes, these eave tiles can be lifted upwardly and blown away.
This disclosure is directed to lightweight tile roofing systems which address the drawbacks noted above. In particular, in one embodiment, a tile roofing system is disclosed wherein a single overlap between two rows of tiles is strengthened along the lowest row of tiles adjacent the eave of a roof.
Moreover, the portion of a waterproofing layer of sheet material exposed between the cracks or openings formed between the sides of adjacent tiles is protected with an overlying strip of water resistant or waterproof material, such as high density polyethylene (HDPE).
In the drawings:
As seen in
As seen in
A wire hook 34 is fastened to the underside of the top strip 24 and projects outwardly from the bottom edge of the top strip for receiving and holding one or more tiles and a weather resistant sheet as described further below. As further seen in
After inserting the starter tiles 40 in the hooks 34 as shown in
Once the water resistant or waterproof roofing material 44 is installed in the hooks 34 and over the starter tiles 40, a mounting strip 48, as seen in
A tile fastener shank portion 72 extends outwardly and downwardly from the mounting portion 60, terminating in an open-mouthed hook 74. The shank portion 72 is shown in this first embodiment as a straight shank, but laterally-extending winged portions as described below can also be used. Added strength can be provided to the base portion 50 and to the shank portion 72 and hook portion 74 by nailing, for example, a one and one half inch stainless steel nail 80 over the looped or U-shaped mounting portion 60, as shown in
In order to provide additional protection for the roofing material 44 against degradation from prolonged exposure to outdoor environments, a shield strip 84 is positioned over each shank 72 and hook 74 as shown in phantom in
The shield strips 84 can be formed of thin sheets of plastic such as HDPE, or thin strips of metal such as stainless steel, copper or other corrosion and/or water resistant metals. Each shield strip 84 can be about, for example, three inches from side to side with a height of about twelve inches from top to bottom and a thickness of about 0.020 inch. The height is about the same as the height of the overlying tiles. A wide range of thickness is possible, depending on the strip material, and the side to side strip lengths can vary depending on the particular application, including local weather conditions.
As shown in
Once the first row or course of tiles 90 is installed along the eave 12, as described above, a second layer of roofing material 44 is rolled out along and over the first mounting strip 48 with the lower edge of the roofing material 44 inserted into the open mouths of the hooks 74 on the mounting strip 48. This is shown in phantom in
At this point, a second mounting strip 48 is fastened to the roof deck 10 along and adjacent to the upper edge of the second course of roofing material 44 as further shown in phantom in
A second row or course of slate tiles 90 is then positioned over the second course of roofing material 44 and over the second series of shield strips 84. Each tile 90 is symmetrically inserted into a respective hook 74 so that each hook 74 is located equidistant from the opposite side edges of each engaged upper tile 90. In addition, each tile 90 is located between an adjacent pair of hooks 74 on the second mounting strip 48.
This sequence of installation is repeated for as many additional courses or upper rows of tiles 90 as is required to cover the roof deck 10, until the ridge top of the roof deck 10 is covered with tiles 90 or with a conventional ridge cover. While this system of tile installation works well, a more efficient installation system has been developed which eliminates the mounting strips 48 and reduces and simplifies the assembly and installation steps of a tile roof.
As seen in
As further shown in
As the weather shields 100 can be provided in a roll in any suitable length from about three feet to fifteen or even twenty feet, up to a dozen or more shield strips 84 can be evenly spaced along a weather shield 100. In
Three, six, ten or even twenty more evenly spaced shield strips 84 can be fixed to a single weather shield 100 and provided in the field as an integral scrolled compact roll which can be easily rolled out flat along a roof deck for installation. In the example of
As further shown in
This construction is shown in
In order to install a tile roof using the weather shield 100 as a weatherproofing base layer, installation begins as described above with the installation of a drip edge assembly 14 along the eave 12 of a roof 10.
As shown in
The next step is to insert a first row of full size (e.g. 12″×12″, 12″×10″, 12″×8″) tiles 90 over the weather shield 100 and into the hooks 34 on the drip edge 14. Each tile is located closely between a pair of adjacent hooks 74 on weather shield 100 as seen in
The second sheet of weather shield 100 can extend, for example, over the top three inches of the underlying tiles 90. Notably, no separate roofing material 44 and shield strip 84 requires field assembly and the mounting strip 48 of the prior embodiment is completely eliminated. This simplifies and expedites the installation of the tiles 90.
In a manner similar to that described above with respect to the previous or first embodiment, a second row or course of tiles 90 is inserted into the hooks 74 projecting upwardly above the first row of tiles 90 and between adjacent pairs of hooks 74 on the second or upper weather shield 100. This arrangement is shown in
The next step is to lay down another or third sheet of weather shield 100 over the top portion of the second row of tiles 90 and into the hooks 74 on the second layer of weather shield 100. The hooks 74 on the third weather shield 100 are located over the centerline or middle of each underlying tile in the second row of tiles 90 in a staggered pattern so that the hooks 74 on a third sheet of weather shield 100 (not shown) are vertically aligned directly in line over the hooks 74 on the first sheet of weather shield 100.
The installation of tiles 90 then proceeds as described above until the tiles 90 reach the top of the roof deck 10. At this point, a conventional roof ridge is installed over the ridge of the roof.
While the two preceding embodiments provide for the convenient installation of tile roofs without the need for highly skilled roofers while reducing the time and cost involved in installing a tile roof as compared to conventional nailing, it is further desirable to provide for increased tile protection against high winds when installing a single overlap tile roof. That is, because the two prior embodiments use less tiles than heavier conventional “three layer” tiles roofs and thereby apply less overlying weight to each underlying tile, the two installation systems described above can be more susceptible to wind damage than conventionally installed tile roofs which use three overlapping layers of tiles.
Wind damage is particularly acute along the first row or course of tiles installed over the eave of a building where wind can more easily flow under the first row or course of tiles and cause damage such as erosion and potential loss of tiles blown away by the wind. A more wind resistant tile eave would decrease wind damage which most often occurs along the eaves of tile roofs.
The next embodiment addresses these problems by providing greater stability and overlying weight along the first course of tiles installed along the eave of a roof. As seen in
Once the eave 12 is covered with the first course of, for example, 12×12 tiles, a mounting strip 48 is aligned over the top edges of these tiles in a close abutting relationship with hooks 74 centered over the top edges of the first layer of tiles 90 and then nailed or otherwise fastened to the roof deck 10. At this point, a second layer of tiles 90 is layered in a staggered pattern, beveled side up, over the first layer of tiles 90 and between adjacent hooks 74 as shown in phantom in
It should be emphasized that the hooks 74 on the mounting strip 48 are aligned over the middle or center line of each tile 90 in the first installed layer of tiles 90 and that the second layer of tiles 90 is positioned between and adjacent or against a pair of adjacent hooks 74. This results in the second layer of tiles 90 being centered over the open joints or cracks 110 in the first layer or course of tiles 90 so as to maximize the protection against rain or moisture leaking through the cracks 110 and onto the roof deck 10.
Once the first two layers of tiles are installed along the eave 12 to form the first tile row, a weather shield 100 as described above is layered over the mounting strip 48 and the top portion (such as the top three inches) of the first double layered row of tiles 90 as shown in
At this point, an upper row of slate tiles 90 is installed over the weather shield 100 by insertion into the hooks 74 on the mounting strip 48 and between adjacent pairs of hooks 74 on the weather shield 100, similar to that described above with respect to the second embodiment (see
Only one tile 90 in this upper or third layer of tiles 90 is shown in phantom in
The second or upper weather shield 100 is inserted into the hooks 74 on the first or lower weather shield 100, with the hooks 74 on the second or upper weather shield 100 aligned directly in line over the hooks 74 on the mounting strip 48 to provide a staggered symmetrical pattern of hooks 74. This results in the hooks 74 on the second weather shield 100 being positioned over the middle of each underlying tile 90 in the second row of tiles.
Tiles 90 are then installed over the second or upper weather shield 100 as described above with respect to the previous embodiment. This installation sequence is repeated until the tiles cover the roof deck 10 up to its ridge or top. It should be noted that the first row or course of tiles along the eave 12 receives the weight of two completely overlapped full size tiles as well as a portion of the weight of the tiles in the upper or second row of tiles. This weight provides increased resistance against wind damage.
The next embodiment enjoys all of the advantages of the previous embodiment while further simplifying tile installation and eliminating the need for mounting strip 48. This is achieved with the use of a modified drip edge 14 having a top strip 24 with an elongated height which exceeds the height of the eave tiles which overlie it. That is, as seen in
The modified or vertically extended drip edge 14 is provided with a first series of hooks 34 along the bottom edge portion of the top strip 24 as described above, but also provided with a second series of upper hooks 74 as shown in
The lateral spacing between the hooks 74 is the same as described above, allowing for the placement of a row of tiles 90 closely between each adjacent pair of hooks 74, as further shown in
Once the modified or enlarged drip edge assembly 14 is fastened over the eave 12 of roof deck 10 as described previously, a first layer of full size (e.g. 12″×12″) tiles is installed over the eave 12 by sliding the upper edge of each tile 90 under the hook 74 and shank 72 of each tile fastener on the drip edge 14 as shown in
The tile fastener shown in
Once the top portion of the tile is secured under the shank and hook of a tile fastener, it is pulled slightly downwardly so that the bottom edge of the tile seats securely in one or more hooks 34 on the drip edge assembly 14, as further shown in
The beveled edges of these first two layers of tiles can be arranged with their bottom chiseled or beveled edges 120 as shown in
Next, a weather shield 100 as described above is placed over the top portion of the upper layer of tiles 90 and inserted into the hooks 74 on the drip edge assembly 14 as shown in
With the weather shield 100 installed in place, a second row of tiles 90 is installed by centering each tile in a respective hook 74 on the drip edge assembly 14 and between a pair of hooks 74 on the weather shield 100. This second row of tiles 90 is shown in phantom in
The hooks 74 on the second weather shield 100 are positioned in line i.e. directly over the hooks 74 on the drip edge assembly 14 and midway between the hooks 74 on the first weather shield 100 to provide the symmetrically staggered tile pattern shown in
At this point, additional rows of tiles 90 and layers of weather shield 100 are installed upwardly along the pitch of the sloping roof deck 10 until the ridge of the roof is reached where a ridge cap or cover is installed.
It will be appreciated by those skilled in the art that the above weather shielding system for slate and tile roofs is merely representative of the many possible embodiments of the disclosure and that the scope of the disclosure should not be limited thereto.
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Number | Date | Country |
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WO 2012148453 | Nov 2012 | WO |