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EP1591601A1 - Roof insulation system - Google Patents

Roof insulation system Download PDF

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Publication number
EP1591601A1
EP1591601A1 EP05251935A EP05251935A EP1591601A1 EP 1591601 A1 EP1591601 A1 EP 1591601A1 EP 05251935 A EP05251935 A EP 05251935A EP 05251935 A EP05251935 A EP 05251935A EP 1591601 A1 EP1591601 A1 EP 1591601A1
Authority
EP
European Patent Office
Prior art keywords
framework
roof
longitudinal members
insulation
roof surface
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP05251935A
Other languages
German (de)
French (fr)
Inventor
Andy Christopher State
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP1591601A1 publication Critical patent/EP1591601A1/en
Withdrawn legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D11/00—Roof covering, as far as not restricted to features covered by only one of groups E04D1/00 - E04D9/00; Roof covering in ways not provided for by groups E04D1/00 - E04D9/00, e.g. built-up roofs, elevated load-supporting roof coverings
    • E04D11/02—Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
    • E04D13/1606—Insulation of the roof covering characterised by its integration in the roof structure
    • E04D13/1668—Insulation of the roof covering characterised by its integration in the roof structure the insulating material being masses or granules applied in situ

Definitions

  • This invention relates to an onsite formed insulation system for new and existing roofs and is particularly concerned with a method of insulating a roof.
  • a high amount of flat roof failures are due to the inability of the roof to shed surface water leading to "ponding" which leads to extra weight on the structure and water penetration.
  • the aim of this invention is to provide a quicker and easier installation that is not so dependent on dry weather conditions.
  • a method of insulating a roof comprising preparing a roof surface; laying a framework consisting of a plurality of first spaced longitudinal members extending substantially parallel to each other and a plurality of second spaced longitudinal members extending substantially parallel to each other and normal to the first longitudinal members on said roof surface; spraying a polyurethane insulation onto the roof surface to bond the framework to said roof surface, curing the insulation, trimming off any excess insulation and securing at least one sheet of rigid material to the framework.
  • the framework further comprises a series of legs which are secured to the longitudinal members at spaced intervals and serve to space the longitudinal members from the roof.
  • the insulation fills the space between the longitudinal members and the roof.
  • the legs are desirably secured to the first of said longitudinal members.
  • the longitudinal members preferably take the form of channel members which are desirably U-shaped in cross-section, the web of the U being located uppermost when the framework is laid on a roof.
  • the legs may be made of the same material as the channel members.
  • the roof insulation system according to the invention may be installed on a flat or a sloping roof. If it is desired to convert an existing flat roof to a sloping roof, the supporting legs of the framework will have differing heights to provide a desired inclination or "slope" of the longitudinal members of the framework.
  • the sheet material consists of plywood which is secured to the longitudinal members of the framework by screws or other suitable fixing means. After fitting, the sheet material will normally be covered by a waterproofing membrane such as a layer of felt.
  • the invention also extends to a roof insulation constructed by the above-described method.
  • the sloping roof structure comprises an existing flat roof 1 including a decking 2 supported on a roof structure 3.
  • the roof decking is covered with a felt roofing layer covered with a bitumen roof membrane having a gritted surface 4 which has deteriorated and is sagging in places forming depressions for ponding water.
  • the existing surface 4 is prepared by removing all surface water and then de-gritting the surface which will remove approximately twenty kilogram per square metre and any damage to the surface is repaired.
  • the bitumen roof membrane now acts as a vapour barrier for the new installation.
  • a series of legs 5 of varying lengths are cut from a lightweight galvanized channel. The lengths of the various legs 5 will depend on the desired inclination or slope of the roof which is to be fitted onto the existing roof 1.
  • a further series of channel members 6 are cut to length from light weight galvanized channel and are of such a length that they can extend over the existing roof 1 at a desired inclination or slope. If necessary, the lengths of metal channel can be joined together by joining strips 10 if the channel members 6 are not long enough to extend over the length of the roof 1.
  • the legs 5 can now be secured to the channel members 6, at suitably spaced intervals, by means of self-tapping screws.
  • Adjacent channel members 6 are connected to each other by further channel members 7 which serve to hold and join the channel members 6 together to form a supporting framework which is positioned on the roof 1.
  • polyurethane insulation 17 is sprayed onto the surface 4 and expands and rises to the top of the channel members 6 and 7. This insulation will bond the framework 5,6,7 to the existing roof surface 4, preventing any wind up lift.
  • the polyurethane is allowed to cure and is then trimmed level with the channel members 6 and 7 after which a layer of plywood 8 is screwed to the channel members.
  • the plywood preferably consists of 9 mm W.B.P. exterior grade plywood but other materials may be used if desired.
  • the existing upstand kerb 19 and tantalised wood fillet 11 can be raised and refitted to the wall and drip battons 12 are fitted to the fascia board 15. It may be necessary to replace an existing fascia board with a new fascia board of increased height to accommodate the increased height of the new roof. Any roof lights (not shown) can also be raised to accommodate the increased height of the new roof decking 8.
  • the insulation system according to the invention is now ready for waterproofing.
  • a new waterproofing membrane for example, a layer of felt 14 can be laid on the decking.
  • a layer of felt 14 can be laid on the decking.
  • the roof insulation system of this invention can be used to insulate and seal a sloped roof, for example an asbestos roof.
  • the legs 5 can be omitted and the framework of channel members 6 and 7 laid directly on the corrugations of the asbestos roof, by first fitting an increased height fascia board 15 to the low point 18.
  • the framework 6 and 7 can be fixed together at ground level in areas of approximately 25 metres and lifted and laid in place and then the system can be carried out as previously described. This will seal in any danger of asbestos spores being airborne again.
  • the system according to the invention can also be used to create the falls on all types of new structures, concrete metal deck roofs and timber. There are no restrictions as to what roof systems this can be used for. On a new roof the foam will create its own vapour barrier.
  • the decking need not be made of plywood but could consist of other suitable materials.
  • the framework need not consist of galvanized metal but could be made of a suitable plastics material.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)
  • Working Measures On Existing Buildindgs (AREA)
  • Building Environments (AREA)

Abstract

A roof insulation system comprises the steps of preparing a roof surface (1), laying a framework of channel members (6) on the roof surface, spraying a polyurethane insulation (17) onto the roof surface (1) to bond the framework to the roof surface, curing the insulation, trimming off any excess insulation and securing at least one sheet (8) of rigid material to the framework. The framework consists of a plurality of first channel members (6) which are spaced apart and extend substantially parallel to each other and a plurality of second channel members (7) which serve to connect adjacent first channel members (6) to one another. The framework may be spaced from the roof surface (1) by a series of legs (5).

Description

  • This invention relates to an onsite formed insulation system for new and existing roofs and is particularly concerned with a method of insulating a roof.
  • A high amount of flat roof failures are due to the inability of the roof to shed surface water leading to "ponding" which leads to extra weight on the structure and water penetration.
  • There are numerous forms of laid to fall roof insulation systems on the market. Slabs of insulation are bonded in hot run bitumen. The existing roof surface of most old flat roofs have ponded and sunken areas. When an insulation board is bonded to the roof it will have a void beneath it. If extra bitumen is applied to fill the void it will burn the insulation. Waterproofing membranes are bonded to the insulation and, when they require renewing, it is impossible to remove the membranes without having to renew the entire insulation system.
  • With the present systems, a large area is needed to store the materials and to keep them dry. The use of hot run bitumen is dangerous.
  • The aim of this invention is to provide a quicker and easier installation that is not so dependent on dry weather conditions.
  • According to the present invention, there is provided a method of insulating a roof comprising preparing a roof surface; laying a framework consisting of a plurality of first spaced longitudinal members extending substantially parallel to each other and a plurality of second spaced longitudinal members extending substantially parallel to each other and normal to the first longitudinal members on said roof surface; spraying a polyurethane insulation onto the roof surface to bond the framework to said roof surface, curing the insulation, trimming off any excess insulation and securing at least one sheet of rigid material to the framework.
  • Preferably, the framework further comprises a series of legs which are secured to the longitudinal members at spaced intervals and serve to space the longitudinal members from the roof. The insulation fills the space between the longitudinal members and the roof. The legs are desirably secured to the first of said longitudinal members.
  • The longitudinal members preferably take the form of channel members which are desirably U-shaped in cross-section, the web of the U being located uppermost when the framework is laid on a roof. The legs may be made of the same material as the channel members.
  • The roof insulation system according to the invention may be installed on a flat or a sloping roof. If it is desired to convert an existing flat roof to a sloping roof, the supporting legs of the framework will have differing heights to provide a desired inclination or "slope" of the longitudinal members of the framework.
  • Preferably, the sheet material consists of plywood which is secured to the longitudinal members of the framework by screws or other suitable fixing means. After fitting, the sheet material will normally be covered by a waterproofing membrane such as a layer of felt.
  • The invention also extends to a roof insulation constructed by the above-described method.
  • The invention will now be described in detail, by way of example, with reference to the drawings, in which: -
  • Fig.1 is a fragmentary perspective view of one embodiment of a sloping roof insulation system according to the invention; and
  • Fig. 2 is a cross-section of the sloping roof insulation system shown in Fig. 1 showing the guttering.
  • Referring now to the drawings in detail, the sloping roof structure comprises an existing flat roof 1 including a decking 2 supported on a roof structure 3. The roof decking is covered with a felt roofing layer covered with a bitumen roof membrane having a gritted surface 4 which has deteriorated and is sagging in places forming depressions for ponding water. The existing surface 4 is prepared by removing all surface water and then de-gritting the surface which will remove approximately twenty kilogram per square metre and any damage to the surface is repaired. The bitumen roof membrane now acts as a vapour barrier for the new installation.
  • A series of legs 5 of varying lengths are cut from a lightweight galvanized channel. The lengths of the various legs 5 will depend on the desired inclination or slope of the roof which is to be fitted onto the existing roof 1. A further series of channel members 6 are cut to length from light weight galvanized channel and are of such a length that they can extend over the existing roof 1 at a desired inclination or slope. If necessary, the lengths of metal channel can be joined together by joining strips 10 if the channel members 6 are not long enough to extend over the length of the roof 1.
  • The legs 5 can now be secured to the channel members 6, at suitably spaced intervals, by means of self-tapping screws. Adjacent channel members 6 are connected to each other by further channel members 7 which serve to hold and join the channel members 6 together to form a supporting framework which is positioned on the roof 1.
  • Once the framework has been positioned on the roof 1, polyurethane insulation 17 is sprayed onto the surface 4 and expands and rises to the top of the channel members 6 and 7. This insulation will bond the framework 5,6,7 to the existing roof surface 4, preventing any wind up lift. The polyurethane is allowed to cure and is then trimmed level with the channel members 6 and 7 after which a layer of plywood 8 is screwed to the channel members.
  • The plywood preferably consists of 9 mm W.B.P. exterior grade plywood but other materials may be used if desired.
  • The existing upstand kerb 19 and tantalised wood fillet 11 can be raised and refitted to the wall and drip battons 12 are fitted to the fascia board 15. It may be necessary to replace an existing fascia board with a new fascia board of increased height to accommodate the increased height of the new roof. Any roof lights (not shown) can also be raised to accommodate the increased height of the new roof decking 8. The insulation system according to the invention is now ready for waterproofing.
  • A new waterproofing membrane, for example, a layer of felt 14 can be laid on the decking. There is no restriction on the type of waterproofing membrane that can be applied over this type of roof insulation system. These may include lightweight tiles and battens.
  • When it becomes necessary to strip the waterproofing membrane this can be readily carried out, for example, first thing in the morning when the air is cool, with little or no damage to the plywood decking 8 or polyurethane insulation 17.
  • Although the installation of the system has been described in respect of an existing flat roof, the roof insulation system of this invention can be used to insulate and seal a sloped roof, for example an asbestos roof. In this case, the legs 5 can be omitted and the framework of channel members 6 and 7 laid directly on the corrugations of the asbestos roof, by first fitting an increased height fascia board 15 to the low point 18. The framework 6 and 7 can be fixed together at ground level in areas of approximately 25 metres and lifted and laid in place and then the system can be carried out as previously described. This will seal in any danger of asbestos spores being airborne again.
  • The system according to the invention can also be used to create the falls on all types of new structures, concrete metal deck roofs and timber. There are no restrictions as to what roof systems this can be used for. On a new roof the foam will create its own vapour barrier.
  • The invention is not restricted to the above-described embodiment but modifications and variations may be made without departing from the scope of the invention. For example, the decking need not be made of plywood but could consist of other suitable materials. Further, the framework need not consist of galvanized metal but could be made of a suitable plastics material.

Claims (10)

  1. A method of insulating a roof characterized in that the method comprises the steps of preparing a roof surface (4); laying a framework consisting of a plurality of first spaced longitudinal members (6) extending substantially parallel to each other and a plurality of second spaced longitudinal members (7) extending substantially parallel to each other and normal to the first longitudinal members on said roof surfaces (4); spraying a polyurethane insulation (17) onto the roof surface (4) to bond the framework to said roof surface, curing the insulation, trimming off any excess insulation and securing at least one sheet of rigid material (8) to the framework.
  2. A method according to claim 1, characterised in that the framework further comprises a series of legs (5) which are secured to the longitudinal members (6,7) at spaced intervals and serve to space the longitudinal members from the roof surface (4).
  3. A method according to claim 2, characterized in that the legs (5) are secured to the first of said longitudinal members (6).
  4. A method according to claim 2 or claim 3, characterized in that the longitudinal members (6,7) take the form of channel members.
  5. A method according to claim 4, characterized in that the channel members (6,7) are U-shaped in cross-section, the web of the U being located uppermost when the framework is positioned on a roof surface (4).
  6. A method according to claim 4 or claim 5, characterized in that the legs (5) are made of the same material as the longitudinal members (6,7).
  7. A method according to any one of claims 2 to 6, characterized in that the legs (5) have differing heights to provide a desired inclination or slope of the longitudinal members (6,7) of the framework for a sloping roof.
  8. A method according to any one of the preceding claims, characterized in that the sheet material (8) consists of plywood.
  9. A method according to any one of the preceding claims, characterized in that the sheet(s) of rigid material (8) is/are secured to the longitudinal members (6,7) of the framework by screws or other suitable fixing means.
  10. A method according to any one of the preceding claims, characterized in that the sheet(s) of rigid material (8) is/are covered by a waterproofing membrane after the sheet material (8) has been secured to the framework, said waterproofing membrane preferably consisting of a layer of felt.
EP05251935A 2004-04-29 2005-03-29 Roof insulation system Withdrawn EP1591601A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0409581A GB2413571B (en) 2004-04-29 2004-04-29 Roof insulation system
GB0409581 2004-04-29

Publications (1)

Publication Number Publication Date
EP1591601A1 true EP1591601A1 (en) 2005-11-02

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ID=32408250

Family Applications (1)

Application Number Title Priority Date Filing Date
EP05251935A Withdrawn EP1591601A1 (en) 2004-04-29 2005-03-29 Roof insulation system

Country Status (3)

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US (1) US20050257491A1 (en)
EP (1) EP1591601A1 (en)
GB (1) GB2413571B (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9500555B2 (en) * 2010-01-19 2016-11-22 Clark Robert Gunness Method and system for leak detection in roofing and waterproofing membranes
CN103174223B (en) * 2013-03-19 2016-12-28 浙江倍特门窗工程有限公司 A kind of building surface heat insulation structural and method of construction thereof

Citations (6)

* Cited by examiner, † Cited by third party
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DE1509482A1 (en) * 1965-07-02 1969-02-20 Alfred Hein Process for the production of a sub-floor for laying parquet, including mosaic parquet and synthetic floors of all kinds, as an alternative or in contrast to conventional cement screeds with a high moisture content and long drying time
GB1468419A (en) * 1973-12-20 1977-03-23 Kullberg B Floor arrangement
DE19744148A1 (en) * 1997-10-07 1999-04-29 Ferdinand Goldenberg Sealing flat roofs to include roof inclines
DE10007101A1 (en) * 2000-02-16 2001-08-23 Peter Suemmerer Levelling device for flat surfaces consists of battens held together by height adjustable fish plates
EP1138846A2 (en) * 2000-04-01 2001-10-04 Auroflex GmbH & Co. KG Covering for balconies and terraces
EP1231336A1 (en) * 2001-02-07 2002-08-14 Fingar d.o.o. Resilient sports floor

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US3320704A (en) * 1964-05-21 1967-05-23 Nat Rolling Mills Co Roof deck and method of construction
US3698972A (en) * 1968-08-14 1972-10-17 James Lenzner Method of sealing and insulating a roof construction
DE2650153A1 (en) * 1976-10-30 1978-05-03 Otto Gregusch Insulation and sealant for flat or slightly sloping roofs - by fitting insulation panels to form drain channels and applying several layers of polyurethane foam
US4253288A (en) * 1979-07-13 1981-03-03 Chun Joo H Prefabricated wall panel
US4324080A (en) * 1979-12-17 1982-04-13 Mullins Wayne L Thermally insulative cementitious block modules and method of making same
US4434601A (en) * 1980-02-26 1984-03-06 Hans Zellmer Heat insulated roof structure
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FR2532673B1 (en) * 1982-09-07 1985-08-09 Smac Acieroid COVERING, INSULATION AND WATERPROOFING
GB2128219B (en) * 1982-10-07 1986-04-03 Linton Systems Ltd Improvements in ceiling/floor or ceiling/roof structure
DE3407459A1 (en) * 1984-02-29 1985-09-26 durol flying lindauer lkh montage GmbH, 8990 Lindau METHOD FOR COATING AND HEAT-INSULATING WALLS AND CEILINGS OR THE LIKE AND DEVICE FOR IMPLEMENTING THE METHOD
US4631878A (en) * 1984-12-19 1986-12-30 Laramore Larry W Pedestal and framing system for supplemental roof construction
US4608791A (en) * 1985-08-05 1986-09-02 Butler Manufacturing Company Slope build-up system for roofs
NL8702908A (en) * 1987-12-03 1989-07-03 D3Bn Adviesbureau Civ Ing COVERING METHOD AND APPARATUS.
US4831794A (en) * 1988-03-07 1989-05-23 Perry Kenneth W System for forming a sloped surface on a flat roof deck
US5442890A (en) * 1993-10-12 1995-08-22 Fligg; Robert E. Installing insulation in buildings
US5799461A (en) * 1995-10-23 1998-09-01 Dittemore; David Method and apparatus for insulating buildings
US5720147A (en) * 1996-05-14 1998-02-24 Owens-Corning Fiberglass Technology, Inc. Method of insulating metal deck roof structures
US5901518A (en) * 1996-07-01 1999-05-11 Harkins; Daniel J. Building insulation system with fall protection
DE19750769C2 (en) * 1997-11-10 2000-09-14 Hema Beschichtungsservice Process for covering asbestos cement surfaces
US6418687B1 (en) * 2000-08-08 2002-07-16 Stanley Alfred Cox Insulated roofing system
US6581348B2 (en) * 2001-06-15 2003-06-24 John P. Hunter, Jr. Seamless foam panel roofing system
FR2838143B1 (en) * 2002-04-05 2005-05-13 Soprema METHOD FOR FASTENING AN INSULATION LAYER AND COATING IMPLEMENTED IN SAID METHOD
US6832460B2 (en) * 2003-02-18 2004-12-21 Robert E. Fligg Method and apparatus for insulating building roofs from above

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1509482A1 (en) * 1965-07-02 1969-02-20 Alfred Hein Process for the production of a sub-floor for laying parquet, including mosaic parquet and synthetic floors of all kinds, as an alternative or in contrast to conventional cement screeds with a high moisture content and long drying time
GB1468419A (en) * 1973-12-20 1977-03-23 Kullberg B Floor arrangement
DE19744148A1 (en) * 1997-10-07 1999-04-29 Ferdinand Goldenberg Sealing flat roofs to include roof inclines
DE10007101A1 (en) * 2000-02-16 2001-08-23 Peter Suemmerer Levelling device for flat surfaces consists of battens held together by height adjustable fish plates
EP1138846A2 (en) * 2000-04-01 2001-10-04 Auroflex GmbH & Co. KG Covering for balconies and terraces
EP1231336A1 (en) * 2001-02-07 2002-08-14 Fingar d.o.o. Resilient sports floor

Also Published As

Publication number Publication date
GB0409581D0 (en) 2004-06-02
GB2413571B (en) 2006-04-12
US20050257491A1 (en) 2005-11-24
GB2413571A (en) 2005-11-02

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