US2048663A - Roof covering - Google Patents

Description

S. P. MILLER ROOF COVERING July 21, 1936.

2 Sheets-Sheet l Filed Dec.

a a SK 5mm lNvENToR Suar 7 /Vl/'l/er ATTORNEY July 21,1936. R MMER A 2,048,663

ROOF COVERIIIG Filed Dec. 22, 1935 I 2 Sheets-Sheei. 2

ATTORNEY Patented July 21, 1936 UNITED' STATES" 'PATENT OFFICE 2,048,663 Boor 4covlmme.

Stuart Parmelee li/Iiller, Scarsdale, N. Y., assignor to The Barrett Company, New York, N. Y., a corporation of New Jersey Application December 22, 1933, Serial No. '703,591

5 One object of this invention is to provide antV improved method of sealing together overlap-jv; ping edge portions of bitumen-coated roofing .i

sheets by the application of cement at atmospheric temperature, i. e., by the application of cement which does not require heating to ren-4 der it Huid.

Another object of this inventionis rto provide selvage roofing sheets whichv can 'be laid in overlapping relation and eifectvelyjoined together along the overlapping edge portions by means of dition at atmospheric temperatures can not sat- `isfactorily be applied to such selvage roofing to such cement to provide a well bonded roof .coverng. Y a

Other objects and advantageswill appeary from 4 the following detailed description yof the inven-4 tion. A

Prior to this invention, it was common practice to manufacture selvage roll-roofing by ap-f-,j' plying a coating of water-proofing material, such" as asphalt or bitumen, tothel lowerv or forwardg5 half of the top sidelof a saturated felt base 'and v surfacing this coating'with crushed slate or other granular mineral material. The upper` half of the top and the entire bottom*A ofthev saturated felt base were left uncoated and unsurfaced. There wasl thus produced `sl1ee't'.lroo`flng having a raised portion substantially parallel to the longitudinal edges of the base wherethe coated and surfaced forward portion met the uncoated and unsurfaced selvage portion. Such roofing was customarily laid in parallel rows or courses with the uncoated and unsurfaced selvage area of one course underlying the coated and surfaced area of the overlying course, the forward edge of the overlying course abutting against the raised area of the underlying course. Before applyingv the next' succeeding c ourse, hot molten asphalt was mopped by the roofer onto the selvage area of the preceding course to cementithe two sheets of roofing together, or, alternatively, the hot molten asphalt was mopped on thel undersurface of the overlying sheet, which was then slapped down and pressed on the underlying sheet.

4This method of "laying the roofing had the dlsadvantage that large quantities of hot coating material had to be employed to get the necessary bonding action between the adjacent sheets.

In addition, such method involved high laborv for application, and the use of special equipment,

phalt from mops.

, pheric temperatures.

suchr as heaters and melting pots, required for this purpose. Moreover, there was always a nre hazard to be considered.

Other disadvantages ofthe hot asphalt methodkof application are: chilling of asphalt in cold 5 Weather before complete adhesion is effected, re-

sulting in poor bond; eXtra labor required in carrying buckets of hot asphalt, and spills and ksmears on roof resulting from this step; smears of asphalt on roof due to `dripping of hot as- 10 Furthermore, rapid cooling of asphalt encourages hurried work which is, therefore, frequently of poor quality.v l

. I have found that the usual bituminous and other cements which can be applied in fluid vcon- 15 obtain a well bonded roof covering. This may be attributed to the absorption of the cement by the y'fbond the overlapping portion of one-sheet with tlieunderlapping portion of an underlying roofing sheet.

" In accordance with myl invention an improved type of roll roofing is produced which can be 25 effectively sealed and bonded together in overlapping relation by means of a bituminous or other waterproof cement which is fluid at latmospheric temperatures and which may be applied Y by brushing or painting. Such roofing differs 30 from the usual type of selvage roofing described ab'ove'in that either the underside of the overlapping sheet or the top side of the underlapping sheet or both of these areas are provided with` a coating of asphalt or other bituminous'35 water-proofing material. For example, the sheet may comprise a 32 inch wide base of saturated felt, asbestos, or other suitable fibrous materiah having theunderside completely coated with bituminous material and dusted with mica flakes, 40 talc, soapstone, or other antistick material, and having on the top side a 15 inch wide coating layer of asphalt surfaced with granular material and a 3 inch wide portion contiguous to the 15 lar to that described above, the overlapping sheets can be effectively joined or sealed together by means of abituminous cement fluid at atmos- The cement may be mopped onto the 'unsurfaced portion of the top 55 side of each sheet after it is applied and thereafter the overlapping sheet placed in desired relation to the underlapping sheetor it may be mopped onto the back of each sheet as it is e placed over the underlapping sheet. A suitable ing the asphalt, fire hazard, and inconvenience' and possible injury to workmen are avoided. 'I'he workmen can take adequate time to do a satisfactory `job, unhurried by fear of the cement setting before the sheets are in place. 'I'he amount of cold cement necessary to secure a proper bond is much less than the amount of hot asphalt customarily used and labor costs are substantially reduced. In actual practice the use of a cold cement in accordance with this invention results in considerable saving in the roof construction (under present market conditions the saving is of the order of about 10 cents per square of roof laid) and in a well bonded and eilicient roof covering. It has been found that so rm a bond may be established between. ad-

jacent layers of roofing that the layers cannot be separated after setting of the cement without tearing the felt.

In the accompanying drawings forming a part of this specicationand showing for purposes of `exempliiication preferred forms of this invention, without vlimiting the claimed invention toisuch illustrative instances.-

Fig. 1 is a side elevation of apparatus for making the selvage roll roofing in accordance with this` invention-the figure being somewhat diagl 4rammatic in character and showing the steps inv.volve'cl in'the manufacture ofv the roofing;

. Figs. 6 to 9 are transverse vertical sectionsvthrough'nmodied types of roofing made'in accordance with this invention.

Referring to the drawings, with particular reference to Fig. 1. numeral I denotesa sheet of flbrous material, for example the usual 'roofing felt made from'rag ber and paper stock with or without suitable fillers as well known in this art. Instead of such roong felt the sheet maybe made of asbestos felt, or other absorbent'- fibrous material. Sheet I is fed by feedrolls 2 from the usual paper making machine, felt roll, or other suitable source of supply into a looping device 3.

From the looping device 3, rolls 4 feed the sheet into any customary type of saturating apparatus, indicated generally by the reference numerall. Saturating tank 6 mayeontain suitable cementitious waterproofing composition, such as as.- phalt or other bituminous material,l utilized for the impregnation and saturation of roofing feits.

Rolls I and 3 feed the saturated sheet to a second looping device 9, thus giving the saturant the necessary opportunity to dry and thoroughly impregnate the fibrous base. Rolls I I and I2 feed the saturated sheet from the looping device 9 to the coating appliances indicated by the reference numeral I3. Feed rolls I2 are preferably driven at substantially the same average peripheral speed'a's that of coating rolls I4 and I5. A suilicient amount of slack should be provided and maintained between the driven rolls I2 and guide roll I6 over which the sheet passes before entering the bite'of the coating rolls I4 and I5 to prevent the sheet from being injured or torn upon slight momentary variations in the .for coating rooiingv felt.

The base or under side of the sheet I is completely coated by roll I5. Simultaneously, waterfprooilng material is applied to the top of the sheet by means of pipe I8. This pipe is arranged to feed coating material to form a stripe or layer on only the lower or forward portion of the base (see Fig. 3). Flow of coating material onto the upper selvage portion of the base, indicated by the reference numeral I3, is prevented by a plate 2| which may be hollow for the introduction of steam thereinto to heat the plate. To produce the type of roofing shown in Fig. 3, coating roll Il may be provided with a narrow metal collar 22 extending thereabout at a point contiguous to plate! I. This collar is of such thick.'- --ness that a small clearance is provided between the collar and the felt base I. Plate 2| is suitably supported so that the felt base in its passage thereunder-,under tendon exerted by the feed ,rolls, contacts with the base of this plate and prevents the coating from spreading.

The coated sheet. leaving coating rolls I4, I5 has on the lower portion of the upper surface a relatively wide layer: or stripe .of coating material 23 .of substantially. 'uniform thickness. Contiguous to the 'wide layer 23 is a relatively narrow layer 24 of coating material, which'layer may be thinner than layer 23. The longitudinal edges of the'coating layers 23 and 24 are substantially parallel to 'each other and also parallel to the longitudinaledges of the base. The remaining portion of the base is constituted of the uncoated selvage area I3.

Upon leaving the coating appliances, and while thev coating material is still tacky, the sheet passes under hopper 25, containing granular material, such as crushed rock, slate, or other comminuted lmineral material customarily used in surfacing rooiingf The granules are showered by means of the usual distributing roll-26 onto the coating stripe 23 of the base passing therebeneath. Hopper 25 is oi' a width such that granular material s ed only onto the coated stripe 23.

vIl desired, a guide plate may be provided beneath hopper 25 to insure that no granules fall on the relatively thin coating stripe 2l. The surfaced sheet then passes about reversing roll 21,' which functions to partially embed the granular mate- 'rial in the plasticy coating stripe 23. In the continued passage ofthe sheet, excess granules fall oi therefrom into hopper25` from whence they were delivered onto the base I.

The rear surface of the sheet I then passes '4(5 Cil posed contiguous to stripe 23.

under hopper 28. Mica. dust, talc, or other composition capable of rendering the back of the sheet non-cementitious is deposited in hopper 28 and discharged therefrom by distributing roll 29 onto the back of the sheet. The mica covered sheet then passes over reversing roll 3 I, which imparts a smooth surface to the back of the sheet. Excess mica falls oif from the base as it passes from roll 3| to the drying and pressing rolls 32. Hopper 28 is preferably so positioned that the excess mica falls back thereinto as shown in Fig. 1.

Feed rolls 33 feed the sheet from the pressing rolls 32 into a looping device or rack 34 where the product is given an opportunity to cool. From the looping rack 34, the completed roofing passes between feed rolls 35, about guide roll 36, and is fed by pull rolls 31 t a suitable winding device (not shown), where the roong is rolled up into the usual roll of commerce. v

Roofing resulting from the operations above described, is shown in vertical section in Fig. 3. From this figure it will be noted that the roofing is composed of a base 38 of saturated felt or other fibrous material. The upper portion of the face or top of the base is constituted of the selvage area I9. Relatively thick coating stripe 23, the forward edge of which coincides with the forward edge of the base, covers the lower portion of the top -of the base. Narrow coating stripe 24 is dis- Granular material 39 is partially embedded in coating stripe 23, and mica dust or talc 4I is dusted over the coating layer 42 coveringy the back of the sheet to render coating 42 nonadhesive. Since coating stripe 24 is substantially thinner than the combined thickness of coating layer 23 and granular surfacing 39, the roofing of-Fig. 3 may bevrolled without danger of plastic coating 24 causing adhesion of successive convolutions of the roll.

In the manufacture of sheet roofing l32 inches wide, the coated stripe 23 is preferably made 15 inches wide andthe coated stripe 24, three inches wide, leaving the uncoated selvage portion I9, fourteen inches wide. l

Instead of simultaneously producing the relatively thin narrow and wide thick coating stripes 24 and 23 respectively by the apparatus shown in Fig. 1, a stripe of uniform thickness and of a width equal to the combined widths of stripes 23 and 24 may be first applied to the saturated base. The coated sheet may then be engaged by a scraper which removes a portion of the coating to form the coating stripe 24.

The sheet roofing described above may be laid in successive overlapping courses on a roof or other surface in the manner shown in Figs. 4 and 5. The first sheet A is unrolled along the roof 44 or other surface and attached thereto in any suitable manner, such as by means of cement, nails, etc. The next sheet of roof-lng, denoted by letter B, is then applied with its forward edge abutting against the upper edge 46 of the granular surfaces portion -39 of the underlying sheet. A suitable cold cement 4B is painted or mopped onto the unsurfaced areas of the top of sheet A, i. e., sely vage area I9 and coating lstripe 24, or onto the coating 42 on the forward portion of the bottom of sheet B before this sheet is contacted with the underlying sheet. Other sheets of roofing C, D,

and E are then laid in a similar manner until the asbestos bers. The relative amount of asbestosv in the composition preferably lies within the range of from 2 to 10%. I have found that a mixture containing 95% cut-back asphalt, i. e.

. asphalt plus solvent, and 5% asbestos fibers gives excellent results. The cut-back asphalt preferably has a specific Engler viscosity of approximately 10'to 15 at 50 C. The solvent component of the cement composition is preferably suiliciently volatile that it will evaporate at substan-` largely due to the uxing or solvent action of the cement on the coating layers on the sheets. When hot, molten asphalt is employed to cement roofing, it is diflicult and often impossible to effect with it a good bond between surfaces covered with soapstone flakes, talc or like noncementitious substances. The cold, cut-back asphalt cements described above, however, penetrate layers of such non-cementitious materials as are used to prevent sticking of adjacent plies of roofing in rolls or packages, and well-bonded n joints result. Since soapstone flakes, talc or the like may be applied to those areas of the roofing which in laying areto be cemented, manufacturing, shipping and handling of the roofing of this invention is greatly facilitated.

The narrow seal coating stripe 24 on the top of the sheet improves the weathering properties ofthe resultant roof structure. Even though the workmen carelessly apply the cold cement to the top of the sheet and fail to apply cement contignous to the granular surfaced edge 46, as has frey-quently been theA case in practice, and even -thiughlue to irregularities in edge 46 and the forward edge of the overlying course, portions of the roofing above edge 46 are left exposed to the The cement quickly dries to produce anA weather, the portions thus left uncovered or exposed are protected by stripe 24.

Figs. 6 to 9 show sectionsthrough modified vtypes of roong sheets which may be manufactured and laid in accordance with this invention. Each of these sheets, like that of Fig. 3, has a 'layer of coating material at least on those portions of the top and/or bottom faces of the sheet adapted to be overlapped when laid, thereby preventing the cold bonding cement from being absorbed by the saturated felt base. Those modiv cations having a coating layer covering' the entire under. surface are heavier (other things being equal), afford better roof protection, are more eiectively sealed against absorbing moisture from 60 4oli' this'invention may be used having both its upper and un er surfaces completely covered with asphalt coati The roofing shown in Fig. 6 differs from that of Fig. 3 in that the under side of the saturated base 39 is provided with a coating layer 50, dusted with mica 5I, covering only'the forward edge of the sheet. i. e., that portion adapted to overlie an adjacent sheet, instead of the entire width of the sheet. If the combined width of the selvage area I9 and the narrow stripe 24 on the top of the sheet is 17 inches, the coating layer 50 on the back of the sheet is preferably also 17 inches. 76

The modified sheet of roofing depicted in Fig. 7 is similar to that shown in Fig. 3 with the exception that no narrow stripe of coating 24 is provided on the upper face of the saturated base 38 adjacent the edge 46 of the coated and surfaced area. Similarly, the roofing of Fig. 8 is the same as that of Fig. 6 with the exception that the coating stripe 24 is omitted.

Fig. 9 shows a sheet of roofing comprising a saturated base 38 having a coating layer 52 covering the entire face thereof. A surfacing of mineral granules 39 covers the coating on the for- A ward portion of the sheet, the coating onthe selvage area having fine mica flakes 54 or other equivalent material applied to the surface thereof. The under side of the sheet is uncoated and unsurfaced.

Numerous other modied types of roofing may be madeand applied in overlapping relation in accordance with this invention. For example, both the selvage area and the entire. bottom or both the selvage area and the rear portion of the, bottom of each sheet may be coated with waterproofing material.

As has been pointed out above, the cement is preferably applied at substantially atmospheric n temperature without externalheating. Under some conditions', however, especially in winter when the outside temperature is very low, I may use the cement at moderately elevated temperatures, e. g., under 100 C. to improve its brushing qualities.

lInstead of using cements comprising a mixture `.of asphalt and a volatile component, i. e., a cutback asphalt, I may employ bituminous emulsions. For example, I may use an emulsion containing volatile components as the continuous phase, such components being sufliciently volatile to evapo- 'rate at temperatures below 100 C.

It will be noted that the laying of the roofing made in accordance with this invention by means of a cold cement is simple. rapid, and eiiicient. 'Ihe overlapping sheets can be cemented together with less inconvenience to workmen`than has -heretofore been possible. All danger of fire hazard and personal injury is removed. My invenvention permits a substantial veconomy to be effected since very little time is required to apply the Vcement by mopping or painting and the use of fuel and heating equipment is avoided. A substantially continuous roof deck is formed owing to the strength and durabilityof the cemented joints. f y

While it is usually preferable to' apply coating during the'manufacturing process to the surface .or surfaces to be cemented, according to this invention such coating may alternatively be applied. as a separate step, and'may even be applied by the roofer on the job before laying. In such an .operation the roofer may apply a sufficiently l heavy coating of a bituminous cement to an uncoated portion of the joint to be lapped, allow the cement to dry or otherwise set, and then proceed as described above.A The cement applied for coating may be of the sam'e type as that used for uniting adjacent layers of roofing. Since certain changes in carrying out the above out departing from itsscope, it is intended that all matter contained in the above description or vshown in the accompanying drawings shall be interpreted as, illustrative land not in a limiting sense.

and a fibrous bituminous cement containing a volatile component, applied cold in readily brushable condition, between the overlapping portions of the sheets, the volatilecomponent of said cement uxing with the bituminous coating between the lapped portions, thereby forming a rm bond between the sheets.

2. A roof coveringv comprising a plurality of bitumen saturated roofing sheets, each having a portion to be exposed and a selvage portion, a coating layer extending over the top side of the portion to be exposed and over ata/least a part of the selvage portion, a layer of granular surfacing material partially embedded in 'the said portion of the coating layer on the `said portion to be exposed, the said portion of the coating layer on the selvage portion being free of granular material, the underside of. each sheet/ hav-I ing a coating layer of bituminous material thereon, said sheets being laid in overlapping relation with the surfaced portion of one sheet overlapping the selvage portion of an underlying sheet 35 so that the coating layer on the underside of the overlapping sheet is superposed on the selvage portion of the underlyingsheet, and a fibrous bituminous cement containing a volatile component applied cold in readily brushable condition to Athe overlapping portions of said sheets, the volatilecomponent of said cement fluxingv with the said coating layer Superposed upon the said selvage portion of v the underlying sheet, thereby forming a firm bond between the sheets. 3. A roof covering comprising a plurality. of bitumen saturated selvage edge felt base roo'nng sheets, each having a top side comprising a coated and surfaced exposed portion and a selvage portion, and the underside of eachsheet having a coating layer completely covering the said underside, said sheets being laid in overlapping relation with the surfaced portion of #one sheet overlapping the selvage portion of an underlying sheet, and a fibrous bituminous cement containing a volatile component applied cold in readily brushable condition between the overlapping portions of said sheets, the volatile component of said cement uxing with the coating on the iinderside of the overlying sheet, thereby forming 60 a firm bond between the sheets.

4. A roof covering comprising a plurality of vbitumen saturated roofing sheets, each having a portion to be exposed anda selvage portion, fa` coating'layer extending overy the top-side Iof the 65 portion to be exposed, a layer of granular surracing material partially. embedded in the vsaid i coating layer on the said portion to be exposed, the underside of each sheetl having a coating layer of bituminous material thereon extending over substantially the entire area of said underside and covered with inely divided antistick material, said sheets being laid in overlapping relation with the vsurfaced portion of one sheet v overlapping the selvage portion of an underlying sheets, the volatile componentl of said cement sheet so that the coating layer on the underside penetrating said antistickmaterial and fiuxing of the overlapping sheet is superposed on the with the said coating layer superposed'upo'n the selvage portion of the underlying sheet, and a. said selvage portion of the underlying sheet,

5 brous bituminous cement containing a volatile thereby forming a firm bond between the sheets. 5

component applied cold in readily brushable condition to the overlapping portions of said mvSTUART P. MILLER.

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