CA1064217A - Shingle-covered building surface, especially a roof, and a method of and means for constructing same - Google Patents

Abstract

Abstract: A roof is constructed by means of rectangular prefabricated shingle--covered roofing modules. The shingle covering of each separate module is almost complete. When modules have been mounted adjacent each other the shingle covering of the roof is com-pleted by inserting shingle members between the shingle elements of the adjacent modules in the module joint a?ea.

Description

The present invention relates to a shingle-covered building sur-face, especially a roof, as well as to a method of and means for constructing same.
In building construction it has become increasingly common to use modular units for the production of various parts of buildings, not hitherto shingle-covered roof structures, however.
For reasons associated with waterproofing and appearance, roof covering materials have hitherto been applied by hand after the production of the roof structure proper, and in some cases the roof structure itself has been provided with a rather simpler form of covering or waterproofing mater-ial in order, during the period of time elapsing between the building of the roof structure and the laying of the actual roof-covering material proper, to protect the building construction against wind and weather. In the latter case, thus an expensive extra, provisional roof covering is used which per-forms no real function when the final roof covering material has been laid, ... this especially in the case where the final roof covering material is to be constituted by shingles which are of course applied with appropriate overlap.
~ According to one aspect of the present invention there is provided , in a shingle-covered building surface comprising a plurality of prefabricated dules, each of which has a standard width, said modules being laid adjacent ; .
one another with at least longitudinal joints between them, a shingle covering on each module comprising a plurality of parallel shingle elements which ~, overlap each other by a predetermined amount each shingle element comprising ~, a plurality of codirectional, identical shingle units arranged in a row, each unit incorporating a base section and a central projecting covering tongue, the improvements that every second shingle element in the longitudinal tirec- :
tion of the module comprises n shingle units and has the same width as the module, and that the other shingle elements in the longitudinal direction of the module comprise odd number less, preferably n-l shingle units, the units of adjacent overlapping elements being laterally offset by half the unit width,

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and shingle units being inserted between the shingle coverings of laterally adjacent modules to overlap longitudinal therebetween and to complete the shingle covering.
According to another aspect of the present invention there is pro-vided in a method of manufacturing a shingle covered building surface com-prising the steps of prefabricating modules of standard witth, covering the modules with parallel overlapping shingle elements with constant overlap, each element comprising a plurality of codirectional identical shingle units arranged in a row, each with a base-section and a central projecting tongue, overlapping elements being laterally offset in relation to one another by half the unit width, mounting the covered modules one beside the other with at least longitudinal joints between them and completing the shingle cover-ing over the joints, the improvements comprising covering the modules with shingle elements of which every second element in the longitudinal direction of the module comprise n shingle units and has the same width as the module and of which the other elements comprises an odd number less, preferably -n-l shingle units, and completing the shingle covering at the lateral joints -between adjacent modules by inserting separate shingle units in the gaps between said other, aligned elements of the modules.
The building surface will usually be a roof, although the invention can be used for other surfaces, such as walls. By using the invention, roof modules, that is to say roof structure elements of predetermined size, may be prefabricated to a great extent, and in association therewith the roof shingle covcring is so arranged that it can be simply completed at the joints between the assembled dules. The modules can be arranged as so-called load-bearing roofing elements; i.e. a kind of structure which has inherent stiffness, for example box constructions of plywood. When using roofing elements of this kind, normally no roof trusses are needed. Alternatively, the modules can be designed in the form of a base plate, for example of ply-wood, it being arranged that the base plate has a width which is a multiple I .

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of the roof truss pitch, which means that vertical joints between adjacent modules are located at the position of roof trusses. The dules which are used in accordance with the invention can have a length which corresponds to -the length of the roof pitch, although for handling reasons it may be desir~
able to design the modules which are to be arranged upon the roof trusses, with a standard length.
In the accompanying drawings which illustrate exemplary embodiments of the present invention:
Figure 1 schematically illustrates a shingle-covered roof module for use in the production of a roof;

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~ ~o642~7 Figures 2a and 2b illustrate the two kinds of shingle elements which are used to cover the module of FiguTe l;
Figure 2c illustrates a shingle unit which can be used to complete the roof shingle covering at the joints between neighbouring modules;
Figure 3 schematically illustrates a simplified version of how : the shingle covering of the roof may be finished off at a vertical joint between two modules;
Figure 4 illustrates how the roof shingle covering may be finished off at a horizontal joint between two assembled modules; -.
, 10 FigUre 5 illustTates how the roof covering may be finished off at x;-~ the base of the roof;
. Figure 6 illustrates a covoring strip designed to finish off the ` roof covering at the base of the roof;
.:- Figure 7 illustrates schematically how an external roof is built up from what are known as load-bearing modules; and Figure 8 schematically illustrates how shingle-covered modules in ` accordance with the invention are assembled upon roof trusses.
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Figure 1 illustrates a roof module 1 in accordance with the inven-` ~ tion, of width B and length L. The module 1 comprises an element 2 having :i;, ; 20 the dimensions B x L, which is covered with roof shingle elements, 3, 4. The .,.^.~`;:~: : single elements 4 and 3 are : ,",. .
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shown in ~igs. 2a and 2b. The elements 3 and 4 comprise a whole number multiple Or shingle units 5 (see Fig. 2c). Each shingle unit 5 comprises a base section 5a of width k and hei~ht s, and a central, projecting tongue 5b of height p. In the preferred embodiment, the tongue 5b has a width equal to k/2.
Referring to Fig. 1, the baseplate 2 is provided at the bottom with an element 3 which is centrally arranged upon the module 1 in such a fashion that the tops of its tonguegcoincide with the bottom edge of the modules. An element 4 is arranged in overlapping fashion on the bottom-most element 3 in such a way that the tops of the tongue of the element 4, substantially coincide with the bottom edge of the base section of the element

3. The width of the element 4 coincides wlth that of the module 1 and is also a whole number multiple n of the width k of the shingle unit 5. A further centrally disposed element 3 is arranged over-lapping the element 4. Although not shown in Fig. 1, the whole module 1 is covered with overlapping alternating elements 3 and 4 in the same way shown in the bottom part of Fig. 1. If required, the shingle covering can be terminated at the top edge of the module in the form of an element 3 which projects beyond the top edge of the module.
Since the element 3 has a width B-k and is centrally located on the module, the interval between the element 3 and the lateral edges of the module, is equal to k/2.
The length of the module 1 is a whole number multiple of the mutual and constant overlap U of the element~, as shown in Fig. 1. In the present case, an overlap U which i9 equal to the tongue length t is preferred. The base section of t~ shingle, in the normal way, has a length s which is > t, but < 2t. The length s, can, however, be made ~ 2t.

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~ ig. 3 schematically illustrates two modules 1 which are placed one beside the oth~r with a vertical joint 8. For reasons of clarity, in Fig. ~ only every other shingle element has been shown, namely the narrower shingle elements 3. To finish off the shingle covering at the joint 8, the shingle eiement 5 is in-serted, in the manner shown in Fig. 2c, between the elements 3, in neighbouring modules, which are directed towards one another, in the manner shown in Fig. 3. In this way, the shingle units 5 are inserted between adjacent rows of shingle elements 4 which have not been shown.
Fig. 4 illustrates a horizontal joint 9 between two adjacent modules 1. The righthand (bottom-most) module 1 has been prefabricated using a module 3 at the top which projects beyond the top edge of the righthand module 1. Because the ~-two modules 1 are to be placed together, the bottom-most element 3 of the lefthand (upper) module is raised so that the shingle coverings of the two modules are assembled together in the correct manner when the modules 1 are placed in contact with one ` another. In order to finish off the roof shingle covering at the joint 9, a roof shingle element 4 is inserted between the bottom--most shingle element 3 of the lefthand module 1 and the top-most ~ shingle element 3 of the righthand module 1.
`~ It should be clearly understood, however, that when pre-fabricating the modules 1, it is quite possible to dispense with arranging a projecting shingle element at the top of the module, ~ and instead of this two shingle elements 3, 4 can be inserted at ;~ the joint 9 in order to finish off the shin~l~ covering. Equally~
it should be clearly understood that it is quite possible when prefabricating the modules to arrange a projecting shingle element at the bottom edge of the modules.
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It should equally be clearly understood that when providing the roof shingle covering on the module plate 2, it is not essenti-al to utilize the arrangement shown in Fig. 1, with an element 3 at the bottom, but it is instead equally possible to use a re-verse arrangement so that an element 4 is located at the bottominstead.
In cases where the module 1 has been manufactured 50 that ; the tops of the bottom-most shingle element 3 (or 4) coincide with the bottom edge of the module plate 2, and the bottom part of the relevant module is to do duty as the roofs base, the ~ . .
roof covering of the module can be finished off by arranging at the very bottom of the module plate 2 a covering strip 6 pre-ferably having a width s. If the shingle covering of the module has the design shown in Fig. 5, then it may be a good idea to design the strips 6 to have the width B of the module and to lay the strip 6 at the bottom of the relevant module because the joints between adjacent strips 6 are then located beneath the covering tongues of the overlapping element 4. If the modules 1 are so designed that the shingle covering is terminated at the bottom in the form of an element 4, then, if strips 6 of width B are to be used, the strip 6 must be offset so that its ends, that is to say the joints between adjacent strips 6, are located (on each module) beneath the covering tongue of an overlapping ~` shingle element 3.
; 25 The module in accordance with the invention can be designed in such a fashion that the base 2 is formed as an inherently rigid or self-supporting structure, for example a plywood box structure, with a length L corresponding to the pitch length of the roof structure, so that a pitched roof (see Fig~ 7) can simply be built up by assembling modules together in pairs. In this case, no roof trusses are required.
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~,~:,'', , ,' ' ' ` . ' ' ~O~i~Z~7 Using the roof structure shown in Fig. 7, o~ly vertical joints 8 occur between modules 1 and in this fashion the work involved in rinishin~ off the roof shingle covering is very con-siderably simplified. The load-bearing module elements which are used in the roof structure of Fig. 7 have a standard width and this width is usually a multiple of a module size, for example a multiple of 60 cm.
; In Fig. 8 a more conventional roof structure in which external roof modules 1 in accordnace with the invention are assembled on roof trusses 12 having a conventional truss interval v (standarized interval), has been shown. The roof truss spacing v is normally 120 cm and the width of the modules 1 is a whole `' number multiple of v. In order to make straig~forward use of the roof modules 1 in accordance with the invention, with varying roof pitch lengths, it may be a good idea to design the modules 1 ~ to have a standard length which will conveniently be a whole j number multiple of some standardized module size, for example a whole number multiple of 120 cm, the external dimensions of the ~ roof modules being chosen in such a fashion that they can easily ¦ 20 be handle~ and transported. A suitable d~mension for the roof modules 1 which are intended to be assembled on roof trusses ~ ~5 for example B = 240 cm and L = 120 cm.
¦~ In this way the shingle units 5 (see Fig. 2c) can have a i width k = 30 cm, a covering tongue height t = 15 cm and a base ~r ¦~ 25 section height of 25 cm. The shingle overlap should be about 30 cm. The material of which the shingles are made can have a - thickness around 2 - 3 mm and consist of some kind of roo~ing board, that is to say a carrier which is covered with a bitumi-nous material which is in turn possibly coated with coloured sand.
~- 30 Although the embodiment of a roof module offered by way 1064~17 Or example in accordance with the invention illustrates the application of shingle elements 3 and 4 each comprising 3 and 4 "units" 5 respectively, it should be clearly understood that the elements 3 and 4 can comprise an arbitrary number Or units 5 as long as the indicated relationship between elements 3 and 4 is maintained.
It should equally be clearly understood that the elements 3 and 4 need not of course consist of a cohesive material but could just as well be constituted by two or more shorter elements or units 5.
It should also be fully realized that the illustrated shingle unit 5 can be replaced by shingle units of different shape. The present claim, however, is based upon the fact that ~,t ,' ~ the covering tongue of the shingle unit is centrally located on the base section of the unit and has a sufficient width to cover an underlying joint although being less than the width of the base section of the unit.
In the foregoing, the term "shinge unit" has been used to 1. . - . .
~ describe a shingle of the kind shown in Fig. 2c. It should be } 20 realised, however, that in the manufacture Or the module 1 the shingle covering need only extend to part of the width of the module and it may therefore be convenient, at the vertical ~ ~ `
joints between adjacent modules, to insert shingle elements of suitable width instead of a plurality of units.
Consequently, in the present context the expression ~shingle unit" should also be understood as referring to the ~hingle element which covers the ~ap between shingle element roWs Or the same kind, facing towards one another, in two adjacent modules.
In a preferred embodiment, a shingle element 4 has the same width as the module 1 which means that no gap ocours between the 106g217 elements 4 of adjacent modules 1. It is furthermore a preferred feature of the invention that the element 3 has a width B-k so that the gap between elements 3 becomes k.
Considering the embodiment of the invention in which modules are placed together with a horizontal joint, the arrangement of the shingle ~lements must be coordinated with the module length L
so that the shingle covering of the roof acquires a uniform appearance.
Referring to Fig. 1 and 2a, consequently, a~ongst other things the following relationships will conveniently be adopted:
L = nl U; s+t = p + U
where nl is a whole number constant;
p is the overlap between elements, and U is the mutal stagger between elements considered in the longitudinal direction of the module.
Making reference to Fig. 1 it should be understood 'hat when producing the roof shingle covering of the module 1, it may be a good idea to use only one kind of shingle element, such as the type 3. This would mean the discarding of the ri~hthand end unit of each element 4 (see Fig. 1).
In the manufacture of roofs in accordance with the invention at the roof ridge the roof covering should be completed by means of a full ridge strip or the like. The ridge strip will convenient-ly consist of the same material as the roof shingles and it should f have such a width that the joints between adjacent shingle ; elements in the topmost shingle rows, are covered by it.
In the manufacture of roofs or modules in accordance with the invention, shingles should be available which have sizes f`~- 30 matching the current size standards. The shingle units can thus 106~Z17 ~or example have widths of k = 60, 30 or 15 cm and tongue lengths t = 30, 15 or 7.5 cm, the width of the tongue preferably being made equal to their length t. The shingle units and shingle elements can be made of strip material having a width 2s~t (or a whole number multiple thereof), a strip of 2s+t being cut central-ly along a "squarewave line", to form the shingle tongues. In the transverse direction, the halves of the strip can be cut off or printed with cut markings at suitable locations, so that shingle elements and joint shingles of requisi~e format can be obtained.
Alternatively, the shingle strip can be provided with colour markings or the like salong which the strip can be cut to form shingle elements 3, 4 and joint shingles 5.
In a situation where the shingles are manufactured in strip form, they can be wound up into coils which are simpler -` 15 to handle, transport and pack. In so doin~, the shingle strips can be laid in such a fashion that the tongues of one locate in the tongue gaps of the other, ~iving the coils the form of right ; cylinders.
In the situation where the shingle strips are cut to form shingle elements of the desired length, the elements can be ~~ assembled in stacks of similar kinds and the tongues of one ~ ~ .
~ stack inserted into the tongue intervals of another so that a ~-,~ .
substant~ly rectangular packing can be formed from two stacks.

The shingle material will conveniently be provided in a manner known per se with adhesive surfaces protected by so-called `~ release paper. The adhesive surfaces can be aontinuous along ~!~ the whole or parts of the shingle elements and/or may be arranged .~, .
at suitable areas on one or both sides of the shingle units 5 and shingle elements 3, 4.
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Claims (17)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. In a shingle-covered building surface comprising a plurality of prefabricated modules, each of which has a standard width, said modules being laid adjacent one another with at least longitudinal joints between them, a shingle covering on each module comprising a plurality of parallel shingle elements which overlap each other by a predetermined amount each shingle element comprising a plurality of codirectional, identical shingle units arranged in a row, each unit incorporating a base section and a central pro-jecting covering tongue, the improvements that every second shingle element in the longitudinal direction of the module comprises n shingle units and has the same width as the module, and that the other shingle elements in the lon-gitudinal direction of the module comprise odd number less, preferably n-l shingle units, the units of adjacent overlapping elements being laterally offset by half the unit width, and shingle units being inserted between the shingle coverings of laterally adjacent modules to overlap longitudinal there-between and to complete the shingle covering.

2. A surface as claimed in claim 1 characterized in that the module length is an odd multiple of the difference between the length of an element and the predetermined overlap between the shingle elements, in that the modules are laid adjacent each other also with lateral joints between them, and in that shingle elements are inserted between the shingle coverings of longitudinally adjacent modules to overlap lateral joints therebetween and complete the shingle covering.

3. A surface according to claim 2, characterized in that said other elements comprise n-l shingle units.

4. A surface as claimed in claim 1, characterized in that one of the shingle elements in each module is laid so that the tops of the tongues of the element substantially coincide with the bottom edge of the module.

5. A surface as claimed in claim 1, characterized in that each module has a standard length.

6. A surface as claimed in claim 1, characterized in that the module has a length corresponding to a predetermined roof pitch length.

7. A surface as claimed in claim 6, characterized in that the module is designed for assembly upon roof trusses of standard spacing; and in that the module width is a multiple of the roof truss spacing, the longitudinal edges of the module being arranged at the roof trusses.

8. A surface as claimed in claim 6, characterized in that the module is self-supporting, so as to form a load-bearing roof element.

9. A surface as claimed in claim 4, characterized in that a strip having substantially the same width as the base section of said one of the shingle elements and consisting of the same material as the shingle elements is laid on the shingle-carrying surface of the module, with its bottom edge substantially coinciding with the bottom edge of the module.

10. In a method of manufacturing a shingle covered building surface comprising the steps of prefabricating modules of standard width, covering the modules with parallel overlapping shingle elements with constant overlap, each element comprising a plurality of codirectional identical shingle units arranged in a row, each with a base-section and a central projecting tongue, overlapping elements being laterally offset in relation to one another by half the unit width, mounting the covered modules one beside the other with at least longitudinal joints between them and completing the shingle covering over the joints, the improvements comprising covering the modules with shingle elements of which every second element in the longitudinal direction of the module comprise n shingle units and has the same width as the module and of which the other elements comprises an odd number less, preferably n-1 shingle units, and completing the shingle covering at the lateral joints between adjacent modules by inserting separate shingle units in the gaps between said other, aligned elements of the modules.

11. A method as claimed in claim 10, characterized by adapting the module length to an odd multiple of the difference between the length of an element and the predetermined overlap between the shingle elements, laying modules adjacent each other also with lateral joints between them, ant in-serting shingle elements between the shingle coverings of longitutinally adjacent modules to overlap lateral joints therebetween and complete the shingle covering.

12. A method according to claim 11, characterized in that said other elements comprise n-1 shingle units.

13. A method as claimed in claim 10, characterized by laying one of the shingle elements on each module in such a fashion that the tops of the tongues of the element substantially coincide with the bottom edge of the module.

14. A method as claimed in claim 10, characterized by fabricating the modules with a standard length.

15. A method as claimed in claim 10, characterized by fabricating the modules with a length corresponding to a predetermined roof pitch length.

16. A method as claimed in claim 15, characterized in that the modules are designed to be assembled on roof trusses, the module width being a multiple of a standard roof truss interval such that vertical joints between the modules will coincide with roof trusses.

17. A method as claimed in claim 15, characterized in that the modules are self-supporting so as to provide loadbearing roof elements.