CA1196167A - Roof decking - Google Patents
Roof deckingInfo
- Publication number
- CA1196167A CA1196167A CA000430783A CA430783A CA1196167A CA 1196167 A CA1196167 A CA 1196167A CA 000430783 A CA000430783 A CA 000430783A CA 430783 A CA430783 A CA 430783A CA 1196167 A CA1196167 A CA 1196167A
- Authority
- CA
- Canada
- Prior art keywords
- panel
- decking
- faceboard
- panels
- purlins
- 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.)
- Expired
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B7/00—Roofs; Roof construction with regard to insulation
- E04B7/20—Roofs consisting of self-supporting slabs, e.g. able to be loaded
- E04B7/22—Roofs consisting of self-supporting slabs, e.g. able to be loaded the slabs having insulating properties, e.g. laminated with layers of insulating material
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
- Roof Covering Using Slabs Or Stiff Sheets (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
The present invention provides a roof decking for use in supporting a built-up roof structure, said roof decking being formed by a plurality of abutting panels laid across a plurality of laterally spaced, substantially parallel purlins supporting the roof structure, adjacent longitudinal edges of the panel extending between the purlins and adjacent lateral edges of the panels extending along the purlins, each said panel comprising a framing including longitudinal linear rigid edge members having a lower faceboard fixedly attached thereto and an upper faceboard fixedly attached thereto to define therewith a central core cavity which is filled with a fire resistant heat insulation material, the longitudinal edges of the faceboards extending beyond the longitudinal linear edge members to define an abutment with the longitudinal edges of the faceboards of an adjacent panel, a longitudinally extending cavity in which is accommodated a fire retardant insulating material extending along said cavity, thus providing a heat insulated fire resistant joint between the adjacent longitudinal edges of the panels.
The present invention provides a roof decking for use in supporting a built-up roof structure, said roof decking being formed by a plurality of abutting panels laid across a plurality of laterally spaced, substantially parallel purlins supporting the roof structure, adjacent longitudinal edges of the panel extending between the purlins and adjacent lateral edges of the panels extending along the purlins, each said panel comprising a framing including longitudinal linear rigid edge members having a lower faceboard fixedly attached thereto and an upper faceboard fixedly attached thereto to define therewith a central core cavity which is filled with a fire resistant heat insulation material, the longitudinal edges of the faceboards extending beyond the longitudinal linear edge members to define an abutment with the longitudinal edges of the faceboards of an adjacent panel, a longitudinally extending cavity in which is accommodated a fire retardant insulating material extending along said cavity, thus providing a heat insulated fire resistant joint between the adjacent longitudinal edges of the panels.
Description
The present invention relates to built-up roof structures and, in particular, to a roof decking for use in such built~up roof structures.
Built-up or laminated roof structures conventionally comprise a roof decking extending across laterally spaced purlins of the building which support the roof structure. The roof decking serves the purpose of supporting, desirably a heat insulating layer usually made of fibreglass disposed thereon and an upper waterproof layer suitably made of a com-bination of bitumen or asphalt and roof felt. Roof deckinghas heretofore been made from sheet metal, particularly sheet steel, which suitably has a castellated surface and is, for example, made of a 22 gauge metal. Such a built-up roof structure, due inter alla to the use of non-combustible metal as the decking, has been found to satisfy the fire test require-ment of the National Building Code of Canada. However, the use of castellated metal sheet decking is expensive and attempts have been made to reduce the cost of the built-up roof structure.
The present invention provides roof decking fabricated ~rom panels which has sufficient strength to support -the roof structure on the purlins thus substantially reducing the cost o the decking and thus the roof and, at -the same time, provides a fire rating which is satisfac-tory to the National Building Codes of Canada. It has now been found that the decking in a built-up roof structure may be formed from a plurality of panels extending across the pur~ins in which adjacent longitu-dinal edges of the panels extending between the purlins cooperate to form a joint between the panel, which joint is capable of maintaining the fire rating or the decking which is satisfactory for the requirements of -the National Building Code of Canada and, is at least a 3/~ hour fire rating and, more preferably, at least a one-hour fire rating.
Thus, in the past all butt type roof insulations and/
or insulated roof panel applications have had a problem with the loss at end or edge joints that were not protected by a second layer of insulation, e.g., staggered joints, or otherwise insul-ated by being located over the purlin. In addition to the actual cost of heat loss, by not having such joints insulated the action of warm air at the joint location causes hardship on the roofing membrane. Thus, in cold weather the roofing membrane over the roof insulation is cold but by way of the butt-joint void the roofing membrane over the joint is relatively warm due to the heat from inside the building. A temperature differential, i.e., the thermal shock, causes fibreglass-type roofing felts to split. Other roo~ing felts will expand or buckle or ridge at the butt-joint locations. Another considera-tion is that the roofing membrane is relatively cold at the butt-joint location and condensation in -the form of water, frost or ice will form on the underside thereof. This also contributes to the deterioration of the roofing membrane. The present invention provides panels which provide a joint on the lateral ~0 edges thereoE in the roof decking which solves the above pro-blems.
According to the present invention there is provided a roof decking for use in supporting a built-up roof structure, said roof decking being formed by a plurality of abutting panels laid across a plurality of laterally spaced, substantially parallel purlins supporting the roof structure from adjacent longitudinal edges of the panel extending between the purlins and adjacent lateral edges of the panels extending along the purlins, each said panel comprising a framing including linear rigid edge members having a lower preferably fire-resistant, faceboard fixedly attached thereto and an upper faceboard fixedly attached thereto to define therewith a central core cavity which i5 filled with a fire resistant heat insulation material, the lcngitudinal edges of the faceboards extending beyond the longitudinal linear edge members to define an abutment with the longitudinal edges of the faceboards of an adjacent panel, a longitudinally extending cavity in which is accom-modated a fire retardant insulating material extendi.ng along said cavity, thus providing a heat insula-ted fire resistant joint between the adjacent longitudinal edges of the panels~
The present invention also provides a panel for use in the construction of a fire retardant roof decking of a built-up roof structure, said panel having a pair of longi-tudinal edges which cooperate ~ith the longitudinal edges adjacent panels to form a joint in said roof decking, said panel comprising a framing including longitudinal linear rigid edge members having a lower preferably, fire resistant, faceboard fixedly attached thereto and an upper faceboard fi~edly attached thereto to define therewith a central core cavity which is filled with a ~ire resistant heat insulation material, the longih7Ain~l edges of the faceboards extending beyond the longitudinal rigid linear edge members to define with longitudinal edges of the aceboards of an adjacent panel, when preset in said decking, a longitudinal extending cavity for the accommodation of a fire retardant insulating material to provide a heat insulated fire re~istant joint between the adjacent longitudinal edges of the panels in the roof decking.
Thus, it has been found that by cantilevering the facing board there is produced a cavity which will accept fire retardant material which is desirably of a similar insulation value to that o the insulation in the cavity of the panel which provi.des the fire rating at the longitudinal edge joints which have a minimum of a 3/4 hour fire rating. It is to be noted that the lateral edge joints are automatically pro-tected by the presence of -the roof purlin, on which they sit, and also have a minimum 3/4 hour rating.
In a preferred embodiment of the present invention the fire retardant insulating material is a preformed semi-rigid non-combustible mineral fibre felt, and a particularly desirable such material is one applied by Double A/D
Distributors, Ltd. of Toronto, Ontario, Canada, under the Trademark " Fire Barrier Firestoppingl' which has been found to completely satisfy the criteria for non combustibility specified by the Underwriters Laboratories of Canada, ULC-S
114 (ASTM E84). This felt is suitably under a compression in the cavity of up to 75~ of its natural thickness and preferably under compression in said cavity of up to 37.5 of its natural thickness.
~n the panel of -the present invention the lower facehoard is preferably a gypsum board which has fire retar-dancy and, in a particularly preferred embodiment of the present invention the protruding longitudinal edges of the gypsum Eacing board is protected by a continuous C-shaped metal channel, the upper leg of which preferably extends be-tween the gypsum Eacing board and the longitudinal rigid edge rnernber. In another embodiment of the present invention the upper facing board is suitably made of plywood or wafer board. For improved strength the panel of the present invention is of -the stressed skin-type design. Suitably, the gypsum facing board is screwed to the underside of the framing and the plywood or wafer board facing board is glued and stapled to the top side, the components together increasing the span of the longitudinal rigid edge framing members.
In a particular embodiment of the present invention the linear rigid members are suitably made o:E wood, w]-lich has preferably been made fire retardant, e.g., by impregnation, ~?6~7 such as, are treated with Fire Safe AD 10~ (a trade mark) manufactured by Amdal Chemical Corporation of Dallas, Texas.
Alternatively, the ~raming members may be metal channel members, suitably C-shaped metal channel members. It is almost im-possible to achieve a contlnuously tight joint by placing wood framing members side by side. Even if these members are relatively straight at the outset, the nature of the wood is to change its shape by way of load stresses and/or a change in the moisture content of the wood fibre~ This problem has been overcome by placing the framing mer~ers back from the edge of the gypsum board which is a stable material, and the metal channel members which are desirably snugly fitted over the longitudinal edges of the gypsum board are roll-formed so as to produce a straight-tight joint. When the fire retardant material is under compression and this compression allows the fire retardant material to follow the framing members by either expanding or contracting, as required. Further, the Building Code advises that the wafer board or plywood roof sheathing shall be installed with at least a 2 mm gap between the boards.
~s the plywood facing board a~d the gypsum facing board are of equal width, the addition of metal end caps to the gypsum panel automatically provide tolerances in the plywood skin and the metal joints of the panels will satisfy such a require-ment by way of customary construction tolerances. The Building Code also requires that there shall be design consideration for contraction or expansion of struc-tural components. The lateral end joints of the panels of the present invention will have good tolerance to prevent creep and the particular design of the edge joint of the present invention is automatically a perfect expansion joint.
Thus, with the lateral joints between the adjacent panels, when the purlins are concrete it is desirable that each purlin has a wood strip fixedly attached along the top surface thereof and, wood strips are fixedly attached to the lateral edge faces of the panels such that the wood strips on the panel edge faces in the dec~ing lie above the wood strip of the purlins and are fixedly attached thereto to form the ~oint between the panels and the purlins. Desirably a filler strip is disposed be-tween the wood strip attached to the lateral edge face of the panel and the upper faceboard to support the edge of the upper faceboard.
Alternatively, when the purlins are made of wood the lateral end edges of the panels having metal C-shaped longitudinal mem~ers are accommodated in metal C-shaped channel members adapted to be fastened to the purlins. When the longi-tudinal members of the panel are wooden members it is preferred to attach wooden strips of L-shaped configuration to the lower portion of the lateral edge faces of the panels with an extended edge of the lower faceboard being accommodated in said L-shape, said L-shape wooden strips being fixedly attached to the purlins to form a joint be-tweerl the panels. Desirably a wooden st:rip is disposed between the upper surface of the L-sllaped wooden strip and the upper faceboard in each panel.
The L-shaped configuration of the wooden strip accommodating the lower faceboard edge allows for poor centering of the panel on the purlin.
The insulatiny material for the central cavity of the panel is suitably plastic foam, fibreglass, mineral wool cellulose wood shavings or cereal grain straw fibre.
Thus the joint between the longitudinal edges of the panels in the roof decking of the present invention is found 3~ to be capable of a fire rating which satisfies the National Building Code and, in particular, to be capable of achie~ing a 3/4 hour fire rating for fire. Thus, with the exception of the joint connection, it is not difficult to achieve a fire rating with gypsum face panels attached to either a metal or wood frame work. In the pas-~ this has been accomplished by placing tape and gypsum ~oint filler over the joints in the gypsum board. This is a relati-vely expensive fire treatment and most difficult for high ceiling application. Tn the present invention the ceiling gypsum board is installed auto-matically with the roof panel and no fur-ther joint treatment is required. The butt-joint gypsum board connection of the present invention is acceptable for most buildings, especially commercial and industrial variety. Again, in addition to eliminating the joint filler application, the attachment of ceiling gypsum panels by way of a roof panel is much easier than attaching them to the underside after the roof framing is in place. A saving is especially valid for high ceilings normally found in commercial and industrial buildings.
Thus, thepanels of the present invention combine the economy of wood products with the fire-resistance of gypsum facing to produce a stress skin-type structural building panel which has full cavity insulation and desirably a factory in-stalled vapor barrier which is suitably on the inside of the ~ypsum facing board, and also on the lower portion of the fire retardant material in the cavi-ty. Particularly, advan-tage-ous embodiments of the present invention, the decking obtained has a 3/4 hour fire rating (combustible) and the decking satis-fies the National suilding Code of Canada, even for relatively ~arge roof areas. For similar span limitations the roof decking of the present invention is equivalent to -the cost of the metal roof decking insulated with a 1 1/2 inch thickness of glass fibre-type rigid insulation. The panels provide over double the amount of insulation value R-13. The gypsum board interi.or facing may be left na-~ural or decorated with a variety of other products, for example, an attractive textured ceiling finish may be top-side applied a-t less than half the cost of a sus-pended rr-bar ceiling system.
The present invention will be further illustra-ted by way of the accompanying drawings in which:-Figure 1 is a perspec~ive view of a roof deckingaccording to one embodiment of the present invention;
Figure 2 is a section through a longitudinal joint in the roof decking of Figure l;
Figure 3 is a section through a lateral joint in the roof decking of Figure l;
Figure 4,which is on the same sheet as Figure 1, is a section through a panel for use in the roof decking of Figure l;
Figure 5 is a section through an alternative panel which may be used in the roof decking of Figure l;
Figure 6 is a section through a still further panel which may be used in the roof decking of Figure l;
Figure 7 is a detail of the end cap of the lateral edge of a panel for use in the roof decking of Figure 1 sup-ported by a concrete purli.n;
Fi.gure 8 is a detail of the formation of the joint between the lateral ends of the panel in a roof decking of Figure 1 supported on concrete purlins;
Figure 9 is a detail of the end cap of the lateral edge of a panel of Figure 3 for use in a roof decking of Figure 1 supported on wooden purlins;
Figure 10 is a detail of the formation of the joint between the lateral ends of the panel of Figure 3 in a roof decking of Figure 1 supported by wooden purlins;
Figure 11 i5 a detail similar to Figure 7 of an alternative form of the end cap of ~he lateral edge of a panel ~or use in the roof decking of Figure 1 supported on concrete purlins; and Figure 12 is a detail of the formation of the joint be~ween the lateral ends of the panel of Figure ~ in a roof decking of ~igure 1 supported on wooden purlins.
Referring firstly to Figure 1, the roof decking 1 is supported by a plurality of spaced parallel concrete purlins
Built-up or laminated roof structures conventionally comprise a roof decking extending across laterally spaced purlins of the building which support the roof structure. The roof decking serves the purpose of supporting, desirably a heat insulating layer usually made of fibreglass disposed thereon and an upper waterproof layer suitably made of a com-bination of bitumen or asphalt and roof felt. Roof deckinghas heretofore been made from sheet metal, particularly sheet steel, which suitably has a castellated surface and is, for example, made of a 22 gauge metal. Such a built-up roof structure, due inter alla to the use of non-combustible metal as the decking, has been found to satisfy the fire test require-ment of the National Building Code of Canada. However, the use of castellated metal sheet decking is expensive and attempts have been made to reduce the cost of the built-up roof structure.
The present invention provides roof decking fabricated ~rom panels which has sufficient strength to support -the roof structure on the purlins thus substantially reducing the cost o the decking and thus the roof and, at -the same time, provides a fire rating which is satisfac-tory to the National Building Codes of Canada. It has now been found that the decking in a built-up roof structure may be formed from a plurality of panels extending across the pur~ins in which adjacent longitu-dinal edges of the panels extending between the purlins cooperate to form a joint between the panel, which joint is capable of maintaining the fire rating or the decking which is satisfactory for the requirements of -the National Building Code of Canada and, is at least a 3/~ hour fire rating and, more preferably, at least a one-hour fire rating.
Thus, in the past all butt type roof insulations and/
or insulated roof panel applications have had a problem with the loss at end or edge joints that were not protected by a second layer of insulation, e.g., staggered joints, or otherwise insul-ated by being located over the purlin. In addition to the actual cost of heat loss, by not having such joints insulated the action of warm air at the joint location causes hardship on the roofing membrane. Thus, in cold weather the roofing membrane over the roof insulation is cold but by way of the butt-joint void the roofing membrane over the joint is relatively warm due to the heat from inside the building. A temperature differential, i.e., the thermal shock, causes fibreglass-type roofing felts to split. Other roo~ing felts will expand or buckle or ridge at the butt-joint locations. Another considera-tion is that the roofing membrane is relatively cold at the butt-joint location and condensation in -the form of water, frost or ice will form on the underside thereof. This also contributes to the deterioration of the roofing membrane. The present invention provides panels which provide a joint on the lateral ~0 edges thereoE in the roof decking which solves the above pro-blems.
According to the present invention there is provided a roof decking for use in supporting a built-up roof structure, said roof decking being formed by a plurality of abutting panels laid across a plurality of laterally spaced, substantially parallel purlins supporting the roof structure from adjacent longitudinal edges of the panel extending between the purlins and adjacent lateral edges of the panels extending along the purlins, each said panel comprising a framing including linear rigid edge members having a lower preferably fire-resistant, faceboard fixedly attached thereto and an upper faceboard fixedly attached thereto to define therewith a central core cavity which i5 filled with a fire resistant heat insulation material, the lcngitudinal edges of the faceboards extending beyond the longitudinal linear edge members to define an abutment with the longitudinal edges of the faceboards of an adjacent panel, a longitudinally extending cavity in which is accom-modated a fire retardant insulating material extendi.ng along said cavity, thus providing a heat insula-ted fire resistant joint between the adjacent longitudinal edges of the panels~
The present invention also provides a panel for use in the construction of a fire retardant roof decking of a built-up roof structure, said panel having a pair of longi-tudinal edges which cooperate ~ith the longitudinal edges adjacent panels to form a joint in said roof decking, said panel comprising a framing including longitudinal linear rigid edge members having a lower preferably, fire resistant, faceboard fixedly attached thereto and an upper faceboard fi~edly attached thereto to define therewith a central core cavity which is filled with a ~ire resistant heat insulation material, the longih7Ain~l edges of the faceboards extending beyond the longitudinal rigid linear edge members to define with longitudinal edges of the aceboards of an adjacent panel, when preset in said decking, a longitudinal extending cavity for the accommodation of a fire retardant insulating material to provide a heat insulated fire re~istant joint between the adjacent longitudinal edges of the panels in the roof decking.
Thus, it has been found that by cantilevering the facing board there is produced a cavity which will accept fire retardant material which is desirably of a similar insulation value to that o the insulation in the cavity of the panel which provi.des the fire rating at the longitudinal edge joints which have a minimum of a 3/4 hour fire rating. It is to be noted that the lateral edge joints are automatically pro-tected by the presence of -the roof purlin, on which they sit, and also have a minimum 3/4 hour rating.
In a preferred embodiment of the present invention the fire retardant insulating material is a preformed semi-rigid non-combustible mineral fibre felt, and a particularly desirable such material is one applied by Double A/D
Distributors, Ltd. of Toronto, Ontario, Canada, under the Trademark " Fire Barrier Firestoppingl' which has been found to completely satisfy the criteria for non combustibility specified by the Underwriters Laboratories of Canada, ULC-S
114 (ASTM E84). This felt is suitably under a compression in the cavity of up to 75~ of its natural thickness and preferably under compression in said cavity of up to 37.5 of its natural thickness.
~n the panel of -the present invention the lower facehoard is preferably a gypsum board which has fire retar-dancy and, in a particularly preferred embodiment of the present invention the protruding longitudinal edges of the gypsum Eacing board is protected by a continuous C-shaped metal channel, the upper leg of which preferably extends be-tween the gypsum Eacing board and the longitudinal rigid edge rnernber. In another embodiment of the present invention the upper facing board is suitably made of plywood or wafer board. For improved strength the panel of the present invention is of -the stressed skin-type design. Suitably, the gypsum facing board is screwed to the underside of the framing and the plywood or wafer board facing board is glued and stapled to the top side, the components together increasing the span of the longitudinal rigid edge framing members.
In a particular embodiment of the present invention the linear rigid members are suitably made o:E wood, w]-lich has preferably been made fire retardant, e.g., by impregnation, ~?6~7 such as, are treated with Fire Safe AD 10~ (a trade mark) manufactured by Amdal Chemical Corporation of Dallas, Texas.
Alternatively, the ~raming members may be metal channel members, suitably C-shaped metal channel members. It is almost im-possible to achieve a contlnuously tight joint by placing wood framing members side by side. Even if these members are relatively straight at the outset, the nature of the wood is to change its shape by way of load stresses and/or a change in the moisture content of the wood fibre~ This problem has been overcome by placing the framing mer~ers back from the edge of the gypsum board which is a stable material, and the metal channel members which are desirably snugly fitted over the longitudinal edges of the gypsum board are roll-formed so as to produce a straight-tight joint. When the fire retardant material is under compression and this compression allows the fire retardant material to follow the framing members by either expanding or contracting, as required. Further, the Building Code advises that the wafer board or plywood roof sheathing shall be installed with at least a 2 mm gap between the boards.
~s the plywood facing board a~d the gypsum facing board are of equal width, the addition of metal end caps to the gypsum panel automatically provide tolerances in the plywood skin and the metal joints of the panels will satisfy such a require-ment by way of customary construction tolerances. The Building Code also requires that there shall be design consideration for contraction or expansion of struc-tural components. The lateral end joints of the panels of the present invention will have good tolerance to prevent creep and the particular design of the edge joint of the present invention is automatically a perfect expansion joint.
Thus, with the lateral joints between the adjacent panels, when the purlins are concrete it is desirable that each purlin has a wood strip fixedly attached along the top surface thereof and, wood strips are fixedly attached to the lateral edge faces of the panels such that the wood strips on the panel edge faces in the dec~ing lie above the wood strip of the purlins and are fixedly attached thereto to form the ~oint between the panels and the purlins. Desirably a filler strip is disposed be-tween the wood strip attached to the lateral edge face of the panel and the upper faceboard to support the edge of the upper faceboard.
Alternatively, when the purlins are made of wood the lateral end edges of the panels having metal C-shaped longitudinal mem~ers are accommodated in metal C-shaped channel members adapted to be fastened to the purlins. When the longi-tudinal members of the panel are wooden members it is preferred to attach wooden strips of L-shaped configuration to the lower portion of the lateral edge faces of the panels with an extended edge of the lower faceboard being accommodated in said L-shape, said L-shape wooden strips being fixedly attached to the purlins to form a joint be-tweerl the panels. Desirably a wooden st:rip is disposed between the upper surface of the L-sllaped wooden strip and the upper faceboard in each panel.
The L-shaped configuration of the wooden strip accommodating the lower faceboard edge allows for poor centering of the panel on the purlin.
The insulatiny material for the central cavity of the panel is suitably plastic foam, fibreglass, mineral wool cellulose wood shavings or cereal grain straw fibre.
Thus the joint between the longitudinal edges of the panels in the roof decking of the present invention is found 3~ to be capable of a fire rating which satisfies the National Building Code and, in particular, to be capable of achie~ing a 3/4 hour fire rating for fire. Thus, with the exception of the joint connection, it is not difficult to achieve a fire rating with gypsum face panels attached to either a metal or wood frame work. In the pas-~ this has been accomplished by placing tape and gypsum ~oint filler over the joints in the gypsum board. This is a relati-vely expensive fire treatment and most difficult for high ceiling application. Tn the present invention the ceiling gypsum board is installed auto-matically with the roof panel and no fur-ther joint treatment is required. The butt-joint gypsum board connection of the present invention is acceptable for most buildings, especially commercial and industrial variety. Again, in addition to eliminating the joint filler application, the attachment of ceiling gypsum panels by way of a roof panel is much easier than attaching them to the underside after the roof framing is in place. A saving is especially valid for high ceilings normally found in commercial and industrial buildings.
Thus, thepanels of the present invention combine the economy of wood products with the fire-resistance of gypsum facing to produce a stress skin-type structural building panel which has full cavity insulation and desirably a factory in-stalled vapor barrier which is suitably on the inside of the ~ypsum facing board, and also on the lower portion of the fire retardant material in the cavi-ty. Particularly, advan-tage-ous embodiments of the present invention, the decking obtained has a 3/4 hour fire rating (combustible) and the decking satis-fies the National suilding Code of Canada, even for relatively ~arge roof areas. For similar span limitations the roof decking of the present invention is equivalent to -the cost of the metal roof decking insulated with a 1 1/2 inch thickness of glass fibre-type rigid insulation. The panels provide over double the amount of insulation value R-13. The gypsum board interi.or facing may be left na-~ural or decorated with a variety of other products, for example, an attractive textured ceiling finish may be top-side applied a-t less than half the cost of a sus-pended rr-bar ceiling system.
The present invention will be further illustra-ted by way of the accompanying drawings in which:-Figure 1 is a perspec~ive view of a roof deckingaccording to one embodiment of the present invention;
Figure 2 is a section through a longitudinal joint in the roof decking of Figure l;
Figure 3 is a section through a lateral joint in the roof decking of Figure l;
Figure 4,which is on the same sheet as Figure 1, is a section through a panel for use in the roof decking of Figure l;
Figure 5 is a section through an alternative panel which may be used in the roof decking of Figure l;
Figure 6 is a section through a still further panel which may be used in the roof decking of Figure l;
Figure 7 is a detail of the end cap of the lateral edge of a panel for use in the roof decking of Figure 1 sup-ported by a concrete purli.n;
Fi.gure 8 is a detail of the formation of the joint between the lateral ends of the panel in a roof decking of Figure 1 supported on concrete purlins;
Figure 9 is a detail of the end cap of the lateral edge of a panel of Figure 3 for use in a roof decking of Figure 1 supported on wooden purlins;
Figure 10 is a detail of the formation of the joint between the lateral ends of the panel of Figure 3 in a roof decking of Figure 1 supported by wooden purlins;
Figure 11 i5 a detail similar to Figure 7 of an alternative form of the end cap of ~he lateral edge of a panel ~or use in the roof decking of Figure 1 supported on concrete purlins; and Figure 12 is a detail of the formation of the joint be~ween the lateral ends of the panel of Figure ~ in a roof decking of ~igure 1 supported on wooden purlins.
Referring firstly to Figure 1, the roof decking 1 is supported by a plurality of spaced parallel concrete purlins
2 and optionally has further layexs 3 of insulation thereon.
The decking 1 comprises a plurality of panels 4 having abutting longi-tudinal edges 5 spanning the purlins and, abutting lateral edges 6 extending along the purlins ~. Referring particularly to Figures 2 through ~, each panel 4 is formed by a framing comprising longitudinal rigid edge members 7 which may be made of wood (Figures 2 and 4), which are suitahly made fire~
resistant, as aforesaid, or may be in the form of C-shaped metal members (Figures 5 and 6). The panel 4 may include inter~
mediate longitudinal rigid members 8 which may also be made of wood (Figures 4 and 6), or be C-shaped me-tal channel members (Flgure 5). Fixedly attached to one side o the panel ~ is a ~ypsum faceboard 9 which in the roof decking 1 is the under-side of the panel, and fi~edly attached to the other side of the panel is a plywood faceboard or waferboard faceboard 10 which in the roof decking 1 is the upper side of the panel.
The panel 4 is desirably of the "stressed skin" type design.
In particular, the gypsum faceboard 9 is screwed to the under-side and the plywood or waferboard faceboard 10 is glued and stapeled to the upper side. In such a stressed skin type design the various components act together to increase the span of the framing members. The panel 4 is loa~ tested in a labora-tory and allowed to be used for longer spans than with the non- "stressed skin" type.
Referring particularly to Figure ~, the joint between the longitudinal edges 5 of the panels 4 in the roof decking 1 comprises a longitudinal cavity 11 which is formed by the cantilevering of the longitudinal edges 12 of the face~oards 9 and 10 over the edge faces of the longitudinal edge members 7 of each panel. The cavity 11 is filled with a fire-re-tardant insulating material, particularly a mineral fibre felt, in particular, the fibre barrier, fibre stopping, pre-formed, semi-rigid, non-combustible fibre felt referred to hereinbefore.
In the formation of the decking 1, just prior to installation of a particular panel 4 on the purlins 2, the fire retardant material is installed by a friction fit into the edge cavity of the panel 4 and protrudes sufficiently so as to fill the edge cavity of an abutting panel 4. Thus, the fire~retardant felt need only be applied to one longitudinal edge cavity of each panel 4 as the opposite longitudinal edge cavity of each panel 4 is automatically filled with the adjacent panel 4 and is brought into substantial abutment therewith. The canti-levered longitudinal edge 12 of the gypsum faceboard 9 of each panel is desirably protected from breakage by a C-shaped metal channel 13, the upper leg of which extends between the longi-tudinal rigid member 7 and the upper face of the gypsum face-board 9. This also provides a gap between the abutting canti-levered edges 12 oE the plywood or waferboard faceboard 10 of each panel 4 forming the joint as required by the Na-tional Building Code of Canada. Fu;^ther, as the fibre insulation in the cavity 11 is under compression, suitably with a com-pression of 37.5% of the natural thic~ness of the insulation, the joint allows for contraction and expansion of the structural components and is thus a good expansion joint.
Referring to Figures 4 to 6, the panel 4, as aforesaid, suitably has intermediate longitudinal framing men~ers 8 extending parallel to the edge members 7 for further strength-ening of the panel and these members 8 may be either of wood or me~al, similar to ~hat used in the edge member 7. The longitudinal edge members 7 and intermediate members 3 define with the faceboards 9 and 10 the central core cavity 15 o~ the panel which is filled with a heat insulation material.
Suitably the fire-retardant material in ~he cavity 11 has an insulation value similar to that of the insulation material in the core cavity 15 of the panel. The upper surface of the gypsum faceboard 9 and the lower surface of the fire-retardant felt in the cavi~ 11 are suitably provided with a vapor barrier (not shown).
The lateral edges 6 of the panels 4 axe located on the purlins 2~ which purlins 2 may be made oE concrete (Figures 2, 3 and 8), or of wood (Figures 10 and 12). Referring to Figures 2, 7 and 8 for use in the roof decking 1 supported by concrete purlins 2, the lateral edges of the panels are provided with fixedly attached wooden strips 16 which are suitably nailed to the ends of the wooden framing members 7 and 8. In forming -the lateral joint between adjacent panels 20 ~, -the panels 4 are disposed on the purlins 2 such that the strips 16 are disposed about a wooden strip 17 fixedly attached by concrete anchors 18 along the purlin 2, the strip 16 being fixedly attached by nails 19 applied on the job-site to the strip 17. The joint is suitably covered by a strip of fibre-board 20 applied at the job-site. As shown in Figure 11 disposed between the strip 16 and the faceboard 10 which has its lateral edge extended beyond that of the lower faceboard 9 is a filler strip 30 suitably made of pl~wood which supports the lateral edge of the upper faceboard 10, provides weather protection and retains the insulation in the panelO Referring to Figures ~ and 10 for use in a roof decking 1 supported by wooden purlins 2, the lateral edges of the panels 4 of ~igure 3 are provided with C-shaped metal end caps 21 which are suitably factory drilled to accept a fastener (not shown) for attachment to the wood purlins 2. Referring to Figure 12 for use in a roof decking 1 supported by wooden purlins 2 the lateral edges of the panels 4 of Figure 4 are provided with L-shaped wooden strips 31, which accommodate in the L-shape the extended end 32 of the lower faceboard 9 and are fixedly attached by rails 33 to the ends of the wooden longitudinal members 8. The strips 31 are fi~edly a-ttache(1 ~o the purlins 2 by means of nails 34. Disposed between the upper surface of the L-shaped strip 31 and the edge of the upper faceboard 10 is a filler strip 35 which supports the edge of the upper face in board 10, provides weather protection and retains the insulation in the panel 4. The recess in the fron-t between -the panels 4 is filled by rigid insulation 36.
The L-shape of the strip 31 accommodating the extended end 32 of the lower faceboard 9 allows for the panel 4 not to be centered on the purlin 2,and still not shown, the lateral joint from below.
In a typical embodiment of the panel of the present invention a four-Eoot wide panel is framed with ei-ther two-by-four nominal wood studs, or metal studs, or channels of the same thickness (89 mm) standard length eight-Eeet.
A standard two-foot wide by ten-foot long panel may be prepared using nominal two-by four wood framing or the e~uivalent metal studs or channels at twelve-inch OC and 89 mm in thickness.
Thus, a typical wood panel of the present invention is a four-foot by eight-foot by four and one-half inches, having waferboard as -the upper faceboard or, four by eight-foot by four and seven-sixteenths inch having plywood as tlle upper faceboard. The framing members are 2 X 4 nominal 16 .
inch OC, the end caps are plywood or wafexboard 4-inch dimen-sion with 2 X 2 nailing strips. The exterior sheathing 3/8-- inch waferboard or 5/16-inch plywood. The interior facing is 5/8-inch type "X" gypsum board with square edges. The cavity insulation can by any insulation as desired. The ca~ity joint insulation is 1 x 3 1/2-inch fibre barrier in-sulation. The metal edge channel is AO.53 mm sheet metal.
The vapor barrier is polyethylene film, This panel has a fire rat:ing of 3/4 of an hour combust;hle. Thelength may be other than eight-feet and can be optional. The alternate panel may be as above but 2 x 10 x 4 1/2-inch when the upper faceboard is a waferboard and 2 x 10 x 4 7/16-inch when the upper face-board is plywood~ Lengths, other than ten-feet are optional.
~ 13 -
The decking 1 comprises a plurality of panels 4 having abutting longi-tudinal edges 5 spanning the purlins and, abutting lateral edges 6 extending along the purlins ~. Referring particularly to Figures 2 through ~, each panel 4 is formed by a framing comprising longitudinal rigid edge members 7 which may be made of wood (Figures 2 and 4), which are suitahly made fire~
resistant, as aforesaid, or may be in the form of C-shaped metal members (Figures 5 and 6). The panel 4 may include inter~
mediate longitudinal rigid members 8 which may also be made of wood (Figures 4 and 6), or be C-shaped me-tal channel members (Flgure 5). Fixedly attached to one side o the panel ~ is a ~ypsum faceboard 9 which in the roof decking 1 is the under-side of the panel, and fi~edly attached to the other side of the panel is a plywood faceboard or waferboard faceboard 10 which in the roof decking 1 is the upper side of the panel.
The panel 4 is desirably of the "stressed skin" type design.
In particular, the gypsum faceboard 9 is screwed to the under-side and the plywood or waferboard faceboard 10 is glued and stapeled to the upper side. In such a stressed skin type design the various components act together to increase the span of the framing members. The panel 4 is loa~ tested in a labora-tory and allowed to be used for longer spans than with the non- "stressed skin" type.
Referring particularly to Figure ~, the joint between the longitudinal edges 5 of the panels 4 in the roof decking 1 comprises a longitudinal cavity 11 which is formed by the cantilevering of the longitudinal edges 12 of the face~oards 9 and 10 over the edge faces of the longitudinal edge members 7 of each panel. The cavity 11 is filled with a fire-re-tardant insulating material, particularly a mineral fibre felt, in particular, the fibre barrier, fibre stopping, pre-formed, semi-rigid, non-combustible fibre felt referred to hereinbefore.
In the formation of the decking 1, just prior to installation of a particular panel 4 on the purlins 2, the fire retardant material is installed by a friction fit into the edge cavity of the panel 4 and protrudes sufficiently so as to fill the edge cavity of an abutting panel 4. Thus, the fire~retardant felt need only be applied to one longitudinal edge cavity of each panel 4 as the opposite longitudinal edge cavity of each panel 4 is automatically filled with the adjacent panel 4 and is brought into substantial abutment therewith. The canti-levered longitudinal edge 12 of the gypsum faceboard 9 of each panel is desirably protected from breakage by a C-shaped metal channel 13, the upper leg of which extends between the longi-tudinal rigid member 7 and the upper face of the gypsum face-board 9. This also provides a gap between the abutting canti-levered edges 12 oE the plywood or waferboard faceboard 10 of each panel 4 forming the joint as required by the Na-tional Building Code of Canada. Fu;^ther, as the fibre insulation in the cavity 11 is under compression, suitably with a com-pression of 37.5% of the natural thic~ness of the insulation, the joint allows for contraction and expansion of the structural components and is thus a good expansion joint.
Referring to Figures 4 to 6, the panel 4, as aforesaid, suitably has intermediate longitudinal framing men~ers 8 extending parallel to the edge members 7 for further strength-ening of the panel and these members 8 may be either of wood or me~al, similar to ~hat used in the edge member 7. The longitudinal edge members 7 and intermediate members 3 define with the faceboards 9 and 10 the central core cavity 15 o~ the panel which is filled with a heat insulation material.
Suitably the fire-retardant material in ~he cavity 11 has an insulation value similar to that of the insulation material in the core cavity 15 of the panel. The upper surface of the gypsum faceboard 9 and the lower surface of the fire-retardant felt in the cavi~ 11 are suitably provided with a vapor barrier (not shown).
The lateral edges 6 of the panels 4 axe located on the purlins 2~ which purlins 2 may be made oE concrete (Figures 2, 3 and 8), or of wood (Figures 10 and 12). Referring to Figures 2, 7 and 8 for use in the roof decking 1 supported by concrete purlins 2, the lateral edges of the panels are provided with fixedly attached wooden strips 16 which are suitably nailed to the ends of the wooden framing members 7 and 8. In forming -the lateral joint between adjacent panels 20 ~, -the panels 4 are disposed on the purlins 2 such that the strips 16 are disposed about a wooden strip 17 fixedly attached by concrete anchors 18 along the purlin 2, the strip 16 being fixedly attached by nails 19 applied on the job-site to the strip 17. The joint is suitably covered by a strip of fibre-board 20 applied at the job-site. As shown in Figure 11 disposed between the strip 16 and the faceboard 10 which has its lateral edge extended beyond that of the lower faceboard 9 is a filler strip 30 suitably made of pl~wood which supports the lateral edge of the upper faceboard 10, provides weather protection and retains the insulation in the panelO Referring to Figures ~ and 10 for use in a roof decking 1 supported by wooden purlins 2, the lateral edges of the panels 4 of ~igure 3 are provided with C-shaped metal end caps 21 which are suitably factory drilled to accept a fastener (not shown) for attachment to the wood purlins 2. Referring to Figure 12 for use in a roof decking 1 supported by wooden purlins 2 the lateral edges of the panels 4 of Figure 4 are provided with L-shaped wooden strips 31, which accommodate in the L-shape the extended end 32 of the lower faceboard 9 and are fixedly attached by rails 33 to the ends of the wooden longitudinal members 8. The strips 31 are fi~edly a-ttache(1 ~o the purlins 2 by means of nails 34. Disposed between the upper surface of the L-shaped strip 31 and the edge of the upper faceboard 10 is a filler strip 35 which supports the edge of the upper face in board 10, provides weather protection and retains the insulation in the panel 4. The recess in the fron-t between -the panels 4 is filled by rigid insulation 36.
The L-shape of the strip 31 accommodating the extended end 32 of the lower faceboard 9 allows for the panel 4 not to be centered on the purlin 2,and still not shown, the lateral joint from below.
In a typical embodiment of the panel of the present invention a four-Eoot wide panel is framed with ei-ther two-by-four nominal wood studs, or metal studs, or channels of the same thickness (89 mm) standard length eight-Eeet.
A standard two-foot wide by ten-foot long panel may be prepared using nominal two-by four wood framing or the e~uivalent metal studs or channels at twelve-inch OC and 89 mm in thickness.
Thus, a typical wood panel of the present invention is a four-foot by eight-foot by four and one-half inches, having waferboard as -the upper faceboard or, four by eight-foot by four and seven-sixteenths inch having plywood as tlle upper faceboard. The framing members are 2 X 4 nominal 16 .
inch OC, the end caps are plywood or wafexboard 4-inch dimen-sion with 2 X 2 nailing strips. The exterior sheathing 3/8-- inch waferboard or 5/16-inch plywood. The interior facing is 5/8-inch type "X" gypsum board with square edges. The cavity insulation can by any insulation as desired. The ca~ity joint insulation is 1 x 3 1/2-inch fibre barrier in-sulation. The metal edge channel is AO.53 mm sheet metal.
The vapor barrier is polyethylene film, This panel has a fire rat:ing of 3/4 of an hour combust;hle. Thelength may be other than eight-feet and can be optional. The alternate panel may be as above but 2 x 10 x 4 1/2-inch when the upper faceboard is a waferboard and 2 x 10 x 4 7/16-inch when the upper face-board is plywood~ Lengths, other than ten-feet are optional.
~ 13 -
Claims (34)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A roof decking for use in supporting a built-up roof structure, said roof decking being formed by a plurality of abutting panels laid across a plurality of laterally spaced, substantially parallel purlins supporting the roof structure, adjacent longitudinal edges of the panel extending between the purlins and adjacent lateral edges of the panels extending along the purlins, each said panel comprising a framing in-cluding longitudinal linear rigid edge members having a lower faceboard fixedly attached thereto and an upper faceboard fixedly attached thereto to define therewith a central core cavity which is filled with a fire resistant heat insulation material, the longitudinal edges of the faceboards extending beyond the longitudinal linear edge members to define an abut-ment with the longitudinal edges of the faceboards of an adjacent panel, a longitudinally extending cavity in which is accommodated a fire retardant insulating material extending along said cavity, thus providing a heat insulated fire re-sistant joint between the adjacent longitudinal edges of the panels.
2. A decking as claimed in claim 1, in which the lower faceboard is fire resistant.
3. A decking as claimed in claim 2, in which the fire retardant heat insulating material has an insulation value similar to that of the insulation material in the panel cavity.
4. A decking as claimed in claim 3, in which the fire retardant insulating material is a preformed semi-rigid non-combustible mineral fibre felt.
5. A decking as claimed in claim 4, in which the felt is under compression in said cavity up to 75% of its natural thickness.
6. A decking as claimed in claim 4, in which the felt is under compression in said cavity up to 37.5% of its natural thickness.
7. A decking as claimed in claim 1, in which the lower faceboard is a gypsum board.
8. A decking as claimed in claim 7, in which each of the longitudinal edges of the gypsum board fits snugly into a C-shaped metal channel member.
9. A decking as claimed in claim 8, in which an upper leg of said C-shaped metal channel member extends bet-ween the faceboard and the longitudinal linear rigid edge member.
10. A decking as claimed in claim 7, in which the upper faceboard is a plywood board or waferboard.
11. A decking as claimed in claim 10, in which the panels are of the stressed skin type.
12. A decking as claimed in claim 10, in which the longitudinal linear edge members are made of wood.
13. A decking as claimed in claim 10, in which the longitudinal linear edge members are metal C-shaped channel members.
14. A decking as claimed in claim 12, in which the purlins are concrete purlins, each purlin having a wooden strip fixedly attached along a top surface thereof, wooden strips being fixedly attached to the lateral edge faces of the panels such that the wood strips on the panel edge faces in said decking lie above said wood strips on said purlins and are fixedly attached thereto to form a joint between said panels and said purlins.
15. A decking as claimed in claim 14, in which a filler strip is disposed between the wood strip attached to the lateral edge face of the panel and the upper faceboard to support the edge of the upper faceboard.
16. A decking as claimed in claim 15, in which the purlins are made of wood and the lateral edges of the panels are accommodated in metal C-shaped channel members adapted to be fastened to the purlins.
17. A decking as claimed in claim 12, in which the purlins are made of wood, wooden strips or L-shaped configura-tion being attached to the lower portion of the lateral edge faces of the panels with an extended edge of the lower face-board being accommodated in said L-shape, said L-shaped wooden strips being fixedly attached to the purlins to form a joint between the panels.
18. A decking as claimed in claim 17, in which a wooden filler strip is disposed between the upper surface of the L-shaped wooden strip and the upper faceboard in each panel.
19. A decking as claimed in claim 12 or 13, including the vapor barrier on the internal surface of the gypsum face-board and also on the lower surface of the fire retardant material in the cavity.
20. A panel for use in the construction of a fire retardant roof decking of a built-up roof structure, said panel having a pair of longitudinal edges which cooperate with the longitudinal edges adjacent panels to form a joint in said roof decking, said panel comprising a framing including linear longitudinal rigid edge members having a lower faceboard fixedly attached thereto and an upper faceboard fixedly attached thereto to define therewith a central core cavity which is filled with a fire resistant heat insulation material, the longitudinal edges of the faceboards extending beyond the longitudinal linear rigid edge members to define with longitudinal edges of the abutting faceboards of an ad-jacent panel, when present in said decking a longitudinal extending cavity for the accommodation of a fire retarant insulating material to provide a heat insulated fire resistant joint between the adjacent longitudinal edges of the panels in the roof decking.
21. A panel as claimed in claim 20, in which the lower faceboard is a fire resistant faceboard.
22. A panel as claimed in claim 21, in which the lower faceboard is a gypsum board.
23. A panel as claimed in claim 22, in which the longitudinal edges of the gypsum faceboard fit snugly into a C-shaped metal channel member.
24. A panel as claimed in claim 23, in which an upper leg of said C-shaped metal channel member extends between the faceboard and the longitudinal frame member.
25. A decking as claimed in claim 23, in which the upper faceboard is made of plywood or waferboard.
26. A panel as claimed in claim 25, which is of the pressed skin type.
27. A panel as claimed in claim 25, in which the linear rigid members are made of wood.
28. A panel as claimed in claim 25, in which the linear rigid members of the frame are C-shaped metal channel members.
29. A panel as claimed in claim 27, having wooden strips fixedly attached to the lateral edge faces thereof, such that said wood strips, when said panel is mounted in said decking, lie above the wood strip on a concrete purlin so as to be fixedly attached thereto to form a joint between said panels and said purlins.
30. A panel as claimed in claim 29, in which a filler strip is disposed between the wood strip attached to the lateral edge face of the panel and the upper faceboard to support the edge of the upper faceboard.
31. A panel as claimed in claim 26, in which the lateral end edges of the panels are accommodated in metal C-shaped channel members which are adapted to be fastened to a wooden purlin.
32. A panel as claimed in claim 26, in which wooden strips of L-shaped configuration being attached to the lower portion of the lateral edge faces of the panels with an extended edge of the lower faceboard being accommodated in said L-shape, said strip being adapted to be attached to the wooden purlin.
33. A panel as claimed in claim 32, in which a wooden filler strip is disposed between the upper surface of the L-shaped wooden strip and the upper faceboard in each panel.
34. A panel as claimed in claim 21, including the vapor barrier of the inside surface of the gypsum faceboard.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000430783A CA1196167A (en) | 1983-06-20 | 1983-06-20 | Roof decking |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000430783A CA1196167A (en) | 1983-06-20 | 1983-06-20 | Roof decking |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1196167A true CA1196167A (en) | 1985-11-05 |
Family
ID=4125520
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000430783A Expired CA1196167A (en) | 1983-06-20 | 1983-06-20 | Roof decking |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1196167A (en) |
-
1983
- 1983-06-20 CA CA000430783A patent/CA1196167A/en not_active Expired
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