CA2562432C - A re-roofing system and a method of installation - Google Patents
A re-roofing system and a method of installation Download PDFInfo
- Publication number
- CA2562432C CA2562432C CA2562432A CA2562432A CA2562432C CA 2562432 C CA2562432 C CA 2562432C CA 2562432 A CA2562432 A CA 2562432A CA 2562432 A CA2562432 A CA 2562432A CA 2562432 C CA2562432 C CA 2562432C
- Authority
- CA
- Canada
- Prior art keywords
- roof
- deck
- existing
- strap
- concrete
- 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 - Fee Related
Links
- 238000009434 installation Methods 0.000 title claims abstract description 5
- 238000000034 method Methods 0.000 title description 7
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 27
- 239000010959 steel Substances 0.000 claims abstract description 27
- 238000009413 insulation Methods 0.000 claims abstract description 23
- 239000002184 metal Substances 0.000 claims abstract description 22
- 239000000463 material Substances 0.000 description 6
- 238000004078 waterproofing Methods 0.000 description 5
- 230000007797 corrosion Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 239000002519 antifouling agent Substances 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 238000002386 leaching Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011253 protective coating Substances 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/36—Connecting; Fastening
- E04D3/3608—Connecting; Fastening for double roof covering or overroofing
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
- E04D13/1606—Insulation of the roof covering characterised by its integration in the roof structure
- E04D13/1643—Insulation of the roof covering characterised by its integration in the roof structure the roof structure being formed by load bearing corrugated sheets, e.g. profiled sheet metal roofs
- E04D13/165—Double skin roofs
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
- E04D13/1606—Insulation of the roof covering characterised by its integration in the roof structure
- E04D13/1662—Inverted roofs or exteriorly insulated roofs
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
- E04D13/1606—Insulation of the roof covering characterised by its integration in the roof structure
- E04D13/1681—Insulating of pre-existing roofs with or without ventilating arrangements
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Working Measures On Existing Buildindgs (AREA)
- Roof Covering Using Slabs Or Stiff Sheets (AREA)
Abstract
The present invention relates to a roof system for installation on an existing roof. The existing roof has a plurality of open web steel joists with an existing metal deck thereon. The roof system includes a plurality of deck straps, a roof deck and roofing and insulation. The plurality of deck straps are attached to the open web steel joist through the existing metal deck. The deck straps have a plurality of alternating lower portions and upper portions. The lower portions are attached to the open web steel joist. The upper portions extend upwardly of the existing metal deck. The roof deck is attached to the upper portions of the continuous deck strap. The roofing and insulation is attached to the roof deck.
Description
A RE-ROOFING SYSTEM AND A METHOD OF INSTALLATION
FIELD OF THE INVENTION
This invention relates to steel roof decks and in particular to replacement steel roof decks.
BACKGROUND OF THE INVENTION
The use of steel roof decks on flat or low slope roofing is intended to perform four primary functions, namely distribution of loads such as snow, rain and wind, diaphragm action for structural purposes, a support element for the waterproofing and insulating components and fire protection for those waterproofing elements.
However, should there be a compromise of the waterproofing, deterioration of the steel occurs either through leaching of corrosive materials or simple rusting. Whether the decking is corrosion resistant coated (e.g. galvanized or painted) or not only affects the time for occurrence, once the decking if corroded its primary functions are compromised and therefore must be corrected.
To date the means of correcting the situations is to either remove the damaged decking and install new decking in its place or place new decking directly over the damaged decking. This also entails a varying degree of removal of the waterproofing and insulation layers. Each of those means has problems.
Removing of the decking requires restricted access to the building areas directly below the roof for safety reasons. There is also a great deal of debris and potential fire hazards created in such removal and replacement. Business costs are substantial. Additionally any services located on the underside of the deck must be disconnected and/or relocated. Re-roof production time is substantially increased, thereby resulting in higher contract costs as well as high business loss costs.
If, as a solution, new decking is placed directly over the corroded deck then the continuation of the corrosion or rust into the new decking will occur. The time of occurrence is dependent on the type and quality of protective coating or paint applied between the new and existing decking.
Accordingly it would be advantageous to provide a re-roofing system that can be installed without completely removing the existing roofing system.
SUMMARY OF THE INVENTION
The present invention relates to a roof system for installation on an existing roof. The existing roof has a plurality of open web steel joists with an existing metal deck thereon. The roof system includes a plurality of deck straps, a roof deck and roofing and insulation. The plurality of deck straps are attached to the open web steel joist through the existing metal deck. The deck straps have a plurality of alternating lower portions and upper portions. The lower portions are attached to the open web steel joist. The upper portions extend upwardly of the existing metal deck.
The roof deck is attached to the upper portions of the continuous deck strap.
The roofing and insulation is attached to the roof deck.
In another aspect of the invention there is a method of re-roofing a roof.
FIELD OF THE INVENTION
This invention relates to steel roof decks and in particular to replacement steel roof decks.
BACKGROUND OF THE INVENTION
The use of steel roof decks on flat or low slope roofing is intended to perform four primary functions, namely distribution of loads such as snow, rain and wind, diaphragm action for structural purposes, a support element for the waterproofing and insulating components and fire protection for those waterproofing elements.
However, should there be a compromise of the waterproofing, deterioration of the steel occurs either through leaching of corrosive materials or simple rusting. Whether the decking is corrosion resistant coated (e.g. galvanized or painted) or not only affects the time for occurrence, once the decking if corroded its primary functions are compromised and therefore must be corrected.
To date the means of correcting the situations is to either remove the damaged decking and install new decking in its place or place new decking directly over the damaged decking. This also entails a varying degree of removal of the waterproofing and insulation layers. Each of those means has problems.
Removing of the decking requires restricted access to the building areas directly below the roof for safety reasons. There is also a great deal of debris and potential fire hazards created in such removal and replacement. Business costs are substantial. Additionally any services located on the underside of the deck must be disconnected and/or relocated. Re-roof production time is substantially increased, thereby resulting in higher contract costs as well as high business loss costs.
If, as a solution, new decking is placed directly over the corroded deck then the continuation of the corrosion or rust into the new decking will occur. The time of occurrence is dependent on the type and quality of protective coating or paint applied between the new and existing decking.
Accordingly it would be advantageous to provide a re-roofing system that can be installed without completely removing the existing roofing system.
SUMMARY OF THE INVENTION
The present invention relates to a roof system for installation on an existing roof. The existing roof has a plurality of open web steel joists with an existing metal deck thereon. The roof system includes a plurality of deck straps, a roof deck and roofing and insulation. The plurality of deck straps are attached to the open web steel joist through the existing metal deck. The deck straps have a plurality of alternating lower portions and upper portions. The lower portions are attached to the open web steel joist. The upper portions extend upwardly of the existing metal deck.
The roof deck is attached to the upper portions of the continuous deck strap.
The roofing and insulation is attached to the roof deck.
In another aspect of the invention there is a method of re-roofing a roof.
2 The existing roof has a plurality of open web steel joists with an existing metal deck and existing roofing and insulation thereon. The method of re-roofing includes the steps of:
removing at least a portion of the existing roofing and insulation over the existing open web steel joists; attaching a plurality of deck straps to the open web steel joist through the existing metal deck; attaching a roof deck to the upper portions of the continuous deck strap; and attaching a roof and insulation to the roof deck. The deck strap has a plurality of alternating lower portions and upper portions. The lower portions are attached to the open web steel joist and the upper portions extend upwardly of the existing metal deck.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only, with reference to the accompanying drawings, in which:
Fig. 1 is a perspective view of an existing roof prior to being re-roofed with the roof system of the present invention;
Fig. 2 is a perspective view of the existing roof with a strip of the existing roofing and insulation being removed;
Fig. 3 is a perspective view of the roof with a continuous deck strap attached to the existing open web steel joist where the strip of the existing roofing and
removing at least a portion of the existing roofing and insulation over the existing open web steel joists; attaching a plurality of deck straps to the open web steel joist through the existing metal deck; attaching a roof deck to the upper portions of the continuous deck strap; and attaching a roof and insulation to the roof deck. The deck strap has a plurality of alternating lower portions and upper portions. The lower portions are attached to the open web steel joist and the upper portions extend upwardly of the existing metal deck.
Further features of the invention will be described or will become apparent in the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only, with reference to the accompanying drawings, in which:
Fig. 1 is a perspective view of an existing roof prior to being re-roofed with the roof system of the present invention;
Fig. 2 is a perspective view of the existing roof with a strip of the existing roofing and insulation being removed;
Fig. 3 is a perspective view of the roof with a continuous deck strap attached to the existing open web steel joist where the strip of the existing roofing and
3 insulation was removed;
Fig. 4 is a perspective view of the roof with a new roof deck attached to the continuous deck strap over the remaining existing roof;
Fig. 5 is a perspective view of the roof with new roofing and insulation installed on the new roof deck;
Fig. 6 is a perspective view of the existing roof similar to that shown in figure 2 but with all of the existing roofing and insulation removed;
Fig. 7 is a perspective view of the roof of figures 6 with a continuous deck strap attached to the existing open web steel joist;
Fig. 8 is a perspective view of the roof of figure 6 and 7 with a new roof deck attached to the continuous deck strap: and Fig. 9 is a perspective view of the roof with new roofing and insulation installed on the new roof deck.
DETAILED DESCRIPTION OF THE INVENTION
The steps of constructing the roof system of the present invention are shown in figures 1 to 5.
Figure 1 shows the existing roof system generally at 10. The existing roof system10 includes a plurality of open web steel joists 12, an existing metal deck 14 and existing roofing and insulation 16.
The first step of re-roofing the existing roof system is to remove a strip 18 of the existing roof and insulation 16 over the open web steel joist 12 as shown in figure
Fig. 4 is a perspective view of the roof with a new roof deck attached to the continuous deck strap over the remaining existing roof;
Fig. 5 is a perspective view of the roof with new roofing and insulation installed on the new roof deck;
Fig. 6 is a perspective view of the existing roof similar to that shown in figure 2 but with all of the existing roofing and insulation removed;
Fig. 7 is a perspective view of the roof of figures 6 with a continuous deck strap attached to the existing open web steel joist;
Fig. 8 is a perspective view of the roof of figure 6 and 7 with a new roof deck attached to the continuous deck strap: and Fig. 9 is a perspective view of the roof with new roofing and insulation installed on the new roof deck.
DETAILED DESCRIPTION OF THE INVENTION
The steps of constructing the roof system of the present invention are shown in figures 1 to 5.
Figure 1 shows the existing roof system generally at 10. The existing roof system10 includes a plurality of open web steel joists 12, an existing metal deck 14 and existing roofing and insulation 16.
The first step of re-roofing the existing roof system is to remove a strip 18 of the existing roof and insulation 16 over the open web steel joist 12 as shown in figure
4 2. A plurality of strips 18 will be removed over the roof of the building.
The next step is to fasten a new deck strap 20 over the open web steel joist 12 as shown in figure 3. The deck strap 20 has a plurality of alternating lower portions 22 and upper portions 24. The lower portions 22 are attached to the open web steel joist 12 through the existing metal deck 14. The upper portions 24 extend upwardly of the existing metal deck 14 and the existing roofing and insulation 16.
Preferably the deck straps 20 are continuous deck straps that extend from one side of the roof to the other.
A new roof deck 26 is attached to the upper portions 24 of the deck straps 20 as shown in figure 4. Thereafter a new roof and insulation 28 are attached to the roof deck 26 as shown in figure 5.
Referring to figures 6 to 9 an alternate method of re-roofing an existing roof is shown. This method is similar to that described above, but rather than only removing a strip of the existing roof and insulation, all of the existing roof and insulation are removed leaving the open web steel joist 12 and the existing metal deck 14. The remainder of the method is the essentially the same. The deck strap 20' can be modified somewhat since the upper portions 24' need only extend upwardly of the existing metal deck 14 and not the existing roofing and insulation 16 since this has been removed.
As will be appreciated by those skilled in the art the re-roofing system shown herein is a solution whereby the contractor is able to leave the existing damaged deck in place and transfer all structural and fire properties to new decking placed above
The next step is to fasten a new deck strap 20 over the open web steel joist 12 as shown in figure 3. The deck strap 20 has a plurality of alternating lower portions 22 and upper portions 24. The lower portions 22 are attached to the open web steel joist 12 through the existing metal deck 14. The upper portions 24 extend upwardly of the existing metal deck 14 and the existing roofing and insulation 16.
Preferably the deck straps 20 are continuous deck straps that extend from one side of the roof to the other.
A new roof deck 26 is attached to the upper portions 24 of the deck straps 20 as shown in figure 4. Thereafter a new roof and insulation 28 are attached to the roof deck 26 as shown in figure 5.
Referring to figures 6 to 9 an alternate method of re-roofing an existing roof is shown. This method is similar to that described above, but rather than only removing a strip of the existing roof and insulation, all of the existing roof and insulation are removed leaving the open web steel joist 12 and the existing metal deck 14. The remainder of the method is the essentially the same. The deck strap 20' can be modified somewhat since the upper portions 24' need only extend upwardly of the existing metal deck 14 and not the existing roofing and insulation 16 since this has been removed.
As will be appreciated by those skilled in the art the re-roofing system shown herein is a solution whereby the contractor is able to leave the existing damaged deck in place and transfer all structural and fire properties to new decking placed above
5 the existing roofing. The new roof is to be located parallel to and directly over the structural roof joists.
The basic proposed means of application is to remove the existing waterproofing and insulating materials or the existing roofing and insulation materials 16 over the areas of damaged existing decking 14, specifically to expose the locations of the structural roof joists 12. The corrosion protected flat roof lift strap 20 would then be mechanically fastened parallel to the structural roof joist without the removal of the existing decking. A flat roof lift strap 20 would be installed at each structural roof joist 12 located in the affected areas. New steel decking 26 of correct structural requirements is then mechanically fastened to the flat roof lift strap, providing a new structural surface maintaining the structural diaphragm, suitable fire protection of new roofing materials 28 and support surface for new low slope or flat roofing materials.
The two possible variations on the application are to either: remove all materials down to the existing decking for the entire affected area as shown in figures 6 to 9 or remove the materials down to the existing decking at the roof joist locations only for a width of the flat roof lift strap as shown in figures 1 to 5.
In order to provide tie-in to existing roofing materials the perimeter of the raised section is suitably canted and sealed to the existing roof.
The strap 20 is varied in dimensions depending on the particular application and the loads required. Specifically the length of the upper portion 24 may vary from the equivalent of one steel deck flute (150mm) to multiple flutes (1220mm) and widths of the strap may vary from 50mm to 200mm. The height of the flat roof lift
The basic proposed means of application is to remove the existing waterproofing and insulating materials or the existing roofing and insulation materials 16 over the areas of damaged existing decking 14, specifically to expose the locations of the structural roof joists 12. The corrosion protected flat roof lift strap 20 would then be mechanically fastened parallel to the structural roof joist without the removal of the existing decking. A flat roof lift strap 20 would be installed at each structural roof joist 12 located in the affected areas. New steel decking 26 of correct structural requirements is then mechanically fastened to the flat roof lift strap, providing a new structural surface maintaining the structural diaphragm, suitable fire protection of new roofing materials 28 and support surface for new low slope or flat roofing materials.
The two possible variations on the application are to either: remove all materials down to the existing decking for the entire affected area as shown in figures 6 to 9 or remove the materials down to the existing decking at the roof joist locations only for a width of the flat roof lift strap as shown in figures 1 to 5.
In order to provide tie-in to existing roofing materials the perimeter of the raised section is suitably canted and sealed to the existing roof.
The strap 20 is varied in dimensions depending on the particular application and the loads required. Specifically the length of the upper portion 24 may vary from the equivalent of one steel deck flute (150mm) to multiple flutes (1220mm) and widths of the strap may vary from 50mm to 200mm. The height of the flat roof lift
6 strap between the upper portion 24 and the lower portion 22 is varied from 50 mm overall to 250 mm.
The type sizing and spacing of fasteners for both the flat roof lift strap and the new decking is determined by the loading requirements on a per project basis.
As used herein, the terms "comprises" and "comprising" are to construed as being inclusive and opened rather than exclusive. Specifically, when used in this specification including the claims, the terms Acomprises and Acomprising and variations thereof mean that the specified features, steps or components are included.
The terms are not to be interpreted to exclude the presence of other features, steps or components.
The type sizing and spacing of fasteners for both the flat roof lift strap and the new decking is determined by the loading requirements on a per project basis.
As used herein, the terms "comprises" and "comprising" are to construed as being inclusive and opened rather than exclusive. Specifically, when used in this specification including the claims, the terms Acomprises and Acomprising and variations thereof mean that the specified features, steps or components are included.
The terms are not to be interpreted to exclude the presence of other features, steps or components.
7
Claims (8)
1. A concrete-free roof system for installation on an existing roof having a plurality of open web steel joists with an existing corrugated metal deck thereon, the existing corrugated metal deck having alternating top portions and bottom portions and being part of the structural diaphragm comprising:
a plurality of deck straps mechanically fastened to the open web steel joists through the existing metal deck, each deck strap having a plurality of alternating spaced apart lower portions and a plurality of alternating spaced apart upper portions, the lower portions being integrally formed with the upper portions, the lower portions being attached to the open web steel joists and the upper portions extending upwardly of the existing metal deck, wherein the lower portions are dimensioned to be received within the corrugations of the existing metal deck and the length of each lower portion does not exceed the width of each bottom portion of the existing metal deck and each upper portion spans at least one of the top portion of the existing metal deck and is spaced above the top portion of the existing metal deck;
a roof deck mechanically fastened to and in direct contact with the upper portions of the deck strap and forming part of the structural diaphragm; and roofing and insulation attached to the roof deck.
a plurality of deck straps mechanically fastened to the open web steel joists through the existing metal deck, each deck strap having a plurality of alternating spaced apart lower portions and a plurality of alternating spaced apart upper portions, the lower portions being integrally formed with the upper portions, the lower portions being attached to the open web steel joists and the upper portions extending upwardly of the existing metal deck, wherein the lower portions are dimensioned to be received within the corrugations of the existing metal deck and the length of each lower portion does not exceed the width of each bottom portion of the existing metal deck and each upper portion spans at least one of the top portion of the existing metal deck and is spaced above the top portion of the existing metal deck;
a roof deck mechanically fastened to and in direct contact with the upper portions of the deck strap and forming part of the structural diaphragm; and roofing and insulation attached to the roof deck.
2. A concrete-free roof system as claimed in claim 1 wherein each deck strap is a continuous deck strap that extends from one side of the roof to the other side of the roof.
3. A concrete-free roof system as claimed in claim 1 wherein the existing roof further includes existing roofing and insulation with strips removed therefrom over the open web steel joists and wherein the plurality of deck straps are installed where the strips of the existing roof have been removed and wherein the upper portions of the deck straps further extend upwardly of the existing roofing and insulation.
4. A concrete-free roof system as claimed in claim 3 wherein each deck strap is a continuous deck strap that extends from one side of the roof to the other side of the roof
A concrete-free roof system as claimed in claim 4 wherein the roof is a flat roof.
6. A concrete-free roof system as claimed in claim 2 wherein the roof is a flat roof.
7. A concrete-free roof system as claimed in claim 4 wherein each strap has a width between 50 mm and 200 mm, a height between the lower portions and the upper portions of between 50 mm and 250 mm and a length of the upper portions between 150 mm and 1220 mm.
8. A concrete-free roof system as claimed in claim 2 wherein each strap has a width between 50 mm and 200 mm, a height between the lower portion and the upper portion of between 50 mm and 250 mm and a length of the upper portion between 150 mm to 1220 mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2562432A CA2562432C (en) | 2006-10-04 | 2006-10-04 | A re-roofing system and a method of installation |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2562432A CA2562432C (en) | 2006-10-04 | 2006-10-04 | A re-roofing system and a method of installation |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2562432A1 CA2562432A1 (en) | 2008-04-04 |
| CA2562432C true CA2562432C (en) | 2013-12-31 |
Family
ID=39264268
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2562432A Expired - Fee Related CA2562432C (en) | 2006-10-04 | 2006-10-04 | A re-roofing system and a method of installation |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2562432C (en) |
-
2006
- 2006-10-04 CA CA2562432A patent/CA2562432C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2562432A1 (en) | 2008-04-04 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20221004 |