EP1496169B1 - Method for the production of a roof made of hollow mission tiles and such a roof - Google Patents

Description

The present invention relates to a method of building round tile roofs on self-supporting bins and a roof obtained.

The technical field of the invention is that of the construction of roof tiles channel or round tiles of cylindro-conical shape.

Traditional roofs are known in round tiles or Roman tiles with juxtaposed rows of tiles whose concavity is turned alternately upwards and downwards. These tiles are usually laid on a sub-roof, for example a sub-roof planks or battens.

In order to facilitate the construction of canal tile roofs while retaining their architectural appearance, several methods have been proposed, in particular a method consisting in laying the channel tiles on a corrugated fiberglass slab underlay which seals and the flow of water. This method makes it possible to use a reduced quantity of tile, all of which have their concavity turned downwards. However, this process is expensive and it involves risks of lack of sealing because the fibro-cement plates can crack, especially under the effect of freezing or expansion. In addition, the fibro-cement plates can not withstand high loads in bending and it is therefore necessary to multiply the failures supporting the plates, which increases the cost of the framework and installation work.

FR 2 541 709 describes a method which makes it possible to provide new roofs in round tiles, which make it possible to preserve the architectural aspect of the traditional roof, process in which the round tiles are placed on a sub-roof which presents a good water and airtightness, which is easy to install and reduces the cost of the roof.

This process involves the implementation of self-supporting metal bins, usually galvanized or oven-lacquered sheet bins, which are used to build roofs of industrial buildings or side siding.

• on fabrique des bacs nervurés autoportants ondulés en créneaux ;
• on pose lesdits bacs sur lesdites pannes, la direction longitudinale des créneaux étant disposée parallèlement à la ligne de pente du toit ;
• on fixe les créneaux desdits bacs auxdites pannes par des boulons et on fixe sur lesdits boulons des armatures en treillis qui s'étendent sur toute la longueur des sommets des créneaux desdits bacs ;
• on dépose un bourrelet de mortier ou de béton autour desdites armatures ;
• et on pose, sur lesdits bourrelets en béton, des files juxtaposées de tuiles rondes dont la face concave est tournée vers le bas.

This process comprises the following operations:

• corrugated self-supporting ribbed troughs are manufactured;
• said bins are placed on said failures, the longitudinal direction of the slots being arranged parallel to the slope line of the roof;
• the slots of said bins are fixed to said failures by bolts and lattice reinforcements are fixed on said bolts, which extend over the entire length of the crest peaks of said bins;
• depositing a bead of mortar or concrete around said frames;
• and laying, on said concrete beads, juxtaposed rows of round tiles whose concave face is facing downwards.

• des bacs nervurés autoportants, ondulés en forme de créneaux, qui sont posés sur lesdites pannes suivant la ligne de pente de la toiture et qui sont fixés auxdites pannes par des boulons qui traversent les ondulations en relief ;
• des nappes d'armatures métalliques qui sont fixées sur lesdits boulons, qui s'étendent sur toute la longueur desdits bacs et qui sont incorporées, chacune, dans un bourrelet de béton qui est posé au-dessus de chaque ondulation en relief et,
• des tuiles rondes, dont la face concave est tournée vers le bas, qui sont posées sur lesdits bourrelets de béton ou de mortier.

The roof according to this method comprises:

• ridge-shaped, self-supporting ribbed bins, which are placed on said failures along the roof slope line and which are fixed to said failures by bolts which pass through the raised corrugations;
• metal reinforcing plies which are fixed on said bolts, which extend over the entire length of said troughs and which are each incorporated into a concrete bead which is placed above each raised undulation and,
• round tiles, whose concave face is turned downwards, which are placed on said concrete or mortar beads.

This process results in round tile roofs all of which have the concavity pointing downwards. Thanks to the self-supporting bins that can have a length equal to the length of the roof slopes, we obtain roofs perfectly watertight and airtight and which maintain their watertightness.

The self-supporting laminated sheet or laminated resin bins have, thanks to their ribbed ribbed form, a very good resistance to bending, so that the purlins that support them can be spaced apart. This crenellated profile makes it possible to stiffen the tray and thus to reduced thicknesses and thus lighter bins compared to a profile tray with fluted corrugations, that is to say of round shape.

The construction of roofs of this type is very fast and does not require a highly qualified workforce and this method of building roofs reduces the time and cost of building round tile roofs.

This method makes it possible to obtain a good mechanical connection between the tiles and the self-supporting bins thanks to the presence of an armature formed of an expanded metal strip or metal mesh extending over the entire length of the bins, which is fixed anchor bolts on the purlins.These self-supporting tanks can be manufactured by hand by cold rolling or bending galvanized steel sheet or kiln-lacquered, standard width.

One advantage of roofs of this type, compared to round tile roofs laid on corrugated fiber cement sheets, is that they make it possible to build roofs with lower slopes thanks to better watertightness and thanks to the form hollow grooves that allow better water flow. However, a disadvantage is that the tiles, whose round concave shape is not supported by the slots whose vertices are flat, must be supported by a spacer material or device adhering to the tray and supporting the tiles.

In this respect, the implementation of a lattice reinforcement, which allows the adhesion of the mortar on the self-supporting tray, represents an additional laying work as well as an additional weight load.

On the other hand, the mortar also has some disadvantage. Firstly, its weight is relatively high, a material with a density of more than 1000 kg / m ³ and, in practice for roofing, a surface density greater than 25 kg / m ² . In addition, the mortar reacts differently from the constituent material of the tile as a function of the ambient temperature, generating different dimensional variations that can induce delamination of the tile, or even the breaking of tiles. Finally, the mortar does not confer steady underside of the tile because, when the mortar dries, it retracts in a non-homogeneous manner, which generates mini void areas under the tile which are as many points of failure of sound insulation but also of risk of detachment or fragility of the tile.

Finally, to complete and consolidate the adhesion of the tiles by the mortar, it is recommended to implement hooks fixed on said lattice metal frames that hold the lower end of sloping tiles. But, the implementation of these hooks represents an additional laying work.

US 6,164,021 A discloses a method of making roofs wherein the corner and ridge tiles are fixed by injection of expanded polyurethane foam under the tiles to fill the voids and seal.

The document FR 2,619,688 describes a method for producing a traditional roof in which concavity-channel tiles are alternately raised upwards and downwards, trapezoidal chevrons making it possible to hold and wedge the tiles placed concavity upwards.

The purpose of the present invention is therefore to provide a method of producing round tile roofs placed on a steel bucket profile slot that does not have the disadvantages of the method of the prior art, in particular described in FR 2 541 709, in particular with means for supporting and adhering the tiles on said self-supporting bins which do not have the disadvantages of the implementation of a metal mesh reinforcement combined with a mortar for the adhesion and support of the tiles on said tray.

To do this, the present invention provides a method for producing a roof tile channel as defined by claim 1 wherein said tiles are placed on supports comprising self-supporting ribbed trays, corrugated crenel, with son of said sloping tiles on the tops of said battlements, and said row tiles overlapping so that the lower end of each tile covers the upper end of the tile located immediately lower in the slope, said tiles having all one Concavity directed downwards.

• soit par des cales préformées de matériau synthétique ou semi-synthétique collées sur ledit bac,
• soit par de la mousse de polyuréthane expansée directement déposée sur lesdits sommets desdits créneaux..

In the method according to the invention, a material forming a continuous bearing surface is inserted between said tiles and said tray, along the entire length of the tile outside the said overlap zone, the said material thus having a top face conforming to the shape concave round of the tile and a lower face matching the essentially flat shape of the tops of said crenellations, said material adhering directly to said tray or being bonded to said tray, without the use of a lattice reinforcement, and said material consisting of:

• either by preformed shims of synthetic or semi-synthetic material glued to said tray,
• either by expanded polyurethane foam directly deposited on said peaks of said crenellations.

The present invention offers several advantages.

Firstly, it provides a means of connection between the tray and the tiles which is both light and easy to install and which adheres directly to the tray or without the implementation of a metal lattice reinforcement or even additional hooks.

On the other hand, the means of connection between the tiles and the steel tanks, according to the present invention, constitutes a continuous bearing surface on the underside of the tile and this, both in the case of tiles with the formerly of irregular non-repetitive shapes for which it will then be advantageously used a said expanded polyurethane foam material in situ, than in the case of industrial tiles of identical regular shapes for which it will then be possible to use both preformed wedges that shims of expanded polyurethane foam in situ.

In a particular embodiment of the invention, said preformed wedges are made of polystyrene or polyurethane.

In a preferred embodiment said material, consisting of said polyurethane foam or said preformed wedges has a density of 35 to 55 kg / m ³ .

In an advantageous embodiment of the invention, said material consisting of said expanded polyurethane foam or said preformed wedges occupies the volume formed between said tiles and said peaks of said crenellations so that said peaks of said crenellations are substantially at a height corresponding substantially to half the depth of said tiles.

The inventors have, in fact, discovered that the amount of said material and in particular expanded polyurethane foam thus set The work is sufficient to provide both adhesion and reliable mechanical support for the tiles on the self-supporting tray.

More particularly, the weight of said material depending on the nature of the material may be from 10 g / m ² to 10 kg / m ² , more particularly from 5 g / m ² to 1000 g / m ² . Thus, for cement shims mixed with aggregates, the weight will generally be 5 to 10 kg / m ² , whereas for polyurethane foam shims, this weight will generally be 100 to 1000 g / m ² and for polyurethane foam beads, the weight of the material will be more particularly from 20 to 500 g / m ² .

More particularly, a laying of about 10 tiles per m ^{2 is carried out} , said tiles overlapping in each line over a length of 5 to 10 cm.

Said peaks of said crenellations comprise two longitudinal grooves, each of said two grooves being disposed along the lateral edges of said crenellations and thus delimiting the width of the zone initially covered by the expanded polyurethane foam at the moment of its deposition on said vertices of said crenellations in the form of of polyurethane foam cords.

Advantageously according to the present invention, said tiles are glued to each other at their ends at said overlap area without fixing hook.

In one embodiment, said tiles are tiles of identical regular shape and said material is constituted by said preformed wedges.

In another embodiment, said tiles are irregularly shaped and non-identical tiles and said material is made of said expanded polyurethane foam.

In a particular embodiment, said peaks of said crenellations have a width of 110 to 115 mm, said crenellations having a height of the order of 50 mm and the sidewall of said trapezoidal crenels diverging upwardly at an angle of between 0 and 15 mm. °.

Advantageously, one starts from sheets having a standard width of 1 meter, which can be delivered in long lengths on a reel, and form, in these, bins having three complete corrugations having a pitch of between 210 mm and 220 mm and a depth of 50 mm, these dimensions are ideal for laying rows of round tiles covering the corrugations in relief, leaving a weak game between the rows of tiles and a weak game between the edge of the tiles and the passage and the circulation of the water of rain.

These self-supporting tanks are made of sheet metal 0.5 to 1 mm thick and have a weight of the order of 4 to 10 kg / m ² which is a relatively low weight compared to that of other known sub-roofs, this which allows to lighten the frame.

Of course, one can choose sheets of different thickness depending on the range between failures supporting the bins.

The present invention also relates to a roof of the type comprising round tiles, obtained by a method according to the invention, characterized in that it comprises, interposed between said tiles and said tray, a said material as defined above .

• la figure 1 représente en perspective une toiture utilisant des cales selon la présente invention.
• la figure 2 représente en perspective une cale selon la présente invention.
• la figure 3 représente en perspective une toiture utilisant un cordon de mousse selon la présente invention.

Other features and advantages of the present invention will emerge in the light of the detailed description which follows, made with reference to FIGS. 1 to 3 in which:

• Figure 1 shows in perspective a roof using wedges according to the present invention.
• Figure 2 shows in perspective a shim according to the present invention.
• Figure 3 shows in perspective a roof using a bead of foam according to the present invention.

The present invention aims to facilitate the construction of roofs of individual houses but it is not limited to this application and roofs according to the present invention can be used to cover other buildings, including collective housing or industrial premises.

The roof according to the present invention results from the laying of frustoconical tiles 1 on a tray 2 of preformed steel, a material 3, 4 ensuring the maintenance of the tile 1 on the tray 2.

Figure 1 shows a first embodiment.

The tray 2 is obtained from a steel sheet, initially flat, whose thickness is of the order of 0.63 mm and whose weight is of the order of 7.6 kg / m ² .

Trapezoidal crenellations 22 are formed in the width of this sheet, for example by rolling.

These crenellations 22 are formed by a succession of surfaces 212 forming the small upper base of the vertices 21, said surfaces 212 being framed by two lateral sides inclined to the convergent blank 211 and 214.

The sheet thus formed advantageously has a variable length, at most 1200 mm, a useful width of 660 mm and a crest height of 50 mm.

A peak 21 forms a convex trapezium the length of the small upper base 212 is about 113 mm. A crenel 22, less wide, forms a concave trapezoid whose length of the small lower base 221 is about 85 mm. The two inclined sides 211, 214 of each concave slit 22 or convex trapezium 21 are respectively divergent or convergent upwards with a draft relief angle of between 0 and 15 °.

These tanks are supported by unrepresented structural elements that may be metal or timber or prefabricated concrete frameworks. They are for example fixed on not-represented battens by bolts or lag bolts, or threaded rods, or any other equivalent fastener, which pass through fixing holes advantageously drilled through the small base 212 of the vertices 21, in contact with the tiles, the small base 221 concave slots 22 being in contact with the battens.

Once a first tray installed, it is positioned in the same way just next to it a second tray. The two edges in contact each have a crenel portion, made so that the slot portion at the edge of the second tray partially overlaps at least the slot portion at the edge of the first tray. Useful width previously mentioned is the width of a tray 2 which is not covered by the bins fixed on either side thereof.

Each tray advantageously has at each of its ends a crown portion 21, made so that the crown portion 21 of a second tank which covers the crown portion 21 of a first tank located next to it, has a a small solid base 212 and a side portion 211 extending over at least one-third of the length of the entire 211 side of the top portion 21 of the first bin. The latter also has a portion of small base 212 which extends under at least half the length of the small base 212 complete the second tray.

This type of assembly ensures the tightness of the device, rain water flows on the side portion 211 of the upper tray and falls on the full 211 side of the lower tray.

Advantageously, each plate has two vertices 21 full and three concave slots 22 full.

Each small base 212 of each vertex 21 has two grooves in "V" 213. These grooves are made during the shaping of the sheet.

Once the roof covered with bins 2, it has in line on the vertices 21 frustoconical tiles gutters 1 whose concavity is directed downwards.

This type of tile is standard and commonly used by those skilled in the art. They can be regular or irregular and generally have a length of 40 or 50 cm, a small width of about 17 cm and a large width of about 21 cm.

The lower part of a gutter tile 1, that is to say the part situated on the side of the large width covers the upper part, that is to say the part situated on the side of the small width of the tile arranged immediately after.

The cover is then at least 60 mm.

Preferably, two tiles are secured together by two studs 5 of about 0.5 cm ³ of mastic made in the overlap area.

One-component polyurethane-based elastomer sealant is preferably used. This type of putty, proposed in particular by the company SIKA under the trade name SIKAFLEX 11FC or FIXOTUILE, is packaged in a cartridge and its installation is done by manual or pneumatic gun.

This type of sealant cures under the action of moisture and wind and has excellent resistance to aging and weathering.

To ensure good stability of the tile, the present invention proposes to interpose between each tile 1 and the tray 2 a material 3, 4.

This material may be a wedge 3 as shown in FIGS. 1 and 2, or a bead of foam 4 as represented in FIG.

In the case of a shim 3, it is obtained by injection molding of a material which can be composed essentially of polystyrene or polyurethane and having a density of 25 to 40 kg / m ³ .

A wedge 3 has a flat bottom face 32, trapezoidal shape, and a convex upper surface 31, frustoconical.

This wedge advantageously has a length L of 150 to 250 mm, a small width I ₁ of 60 to 110 mm, a large width I ₂ of 80 to 120 mm, a small height h ₁ of 15 to 30 mm and a large height h ₂ from 20 to 45 mm.

More particularly still with reference to FIG. 2 L = 210 mm, I ₁ = 85 mm, I ₂ = 109 mm, h ₁ = 23 mm, h ₂ = 33 mm, e ₁ = 6 mm and e ₂ = 8 mm.

A shim 3 is then inserted between each tile 1 and the tray 2, the flat bottom face 32 is then in contact on the tray 2, the convex upper face 31 then cooperates with the concavity 12 of the tile 1, thus ensuring good stability of it.

The tiles are glued on the shims 3 with the polyurethane sealant mentioned above.

The shims 3 may be replaced by a bead of foam 4 as shown in Figure 3. This cord 4 allows including the installation and fixing of tiles 1 of different sizes.

This cord consists of an expansive polyurethane foam and occupies about a volume of 1.4 liters per tile and has a weight of about 56 g per tile.

The expansive polyurethane foam is contained in an aerosol in which an authorized propellant gas is injected to allow the extrusion of the product.

More specifically, the aerosol contains an expansive foam based on polyurethane prepolymer, and an authorized propellant is injected to allow extrusion of the product that expands between the tray and the tile by sticking it, and after a few hours the product hardens by polymerization in the form of polyurethane in contact with air.

Different product products are commercially available, especially sold by different manufacturers, especially in the SIKA company under the trade reference SIKABOOM

The two "V" shaped grooves 213 made on the small base 212 of a convex slot 21 serve to limit the area in which the foam is to be extruded. Once in contact with the air, it expands, we can then have the tile 1 and the cord made comes into contact with it. The tiles are joined together as before, with two pads of putty. The foam bead 6, drying, hardens and solidifies the assembly.

In order to verify that the fixing of the tiles on the polyurethane foam bead is sufficient, mechanical tests have been carried out and show that this assembly guarantees the tile good mechanical strength, in particular the tensile and shear forces. The tests were carried out on several types of tiles. The tensile stress resistance tests were carried out by subjecting an increasing load at a constant loading speed, in a direction perpendicular to the inner surface 32 of a shim 3, to two sides 13 and 14 of a tile 1 laid down and maintained on a tray 2 according to the present invention, until the tile 1 comes off. The device used allows to draw vertically on the two lateral lips of the tile through an articulated stirrup.

The shear strength, or lateral tensile, results were obtained by subjecting an increasing load at constant loading speed, in a collinear direction to the surface 32 of a shim 3, the tile being laid and held according to the present invention on a tray 2 in a vertical position, through a curved bracket making a grip on one side 13 of the tile.

It has been observed a tensile strength greater than 125 daN up to 250 daN and a shear strength greater than 200 daN up to 430 daN

By way of comparison in similar tests carried out on the same tiles, but these being directly bonded to fibrocement plates corrugated according to the traditional method, tensile strengths of less than 100 daN and shear strengths of 100 to 195 were observed. daN.

Claims (11)

1. A method of making a roof with channel-shaped or "Roman" tiles (1) in which said tiles (1) are laid on supports comprising self-supporting ribbed sheets (2) with straight-sided corrugations, by laying sloping rows of said tiles on the ridges (21) of said corrugations (22), the tiles overlapping one another in such a way that the bottom end of each tile overlaps the top end of the tile situated immediately below it along the slope, all of said tiles presenting their concave sides facing downwards, in which method,
   a material (3, 4) is interposed between said tiles (1) and said sheet (2), the material forming a continuous support surface over the entire length of said material in contact with the tiles outside said overlap zones, said material thus presenting a top face matching the concave round shape of the tile and a bottom face matching the essentially plane shape of the ridges of said corrugations, said material adhering directly to said sheet or being stuck to said sheet, without using wire mesh reinforcement, and said material being constituted:

   - either by preshaped spacers (3) of synthetic or semi-synthetic material stuck onto said sheet and each presenting a plane bottom surface (32) and a convex frustoconical top face (31) co-operating with the concave round shape (12) of a tile;

   - or else by expanded polyurethane foam (4) deposited directly on said ridges of said corrugations between two longitudinal grooves (213) disposed in the top surfaces of the ridges of the corrugations and along and between the side edges of the corrugations, and defining the width of the zone that is initially covered by polyurethane foam when it is deposited.
2. A method according to claim 1, characterized in that said material, constituted by said polyurethane foam (4) or said preshaped spacers (3) presents a density of 35 kg/m³ to 55 kg/m³.
3. A method according to claim 1 or claim 2, characterized in that said preshaped spacers are made of polystyrene or of polyurethane.
4. A method according to any preceding claim, characterized in that said material constituted by said expanded polyurethane foam (4) or by said preshaped spacers (4) occupies the volume formed between said tiles and said ridges of said corrugations in such a manner that said ridges of said corrugations are situated substantially at a height corresponding substantially to half the depth of said tiles.
5. A method according to any preceding claim, characterized in that the weight of said material is 10 g/m² to 10 kg/m², and preferably 20 g/m² to 1000 g/m².
6. A method according to any preceding claim, characterized in that about ten tiles are laid per square meter, said tiles overlapping over a length of 5 cm to 10 cm.
7. A method according to any preceding claim, characterized in that said tiles are stuck to one another at their ends in said overlap zones without any fastener hooks.
8. A method according to any one of claims 1 to 7, characterized in that said tiles are tiles of identical regular shape and said material is constituted by said preformed spacers (3).
9. A method according to any one of claims 1 to 7, characterized in that said tiles are not identical and are irregular in shape, and said material is constituted by said expanded polyurethane foam (4).
10. A method according to any one of claims 1 to 9, characterized in that said ridges (21) of said corrugations (22) present a width of 110 mm to 115 mm, said corrugations presenting a height of about 50 mm, and the flanks (211, 214) of said trapezium-shaped corrugations diverging upwards at an angle lying in the range 0° to 15°.
11. Roofing of the type comprising round tiles obtained by a method according to any one of claims 1 to 10, the roofing being characterized in that it includes a said material interposed between said tiles and said sheet.

Images