EP2021559A1

EP2021559A1 - Roofing and its manufacturing method

Info

Publication number: EP2021559A1
Application number: EP07730800A
Authority: EP
Inventors: Marko Moisio
Original assignee: Rautaruukki Oyj
Current assignee: Rautaruukki Oyj
Priority date: 2006-06-02
Filing date: 2007-05-31
Publication date: 2009-02-11
Also published as: RU2008147069A; FI20065374L; FI20065374A0; WO2007141379A1; RU2431724C2; EP2021559A4

Abstract

The invention relates to roofing that comprises two or more sandwich elements (2) that are tightly attached to each other and comprise a first sheet (4) forming an outer roof surface, a second sheet (6), and filling material (10) between the first and second sheets (4, 6). According to the invention, at least the first sheet (4) of the sandwich element (2) is furnished with water-proofing.

Description

ROOFING AND ITS MANUFACTURING METHOD

BACKGROUND OF THE INVENTION

[0001] The invention relates to roofing according to claim 1 and to a method for the manufacturing of roofing according to claim 12.

[0002] Conventionally, the roofs of buildings, such as various halls or warehouses, are made of several parts that, are designed for use specifically in roof structures. Such a roof structure often comprises an outer roofing material, a roof sheeting material, insulation, and a support structure or load-bearing structure that are all put together into an assembly that is mounted on the beam or purlin structure of a building. In addition to this, roof structures often need separate water-proofing. Roof structures of this type are designed for use only in roof structures.

[0003] A problem with the above arrangement is that installing multipart roof structures of this type is a labour- and time-consuming process that considerably increases building costs. Known roof structures are also complex in structure. In addition, parts of these conventional roof structures cannot be utilised in other structures of a building. This means that known roof structures and their installation cause considerable costs.

BRIEF DESCRIPTION OF THE INVENTION

[0004] It is thus an object of the invention to develop roofing and a method for manufacturing it so as to solve the above-mentioned problems. The object of the invention is achieved with the roofing described in the characterising part of claim 1 and characterised in that the roofing comprises one or more sandwich elements that comprise a first sheet forming an outer roof surface, a second sheet, and a filling material between the first and second sheets, with at least the first sheet of the sandwich element having water-proofing. The object of the invention is further achieved with the method described in the characterising part of claim 12 and characterised in that the method produces one or more sandwich elements that comprise a first sheet, a second sheet, and a filling material between the first and second sheets, and that water-proofing is provided at least on the first sheet of the sandwich element that forms the outer roof surface.

[0005] Preferred embodiments of the invention are disclosed in the independent claims. [0006] The invention is based on producing the roof structure of a building, such as a hall or warehouse or any other building, by utilising elements that can also be used as wall elements or the like. According to the invention, the roof structure utilises a sandwich element or some other corresponding element or layered slab that comprises a first sheet, a second sheet, and a filling material installed between them. In this context, a sandwich element refers generally to all elements that comprise the above-mentioned layered structure in which a filling material, such as an insulation material, is mounted between two sheets, preferably metal sheets. The sandwich element is produced for instance by fastening surface sheets together by laser welding between them a profile sheet having a thermo-perforation that preferably reduces heat conduction.

[0007] According to the invention, roofing is made of one or more sandwich elements that comprise a first sheet, a second sheet, and a filling material installed between them. Sandwich elements of this type are arranged to be installed in place such that the outer side of the first sheet, the side opposite to the filling material and second sheet, forms the outer roof surface. Thus, this first sheet, and especially its outer side, is furnished with waterproofing that is provided on top of the outer side of the first sheet. Waterproofing is made preferably by laminating a water-proofing material, such as a chloropolyethylene or polyester, on the outer side of the second sheet. The lamination can be done during the manufacture of the sandwich element. This way, the water-proofing does not suffer during the other manufacturing steps. The sandwich element is also furnished with a load-bearing structure to support it. This load-bearing structure can be a metal profile sheet, corrugated sheet, smooth sheet, or any other load-bearing structure that supports the sandwich element and can be fastened on the underside of the sandwich element to the second sheet or alternatively formed in the space between the first and second sheets. Several water-proofed sandwich elements of this type can be attached to each other with interlocking, for instance, to form an extensive roof surface.

[0008] The method and system of the invention provide the advantage that with the roofing structure described above, it is possible to provide quickly and easily a finished roof surface. In addition, in the roofing structure of the invention, it is possible to utilise elements and parts that are used in wall elements, for instance, so there is no need to manufacture separate elements for the roof. Thus, the roofing of the invention and its manufacturing method provide a simple structure and method, and consequently reduce costs.

BRIEF DESCRIPTION OF THE INVENTION

[0009] The invention will now be described in more detail by means of preferred embodiments and with reference to the attached drawing, in which

Figure 1 is a schematic representation of a roofing of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0010] Figure 1 shows an embodiment of the present invention, which comprises a sandwich element 2. The sandwich element 2 comprises a first sheet 4 and a second sheet 6 with filling material 8 installed between them. The first and second sheets 4, 6 are preferably made of metal, such as galvanised and/or machine-painted sheet metal or thin plate or some other corresponding material suitable for use in sandwich elements. In this example, the first and second sheet 4, 6 are smooth sheets that are parallel to each other. Alternatively, the first or second sheet 4, 6 or both can also be of another shape, such as wavy, profile, or corrugated sheets or the like. They then do not both need to be similar. When the sheets 4, 6 are other than smooth, the cross-profile of the filling material 8 also changes to correspond to the shape of the sheets 4, 6.

[0011] Filling material 8 that is preferably insulating material, such as polyurethane, soft wool, hard wool, or the like, is installed between the first and second sheets 4, 6, whereby the sandwich element comprises a fixed insulation. However, the filling material 8 can also be some other material suited for installation between the sheets 4, 6 depending on the application. The filling material 8 can be fastened to the first and second sheets 4, 6 during the manufacture of the sandwich element 2 with glue, mechanically, or with some other corresponding method.

[0012] As in Figure 1 , the sandwich elements 2 are installed on the roof of the building in such a manner that the first sheet 4 and especially its outer surface, i.e. the surface opposite the filling material 10, forms the outer roof surface. According to the invention, this first sheet 4 has water-proofing so that it is suitable for use as an outer roof surface. This water-proofing can be provided with any known technique by using materials suitable for waterproofing. Preferably, water-proofing is made by laminating a suitable water- proofing material directly on the outer surface of the first sheet 4. The waterproofing material to be laminated can then be chloropolyethylene (CPE laminate) or polyester (PET laminate). This way, it is possible to produce waterproofing that is an integral part of the sandwich element and especially the first sheet 4. However, it should be noted that water-proofing can be provided on the sandwich element 2 separately, in which case water-proofing and the structure providing it is fastened or mounted on top of the first sheet of the sandwich element 2 as a water-proofing coating.

[0013] Water-proofing can be provided on the first sheet 4 during the manufacturing of the sandwich element 2 or during the manufacturing of the sheets 4, 6 of the sandwich element, which means that a separate process is not needed. However, it is naturally also possible to perform it as a completely separate process. Further, water-proofing can also be made on both the first and the second sheet 4, 6, whereby possible installation errors are avoided during the installation of the roofing of the invention, when the sandwich element 2 is installed the wrong way. In water-proofing it is also possible to use bitumen-based roofing or materials and especially single-layer roofing and any other known water-proofing. In addition, water-proofing can be furnished with wool, preferably hard wool, or this can be fastened to it, to settle between the first sheet 4, i.e. the top sheet, of the sandwich element 2 and the water-proofing. Wool thus provides an additional insulation.

[0014] The ends or edges of the sandwich elements 2 preferably have interlocks 12 to join the sandwich elements 2 together. The interlock 12 can be of any shape, as long as the male and female interlocks of the elements 2 fit together to tightly join the sandwich elements 2 to each other. A machine joint 14 is provided at the joining point of the sandwich elements 2 to seal the joining point. The machine joint can be made with any known machine joining technique.

[0015] Because the sandwich elements 2 are normally not sufficiently robust and rigid in structure, a load-bearing structure can be made to them for support. In the case of Figure 1 , this load-bearing structure is formed by fastening to the second sheet 6 of the sandwich element 2 a load-bearing structure that is formed of a load-bearing profile sheet 10. The profile sheet 10 is preferably fastened to the second sheet 6 by laser welding. Alternatively, the profile sheet 10 or another load-bearing structure can also be fastened to the second sheet 6 mechanically with screws, for instance, or with some other suitable fastening method. Several profile sheets can also be installed after each other, in which case they can be installed to overlap slightly as shown in Figure 1 and fastened to each other mechanically with screws, for instance, at the joining point 18. Instead of profile sheets 10, the load-bearing structure can be a corrugated sheet, smooth sheet, rods, beams, or any other structure that provides sufficient support for the sandwich element when it is installed on the roof of a building. The profile sheet can be made of a galvanised sheet, sheet metal or thin plate.

[0016] Alternatively, the load-bearing structure can be formed by providing a load-bearing structure, such as a honeycomb structure, between the first and second sheets 4, 6. The honeycomb structure can be made of a profile sheet or corrugated sheet whose corrugations or waves extend between the first and second sheets 4, 6. This honeycomb structure can thus be fastened to both the first sheet 4 and the second sheet 6 by laser welding, for instance. The spaces remaining between the first and second sheets 4, 6 and the honeycomb structure are preferably filled with filling material. As stated above, the filling material can preferably be an insulation material, such as polyurethane, soft wool, hard wool or some other corresponding insulation material. The profile sheet or some other corresponding load-bearing structure can also be furnished with thermo-perforation. The bottom sheet 6 can also act as a vapour barrier.

[0017] According to the invention and the above-mentioned embodiments, roofing is provided comprising a sandwich element with a first sheet 4 or a first sheet 4 and a second sheet 6 furnished with water-proofing. In addition, the sandwich element 2 is furnished with a load-bearing structure 10 to support the sandwich element 2. This way, simple roofing is provided for installation directly on the beam or purlin structure of a building, whereby finished roof surface is quickly achieved and, in the manufacturing of the roofing, it is also possible to utilise synergy advantages for other purposes, such as for the making of wall elements.

[0018] It is apparent to a person skilled in the art that as technology advances, the basic idea of the invention can be implemented in many different ways. The invention and its embodiments are thus not limited to the above examples, but may vary within the scope of the claims.

Claims

1. Roofing, characterised by comprising one or more sandwich elements (2) or corresponding elements that comprise a first sheet (4) forming an outer roof surface, a second sheet (6), and a filling material (8) between the first and second sheets (4, 6), with at least the first sheet (4) of the sandwich element (2) having water-proofing.

2. Roofing as claimed in claim 1, characterised in that the water-proofing is an integral part of at least the first sheet (4).

3. Roofing as claimed in claim 2, characterised in that the water-proofing is provided by laminating water-proofing material on at least the first sheet (4) of the sandwich element (2).

4. Roofing as claimed in any one of claims 1 to 3, characterised in that the water-proofing material is chloropolyethylene.

5. Roofing as claimed in any one of claims 1 to 3, characterised in that the water-proofing material is polyester.

6. Roofing as claimed in claim 1 or 2, characterised in that the water-proofing is made of bitumen-based roofing.

7. Roofing as claimed in any one of claims 1 to 6, characterised in that the sandwich element (2) is furnished with a load-bearing structure (10) to support it.

8. Roofing as claimed in claim 7, characterised in that the load-bearing structure (10) is fastened to the second sheet (6) to support the sandwich element (2).

9. Roofing as claimed in claim 7, characterised in that the load-bearing structure (10) is installed between the first and second sheets (4, 6).

10. Roofing as claimed in claim 7, 8, or 9, c h a r a c t e r i s e d in that the load-bearing structure (10) is formed of one or more profile sheets or corrugated sheets.

11. Roofing as claimed in any one of claims 1 to 10, character- is e d in that adjacent sandwich elements (2) are attached to each other by interlocking (12) their ends.

12. Roofing as claimed in any one of claims 1 to 11, character- is e d in that the joining points of adjacent sandwich elements (2) are joined by machine joints (14) to seal the joining points.

13. Roofing as claimed in any one of claims 1, 2, or 6 to 12, characterised in that the water-proofing is furnished with wool that settles between the first sheet (4) of the sandwich element (2) and the waterproofing.

14. A method for manufacturing roofing, characterised by producing one or more sandwich elements (2) or corresponding elements that comprise a first sheet (4), second sheet (6) and a filling material (10) between the first and second sheets (4, 6), and providing water-proofing on at least the first sheet (4) of the sandwich element (2) that forms an outer roof surface.

15. A method as claimed in claim 14, characterised in that the water-proofing is made an integral part of at least the first sheet (4).

16. A method as claimed in claim 14 or 15, characterised in that the water-proofing is provided by laminating water-proofing material on at least the first sheet (4) of the sandwich element (2).

17. A method as claimed in any one of claims 14 to 16, character i s e d in that the water-proofing is provided during the manufacturing process of the sandwich element (2) and/or sheets (4, 6).

18. A method as claimed in any one of claims 14 to 16, character i s e d in that the water-proofing is provided to the sandwich element during a separate process.

19. A method as claimed in any one of claims 14to 18,charac- t e r i s e d in that chloropolyethylene, polyester, a bitumen-based roofing material, or a mixture thereof is used as the water-proofing material.

20. A method as claimed in any one of claims 14 to 19, character i s e d in that the water-proofing is done on the first and second sheets (4, 6) of the sandwich element.

21. A method as claimed in any one of claims 14 to 19, characterised in that two or more sandwich elements (2) are attached to each other.

22. A method as claimed in claim 21. characterised in that adjacent sandwich elements (2) are attached to each other by interlocking their ends.

23. A method as claimed in claim 22, characterised in that the joining points between adjacent sandwich elements (2) are sealed by a machine joint (14).

24. A method as claimed in any one of claims 14 to 23, c h a r a c - t e r i s e d in that the sandwich element (2) is furnished with a load-bearing structure to support it.

25. A method as claimed in claim 24, characterised in that the load-bearing structure (18) is fastened to the second sheet (6) of one or more sandwich elements (2) to support the sandwich element (2).

26. A method as claimed in claim 24 or 25, c h a r a c t e r i s e d by creating the load-bearing structure (18) from one or more profile sheets or corrugated sheets.

27. A method as claimed in any one of claims 24 to 26, c h a r a c - terised in that the load-bearing structure (18) is fastened to the second sheet (6) of the sandwich element (2) by laser welding.

28. A method as claimed in claim 24, characterised in that the load-bearing structure is provided in the space between the first and second sheets (4, 6) of the sandwich element (2).

29. A method as claimed in any one of claims 14 to 28, c h a r a c - terised in that the water-proofing is furnished with wool that settles between the first sheet (4) of the sandwich element (2) and the water-proofing.