EP4644633A1

EP4644633A1 - Insulated roofing, flat or pitched, for construction

Info

Publication number: EP4644633A1
Application number: EP25171968.8A
Authority: EP
Inventors: Massimiliano STIMAMIGLIO; Fabio RAGGIOTTO
Original assignee: Stiferite SpA
Current assignee: Stiferite SpA
Priority date: 2024-04-30
Filing date: 2025-04-23
Publication date: 2025-11-05

Abstract

The present invention relates to an insulated roofing (10), flat or pitched, for building construction, characterised in that it comprises, arranged in the following order- a support structure (11) arranged substantially horizontally or inclined- a vapour barrier layer (30) placed on said support structure (11),- an insulating layer (12) made from a plurality of insulating panels (16) attached to said support structure (11),- a plurality of load-distributing profiles (13) which are facing in contact with said insulating layer (12) and are operatively connected to said insulating layer (12) by means of fastening and load distribution means, said plurality of load distribution profiles (13) being fixed to said support structure (11) by means of adhesives and/or first fastening means (17), each load distribution profile (13) comprising a longitudinal plate (20a) configured to face said one or more side-by-side insulating panels (16)- a plurality of cladding elements (14) defining a waterproofing or rainwater-diverting covering (40), said cladding elements (14) being connected to said plurality of load-distributing profiles (13) by means of second fastening means (18).

Description

Technical field

The present invention relates to an insulated roofing, flat or pitched, for building construction.
The present invention is applicable in the building industry in the construction of roofs for buildings with thermal insulation.

Technical background

Nowadays, the following steps can be taken to construct a building with insulated roofs with continuous insulation:

a support structure is built, which may be a concrete and brick slab, with or without screed, or a CAP roof tile, or a wooden beam or plank slab, or a metal slab;
a plurality of slabs of insulation, arranged so that the edges match as closely as possible, are fixed to the support plane defined by this support structure, and bound to the support by means of adhesives and/or dowels, where these slabs of insulation are either interspersed with laths or rafters to support and anchor the loads, which loads would otherwise have to be fixed to the slabs with a serious risk of damaging them, or incorporate load-supporting laths, as is typically the case in pitched roofs, laths having the same functions of accommodating the means of fixing, such as nails, dowels and the like, which would otherwise perforate the insulation slabs; the main damage that the insulating sheets may suffer concerns the reduction of their thickness; since thermal resistance is equal to the ratio between thickness and thermal conductivity, the loss of thickness leads to a reduction of the thermal properties of resistance and transmittance that the structure has compared to the design values. The law in force today requires that the design characteristics be maintained for at least twenty-five years, where the builder and designer have criminal and civil liability for at least ten years;
Subsequently, either a roof covering, e.g. made of pantiles, tiles or other bricks, is placed on the insulating layer, or a plurality of spacer profiles are arranged to support the roof covering while defining a ventilation gap. The insulation layer almost never has mechanical strength characteristics that guarantee the windtightness of the pull-out element.

In flat roofing, the insulation is generally laid continuously and no battens are used to secure the loads. In flat roofing, a waterproofing element is generally bonded, either hot or cold, to the insulation. The flat roof is thus finished. Insulators used in flat roofs normally have high load-bearing strengths, even mineral wools, although they perform significantly less well than synthetic materials.
Such insulated roofing systems, although widespread and appreciated, have some aspects that can be perfected.
A first limitation of the known technique lies in the fact that the integrity of the insulation boards is delegated to the presence of wooden battens, interposed between ordered rows of insulation boards or embedded in the insulation boards themselves. In some cases the batten element could be metal, with the limitation of defining a diffuse thermal bridge.
The use of battens or joists between two rows of panels results in an undesirable discontinuity in the insulation.
On the other hand, the use of slabs, or panels, of insulation incorporating battens entails a higher overall cost due to the higher cost of the panel reinforced with wooden or metal battens.
Furthermore, although they are designed to absorb a large part of the loads attached to them, laths or joists made of wooden material do not lend themselves well to optimal load distribution behaviour on the surface below and around the fastening area between the load and the lath itself.
Additionally, when constructing a roof with standing seam metal sheets, it is now obligatory to create a layer of wood on top of the insulation, in order to fix the sheet metal elements to it, which will have a characteristic pitch according to the specific site and the specific finish. This wood layer has a significant cost. Another limitation of the known technique is that when setting up the roof, the fitters must pay attention to the orientation of the insulation panels with embedded wooden battens, since, for example, in the case of unventilated sheet metal roofs, the insulation panels must be positioned with battens parallel to the eaves line. The task of the present invention is to develop an insulated roofing, flat or pitched for building construction that is capable of improving on the known technique in one or more of the above-mentioned aspects.
In the context of this task, one aim of the invention is to realise an insulated roofing that can reduce the time and costs for its construction and assembly. Yet another aim of the invention is to realise an insulated roofing with great application versatility.
Yet another aim of the invention is to develop an insulated roofing that is easy to install, even for users with no special pre-training.
This task, as well as these and other purposes that will better appear later, are achieved by an insulated roofing, flat or pitched, for building construction as set out in independent claim 1.
Further features and advantages of the invention will be more apparent from the description of certain preferred, but not exclusive, forms of execution of the insulated roofing according to the invention, illustrated, by way of indication and not limitation, in the accompanying drawings, wherein

figure 1 illustrates a perspective view of an insulated roofing according to the invention in a first construction variant;
figure 2 represents a sectional view of a portion of the insulated roofing of figure 1;
figure 3 represents a detail of a partial exploded view of the insulated roofing according to the invention;
figure 4 represents another perspective exploded view of some components of the insulated roofing according to the invention;
figure 5 represents an overall perspective view of the exploded view of the insulated roofing in figure 4;
figure 6 represents a cross-section of a portion of a roof according to the invention;
figure 7 depicts a perspective view of a roof according to the invention in a second design variant;
figure 8 depicts a perspective view of a roof according to the invention in a third construction variant;
figure 9 depicts a cross-section of the third variant, figure 8, of the insulated roofing according to the invention.

With reference to the above-mentioned figures, an insulated roofing, flat or pitched, for building construction, according to the invention is indicated, in the whole of a first embodiment variant thereof, by reference number 10.
This insulated roofing 10 comprises arranged in the following order:

a support structure 11 arranged substantially horizontally or inclined
a vapour barrier layer 30 placed on the supporting structure 11,
an insulating layer 12 made of a plurality of insulating panels 16 attached to said support structure 11,
a plurality of load-distributing profiles 13 which face in contact with said insulation layer 12 and are operatively connected to said insulation layer 12 by means of fastening and load distribution means, further described below; the load-distributing profiles 13 are fixed to said support structure 11 by means of adhesives, or by means of adhesives and first fastening means 17, or by first fastening means 17; said first fastening means 17 are, for example, dowels or screws; each load-distributing profile 13 comprises a longitudinal plate 20a configured to be facing one or more insulating panels 16 placed side by side;
a plurality of cladding elements 14 defining a waterproofing or rainwater-deflecting covering 40; said cladding elements 14 are connected to the plurality of load-distributing profiles 13 by means of second fastening means 18.

Therefore, the fasteners for the panel and load-distributing profiles are different; the fasteners for the panels have a flat head and a diameter of a few centimetres, usually 4-6 cm; the fasteners for the profiles are dowels, i.e. screws for wooden supports and screws with termostoppers for concrete or prestressed reinforced concrete or brick supports, do not need the flat head and have a larger diameter, because they fit onto the profiles.
Load-distributing profiles 13 are only mechanically bound.
Insulating panels 16, on the other hand, can also be bonded to the supporting structure by means of glue.
In the first embodiment of the invention, depicted in figures 1 to 5, the second fastening means 18 comprise a plurality of longitudinal spacer profiles 50 anchored by fastening means to said load-distributing profiles 13.
Such longitudinal spacer profiles 50 are configured and positioned to support said cladding elements 14 at a predetermined distance from the underlying insulating panels 16 so as to define with them a ventilation gap 60.
Such longitudinal spacer profiles 50 are, for example, omega-shaped, but are also intended to be of a different cross-section, e.g. 'H' or 'L' cross-section Alternatively, such longitudinal spacer profiles can also be wooden morals.
The second fastening means 18 also comprise threaded elements 51, or nails, or dowels, for anchoring the longitudinal spacer profiles 50 to the load-distributing profile 13, as exemplified in figures 4 and 5.
Equivalently, in a non-illustrated embodiment variant of the invention, the second fastening means 18 may comprise a plurality of spacer bodies, such as posts or brackets. Such spacer bodies are arranged in ordered rows above the insulating panels 16 so as to support the cladding elements 14.
The first fastening means 17 may be dowels, or self-tapping screws or other equivalent mechanical fasteners.
In particular, the first fastening means 17 fixes a load-distributing profile 13 to the support structure 11 and then also fixes the insulating panel 16, which is interposed between the support structure 11 and the load-distributing profile 13, to the support structure 11.
There may also be panel stop plugs 17a, configured to anchor only the insulation panels 16 to the support structure 11.
By way of example, but not limited to, the load-distributing profiles 13 each comprise a longitudinal profile having a substantially 'C'-shaped cross-section, said longitudinal profile comprising in turn the longitudinal plate 20a and two opposite side parts 20b, 20c extending from said longitudinal plate 20a in a substantially orthogonal direction to it, as exemplified in figures 3 and 4.
The side parts 20b, 20c each have a row of clinging reliefs 21 configured to penetrate an underlying insulation panel 16.
The row of pointed reliefs 21 consists of an ordered series of equal sawtooth reliefs.
Load distribution profiles are intended to be able to have a cross-sectional shape other than the 'C' shape mentioned above; example, load distribution profiles are intended to be able to have an 'L' or 'T' cross-sectional shape; alternatively, load distribution profiles can be flat.
Load-distributing profiles 13 with side parts 20b, 20c with clinging reliefs 21 allow them to be mounted even on insulation board areas that are not supported on a purlin, as they cling to the panels independently.
Insulating panels 16 are sandwich panels comprising a polyurethane foam
These insulating panels 16 may be sandwich panels comprising a polyurethane foam of a type of your choice from those known under the trade name Stiferite FIRE B, CLASS SK, CLASS S, GT, GTE, VV, ISOVENTILATED, CLASS SH, or Ai5 Building, produced by the Applicant himself.
In particular, such insulation panels 16 are understood to be without internal, or partially internal, rigid reinforcing parts, such as wooden battens, metal plates or bars, or other internal or partially internal reinforcing elements.
In particular, these insulating panels 16 have a parallelepiped shape.
Insulating panels 16 have no recesses in relation to the parallelepiped shape, neither at the edges nor in the inner areas in relation to the edges.
Insulation panels 16 comprises polyurethane foam evenly distributed throughout the body of insulation board 16 itself.
Each insulation panel 16 comprises a polyurethane foam, which is perforable by the side parts 20b and 20c of a load-distributing profile 13.
Alternatively, insulation panels 16 may also be polystyrene or polystyrene-based insulation boards, or phenolic foam-based insulation boards, or insulation panels based on a wool of mineral origin or based on a wool in general, such as rock wool and glass wool.
In a first construction variant of the insulated roofing 10, the support structure 11 comprises a floor with planks 11a and beams 11b of wood material.
Support structure 11 is intended to include either only planks or only beams.
In a second embodiment of an insulated roof according to the invention, exemplified in figures 8 and 9 and referred to therein as number 110, the support structure 111 comprises a concrete and brick slab.
The support structure 111 with a concrete and brick slab is intended to be able to present in combination with the other described construction variants, remaining within the scope of the present invention.
In another embodiment of an insulated roof according to the invention, the support structure comprises one or more CAP (prestressed reinforced concrete) tiles.
In another embodiment of an insulated roof according to the invention, the support structure is made of metal material.
The cladding elements 14 comprise, or consist of, roof tiles or other brick bodies, as in the construction variant of Figures 1 and 2.
In a second implementation variant, depicted in figures 8 and 9, the cladding elements 114 comprise or consist of sheets of metal material.
In this realisation example, the sheets of metal material, e.g. corrugated sheets, are supported and fixed directly on the load-distributing profiles 13, and the fastening means 18 comprise only screws, or dowels, or nails to anchor the cladding elements 114 to the load-distributing profiles 13.
In a third embodiment of an insulated roofing according to the invention, exemplified in figure 7 and referred to therein by the number 210, said cladding elements 214 comprise or consist of planks or boards of wood material.
These 214 cladding elements are waterproofed.
Waterproofing is defined as either a waterproofing element, such as a bitumen sheathing, or a rainwater diversion membrane comprising tiles or roof tiles, or other similar and equivalent waterproofing elements.
The insulation panels 16 are fixed to the said support structure 11 by means of anchor bolts 17a, mentioned above, which can either dowels or self-tapping screws depending on the material of the support structure 11 or 111.
The longitudinal spacer profiles 50, anchored by means of fasteners to said load-spreading profiles 13, are intended to support any of the cladding elements 14, 114, 214 of the exemplary construction variants.
In practice, it was found that the invention achieves its task and purpose by producing an insulated roofing that reduces the cost and time required for its realisation.
In addition, the invention resulted in an insulated roofing with great versatility of application.
Again, the invention developed an insulated roofing that is easy to install even for users without any special pre-training.
In practice, the materials used, as long as they are compatible with the specific use, as well as the contingent dimensions and shapes, can be any according to the requirements and the state of the art.
Where the characteristics and techniques mentioned in any claim are followed by reference marks, those marks have been affixed for the sole purpose of increasing the intelligibility of the claims and consequently those reference marks have no limiting effect on the interpretation of each element identified by way of example by those reference marks.

Claims

Insulated roofing (10), flat or pitched, for building construction, characterised in that it comprises, arranged in the following order
- a support structure (11) arranged substantially horizontally or inclined

- a vapour barrier layer (30) placed on said support structure (11),

- an insulating layer (12) made from a plurality of insulating panels (16) attached to said support structure (11),

- a plurality of load-distributing profiles (13) which are facing in contact with said insulating layer (12) and are operatively connected to said insulating layer (12) by means of fastening and load distribution means, said plurality of load distributing profiles (13) being fixed to said support structure (11) by means of adhesives and/or first fastening means (17), each load-distributing profile (13) comprising a longitudinal plate (20a) configured to face said one or more insulating panels (16) placed side by side,

- a plurality of cladding elements (14) defining a waterproofing or rainwater-diverting covering (40), said cladding elements (14) being connected to said plurality of load-distributing profiles (13) by means of second fastening means (18).
Insulated roofing according to claim 1, wherein said insulating panels (16) are sandwich panels comprising a polyurethane foam, or, alternatively, said insulating panels (16) are of the polystyrene or polystyrene-based type, or phenolic foam-based insulating panels, or insulating panels based on a wool of mineral or vegetable origin, or based on a wool in general.
Insulated roofing according to one or more of the preceding claims, wherein said support structure (11) comprises a floor with planks (11a) and/or with beams (11b) of wood material.
Insulated roofing according to any one or more of claims 1 to 3, wherein said support structure (111) comprises a concrete slab and bricks.
Insulated roofing according to any one or more of claims 1 to 3, wherein said support structure comprises CAP (prestressed reinforced concrete) tiles.
Insulated roofing according to one or more of claims 1 to 3, wherein said support structure is of metallic material.
Insulated roofing according to one or more of the preceding claims, wherein said roofing elements (14) comprise or consist of pantiles or tiles or other brickwork.
Insulated covering according to one or more of claims 1 to 6, wherein said cladding elements (114) comprise or consist of sheets of metallic material.
Insulated roofing according to any one or more of claims 1 to 6, wherein said cladding elements (214) comprise or consist of boards of wooden material.
Insulated roofing according to one or more of the preceding claims, wherein said insulating panels (16) are fixed to said support structure (11) by first fixing means (17), wherein said first fastening means (17) comprise dowels or self-tapping screws.
Insulated roofing according to one or more of the preceding claims, wherein said second fastening means (18) comprise a plurality of longitudinal spacer profiles (50) anchored by fastening means to said load-distributing profiles (13), said longitudinal spacer profiles (50) being configured and positioned to support said cladding elements (14, 114, 214) at a predetermined distance from the underlying insulating panels (16) so as to define a ventilation gap (60) therewith.
Insulated roofing according to one or more of the preceding claims, characterised in that said load-distributing profiles (13) each comprise a longitudinal profile having a substantially 'C'-shaped cross-section, said longitudinal profile comprising in turn the longitudinal plate (20a) and two opposite side parts (20b, 20c) developing from said longitudinal plate (20a) in a substantially orthogonal direction thereto.
Insulated roofing according to any preceding claim, characterised in that said side parts (20b, 20c) each have a row of clinging reliefs (21) configured to penetrate an underlying insulation panel (16).
Insulated roofing according to one or more of the preceding claims, characterised in that said insulating panels (16) have a parallelepiped shape; said insulating panels (16) have no recesses with respect to the parallelepiped shape, neither at the edges nor in the inner areas with respect to the edges.
Insulated roofing according to one or more of the preceding claims, characterised in that said insulating panels (16) comprise polyurethane foam homogeneously distributed throughout the entire body of said insulating panel (16); each insulating panel (16) comprising a polyurethane foam, which is perforable from the side parts (20b, 20c) of a load distribution profile (13).