GB2345498A

GB2345498A - A hipped roof construction formed from wooden roof and floor panels

Info

Publication number: GB2345498A
Application number: GB9930470A
Authority: GB
Inventors: Peter G Mccaughey; Joseph Keenan; Staunton Peter De-Lacy
Original assignee: Maca R & D Ltd
Current assignee: Maca R & D Ltd
Priority date: 1998-12-23
Filing date: 1999-12-23
Publication date: 2000-07-12
Anticipated expiration: 2019-12-23
Also published as: GB2345498B; IE991101A1; IES991102A2; GB9930470D0

Abstract

A free standing roof assembly is formed from pre-assembled roofing and flooring connected rigidly together. The roofing is formed from rectilinear roof panels (2), each including spaced apart rafters (6) connected to a cladding sheet (7). The flooring (fig 6) is formed from similar floor panels. Connector means (15, fig 6, not shown) integral with and protruding from the floor panels join the floor and roof together. At least two triangular end gable forming roof panels (3, fig 1, not shown) are each secured to an adjacent panel at the outside of the rafters. The roof panels have ridge plates (9), which may be hinged together, to allow limited movement to form the desired roof pitch (figs 9a-c).

Description

'^Root Constructlon" The present invention relates to a construction of free standing prefabricated roof assemble and in particular to a construction of hipped roof.

It is known to provide a roof manufactured from a roof panel comprising a ridge board, a plurality of rafters depending therefrom and means adjacent the free end of each rafter or at least some of the rafter for connection to a wall of a building.

Effectively the panels are placed in position and the two ridge boards abut each other, they are secured together and at the same time the ends of each rafter connects onto the top of the wall so that the panels form an inverted v-shaped roof.

These roofs have heretofore only been provided with flat end gable walls. It has not heretofore been possible to provide such prefabricated roofs of a hipped roof construction. Aesteticalty such a hipped roof construction is more leasing that those with plain end gables.

A further probiem with some hipped roof constructions is that heretofore they have required considerable additional support such as A frames which has in turn reduced the amount of available space that can be used above the flooring and beneath the pitched roof. This is particularly a problem with, for example, the construction of dormer bungalows.

The present invention is directed towards providing such a hipped roof construction and in particular to a panel for manufacturing such a hipped roof.

Statements of Invention According to the invention there is provided a free-standing roof assembly comprising: roofing formed by rectilinear planar roof panels including rafters secured in spaced apart relationship to a cladding sheet having an eaves edge for projecting over a support wall and at least two outside rafters for connection to an adjacent roof panel ; floonng formed by one or more floor panels, each floor panel including rafters secured in spaced-apart relationship to flooring sheets ; and connector means integral with and projecting proud of the flooring around the peripheral edge thereof for connection to the roof panels, said connector means being formed integral with some or all of the floor panels ; and in which: at least two pairs of rectangular roof panels each having a ridge plate are connected together at the ridge plates to form the roof apex; and at least two triangular end gable forming roof panels each secured to an adjacent panel at the outside rafters.

The advantage of this is because each of the floor and roof panels are themselves structurally strong, there is no need for any intermediate structural support members such as, for example, purlins and the full space beneath the flooring and roofing is available for use. It is also particularly suitable for erection.

In one embodiment of the invention the roof has at least one pitched end wrth an inciined gable end and comprises at ! easl two additional triangular roof panels between the inclined gable end and adjacent rectangular roof panels. Because of the construction of panel it is possible to provide the hipped roof with no obstruction in headroom.

In a parucular embodiment of pitched roof there are four triangular roof panels at the inciined gable end, two between the rectangular roofing panels and the inclined gable end and the other pair forming the inclined gable end.

In this latter embodiment of the invention an additional upstanding frame member may be formed integral with the flooring panel forning the flooring beneath the hipped portion of the roof to engage the rafters on the inclined gable end of the roof intermediate the apex and eaves. Such a frame member will not obstruct the headroom because they can be placed sufficiency close to the eaves of the building to avoid any restriction.

In one embodiment of the invention any triangular roofing surface is formed by side by side roofing panels namely a triangular roof panel and a parallelepiped panel and indeed the triangular gable end may be formed from two triangular roof panels and a central quinquelateral roof panel.

In one embodiment of the invention the connector means comprises an upstanding rib triangular in cross section at its upper free end and in which a birds mouth triangular slot is cut in each rafter. This may just be a simple batten triangular in shape of a suhable hardwood, or aiternatively the rib may extend across the edge of the flooring. This can advantageous in certain instances, particularly where the roof is not particularly large.

Ideally some of the roof panels are hingedly connected together adjacent their outside rafters for limrted pivotal movement from a face-to-face position superimposed on each other to a position with their outside rafters contacting for connection together. This is particularly useful for erection in that more than one roof panel can be lifted at the one time and the panels hinged apart and placed in position.

For example, all triangular roof panels could be hingedly connected to larger panels which would facilitate storage and transport.

It 15 partjoular sultable that each pair of roof panels are hingedly connected adjacent their ridge plates for limited pivotal movement from a face-to-face position superimposed on each other to a position to form the desired roof pitch. The great advantage of this is that the panels can be lifted above the roof and then splayed apart and easily fitted in position.

The invention provides a method of erecting the roof assembly as described above comprising : laying floor panels on the load bearing walls ; connecting the floor panels together and to the load bearing watts to form the flooring: erecting a frame over the flooring defining a plurality of roof panel receiving openings ; inserting a roof panel into the opening; engaging the roof panels with the connector means; and securing the ridge plate and outside rafter of the roof panels to the frame and to each other.

Indeed in relation to these latter embodimerrts where the roof panels are hinged together there vs provided a method of erecting on the load bearing walls of a building in which the steps are performed ot laying floor panels on the load bearing watts ; connecting the floor panels together and to the load bearing walls to form the flooring ; lifting a pair of rectangular roof panels above the flooring in the face-to-face posftion ; splaying the rectangular roof panels apart; engaging the rectangular roof panels with the connector means; securing the rectangular roof panels to the connector means : securing the ridge plates together ; placing additional root panels in position ; and securing the additional roof panels to the connector means and to each other.

Detatled Description of the Invenleoi The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only described with reference to the accompanying drawings in which: Fig. 1 is a perspective view of a panially erected hipped roof according to the invention; Fig. 2 is a perspective view of the hipped roof with the roof dadding and flooring sheets removed ; Fig. 3 is a plan view of the roofing only again with the cladding sheet removed; Fig. 4 is a plan view of portion of a roof panel according to the invention; Fig. 5 is a sectional view along the lines V-V of Fig. 4; Fig. 6 is a perspective view of portion of a floor panel according to the invention; Fig. 7 is a perspective view along the lines VIT-VIT of Fig. 6 ; Fig. 8 is a typical sectional view of portion of the roof ; Fig. 9 (a) to (b) are partially diagramrnabc views showing erection of portion of the roof ; Fig. 10 is a sectional view similar to Fig. 8 of an alternative construction of roof according to the invention; Fig. 11 is a perspective view of connector means used in the roof of Fig. 10 ; Fig. 12 is a perspective view of an altemative construction of floor panel according to the invention ; Fig. 13 is a sectional view similar to Figs-8 and 10 of a roof using the floor panel of Fig. 12 ; Fig. 14 is a perspective view of an alternative construction of flooring, Fig. 15 is a perspective view of a construction of frame used in forming another construction of roof ; and Fig. 16 (a) to (c) are diagrammatic views of various constructions of tnangu ! ar roof panels according to the present invention.

Referring to the drawings and initial to Figs. 1 to 9 thereof is illustrated a hipped roof indicated generally by the reference numeral 1 The hipped roof 1 is formed from roofing and flooring connected rigidly together. The roofing is formed from rectilinear roof panels 2 and triangular roof panels 3 and the flooring is provided by floor panels 4 which are illustrated m Fig. 1 mounted on load bearing walls 5 of a building.

Referring specifically to Figs. 4 and 5 there is illustrated a rectangular roof panel 2 having a plurality of rafters 6 above which are secured in spaced apart relationship by a cladding sheet 7 to which they are attached. The outermost rafters namely the outside rafters are identified by the reference numeral 8, the rafters 8 provide two s'de plates for connection to an adjacent roof panel 2. Each rectangular roof panel 2 is provided with a ndge plate 9. Each rafter 6 and 8 has cut away triangular slots 10. The cut out portion or slots 10 are triangular slots and are known generally in the industry as bbirds mout slots and thus this term is used in this specification.

Referring now to Figs. 6 and 7 there is illustrated floor panels 4. Each floor panel 4 comprises a plurality of rafters 11 secured in spaced apart relationship by flooring sheets 12. Mounted against the edge of the rafters 11 is a connector board 15 in this embodiment forming a connector means which is secured to the floor and projects proud of the flooring around the peripheral edge thereof for connection to the roof panels 2 and 3. The connector board 15 is an extension of the load bearing wall 15. The connection can be clearly seen in Fig. 8. Also illustrated in Fig. 8 is a fascia board 16, soffit 17 and an outer masonry wall 18.

In this embodiment there are two triangular roof panels 3 forming the inclined gable end of the pitched roof. When all the various panels are manufactured, the rectangular roof panels 2 are hingedly connected together by straps 20 (see Fig 9) In use, to erect the hipped roof 1 the floor panels 4 are placed in position on the load bearing walls 5 and secured together and to the load bearing walls 5.

Referring specifically to Fig. 9 a pair of rectangular roof panels 2 are lifted in the direction of the arrow A until they are suspended above the flooring. Then they are lowered adjacent the flooring where they are splayed apart in the direction of the arrows B until the birds mouth slots 10 engage the connector boards 15 as can seen clearly from Fig. 8. Then the triangular roof panels 3 are placed in position and secured by means of the outside rafters 8 to each other and to the rectangular roof panels 2.

Referring now to Figs. 10 and 11 there is illustrated an alternative construction of roof indicated generally by the reference numeral 20 in which parts similar to those described with reference to the previous drawings are identifie by the same reference numerals. In this embodiment the connector means comprises an upstanding rib 21 of triangular cross section which is secured to the flooring sheet 12 and the rafters 11 The rib 21 is of a suitable hardwood and is nailed in position by closely spaced apart nails 22. It should be noted that this rib 21 forms a suitable peripheral ngid support or connector means around the periphery of the flooring.

This has been found to be a partcularly suitable construction of connector. The particular construction of roof assembly can be easily erected and is a practical and cost effective way of carrying out the invention.

Refernng now to Figs. 12 and 13 there is illustrated an alternative construction of floor panel indicated generally by the reference numeral 25 forming part of a roof assembly indicated generally by the reference numeral 30. The roof assembly 30 is illustrated in Fig. 13 and again parts similar to those described with reference to the previous drawings are identifie by the same reference numerals. In this embodiment there is provided an additional upstanding frame member indicated generally by the reference numeral 26 having a roof panel support cross member 27 carried on upstanding struts 28. The frame member 26 is secured in position by buttress pieces 29.

Fig. 14 illustrates an alternative construction of flooring in which an upstanding frame member indicated by the reference numeral 35 is sandwiche between two floor panels 4. Again parts similar to those illustrated in Fiv. 11 are identifie by the same reference numerals.

Referring now to Fig. 15 there is illustrated a roof indicated generally by the reference numeral 40 in the process of construction. In this embodiment the flooring 4 is already in position and a sub-frame almost in the form of a fixture formed from a plurality of wooden boards 41 and a ridge board 42 has been placed in position.

Within the gap provided between the boards 41 and 42 roof panels whether they be rectangular roof panels 2 or triangular roof panels 3 may be placed. Advantageously these boards 41 and 42 may be provided with laterally projecting studs or the like so as to support a roof panel therein until it has been secured in position. The ridge board 42 may not always be used.

Figs. 16 (a) to (c) shows various constructions of triangular roofing panel 3 and other shapes of roofing panel 45 and 46 which may be used in combination with triangular roofing panels to form what is in effect a composite triangular roofing panel.

While only the rectangular roof panels have been shown hinged together, it will be appreciated that any adjacent panels or more properiy those panels that will be subsequently adjacent may be hinged together.

It is envisaged that the flooring used in the present invention may be the flooring descnbed and claimed in our copending patent application endtled"A Timber Floor Panel"and filed on the same date as this application.

While in the embodiments described above, there has only been described the hinging together of two rectangular roof panels, it will be appreciated that any number of panels may be hinged together and pushed apart to erect the roof.

In the specification the terms"comprise, comprises, comprised and comprising"or any variation thereof and the terms"include, includes, included and including'or any variation thereof are considered to be totalty interchangeable and they should all be afforded the widest possible interpretation and vice versa.

The invention is not limited to the embodiment hereinbefore described, but may be varied in both construction and detail.

Claims

CLAIMS 1. A free-standing roof assembly comprising: roofing formed by rectilinear planar roof panels including rafters secured in spaced apart relationship to a cladding sheet having an eaves edge for projecting over a support wall and at least two outside rafters for connection to an adjacent roof panel ; flooring formed by one or more floor panels, each floor panel including rafters secured in spaced-apart relationship to flooring sheets; and connector means integral with and projecting proud Df the flooring around the peripheral edge thereof for connection to the roof panels, said connector means being formed integrai with some or all of the floor panels, and in which: at least two pairs of rectangular roof panels each having a ridge plate are connected together at the ridge plates to form the roof apex; and at least two triangular end gable forming roof panels each secured to an adjacent panel at the outside rafters.
2. A roof assembly as claimed in claim 1 in which the roof has at least one pitched end with an inclined gable end and comprises at least two additional triangular roof panels between the inclined gable end and adjacent rectangular roof panels.
3 A roof assembly as claimed in claim 2 in which there are four triangular roof panels at the inclined gable end, two between the rectangular roofing panels and the inclined gable end and the other pair forming the inclined gable end.
4. A roof assembly as claimed in daim 2 or 3 in which an additional upstanding frame member is formed integral with the flooring panel forming the flooring beneath the hipped portion of the roof to engage the rafters on the inclined gable end of the roof intermediate the apex and eaves.
5. A roof assembly as daimed in any preceding claim in which any triangular roofing surface is formed by side by side roofing panels namely a triangular roof panel and a parallelepiped panel.
6. A roof assembly as claimed in any preceding claim in which the triangular gable end is formed from two triangular roof panels and a central quinquelateral roof panel.
7 A roof assembly as claimed in any preceding daim in which the connector means comprises an upstanding rib triangular in cross section at its upper free end and in which a birds mouth triangular Slot is cut in each rafter.
8. A roof assembly as claimed in any preceding daim in which the rib extends across the edge of the flooring.
9. A roof assembly as daimed in any preceding claim in which some of the roof panels are hingedly connected together adjacent their outside rafters for limited pivotal movement from a face-to-face position superimposed on each other to a position with their outside rafters contacting for connection together.
10 A roof assembly as claimed in any preceding claim in which each pair of rectangular roof panels are hingedly connected adjacent their ridge plates for limited pivotal movement from a face-to-face position superimposed on each other to a position to form the desired roof pitch.
11. A roof assembly substantially as described herein with reference to and as illustrated in the accompanying drawings.
12 A method of erecting on the ioad bearing walls of a building a roof assembly as claimed in any preceding claim comprising : laying floor panels on the load bearing walls ; connecting the floor panels together and to the load bearing walls to form the flooring ; erecting a frame over the flooring defining a plurality-of roof panel receiving openings; inserting a roof panel into the opening; engaging the roof panels with the connector means ; and securing the ridge plate and outside rafters of the roof panels to the frame and to each other
13. A method of erecting on the load bearing walls of a building a roof assembly as claimed in claim 8 or 9 comprising : laying floor panels on the load bearing walls ; connecting the floor panels together and to the load bearing watts to form the flooring ; lifting a pair of rectangular roof panels above the flooring in the face to-face position ; splaying the rectangu) ar roof panels apart : engaging the rectangular roof panels with the connector means ; securing the rectangular roof panels to the connector means ; securing the ridge plates together; placing additional roof panels in position ; and securing the additional roof panels to the connector means and to each other.
14. A method of erecting a roof assembly substantially as described herein with reference to and as illustrated in the accompanying drawings.