GB2349158A - Roofing elements for a stack of bales - Google Patents

Abstract

A roof structure for a stack 1 of bales 2, for example bales of straw, comprises a plurality of roof elements 9,10. Each roof element 9,10 comprises a roof surface 12,13 for preventing rain from passing through the roof element and stands upon and is supported by one or more of the uppermost bales of the bale stack. The roof elements may be placed upon a flat or stepped stack (as shown), and may form a roof structure having an apex. In addition the roof elements may be attached to the bales by means of straps (see figure 6) and may have slots 16 to allow them to be lifted into place by means of a fork-lift truck.

Description

A Roof The present invention relates to a roof, more particularly it relates to a roof of a stack of bales.

Many materials are conveniently handled and stored in baled form. Such materials are commonly fibrous or have sheet structures, for example agricultural products such as straw, hay and cotton, waste material for recycling such as paper and cloth and synthetic fibres such as polyester.

Bales are formed in a variety of shapes and sizes. A very common shape is the cuboidal form well known for use with hay and straw, although cotton is known to be transported as approximately cubic bales and straw is often made up into bales of short cylindrical form. One type of bale which is well known for use with agricultural products such as straw is the Heston bale which has dimensions of approximately l. lm x 1.2m x 2.75m, although the dimensions are somewhat variable, in particular the longest dimension.

The regular shape and firm, dense nature of baled material allows bales to be conveniently stored in stacks.

Such stacks are made up of layers of bales placed one on top of the other; and often have a rectangular horizontal cross-section. The top of the bale stack may consist of a single layer of bales occupying the whole horizontal area of the bale stack to give a single flat upper surface or it may be stepped, that is to say, made up of layers where the horizontal surface of each layer is of a smaller area than the layer below, thereby giving a stepped or terraced appearance. The term uppermost bales as used herein should not be taken to mean only those bales which are furthest from the ground but also includes each bale which has a substantial part or all of its upper face exposed.

It is frequently necessary to store bales for an extended time, especially in the case of agricultural products which may be produced in one particular season of the year and require storage until they are used. During storage, exposure to the rain and snow causes the bales to become wet which can lead to degradation of the baled material.

One solution is of course to put the bales in a barn, for example a Dutch barn which comprises a roof supported on metal girders. This suffers from the disadvantages that the barns are expensive to construct, they are difficult to extend if more storage space is required and it is also necessary to transport the bales from the site of production to the barn. One alternative approach has been to cover bale stacks with a sheet of waterproof material but this suffers from various problems including one that the sheet must be positioned with the aid of a person standing on top of the stack and with tall bale stacks, such as stacks of Heston bales, this is inconvenient and dangerous.

Thus there remains a need for a roof of a bale stack which mitigates at least some of the above disadvantages.

The present invention provides a rooved stack of bales comprising a plurality of layers of bales and a plurality of roof elements, each roof element comprising a roof surface for preventing rain from passing through the roof element and standing upon and being supported by one or more of the uppermost bales of the bale stack.

Because the roof elements stand upon and are supported by the bales themselves there is no need for a permanent, fixed support structure for the roof as is required in a barn. Thus a stack of bales can be assembled at any convenient place, for example a field, and the roof elements placed on top to provide the roof. The number of roof elements used can be chosen according to the size of the stack and if the length or width of the stack is increased more roof elements can be added. Furthermore, the roof elements may be sized and designed so as to allow them to be easily transported, for example, on a farm trailer, and to allow them to be easily lifted into position on the top of the bale stack from the ground using the machinery used to stack bales.

The roof surfaces of the roof elements together form a protective barrier which protects the uppermost bales of the bale stack from precipitation. The roof surfaces may fit together to form an unbroken barrier across the top of the bale stack or there may be gaps provided. For example, gaps may be provided to allow for ventilation.

It should be understood that the term roof as used herein does not imply a single, interconnected structure.

The roof of the present invention may in fact consist of roof elements arranged in a number of separate regions which may for example be at different levels.

Advantageously, the roof surfaces of the roof elements are rectangular in shape. They may also be square. These shapes allow the individual roof surfaces to co-operate (tessellate) to form a barrier protecting the top of the bale stack from the rain and snow. Furthermore, a rectangular or square shaped roof surface allows for ease of manufacture of the roof elements.

Preferably, the roof elements are secured to one or more of the bales of the bale stack.

Each roof element will occupy an area on the upper surface of the bale stack. Generally, the bale stack will have an approximately flat upper surface or, where the top of the bale stack is stepped, the upper surface of the bale stack will comprise a plurality of approximately horizontal regions of different heights.

Preferably, each roof element has a footprint of substantially the same shape and size as the shape and size of the upper face of a single bale, thereby giving a roof where each roof element stands upon a single bale of the uppermost bales of the bale stack. This has the advantage that no matter how many bales form the uppermost layer of the bale stack, each bale can be covered by a roof element with no substantial overhangs at the edges of the roof.

Each roof element may have a footprint, at least one of the principal dimensions of which correspond to an integral or non-integral multiple of at least one of the principal dimensions of the upper face of a bale. This is advantageous in that the roofing elements will extend across the gaps between the uppermost bales of the bale stack, thereby helping to even out variations in the height of adjacent bales. In the case where the multiple is nonintegral it is preferably 1/2,1/3 or 1/4 of an integral multiple so that 2,3 or 4 roof elements placed side-by-side have a dimension corresponding to an integral multiple of a principle dimension of a bale. The roof may comprise roof elements having a footprint one of whose principle dimensions is 1 times a corresponding dimension of the upper face of a bale. The roof may also comprise roof elements of more than one type, each type having a different footprint area.

The term footprint is used herein to describe the horizontal area on the upper surface of the bale stack which is covered by a single roof element.

The above discussion regarding footprint size and its relation to the upper surface of a bale assumes that each of the uppermost bales is placed so that the uppermost faces have substantially the same shape and size (allowing for a normal variation in size between bales). In the case of a cuboidal bale, for example a Heston bale, each bale has three pairs of sides, each pair of sides having a different shape and size. It can, therefore, happen that a roof element has a shape and size corresponding to the shape and size of a particular face of a bale, but if the bales are stacked with a face having a different face uppermost, the footprint of the roof element will not correspond to the uppermost surface of the bale and will extend across the gaps between the bales. All such variations are within the scope of the invention.

Roofs comprising roof elements having footprints smaller than the upper face of a bale are within the scope of the invention but are not considered particularly advantageous.

Preferably, the roof elements are adapted so that they may be placed in position on top of the bale stack using a fork-lift truck. Thus, each roof element may be provided with openings or recesses configured for receiving the forks of a fork-lift truck. The term fork-lift truck'is to be understood to include farm machinery such as tractors that are adapted to lift in the same manner as a fork-lift truck.

Such machines are used to stack the bales to make the bale stack and it is therefore most convenient that the same machines can be used to move the roof elements and position them on top of the bale stack.

Preferably, each of the roof surfaces of some or all of the roof elements has at least a portion that is inclined and the roof is at least partly pitched.

This arrangement has the advantage common to pitched roofs in general, that rain water on the roof can run away down the incline of the roof rather than gathering in puddles and leaking through. It is therefore advantageous that each level of roof surface overlaps the level below in the manner of tiles on a roof although the levels of roof element need not be in contact. As noted above, gaps may be present between the levels. All that is desirable is that rainwater falling from one level should land on the roof surfaces of the level of roof elements immediately below and so on until it runs over the edge of the outermost roof elements, falling from there to the ground.

An especially advantageous form of the pitched roof is one where the angle of pitch of the roof is substantially equal to the overall inclination of a stepped bale stack, the roof elements standing upon the stepped upper surface of a bale stack. This has the advantage that the pitch of the roof is provided by the stepping of the bales, thus allowing the roof elements on different levels to be of the same construction. Preferably, such a pitched roof comprises a first type of roof element wherein the at least one inclined portion of the roof surface of each roof element defines over its length a decrease in height not greater than the vertical dimension of a bale, the first type of roof element standing upon the stepped upper surface of a bale stack wherein the step height is equal to one bale.

The roof may be pitched in one direction.

Alternatively, the roof may be pitched in two directions and have an apex. Advantageously, such a roof comprises a second type of roof element having a roof surface having two oppositely inclined portions, the second type of roof element being arranged to stand upon the highest level of bales in the stack thereby forming the apex of the roof. A single bale stack may have a roof wherein there is a plurality of apexes.

Preferably, the roof surface of each roof element overlaps or is overlapped by at least one of the adjacent roof elements. This helps to ensure that the rainwater does not leak onto the bales.

Preferably, the roof elements are secured together.

This has the advantage of making the roof more stable, that is, of decreasing the possibility of any roof element falling off the bale stack.

Advantageously, the bale stack consists of Heston bales, especially Heston bales of straw.

The invention also provides a roof element for use in a roof as described above, the roof element comprising a roof surface and support means.

Preferably, the roof element also includes securing means for securing the roof element to a bale upon which it stands. The securing means may comprise one or more adjusting straps.

Advantageously, the roof element includes ballast material which helps to maintain the roof element in position against the influence of wind. The roof element may include straw bales used as spacers. The roof element may be of moulded construction.

One form of the roof will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of a partially assembled bale stack having a pitched roof with an apex; Figure 2 is a perspective view of a roof element; Figure 3 is a perspective view of an alternative embodiment of a fully assembled bale stack having a pitched roof and an apex; Figure 4 is a perspective view of the bale stack of Figure 3 when partially assembled; Figure 5 is a partial horizontal view showing the upper layer of bales and roof elements of the bale stack of Figure 3; and Figure 6 is a perspective view of an adjustable strap used to secure the roof elements shown in Figures 4 and 5 to a bale (the bale is not shown).

Referring to Fig. 1, the bale stack 1 is partially assembled and is assembled from bales 2 which have four long sides 3 of length 1, four shorter sides 4 of length w and four shortest sides 5 of length h. The bales are oriented so that the longer sides 3 and the shorter sides 4 lie parallel to the ground with the shortest sides 5 being perpendicular to the ground. The bale stack 1 has a generally cuboidal base 6 and a stepped top 7. The base 6 is made up of five layers and thus has a height of five x h.

Each layer is seven bales across such that the width of the base is seven x 1 and four bales deep making the length of the base four x w. The stepped top 7 of the bale stack comprises three layers of bales, the lowest of those layers being five bales across, the middle being three bales across and the highest layer being only one bale across. Thus at its highest point, the bale stack is eight bales high. The bales of the stepped top 7 are in the same orientation as the bales of the base but are offset by half a bale lengthwise along the stack from the bales of the base 2.

Upon the upper faces 8 of the uppermost bales stand roof elements 9,10. The roof elements are of two types.

The first type of roof element 9 has a roof surface 12 which is inclined in one direction whereas the second type of roof element 10 has a roof surface divided into two equal, oppositely inclined portions 13. The second type of roof element 10 stands upon the upper faces 8 of the highest level of bales 2 to form the apex of the roof 14 whereas roof elements of the first type stand on the lower levels to form the flanks of the roof. The roof surfaces 12,13 slightly overlap the roof elements of the next lower layer.

Both first and second types of roof element 9,10 comprise support means 15 to support the roof surfaces 12, 13 and comprise slots 16 to be engaged by the forks of a fork-lift truck.

The roof elements can be made of plastics material.

The roof element can be ballasted with water, gravel or other suitable dense material.

As can be seen from Fig. 1, roof elements 9,10 are placed on the stack as the stack is assembled. The height of the stack is limited by the vertical extension of the fork-lift truck.

Fig. 2 shows a different form of roof element 9. It comprises two concrete blocks 17 which in use, stand upon the upper face of one or more of the uppermost bales.

Fixed upon the concrete blocks 17 is a support structure 18 which supports an inclined, rectangular, corrugated roof surface 19. The roof element 9 may be lifted by a fork-lift truck placing its forks underneath the support structure 18 between the concrete blocks 17.

Figures 3 to 6 show an alternative embodiment of the bale stack according to the invention. The bales 2 are Heston bales which, like those shown in Figures 1 and 2, have four long sides 3 of length 1, four shorter sides 4 of length w and four shortest sides 5 of length h. The bales are also orientated in the same way as shown in Figures 1 and 2 with the shortest sides 5 being perpendicular to the ground.

Figure 3 shows a bale stack 20 having a base 21 and a roof 22. The base 21 is made up of eight layers and thus has a height of eight x h. Each layer is seven bales across such that the width of the base 21 is seven x 1 and 40 bales deep making the length of the base 21 40 x w. The upper two layers of the base 21 are offset lengthwise by half a bale and those two upper layers are therefore only 39 bales deep.

A row 23 of bales is arranged to stand upon the middle bales of the uppermost layer of the base 21 such that the row 23 runs lengthwise along the middle of the upper surface of the base 21 and forms a step of height h.

Upon the uppermost bales stand roof elements 24,25,26 and 27, apart from at each of the lengthwise ends where there is a further row of seven bales across the width of the bale stack with a further two bales placed centrally upon that row; the nine bales together forming a gable end, 28.

The roof elements 24,25,26 and 27 each stand upon the upper surfaces 8 of a single uppermost bale and together the roof elements form the roof 22 which lies between the two gable ends 28. The roof 22 is pitched, having a single apex which runs centrally, lengthwise along the bale stack 20.

The roof elements 24,25,26 and 27 are arranged in longitudinal rows such that roof elements 24 form the outermost rows and overhang slightly the long sides of the base 21. The roof elements 27 are arranged in a single longitudinal row down the middle of the roof 22 and stand upon the central row of bales 23 thereby forming the apex of the roof. Roof elements 25 and 26 are arranged in longitudinal rows between roof elements 24 and 27, with roof elements 25 being adjacent roof elements 24 and roof elements 26 being adjacent roof elements 27.

As can be seen from Figure 5, each of the roof elements 24, comprises a single rectangular roof surface 29 which stands upon two support members 30 and 31 which are of differing height such that when the roof element 24 stands upon the horizontal surface 8 of a bale the roof surface 29 is at an angle to the horizontal. The roof elements 25 also have a roof surface 29 and support members 30 and 31 but also include two small bales of straw 32 upon which the support members 30 and 31 each stand. The small bales of straw 32 act as spacers between the support members 30,31 and the upper surfaces 8 of the Heston bale 2, such that the roof surface 29 of the roof element 25 is higher than, and overlaps, the roof surface 29 of the adjacent roof element 24.

The roof elements 26 include four small bales of straw 32 arranged in 2 columns, each of the support members 30,31 standing upon a column such that the roof surface 29 of the roof element 26 is higher than, and overlaps, the roof surface 29 of the adjacent roof element 25.

Of course, it is not necessary that the spacers be small straw bales as hollow or solid blocks of other material or other suitably shaped objects would do. Small straw bales, however, have the advantages of being inexpensive and readily available. The use of such spacers allows the roof surface and support members of roofing elements 24,25 and 26 to be identical, thus simplifying their manufacture.

The roof elements 27 have a roof surface divided into two, equal, oppositely inclined portions 33 which are each supported by a support member 34. The roof surface portions 33 slightly overlap the roof surface 29 of the adjacent roof elements 26.

Each of the roof elements 24,25,26 and 27 is secured to the Heston bale 2 upon which it stands by means of 2 or 3 adjustable straps (not shown in Figures 4 and 5). Such a strap is shown in Figure 6 (with the roof element and Heston bale omitted for clarity) and comprises a strap 35 having hooks 36 at each end for engaging the roof element and an adjuster/tightener mechanism 37.

In use, the straps are laid on the ground and a Heston bale 2 is placed on top of them. The roofing element, including any necessary small straw bales 32, is then placed on top of the Heston bale 2 and the straps are hooked to suitable fixings provided on the roof element and tightened.

The Heston bale/roof element assembly is then lifted by fork-lift truck into position on top of the bale stack 20.

The Heston bale acts as an anchor and helps to prevent the roof element being blown away by the wind.

It will be appreciated that as the height of the uppermost regions of the bale stack is limited by the extension of the fork-lift truck, a roof having a low angle of pitch, that is a roof which is closer to the horizontal, will protect more bales than a more steeply pitched roof or equivalent area. However, if the angle of pitch of the roof is too low, rainwater will not flow from the roof efficiently.

Claims (25)

1. Claims 1. A rooved stack of bales comprising a plurality of layers of bales and a plurality of roof elements, each roof element comprising a roof surface for preventing rain from passing through the roof element and standing upon and being supported by one or more of the uppermost bales of the bale stack.
2. 2. A rooved stack of bales as claimed in claim 1 wherein the roof surface of each roof element is rectangular in shape.
3. 3. A rooved stack of bales as claimed in claim 1 or claim 2 wherein each roof element is secured to one or more of the bales.
4. 4. A rooved stack of bales as claimed in any of claims 1 to 3 wherein each roof element has a footprint of substantially the same shape and size as the shape and size of the upper face of a single bale.
5. 5. A rooved stack of bales as claimed in any of claims 1 to 3 wherein each roof element has a footprint at least one of the principal dimensions of which correspond to an integral or non-integral multiple of at least one of the principle dimensions of the upper face of a bale.
6. 6. A rooved stack of bales as claimed in claim 5 wherein each roof element has a footprint at least one of the principal dimensions of which is 1/2,1/3 or 1/4 of an integral multiple of at least one of the principle dimensions of the upper face of a bale.
7. 7. A rooved stack of bales as claimed in any of claims 1 to 6 wherein each roof element is adapted so that it may be placed in position on top of the bale stack using a forklift truck.
8. 8. A rooved stack of bales as claimed in any of claims 1 to 7 wherein the roof surfaces of some or all of the roof elements have at least a portion that is inclined and the roof is at least partly pitched.
9. 9. A rooved stack of bales as claimed in claim 8 wherein the angle of pitch of the roof is substantially equal to the overall inclination of a stepped bale stack, the roof elements standing upon the stepped upper surface of a bale stack.
10. 10. A rooved stack of bales as claimed in claim 9 wherein the roof comprises a first type of roof element wherein the at least one inclined portion of the roof surface of each roof element defines over its length a decrease in height not greater than the vertical dimension of a bale, the first type of roof element standing upon the stepped upper surface of a bale stack wherein the step height is equal to one bale.
11. 11. A rooved stack of bales as claimed in any of claims 8 to 10 wherein the roof is pitched in one direction.
12. 12. A rooved stack of bales as claimed in any of claims 8 to 10 wherein the roof is pitched in two directions and has an apex.
13. 13. A rooved stack of bales as claimed in claim 12 which also comprises a second type of roof element having a roof surface having two oppositely inclined portions, the second type of roof element being arranged to stand upon the highest level of bales in the stack thereby forming the apex of the roof.
14. 14. A rooved stack of bales as claimed in claim 12 or claim 13 wherein there is a plurality of apexes.
15. 15. A rooved stack of bales as claimed in any of claims 1 to 14 wherein the roof surface of each roof element overlaps or is overlapped by at least one of the adjacent roof elements.
16. 16. A rooved stack of bales as claimed in any of claims 1 to 15 wherein the roof elements are secured together.
17. 17. A rooved stack of bales as claimed in any of claims 1 to 16 wherein the bales are Heston bales.
18. 18. A rooved stack of bales substantially as described herein with reference to Figures 1 to 6.
19. 19. A roof element for use in a rooved stack of bales as claimed in any of claims 1 to 18, comprising a roof surface and support means.
20. 20. A roof element as claimed in claim 19 which also includes securing means for securing the roof element to a bale upon which it stands.
21. 21. A roof element as claimed in claim 20 wherein the securing means comprises one or more adjusting straps.
22. 22. A roof element as claimed in claim 19 which also includes ballast material.
23. 23. A roof element as claimed in any of claims 19 to 22 which also includes straw bales used as support means.
24. 24. A roof element as claimed in claims 19 or 22 which is of moulded construction.
25. 25. A roof element substantially as herein described with reference to Figures 1, 2,4,5 and 6.