GB2432855A

GB2432855A - A prefabricated hinged roof structure

Info

Publication number: GB2432855A
Application number: GB0623417A
Authority: GB
Inventors: Patrick Mcdonnell
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-12-02
Filing date: 2006-11-24
Publication date: 2007-06-06
Anticipated expiration: 2026-11-24
Also published as: GB0524631D0; GB0623417D0; GB2432855B

Abstract

The invention relates to a prefabricated roof structure 10 and comprises a plurality of rafters 12a and a roof covering 44, in which the rafters are hinged so as to enable the roof structure to be unfolded from a first configuration into a second, in-use configuration, having a plurality of sloping walls. The roof structure may also comprises purlins 14a and rafter support stays 32. The rafters, purlins and stays may be manufactured from a metal preferably steel, and the roof covering may be a plurality of metal sheets. Later embodiments relate to a prefabricated roof structure and a method of assembling a prefabricated roof structure, both comprising hinged rafters.

Description

I

Roof Structure and Methods of Assembling a Roof This invention relates to prefabricated roof structures and methods of assembling a roof.

There is currently a great deal of interest in providing low cost housing that is nevertheless of an acceptable quality. An important aspect of such housing is the provision and assembly of the roof. The present invention, in at least some of its embodiments, addresses these problems and provides a highly cost effective roof structure.

According to a general aspect of the invention there is provided a prefabricated roof structure including a plurality of rafters and a roof covering therefor, in which the rafters are hinged so as to enable the roof structure to be folded or unfolded from a first configuration into a second, in-use, configuration having a plurality of sloping walls. In this way, the roof structure can be assembled at a manufacturing site and conveniently transported in a transportation friendly configuration to the point of use, where upon a roof for a building can be provided by causing relative rotation of the walls of the roof structure so as to set the pitch of the sloping walls, with minimal further installation steps being required. Roof structures of this type can be produced very cost effectively.

Preferably, the rafters include a plurality of spaced apart pairs of rafters, the rafters in each pair of rafters being joined at one end thereof by a hinge. In this way, a roof structure that is foldable and unfoldable about its apex can be produced. Advantageously, the roof structure further includes a plurality of rafter support stays, each of which is pivotable and connects rafters in a pair of rafters.

Typically, the rafter support stays are substantially horizontal when the roof is in the second, in-use configuration.

The roof structure may further include a plurality of purlins which support the plurality of rafters.

Very preferably, the roof structure is unitary in nature. In this way, the roof structure can constitute essentially a complete roof. Thus, it is not necessary to perform major constructional tasks in situ.

It is a preferred aspect of the invention that the rafters are fabricated from a metal, preferably steel. A lightweight steel is particularly suitable. Preferably, the rafters are of box section, most preferably C-section.

Similarly, it is preferred that the rafter support stays and/or the purlins are fabricated from a metal, preferably steel. Again, lightweight steel is particularly

suitable.

It is highly preferred that the roof covering is fabricated from a metal, preferably steel. Advantageously, the roof covering includes a plurality of metal sheets, which may be formed of steel sheeting. A preferred type of roof covering is sold by Lafarge Roofing GmbH of Oberursel, Germany under the trade name "Kami" (RTM), and consists of undulating or corrugated compressed steel sheeting. Typically, a metal sheet runs along the complete length of the roof structure.

The roof covering may be fixed to the purlins.

The roof structure may further comprise insulating material. Preferably, the roof structure is blown with insulating material. A warm roof construction can be provided in this way.

The roof structure may further include a soffit, which may contain insulating material. Additionally or alternatively, the roof covering may be provided with insulating material.

The roof structure may further include a plurality of wall post connecting stays having one portion for connecting to a wall post and at least one other portion in connection with a rafter.

According to another aspect of the invention there is provided a roof consisting essentially of a prefabricated roof structure including a plurality of rafters and a roof covering therefor, in which the rafters are hinged so as to enable the roof structure to be folded or unfolded from a first configuration into a second, in-use, configuration having a plurality of sloping walls.

According to a further aspect of the invention there is provided a method of assembling a roof including the steps of: providing a prefabricated roof structure including a plurality of rafters and a roof covering therefor, in which the rafters are hinged so as to enable the roof structure to be folded or unfolded from a first configuration into a second, in-use, configuration having a plurality of sloping walls; transporting the roof structure to the site of a building in its first configuration; manipulating the roof structure into its second, in-use, configuration; and positioning the roof structure on the building.

The order of the third and fourth steps may be interchanged, or these steps may be performed simultaneously.

Embodiments of roof structures and methods of assembling same will now be described with reference to the accompanying drawings, in which:-Figure us a plan view of an arrangement of rafters and purlins; Figure 2 shows a roofing structure in its in-use configuration in the vicinity of the apex of the roof; Figure 3 is an end view of a roof formed by connecting a roof structure of the invention to a building structure; Figure 4 shows a hinge plate; Figure 5 shows (a) an end perspective view of a wall plate bracket and (b) and end perspective view of a rafter connected to a wall with a wall plate bracket; and Figure 6 is an end perspective view of the lower portion of a roof formed by connecting a roof structure of the invention to a building structure.

Figure 1 depicts a roofing framework, shown generally at 10, which comprises a first arrangement of rafters 12a and purlins 14a disposed horizontally with respect to the rafters I 2a, and a second arrangement of rafters 12b and purlins 14b positioned horizontally with respect to the rafters 12b. In use, the first arrangement of rafters 12a and purlins 14a corresponds to one face of a roof, and the second arrangement of rafters 12b and purlins 14b corresponds to the other face of the roof. The complete roof structure further comprises a roof covering (not shown) which covers the first arrangement of rafters 12a and purlins 14a and the second arrangement of rafters 12b and purlins 14b so as to provide an exterior surface of the roof. The rafters form a series of spaced apart pairs, each pair having a rafter of the first arrangement and a rafter of the second arrangement. In each pair, one end of the rafter 12a of the first arrangement is in hinged connection with an end of the rafter 1 2b in the second arrangement in the region shown generally at 16 in Figure 1. This region corresponds to the apex of a roof formed by the roofing structure in its in-use configuration.

Figure 2 shows the apex region of the roof structure of Figure 1 in its bent, in-use, configuration. Once again, the roof covering is not shown. Each rafter 12a, 12b in a pair of rafters has a top bore formed near the end which is in operative connection with its partner rafter in the pair. Disposed in the top bore is a bolt 20 which acts as a pivot. Each rafter 12a, 12b is in connection with a hinge plate 22. Each hinge plate 22 is connected to its respective rafter 12a, 12b through the bolt 20 and further bolts 24 disposed in further bores which are longitudinally spaced from the to bore. Each ridge plate 22 has a slot 26 formed therein which is in register with the slots 26 on the corresponding ridge plate 22.

Once rotation to a desired configuration has been achieved, the configuration is fixed by securing a nut and washer (not shown) against a bolt 28 which is disposed in the slots 26. Figure 4 shows a single hinge plate 22 in more detail.

As noted above, the hinge plate has a slot 26 formed therein, and further comprises a series of bores 30 enabling the hinge plate 22 to be connected to a rafter. Turning now to Figure 2, it can be seen that the roof structure further comprises a support stay 32 which connects rafters 12a, 12b in a pair of rafters.

In the in-use configuration, the support stay 32 substantially horizontal. The support stay is articulated about a pivot bolt 34, and further pivot bolts 36 connect the support stay 32 to the rafters 12a, 12b. Thus, when the rafters 12a, 12b are rotated away from the configuration shown in Figure 2, the support stay can pivot to provide an associated folding motion.

Figure 3 is a fuller view of the roof structure and Figures 1 and 2 in its in-use configuration. Identical numerals are used to depict features that are shared with Figures 1 and 2. The rafters 12a, 12b at each end of the roof structure have further rafter support stays 38 connected thereto. The rafter support stays 38 comprise a pair of connected, perpendicular arms. The free ends of the rafter support stays 38 are each in connection with a portion of a rafter 12a, 12b, and the bend portion of a rafter support stay 38 formed by the conjunction of the arms is connected to a wall plate post 40 which forms part of a building structure shown generally at 42 to which the roof structure may be connected. The rafter support stays 38 might be installed in situ, i.e., when the roof structure is brought into connection with the building structure 42. Alternatively, the rafter support stays 38 might be provided with pivoting functionality somewhat akin to that of the support stay 38, thereby allowing the rafter support stays 38 to form part of the prefabricated structure. Also shown in Figure 3 is the roof covering 44. The roof covering 44 can be attached to the framework of rafters and purlins in any appropriate way, although it is preferred that the roof covering 44 is attached to the purlins.

Figures 5 (a) and (b) show a wall plate, depicted generally at 50, comprising a sloping platform 52, sidewall 54 upstanding therefrom and faceplate 56. As shown in Figure 5(b), in use, the base 52 and sidewall 54 are connected to a rafter 58, and the face plate 56 is connected to the inner surface of an inner wall 60 of the building structure to which the roofing structure is fitted.

Figure 6 shows an end portion of a roof structure positioned on a building structure comprising an outer wall 62 and an inner wall 64. Figure 6 shares some of the elements depicted in earlier Figures, and identical numerals are used to denote such shared features. At the end of a sloping wall of the roof structure, corresponding to the eaves of the roof, is provided a powdered coating soffit/facia 66 which is blown filled with insulation (the region beneath the roof covering can be filled with insulation in this way as well). The soffit/facia 66 comprises part of the prefabricated roof structure i.e., it does not need to be fitted in-situ.

The roof structure of the present invention can be prefabricated, either nearly completely or completely, at a manufacturing site and transported in a transportation friendly configuration to a building site, where the roof structure can be rotated about the hinges to provide the bent, in-use configuration with the sides of the roof slope at an appropriate pitch angle. Typically, the prefabricated roof structure is folded somewhat for transportation, allowing the roof structure to be positioned conveniently on a lorry or like vehicle. On-site, the roof structure is unfolded somewhat to the in-use configuration. Air jacks can be used to unfold the roof structure. Alternatively, a "flat packed" configuration might be used in which the roof structure is rotated so that the roof covering of the first arrangement of rafters and purhns is substantially brought into contact with the roof covering over the second arrangement of rafters and purlins. It is also possible to provide a truly "flat packed" configuration in which the first arrangement of rafters and purlins is coplanar with the second arrangement of rafters and purlins.

It is very much preferred that the roof structure is substantially manufactured from steel. Steel rafters, purlins and stays are preferably utilised.

It is convenient that the rafters are of box section, most conveniently of C-section. It is also highly preferred that the roof covering is fabricated from steel sheeting, such as compressed steel sheeting. A preferred form of roof covering is provided by various roofing products produced by Lafarge under the trade name Kami (RTM). The sheeting can be disposed on the structure provided by the rafters and purlins so as to run along the complete length of the roof. It is preferred that the roof covering is fixed to the purlins, although other fixing arrangements readily occur to the skilled person.

The roofing structures of the present invention can be installed conveniently with a minimum of in situ installation steps. Furthermore, and very importantly, prefabricated roofing structures of the invention can be produced in an extremely economical manner.

Claims

I

Claims 1. A prefabricated roof structure including a plurality of rafters and a roof covering therefor, in which the rafters are hinged so as to enable the roof structure to be folded or unfolded from a first configuration into a second, in-use, configuration having a plurality of sloping walls.

2. A roofing structure according to claim I in which the rafters include a plurality of spaced apart pairs of rafters, the rafters in each pair of rafters being joined at one end thereof by a hinge.

3. A roofing structure according to claim 2 further including a plurality of rafter support stays, each of which is pivotable and connects rafters in a pair of rafters.

4. A roofing structure according to any previous claim further including a plurality of purlins which support the plurality of rafters.

5. A roofing structure according to any previous claim which is unitary and constitutes essentially a complete roof.

6. A roofing structure according to any previous claim in which the rafters are fabricated from a metal, preferably steel.

7. A roofing structure according to claim 6 in which the rafters are of box section, preferably C-section.

8. A roofing structure according to claim 3 or any of claims 4 to 7 when dependent on claim 3 in which the rafter support stays are fabricated from a metal, preferably steel.

9. A roofing structure according to claim 4 or any of claims 5 to 8 when dependent on claim 4 in which the purlins are fabricated from a metal, preferably steel.

10. A roofing structure according to any previous claim in which the roof covering is fabricated from a metal, preferably steel.

11. A roofing structure according to claim 10 in which the roof covering includes a plurality of metal sheets.

12. A roofing structure according to any previous claim further comprising insulating material, preferably in which the roof structure is blown with the insulation material.

13. A roofing structure according to any previous claim further including a soffit which preferably contains insulating material.

14. A roof consisting essentially of a prefabricated roof structure including a plurality of rafters and a roof covering therefor, in which the rafters are hinged so as to enable the roof structure to be folded or unfolded from a first configuration into a second, in-use, configuration having a plurality of sloping walls.

15. A method of assembling a roof including the steps of: providing a prefabricated roof structure including a plurality of rafters and a roof covering therefor, in which the rafters are hinged so as to enable the roof structure to be folded or unfolded from a first configuration into a second, in-use, configuration having a plurality of sloping walls; transporting the roof structure to the site of a building in its first configuration; manipulating the roof structure into its second, in-use, configuration; and positioning the roof structure on the building.

16. A roof structure or roof substantially as described herein with reference to the accompanying drawings.