GB2584673A

GB2584673A - Upstand module for a flat roof

Info

Publication number: GB2584673A
Application number: GB1908271.8A
Authority: GB
Inventors: White Paul
Original assignee: Whitesales Group Ltd
Current assignee: Whitesales Group Ltd
Priority date: 2019-06-10
Filing date: 2019-06-10
Publication date: 2020-12-16
Anticipated expiration: 2039-06-10
Also published as: GB201908271D0; GB2584673B

Abstract

The upstand module comprises a wall 14 and a base 12 for attachment to a flat roof. A waterproof membrane 18 is adhered or bonded to a part 50 of the wall and extends to form a skirt which extends past the base in use. The waterproof membrane is secured to the wall of the upstand is attached or pre-attached before installation of the upstand on a roof. Also claimed is a method of adhering a waterproof membrane around the periphery of an upstand module by producing a template to form the membrane and adhering a first part of the membrane to the wall. The base module may be its own module or integral to the rest of the upstand. The membrane may be made from rubber or include bitumen.

Description

UPSTAND MODULE FOR A FLAT ROOF

The present invention relates to an upstand module for a flat roof and a method of adhering a waterproof membrane to an upstand module under factory conditions.

BACKGROUND TO THE INVENTION

When fitting a skylight to a flat or substantially flat roof, an upstand is attached to the roof around a roof opening in order to lift the glazing clear of the roof surface. In the UK, at least 150 mm of upstand is required, but the upstand may be larger. Whilst some upstands are manufactured on site, it is generally preferable to provide a proprietary upstand, which can be fastened in position.

The roof and the upstand require weather proofing. The process of weather proofing a skylight may vary depending on the type of roof or skylight. Generally, the process is time intensive involving substantial skill and can be hazardous to the fitter as it is performed in situ. When applying weatherproofing, the ability to work quickly is advantageous, particularly in countries where there is a continuous prospect of wet weather.

The upstand is weather proofed by applying a waterproofing membrane around the upstand. The process may be dependent on the size of roof, the type of weatherproofing membrane used, and/or the skylight.

For example, the weatherproof membrane may be formed from a single sheet covering the roof In such cases, an aperture is cut in the membrane by hand to correspond with the roof opening and fit around the periphery of the skylight upstand. A diagonal cut is made between each opposite corner of the marked periphery. The resulting flaps are then folded out of the aperture and the upstand placed and secured to the roof The flaps are trimmed so as to fit on the upstand of the skylight. The fitter then bonds the waterproof membrane to the skylight using an adhesive. Once bonded, the fitter applies additional layers of weatherproofing such as flashing at the joints.

In another example, the weatherproof membrane is formed from a plurality of sheets being bonded to the upstand and the roof Each sheet is cut to an appropriate size before being bonded During the process of bonding, or prior to, additional cuts are made allowing the sheet to fold and shaped to the upstand and roof Once bonded, the fitter may apply additional layers of weatherproofing. In some examples, the weatherproofing is provided by roof felt and bitumen, which is heated with a blowtorch to make the bonds.

The process of weatherproofing is time intensive involving substantial skill and can be hazardous to the fitter as it is performed in situ. When applying weatherproofing, the ability to work quickly is advantageous, particularly in countries where there is a continuous prospect of wet weather, and more particularly where the spaces under the skylight have to be vacated.

A significant problem in weatherproofing upstands is caused by the lack of accessibility for fastening and sealing the waterproofing membrane at the upper end or top edge of the upstand. Existing proprietary upstands are provided with an integral upper flange, known as the top flange, which extends outwardly and then downwardly around the periphery of the upstand, forming an inverted channel around the upper end of the upstand. The purpose of the top flange is to protect the upper edge of the waterproofing membrane. However, it is very difficult to terminate and seal the weatherproofing membrane in a position underneath the upper flange, ie inside the channel, because of a lack of accessibility.

It is an object of the present invention to reduce or substantially obviate the aforementioned problems.

STATEMENT OF INVENTION

According to the present invention there is provided a skylight upstand module with pre-attached waterproof membrane for weatherproofing the skylight, the upstand module comprising a wall, a base for attachment to a flat roof, and a pre-attached waterproof membrane adhered to at least part of the wall extending around the periphery of the upstand and forming a skirt extending past the base.

The above upstand module provides a weatherproof membrane adhered to the upstand during the manufacturing stage. By having the waterproof membrane in place prior to the upstand being installed on a roof or delivered to a site it is possible to decrease the installation time while ensuring a high quality and consistent application of weatherproofing. The decreased installation times reduce both the risk to the skylight fitters and allows rooms under the work area to come back into use sooner. Furthermore, Personnel dedicated to the application and production of the waterproof membrane can result in a higher quality finished product. I 0

The waterproof membrane may be formed from a plurality of waterproof membrane panels.

Each of the waterproof membrane panels may overlap a portion of an adjacent waterproof membrane panel.

It is possible to create a pre-attached waterproof membrane for any size or shape of skylight upstand using a plurality of panels.

The waterproof membrane may be rubber, preferably a synthetic rubber, and more preferably ethylene propylene diene monomer (EPDIV) rubber.

The or each waterproof membrane panel may include at least one fibrous material sheet. The fibrous material is suitable for combining with a waterproof material. The fibrous material may be fibreglass, polyester, hessian or similar known material.

The waterproof membrane may include bitumen. The waterproof membrane may be a bituminous felt.

The waterproof membrane may include a polyester resin or epoxy resin.

The waterproof membrane may comprise a polymer membrane which includes at least one of the following: polyvinyl chloride, chlorinated polyethylene, ethylene propylene diene terpolymer, flexible polyolefin, thermoplastic polyefin elastomer, polyisobutylene and vinyl ethylene terpoloymer.

The second region of the waterproof membrane may be releasably restrained against the first region by a restraint means, such as tape or plastic film. The restraint means may be released destructively or non-destructively, for example, cutting or removing adhesive backed tape or thin film plastic wrap.

The waterproof membrane may be adhered to the wall by an adhesive. The waterproof membrane may be adhered to the wall by heat.

The second region may be foldable.

The base may not be adhered to the waterproof membrane By providing a foldable second region and/or a non-adhered base the upstand may be installed with fixing means, such as screws, through the base without going through the waterproof membrane.

The upstand may provide a gap between an upper section of the waterproof membrane and a capping element of the upstand. The gap may be less than 50 mm. Alternatively, the gap may be more than 50 mm. The gap may be determined based on the design of the wall and/or capping element. The gap may also be based on the size of a weatherproofing clamp.

The skirt may extend past an edge of the base by a predetermined distance. The predetermined distance may be at least 100 mm. Preferably, the predetermined distance may be at least 150 mm By providing a predetermined length of skirt it is possible to ensure that there is suitable material for weatherproofing the skylight.

The base may be integrally formed with the wall. The wall and base may be separable. The wall, base and capping element may be modular.

The waterproof membrane panels may be made from a stencil. The stencil may be a cutting die. The waterproof membrane panels may be made by a CNC cutting machine.

The wan and base of the upstand may be plastic. The capping element may also be plastic.

In a further aspect of the present invention there is provided a method of manufacturing the upstand according to the first aspect of the present invention, the method may comprise the steps of creating the waterproof membrane from at least one stencil, the waterproof membrane including a first region corresponding to at least part of the upstand wall and a second region forming a skirt for extending past the base, and adhering the first region to at least a part of the wall.

By using at least one stencil it is possible to increase productivity while maintaining a high-quality finished product which decreases the installation time and ensure reliable weatherproofing. This has the added advantage of improving the economies of scale.

The step of producing the waterproof membrane may further comprise placing the at least one stencil on a sheet of waterproof membrane and cutting around the stencil. The stencil may be a cutting die. The stencil may be a set of computer readable instructions used by a computer to machine waterproof panels, such as a CNC cutting machine.

The method may further comprise the step of wrapping the upstand module so that the skirt of the waterproof membrane is releasably held against the first region for transport and storage.

The step of adhering the first region of the waterproof membrane to the wall may require applying an adhesive to the waterproof membrane and/or the wall.

The step of adhering the first region of the waterproof membrane to the wall may require applying heat to the waterproof membrane.

There may be a plurality of stencils with each stencil corresponding to a section of the upstand module. For example, there may be one stencil for a waterproof membrane panel which will fit around a corner of the upstand module and another for a straight side of the upstand module.

BRIEF DESCRIPTION OF THE DRAWINGS

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made by way of example only to the accompanying drawings, in which: Figure 1 shows a cross-sectional view through a first embodiment of the upstand of the invention; Figure 2 shows a cross-sectional view through a second embodiment of the upstand of the invention; Figure 3 shows an isometric view of an upstand according to the first embodiment of the invention; Figure 4 shows a view of the upstand according to the first embodiment of the invention, Figure 5 shows a view of a section of the upstand module according to the second embodiment of the invention; Figure 6 shows an isometric view of stacked upstand modules according to the first embodiment of the invention with a restrained waterproof skirt; and Figure 7 shows another isometric view of stacked upstand modules shown in figure 6.

DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to Figures Ito 7, an upstand is generally indicated at 10. Figure 1 shows an upstand 10 according to a first embodiment while figure 2 shows an upstand according to a second embodiment. In both embodiments, the upstand 10 is constructed from a base 12, a wall 14, a capping element 16 and a waterproof membrane 18 extending around the periphery of the upstand 10. The waterproof membrane 18 is applied prior to the upstand being fitted to a flat roof, i.e. it is factory fitted. The upstand 10 is shaped to fit the skylight, for example in the current embodiment the upstand 10 is square to fit a square skylight. It will be appreciated that the parts of the upstand 10 are provided as extruded linear mouldings, cut to length and bonded together to make the required shape and size of upstand.

In the embodiment shown in Figure 1, the wall 14 extends from the base 12 to the capping element 16, preferably providing the upstand with a height of 350 mm. In other embodiments, the height is based on the design of the upstand. The base 12 has a flat lower or under surface 20 for resting flat against a flat roof (not shown) and a flat upper surface. The base 12 extends from the second wall by a predetermined distance based on the design of the upstand 10, preferably 60 mm to 150 mm, more preferably by 110 mm. The wall 14 has three sections, the first section 22 extends substantially perpendicular from the base 12, the second section 26 extends at an angle from the first section 22, and the third section 28 extends substantially vertical, in use, from the second section 26 to the capping element 16.

In the embodiment shown in Figure 2, the wall 14 extends from the base 12 to the capping element 16, preferably providing the upstand with a height of 300 mm. In other embodiments, the height may be determined based on the design of the upstand. The base 12 has a lower flat surface 30 for resting flat against a flat roof and an angled upper surface 32. In the current embodiment, the lower surface of the base 12 is 95 mm in width. In other embodiments, the width may be different based on the design of the upstand. The wall 14 is formed from two sections, the first section 36 extending at an angle from the base 12 to the second section 38 which extends, from the first section 36, substantially vertically to the capping element 16 in use.

In the embodiments shown in Figures 1 and 2, the wall 14 is formed from a first wall 40 and the second wall 42. The first wall 40 forms the outer edge of the upstand 10 and the second wall 42 forms the inner edge of the upstand 10. The first wall 40 is joined to the second wall 42 by internal elements 44 such as webbing. Although not shown in the current embodiments, insulation material may be located between the first 40 and second 42 walls. The first wall 40 has alternating substantially smooth and patterned sections. The patterned sections provide more surface area for better adhesion of the waterproof membrane 18. In the embodiment shown in Figure 2, the angled upper surface 34 of the base 12 may be integrally formed with the first wall 40 of the wall 14.

Furthermore, internal elements 44, such as webbing, may be provided between the angled upper surface 34 and the lower flat surface 32.

In the embodiment shown in Figure 1, the width of the upstand footprint, from the edge of the base 12 to the second wall 42 of the third section 28 is 260 mm. In the embodiment shown in Figure 2, the width of the upstand footprint, from edge of the base 12 to the second wall 42 of the second section 38 is 195 mm. In other embodiments, the width of the upstand footprint is predetermined based on the design.

In the embodiment shown in Figures 1 and 2, the capping element 16 extends perpendicularly from an upper end of the wall 14 and includes a downward facing flange extending from one end. The downward flange has a drip bead formed on one end.

The waterproofing membrane 18 is formed from a plurality of waterproofing membrane panels adhered around the periphery of the upstand 10, as shown in Figure 3. The waterproof membrane 18 has a first region 46 which is adhered to the wall 14 and a second region 48 which forms a skirt extending past the base 12. The second region 48 is not adhered to the base 12. In the embodiments shown in Figures 1, 2, 3, 4 and 5, the second region 48 extends 150 mm beyond the edge of the base 12. In other embodiments, the second region 48 may extend by a predetermined distance, for example it could extend by at least 200 mm, or by at least 100 mm. Each waterproofing panel also comprises a third region 49 which overlaps an adjacent waterproofing panel in the first and/or second regions 46, 48. At least part of the third region 49 is adhered to part of the first region 46 of the adjacent waterproof membrane panel.

Each waterproofing panel is formed using a stencil (not shown). The stencil corresponds to at least a portion of the upstand 10 The use of the stencil allows an operator to repeatedly and reliably form a waterproofing panel appropriate to a section of the upstand 10 In some embodiments, the waterproof membrane 18 is bonded to at least a portion 50 of the wall 14 by applying heat from a torch. Prior to the bonding, a primer may be applied to both the first 22, 36 and second sections 26, 38. Heat is applied to the first region 46 of the waterproof membrane 18. The first region 46 is than placed on area 50, which is a predetermined distance from the capping element 16, preferably no more than 50 mm. Once in place, pressure is applied to the first region 46 so as to bond the waterproof membrane 18. The second region 48 of the waterproof membrane 18 is not bonded to the base 12 of the upstand 10. This allows the second region 48 of the waterproof membrane to be folded up against the first region 46 during transport.

Furthermore, it allows fixing means, such as screws, to attach the base 12 to the flat roof without having to damage the waterproofing membrane 18.

In other embodiments, an adhesive is applied to at least a portion 50 of the wall 14. The portion 50 of the wall corresponds to parts of both the first 22, 36 and second sections 26, 38 of the wall 14. However, in other embodiments, the portion 50 of the wall may correspond to either the first 22, 36 or second section 26, 38 of the wall 14. No adhesive is applied to the base 12. This allows the second region 48 of the waterproof membrane to be folded up against the first region 46 during transport. Furthermore, it allows fixing means, such as screws, to attach the base 12 to the flat roof without having to damage the waterproofing membrane 18. The first region 46 of the waterproofing membrane panel is positioned in area 50, subsequently, pressure is applied to ensure bonding. The first region is bonded a predetermined distance from the capping element 16, preferably no more than 50 mm.

A subsequently place waterproof membrane panel is bonded to the previously placed waterproof membrane panel In some embodiments, the third region 49 of the subsequently placed panel is heated with the first region 46 of the subsequently placed panel. The third region 49 is placed so as to overlap the first region of the previously placed panel. The heat causing both panels to bond. In other embodiments, adhesive is applied to a portion of the panel to allow a subsequently placed waterproof membrane panel to partially overlap and adhere to the previously placed membrane panel. This process is repeated until the waterproof membrane 18 extends around the periphery of the upstand 10.

Figures 6 and 7 show the second region 48 of the waterproof panel being releasably restrained for storage and transportation. Once the first region 46 of the waterproof membrane 18 has fully adhered to the upstand wall 14, the second region 48 of the waterproof membrane 18 is folded towards the first region 46. A releasable retainer is used to releasably restrain the second region 48 in the folded position. In the current embodiment, a thin film plastic wrap 52 is applied around the periphery of a bottom upstand module 10, an adhesive back tape 54 restrains the waterproof membrane skirt 48 by wrapping around the periphery of a further upstand module 10 stacked on the bottom upstand module. By having the second region 48 restrained in the fold position provides protection against damage to the waterproof skirt.

By providing a premade upstand with a waterproof membrane already attached it is possible to improve the speed and reliability of weatherproofing roofs. Furthermore, by applying the waterproof membrane prior to installation a significant increase in the consistency and quality of application is achieved.

The embodiments described above are provided by way of example only, and various changes and modifications will be apparent to persons skilled in the art without departing from the scope of the present invention as defined by the appended claims.

Claims

CLAIMS1 An upstand module for a skylight comprising a wall, a base for attachment to a flat roof, and a pre-attached waterproof membrane having a first region adhered to at least part of the wall and a second region forming a skirt, the second region extending a predetermined distance past the base, the waterproof membrane extending around the periphery of the upstand.
2. An upstand module as claimed in claim 1, in which the waterproof membrane has a plurality of waterproof membrane sections.
3 An upstand module as claimed in claim 2, in which each of the waterproof membrane sections include an overlap region for overlapping an adjacent waterproof membrane section.
4. An upstand module as claimed in any preceding claim, in which the waterproof membrane includes rubber.
5. An upstand module as claimed in claim 4, in which the rubber is synthetic rubber
6. An upstand module as claimed in claim 4 or claim 5, in which the rubber is ethylene propylene diene monomer rubber.
7. An upstand module as claimed in any of claims 1 to 3, in which the waterproof membrane includes at least one fibrous material sheet.
8. An upstand module as claimed in claim 7, in which the waterproof membrane includes bitumen.
9. An upstand module as claimed in claim 7, in which the waterproof membrane includes a polyester resin or epoxy resin
10. An upstand module as claimed in any preceding claim, in which a predetermined gap is provided between the waterproof membrane and a capping element of the upstand
11 An upstand module as claimed in claim 10 in which the predetermined gap is no more than 50 mm.
12 An upstand module as claimed in any preceding claim, in which the skirt extends past an edge of the base by at least 100 mm.
13. An upstand module as claimed in claim 12, in which the skirt extends by at least 150 mm.
14. An upstand module as claimed in any preceding claim, in which the base is integrally formed with the wall
15. An upstand module as claimed in any of claims 1 to 13, in which the wall and the base are modular.
16 An upstand module as claimed in any preceding claim, in which the second region of the waterproof membrane may be releasably restrained in a folded position by a restraint means.
17. A method of adhering a waterproof membrane around the periphery of an upstand module, the upstand module comprising a wall and a base for attachment to a flat roof, the method comprising the steps of: producing a waterproof membrane using at least one template, the waterproof membrane including a first region corresponding to at least part of the upstand wall and a second region forming a skirt for extending past the base; and adhering the first region to at least a part of the wall.
18. A method as claimed in claim 17, in which the step of producing the waterproof membrane comprises placing the template on a sheet of waterproof membrane material and cutting around the template
19 A method as claimed in claim 17 or claim 18, in which the waterproof membrane is formed from a plurality of membrane sections each having the first region and second region.
20. A method as claimed in any of claims 17 to 19, in which the membrane section further includes a third region for providing a portion to be used as an overlap.
21 A method as claimed in claim 20, in which the method further comprises the step of adhering at least a portion of the third region to the first region of an adjacent membrane section.
22. A method as claimed in claim 20 or claim 21, in which the third region is formed from a portion of the first region and the second region
23 A method as claimed in any of claims 17 to 22, in which the method further comprises the step of wrapping the upstand module so that the second region is releasably held against the first region for transport and storage.
24. A method as claimed in any of claims 17 to 23, in which there are a plurality of templates, each template corresponding to a section of the upstand module. 1:3