IES77876B2 - A method for constructing a roof and a roof panel for use in the method - Google Patents

Abstract

A method for constructing a roof (1), the method comprising the steps of assembling a plurality of preformed panels (9) of lamella construction on a building to form a roof structure (1) of lamella arched roof construction, and cladding the assembled roof structure (1) with weatherproofing cladding.

Description

A method for constructing a roof and a roof panel for use in the method The present invention relates to a method for constructing a roof. The invention also relates to a method for constructing a roof for providing attic space on a building provided with a flat roof.

A number of methods exist for constructing roofs. In a commonly used method vertically disposed (pre-assembled) support trusses are arranged to define a roof structure having attic space defined beneath or in the roof structure. Generally such trusses are used in the construction of pitch, hip, mansard roofs and the like. However, a disadvantage of such trusses is that the transverse or crossover arrangement results in a roof structure having a restricted attic space. The head space of the attic is also obstructed by the transverse trusses which limits the usefulness of the attic space.

Moreover, known trussed roofs are extremely flexible when constructed particularly when subjected to loads normal to the direction of the truss which can give rise to mechanical weakness and difficulties in construction.

Other forms of roofs are also known. Lamella roofs are made up of lengths of solid timber connected together in a diamond shaped pattern to define a curved roof structure. Lamella roofs are constructed in-situ on a building and benefit from an absence of transverse trusses and do not suffer from excessive flexibility. However, such lamella roofs can be time consuming to construct due to the necessity of in-situ assembly. In addition in-situ assembly can result in damage and loss of individual lengths of solid timber which can increase the cost of the roof. Lamella roof constructions are also restricted to non-planar or curved e.g. barrel-vault, arched or dome shaped structures which are not suitable for many building shapes, sites and locations.

Moreover, known lamella roof constructions are difficult to apply to existing flat roofed buildings due to the elaborate construction supports etc. required to construct the lamella roof in-situ.

Many buildings, particularly, buildings which are constructed of reinforced or prestressed concrete are topped with a flat roof. A disadvantage of such constructions is that flat roofs provide no attic space whereas properly constructed attic space can be of significant value, and indeed, can be constructed to a standard which is suitable for providing accommodation. The lack of attic space in such buildings is disadvantageous, firstly, in that the full potential floor area which such buildings could provide is not achieved, and secondly, flat roofed buildings, in general, are not as aesthetically pleasing as buildings with hip or pitched roofs and the like.

A need exists for a method for constructing a roof which overcomes the problems of the prior art.

An object of the invention is to provide an improved method of constructing a roof.

A further object of the invention is to provide a modular method of constructing a roof and a modular lamella panel for use in such a method.

Yet a further object of the invention is to provide a method of constructing a roof having optimal attic space.

A still further object of the invention is to provide a method for constructing a roof on a building topped with a flat roof, and in particular a flat reinforced or prestressed concrete roof.

According to the invention there is provided a method for constructing a roof, the method comprising the steps of assembling a plurality of preformed panels of lamella construction on a building to form a roof structure of lamella arched roof construction, and cladding the assembled roof structure with weatherproofing cladding.

Preferably, the roof structure is clad with at least one framework for receiving the weatherproofing cladding. More preferably, the framework comprises at least one panel for forming a mansard roof. Most preferably, the framework comprises at least one panel for forming a pitched roof.

Suitably, the framework is preformed.

Advantageously, the framework comprises rafters or purlins mounted in a frame.

Preferably, the lamella panels are mounted on a wall plate on the building. More preferably, the roof is constructed on a preexisting flat roof.

Most preferably, the flat roof is a reinforced or prestressed concrete flat roof.

Advantageously, the roof defines an attic space below the roof.

Preferably, the panel is preformed on a former. More preferably, the panel comprises an outer frame. Most preferably, the outer frame is substantially rectangular in shape to define a gothic arch roof structure. Advantageously the gothic arch roof structure comprises spaces or gaps disposed between the lamella panels along the longitudinal axis defined by the gothic arch roof structure. Suitably, the lamella panel is constructed of timber.

Alternatively, the lamella panel is constructed of steel.

The invention also provides a method for constructing a roof defining an attic, the method comprising the steps of assembling a plurality of preformed panels of lamella construction on a building to form a roof structure of lamella arched roof construction, and cladding the assembled roof structure with weather proofing cladding.

The invention also extends to a lamella panel for the construction of a roof structure characterised in that the lamella panel is a modular panel.

Advantageously, the panel is attachable to a second panel to define the roof structure. Preferably, the panel comprises support means for supporting cladding means. More preferably, the support means comprises support cells.

Suitably, the support cells are defined by interlinked elements. Advantageously, the support cells comprise diamond shaped cells.

Suitably, the elements are interlinked by support plates.

In a preferred embodiment of the invention, the panel comprises an outer frame. Suitably, the frame is substantially rectangular in shape. Advantageously, the frame comprises interlinked elements. Preferably, the elements are interlinked contiguously to define the sides of the frame.

Preferably, the elements comprise elongate elements having a deepened profile variable in depth along the longitudinal axis of the elongate element.

Advantageously, the panel comprises attachment means for attaching the panel to a second panel.

The invention also provides a roofing kit comprising a lamella panel as hereinbefore described and a cladding support means comprising a cladding panel mountable on the lamella panel to define a roof shape.

Suitably, the cladding panel comprises interlinked rafters. Preferably, the cladding panel is mountable on at least one purlin. Advantageously, the cladding panel is shaped to define a hip roof. Suitably, the cladding panel is shaped to define a pitched roof. Alternatively, the cladding panel is shaped to define a mansard roof.

The invention also extends to a roof made up of panels as hereinbefore defined. Suitably, the roof is free of vertically disposed trusses.

The invention also provides a method for constructing a roof, the method comprising the steps of assembling a plurality of preformed panels of lamella construction on a building to form a roof structure of lamella roof construction, and cladding the assembled roof structure with weatherproofing cladding.

In one aspect of the invention each lamella panel is of width not exceeding 5M, the width of the lamella panel being measured along a lower edge which in use engages a wall plate fixed onto the building.

Preferably, the width of each lamella panel does not exceed 3M.

Advantageously, the width of each lamella panel does not exceed 2.4M.

In another aspect of the invention each lamella panel is constructed of timber, and in an alternative aspect of the invention each lamella panel is constructed of steel.

Suitably, the panel defines a rise. Advantageously, the rise in the panel varies between 10% and 20% of its long dimension.

Additionally, the invention provides a lamella panel for use in the method according to the invention, the lamella panel being of a size as to be positionable on the building by a crane or other lifting apparatus.

In one aspect of the invention the maximum dimension in length or width of the lamella panel does not exceed 15M. Preferably, the maximum dimension in length or width of the lamella panel does not exceed 12M. Advantageously, the maximum dimension in length or width of the lamella panel does not exceed 10M. Ideally, the maximum dimension in length or width of the lamella panel does not exceed 8M.

Ideally, the width of the panel is 3M and the length of the panel 8M.

Ideally, the panel is preformed in a factory, and transported to a 15 building site on which the building is being constructed.

Alternatively, the panel can be constructed on site.

Additionally, the invention provides a roof constructed according to the method of the invention.

The invention also extends to the use of a preformed panel of 20 lamella construction in the construction of a roof. Preferably, the roof defines an attic.

The invention will be more clearly understood from the following description of embodiments thereof given by way of example with reference to the accompanying drawings, in which: Fig. 1 is a partially cut away perspective view from above of a portion of a roof constructed according to a first embodiment of a method of the invention; Fig. 2 is a perspective view of a panel for use in the construction of the roof of Fig. 1; Fig. 3 is a side elevation of the panel of Fig. 2; Fig. 4 is a partially cut away end perspective view of the bottom end of the panel of Fig. 2; Fig. 5 is a partially cut-away end perspective view of the top end of the panel of Fig. 3, and Fig. 6 is a partially cut away perspective view of a portion of a roof constructed according to a second embodiment of a method of the invention.

Referring first to Fig. 1 of the drawings there is illustrated a portion of a roof according to a first embodiment of the invention indicated generally by the reference numeral 1 constructed by a method also according to a first embodiment of the invention. The roof 1 is illustrated constructed on a top portion of a building 2. The building 2 is typically of a reinforced concrete construction, and comprises a flat roof 3 also of reinforced concrete defined between a front wall 4, a rear wall 5 and an end wall 6 of the building 2. The roof 3 can also be of strengthened timber construction, of strength sufficient to support a roof in accordance with the invention. A pair of elongate wall plates 7 and 8 of timber are mounted and securely fixed on front and rear walls 4 and 5, respectively, of the building 2.

The roof 1 is constructed from a plurality of modular panels 9 of lamella construction. Each panel 9 is substantially arcuately or curved rectangular in shape. The panels 9 are disposed over the flat roof 3 to define a vaulted or arched attic 10 as shall be explained more fully below. The panels 9 are of timber and are preformed off-site or in an on-site factory, typically, in a factory, and are transported by road or other suitable transportation to the site. A crane (not shown) lifts the panels onto the building 2 where they are mounted on and secured to the wall plates 7 and 8 as shown in Fig. 1.

Cladding receiving panels 11 also of timber are secured to the lamella panels 9 to form a mansard roof with a double slope made up of an upper slope 12 and lower slope 13 of steeper incline than the upper slope 12. It will be appreciated that the cladding receiving panel 11 structure can be altered as desired to produce a roof finish of the desired shape, e.g. hip, pitch, etc.

Suitable weather proofing cladding (not shown) is secured to the cladding receiving panels 11. Such cladding, may comprise felt covered with slates on battens, tiles on battens, and the like.

The cladding receiving panels 11 are modular in construction as shown in Fig. 1. As shown in the drawing the cladding panel 11 of the upper slope 12 is smaller than the panel of the lower slope 13. The cladding receiving panels 11 are made up of interlinked rafters 37 which can be affixed to purlins 35 disposed between the cladding receiving panels 11 and the lamella panels 9. The panels 11 can be reinforced by cross-wires or stays 40 and the like and as shown in the drawing can be provided with a skin of felt 41, and a skin of plywood or oriented strand board (OSB) 42 for receiving cladding 43.

Figs. 2 to 5 show enlarged views of the lamella panels 9 of Fig. 1. As shown in the drawings each panel 9 comprises a rectangular frame 14 having a pair of parallel side members 15,16 joined by top and bottom end members 17 and 18, respectively, all of timber material. The side members 15,16 are made up of individual timber elements 19 secured together at their ends by planar plates 20 on the outer surface of the elements 19. The plates 20 are secured to the elements 19 by screws 21. As shown in Fig. 2, each side member 15,16 is made up of two comparatively long elements 19 secured together by a plate 20 and two comparatively short end elements 22 disposed either side of the long elements 19.

The plates 20 can be standard punched nail plate connectors.

The elements 19,22 of the side members 15,16 are contiguous and are connected together at the plates 20 and at the top and bottom members 17,18 in an angled fashion so that the side members 15,16 are arcuate as shown in Fig. 3. The top and bottom members 17,18 are angled so that the top member 17 defines a vertical abuttal ridge 23 for attachment to an opposing facing ridge 23 of a second lamella panel 9 in the upright assembled position shown in Fig. 1. Similarly, the bottom member 18 is angled to form a horizontal mounting ridge 24 for attachment to the wall plates 7,8 of the wall portion of the building 2 in the upstanding position shown in Fig. 1.

Each lamella panel 9 also comprises a plurality of internal timber elements 25 which are joined together end to end and transversely in a diamond shaped pattern in conventional lamella construction to define support cells and the arcuate or curved shape of the panel 9. The elements 25 within the panel can have varying lengths to make up a modular panel 9 of the required dimensions. The elements 25 are made up of primary elements 25 and secondary elements 25, a primary element 25 being one which passes between the ends of two contiguous elements 25 at an intersection 27, the elements 25 being intersected being referred to as secondary elements. The elements 25 in the frame 14 are interlinked by curved plates 26 disposed at the intersections 27 of the elements 25.

In order to enhance the load capacity of the panel 9, a primary element 25 intersects a pair of contiguous secondary elements 25 once only. The pair of contiguous elements 25 are therefore contiguous either side of a primary element 25 while primary elements 25 can also function as contiguous elements.

The primary elements 25 and contiguous elements 25 are connected by the curved plates 26 disposed either side of the intersections 27. The plates 26 are attached to the elements 25 by screws 21 while the plates 26 either side of the intersection points 27 are connected to each other by a bolt and washer 28 and nut 29 arrangement as shown in Fig. 2. Where an intersection 27 occurs at a side member 15,16 a bolt 28 extends through the element 19 of the side member 15,16 as shown in Fig. 3.

The elements 25 extending into each of the four corners of the rectangular frame 14 in a diagonal fashion can simply be secured by screw fixing or by adhesive means to the frame 14 as shown in Fig. 2.

The top member 17 is provided with a reinforcing wedge 30 disposed between transversely opposed elements 25 as shown in Fig. 4.

Bolts 28 extend through the top member 17 and the reinforcing members 13 to engage nuts 29 disposed on the inside face of the reinforcing members 30.

As shown in Fig. 5, the outer face of the top ridge 23 is defined along the top member 14.

In use, connection of the opposing panels can be achieved by steel plates 31 which can be attached to the top ridge 23 so that rapid bolting and therefore rapid roof construction can be achieved.

The bottom member 18 is also provided with angled reinforcing inserts 33 disposed between the elements 25 as shown in Fig. 2.

The angled reinforcing inserts 33 are connected to the bottom member 18 by a nut and bolt mechanism 28,29 as previously described.

The elements 19, 22 and 25 are made up of elongate four-sided timber elements 25 having side faces 38 and top and bottom edges 39. One side face 38 is profiled to curve arcuately and transversely outwards so that the elements 19,22,25 increase and decrease in depth along their longitudinal axis - being at maximum depth approximately midway along the length of the element 19,22,25.

Accordingly, each element 25 within the frame 14 of the lamella panel 9 varies in thickness across the diamond shaped pattern disposed between the frame 14.

Alternatively, the four side timber elements 25 can have identical non-profiled side faces. Accordingly, when viewed from the side such a lamella panel 9 would be provided with a series of angled or stepped joints at the intersection of contiguous elements 25 of the frame 14.

Each lamella panel 9 as discussed above is factory manufactured, and is formed on a former of the appropriate curvature.

In the embodiment of the invention shown in Figs. 1 to 5 the length of each lamella panel 9 from top to bottom is typically 8M, and the width of each panel 9 along the top and bottom end members 17 and 18 is typically 3M.

When the lamella panels 9 have been assembled and secured together to form the roof 1 of lamella construction, purlins 35 are then mounted on the lamella panels 9 followed by the cladding receiving panels 11. More particularly, purlins 35 are first secured to the lamella panels 9. The cladding receiving panels 11 are then secured to the purlins 35. Soffit boards 36 and other boards, for example fascia boards and the like are then secured in conventional fashion to the cladding receiving panels 11. Thereafter cladding of the cladding receiving panels 11 with suitable weatherproofing material is carried out in conventional fashion. For example, felt followed by battens and slates can then be affixed to the cladding receiving panels li.

A roof-light can be installed in the roof 1 by either leaving a space between a pair of adjacent lamella panels 9 and forming the roof-light in the space between the adjacent panels 9. If necessary reinforcing members may be secured between the adjacent panels 9 above and below the roof-light space. Alternatively, one of the lamella panels 9 may be constructed with a roof-light opening provided within the frame 14.

In an alternative embodiment, due to the strength of the lamella panels 9, the lamella panels 9 can alternate with spaces where no lamella panels 9 are present. The portion of the roof omitted can be covered with cladding receiving panels 11 in conventional fashion.

In addition, the cladding receiving panels 11 can span longitudinally parallel to the wall plate instead of vertically on the lamella panels 9.

Fig. 6 shows the partially cut-away perspective view of a portion of roof constructed according to a second embodiment of the invention. The embodiment shown in Fig. 6 is similar to the embodiment shown in Fig. 1 and like numerals indicate like parts. However, in the present embodiment, the cladding receiving panel 11 comprises a single slope 37 defined by the rafters 37. Accordingly, the rafters 37 have a single slope instead of a double slope, such that the cladding receiving panel 11 is shaped to define a pitched roof compared with the mansard roof of Fig. 1.

The abuttal ridge 23 as previously described is created between opposing panels 9. If desired, the cladding receiving panels 11 can be reinforced by struts onto the lamella panels 9 below in the space defined between the lamella panels 9 and the cladding panels 11.

In use, the lamella panels 9 are factory manufactured according to the size of panel 9 required, and transported to a building site or an already existing building. A crane (not shown) lifts the lamella panels 9 onto the building where they are assembled and secured together and to the wall plates 7 and 8 to form the roof structure 1 of lamella construction. If a roof-light is required, a roof-light opening is formed as already described between adjacent lamella panels 9, or may be preformed in one of the lamella panels 9.

The cladding receiving panels 11 are then secured to the purlins 35 mounted on the lamella panels 9 as previously described, and soffit 36 and/or fascia boards are secured to the cladding receiving panels 11. Weatherproofing cladding is then secured to the cladding receiving panels 11 in conventional fashion.

In an alternative embodiment of the invention, the lamella panels 9 can be mounted between reinforcing composites e.g. of steel, concrete and the like to reinforce the modular lamella roof structure. Such a construction could be analogous to a flitched beam construction such that in a gap created between adjacent panels 9 steel, reinforced concrete can act compositely with the timber.

In a further embodiment, the diamond structures formed by elements 25 within the frame 14 could be reinforced with transverse members to create triangular cells having increased strength.

The advantages of the invention are many. The invention provides a relatively simple and straight forward construction method for constructing a roof 1 having an attic using lamella construction which in this method is a particularly strong form of construction. The method according to the invention also provides for a particularly speedy construction of roof, which is made rapidly water-tight and particularly weather-resistant.

The roof constructed according to the invention provides significant attic space at a relatively low cost, and where applied to existing buildings, increases the floor space of the building. The roof according to the invention may be incorporated in the design of a building under construction or may be retrofitted to existing buildings.

A particularly important advantage of the invention is that it permits the construction of modular lamella panels 9 in a factory where their construction can be controlled within narrow tolerance limits. By virtue of the fact that lamella roofs are formed from a plurality of relatively short elements 19,22,25, this is a particularly important advantage, since on a building site, loss and damage of such elements is relatively high. Furthermore, by constructing the lamella panels 9 in a factory, appropriate formers can be provided and the panels constructed on the formers, thereby further increasing the precision with which the lamella panels 9 can be produced.

By virtue of the fact that the lamella roof can be constructed with such relative ease, roof construction on buildings originally designed and/or built with flat roofs can readily easily be provided with attic space, which may be constructed to a standard suitable for accommodation.

Additionally, a building which is topped with a roof according to the invention looks significantly more aesthetically pleasing than conventionally finished flat roof buildings.

While the lamella panels have been described as being of a specific size, it will be readily apparent to those skilled in the art that lamella panels of other sizes may be provided. It will be appreciated that any other suitable cladding arrangement may be provided for cladding the roof, for example, in certain cases, it is envisaged that weatherproof cladding may be secured directly to the lamella panels 9.

While the roof according to the invention has been described as providing attic space, it will be readily apparent to those skilled in the art, that within the roof space itself, in other words, within the roof space formed by the lamella panels, one or more additional floors may be added. These floors may be supported by the lamella panels and/or by stanchions extending upwardly from a flat roof or flooring.

It is also envisaged that the lamella panels, instead of being mounted on the walls of a building, where retrofitted to a flatroofed building may be mounted directly onto the flat roof of a building, and moreover may be mounted on the flat roof, within parapet walls of the building, or on an extension of the flat roof of the building which may extend beyond the walls of the building.

The roof according to the invention may be mounted on a building of any construction, whether of reinforced concrete, prestressed concrete, masonry, timber construction, steel construction, or any other construction of building, whether it be an existing building, or a building under construction.

The roof of the building on which the roof according to the invention is to be constructed, as well as being reinforced or precast, may be a cast in-situ roof, may be a timber deck, a steel roof deck, a metal decked roof, or any other construction of roof.

It will of course be appreciated that the lamella panel 9 may be constructed of any suitable material such as timber, concrete, steel or the like, and where constructed of concrete, the elements may be provided as individual elements, which may be prestressed, reinforced or the like. It is also envisaged that the side members of the lamella panels may be omitted during construction.

Where the lamella panels are mounted on a wall plate, the wall plate may be of any suitable material such as timber, concrete, steel or the like. In addition, the method of construction of lamella panels of materials other than timber could be varied without departing from the scope of the invention e.g. a steel lamella structure could be constructed from welded elements. It should be noted that buildings to which the lamella panels of the invention are applied should be sufficiently robust to support the resulting roof.

It is also envisaged that the lamella panels 9 may be clad with ply-wood, or any other suitable sheet material.

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

Claims (5)

1. A method for constructing a roof, the method comprising the steps of assembling a plurality of preformed panels of lamella construction on a building to form a roof structure of lamella 5 arched roof construction, and cladding the assembled roof structure with weatherproofing cladding.

2. A method as claimed in Claim 1 characterised in that the roof structure is clad with at least one framework for receiving the weatherproofing cladding. 10

3. A method for constructing a roof defining an attic, the method comprising the steps of assembling a plurality of preformed panels of lamella construction on a building to form a roof structure of lamella arched roof construction, and cladding the assembled roof structure with weather proofing cladding. 15

4. A lamella panel for the construction of a roof structure characterised in that the lamella panel is a modular panel.

5. A lamella panel as claimed in Claim 4 characterised in that the panel is attachable to a second panel to define the roof structure.