US20140202101A1

US20140202101A1 - Roof structure

Info

Publication number: US20140202101A1
Application number: US13/796,060
Authority: US
Inventors: Mario Hurst
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-11-05
Filing date: 2013-03-12
Publication date: 2014-07-24
Also published as: NZ620213A

Abstract

The present invention relates to a roof structure. The structure comprises support members defining openings. Bridge members extend between the support members. End portions of the bridge members are able to be received by the openings in the support members such that the end portions can be inhibited from being withdrawn from the openings. A safety barrier is supported by the bridge members. The structure also comprises an insulating layer including insulation pockets and being supported by the safety barrier.

Description

FIELD OF THE INVENTION

The present invention relates generally to a building roof structure. The present invention also relates to a method of building a roof structure.

BRIEF DISCUSSION OF THE PRIOR ART

The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.
A typical building roof structure includes a plurality of support members and a roofing layer which is secured to and supported by the support members. The support members are typically provided by purlins which are secured to one or more rafters, and the roofing layer is usually provided by a plurality of tiles, roof panels, shingles, or the like which are secured to and supported by the purlins.
Sometimes the roof structure will include a fall protection system for preventing a person or other objects from falling through the roof structure. The fall protection system typically comprises a safety barrier in the form of safety mesh or the like which is placed on top of the purlins and which is secured to the purlins.
A layer of thermal insulation is often included in the roof structure to inhibit the transfer of heat through the roof structure. The layer of insulation is typically placed on top of the purlins, and the roofing layer is then placed on top of the insulation. This tends to compress areas of the insulation which are located between the roofing layer and the purlins.
Compressing the insulation can be problematic in that the compressed areas of the insulation usually do not perform at an optimum level. In other words, compressing the insulation can compromise the thermal insulating properties of the insulation. If the performance of the insulation is compromised, the energy efficiency of the building can be impaired so that more energy is required to cool or heat the interior of the building to maintain it at a desired temperature.
In order to improve the energy efficiency of new buildings, Section J of the Building Code of Australia (“BCA”) was introduced by the Australian Building Codes Board. Section J of the BCA requires the roof structure of a new building to have a minimum R-value of 3.2, and stipulates that, in order to achieve this, there must be a recovery air gap between the roofing layer and the insulation so that the insulation is not compressed between the purl ins and the roofing layer.
U.S. Pat. No. 4,047,346 (Alderman) and U.S. Pat. No. 4,379,381 (Holcombe) disclose thermally insulated roof structures which include an air gap between a roofing layer and a thermal insulation layer.
Alderman discloses an insulated roof structure formed on an industrial building by mounting a support framework on the purlins of the partially completed roof structure and moving the framework along the length of the purlins. A reel of wire mesh and a reel of sheet material are carried by the framework over each of the spaces between adjacent ones of the purlins, and the reels are progressively unrolled, and the layers of wire mesh and sheet material are applied to the spaces between the purlins as the support framework moves. Additional insulation can be blown upon or otherwise applied to the sheet material to fill the spaces between the purlins, and hard sheets of roofing material are applied to the purlins as the support framework progresses across the structure.
A central web of each purlin of the insulated roof structure disclosed by Alderman includes a plurality of openings. The roof structure also includes a plurality of support straps. Each support strap is threaded through one of the openings in each purlin. The support strap is placed under tension so that it extends in a substantially flat plane between adjacent ones of the purlins.
Being straps, the support straps are quite flexible. Consequently, the support straps are not particularly well-suited to spacing the purlins apart from each other, or to maintaining the spacing between the purlins.
Each of the support straps is inhibited from being withdrawn from the opening through which it extends by a retaining clip which is wedged in the opening so as to form a friction connection between the purlin and the support strap.
The layers of wire mesh which are applied to the spaces between the purlins are placed on the support straps. The support straps support the mesh at spaced intervals along the lengths of the purlins, and tension is applied to the mesh so as to prevent the mesh from sagging extensively between adjacent ones of the support straps.
The sheet material is placed upon the mesh, and a quantity of heat insulation material is disclosed inserted in the spaces between adjacent ones of the purlins and onto the sheet material. The insulation material can be in the form of blocks of solid material, sheets of material, loose material, or material that was initially loose when placed in the space but sprayed or otherwise mixed with adhesive as or after being inserted into the spaces so as to become substantially rigid.
An additional sheet of insulation material is applied to the top surface of the upper flange of each of the purlins, and the hard sheets of roofing material are placed on the sheet insulation material and connected to the purlins by self-tapping screws or other fasteners.
The additional sheet of insulation material functions to reduce the transfer of heat between the hard sheets of roofing material and the purlins, and the insulation material in the spaces between adjacent ones of the purlins function to inhibit the transfer of heat between inside the building and the hard sheets of roofing material by means of convection and radiation.
FIG. 1 of Alderman depicts an air gap which separates the sheets of roofing material from the heat insulation material which is supported by the sheet material.
Holcombe discloses an insulation system for a roof structure which includes a semi-rigid insulation blanket overlying a support structure across roof purlins and having additional insulation material filling a U-shaped trough created by the blanket between adjacent purlins. The semi-rigid insulation blanket is notched by the manufacturer at predetermined points to enable the blanket to easily and securely fold over and around the support structure and roof purlins.
The support structure of the Holcombe insulation system includes main support brackets which extend between and rest on top of the purlins, and longitudinal support brackets which extend between and rest on top of the main support brackets. The main support brackets and the longitudinal support brackets include fastening holes for receiving plastic snap-in fasteners which secure the main support brackets to the purlins and which secure the longitudinal support brackets to the main support brackets.
FIG. 2 of Holcombe depicts an air gap separating the roof panel and an insulation bat of the roof structure.
It would be desirable to provide bridge and support members for a roof structure which are able to be secured together in a different manner to the bridge and support members of the aforementioned prior art roof structures.
Also, it would be desirable to provide a roof structure which includes a plurality of the aforementioned bridge and support members. It would be desirable for the roof structure to incorporate a fall protection system. It would also be desirable for the roof structure to comply with Section J of the BCA.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, there is provided a roof structure comprising:
support members defining openings;
bridge members extending between the support members, end portions of the bridge members able to be received by the openings in the support members such that the end portions can be inhibited from being withdrawn from the openings;
a safety barrier supported by the bridge members; and
an insulating layer including insulation pockets and being supported by the safety barrier.
The insulation pockets may be arranged in a cellular manner between a pair of sheets. The sheets may be metallic foil sheets. The sheets may include reflective aluminium foil. The insulation pockets may be sealed air or foam pockets. The insulating layer may rest directly on the safety barrier.
According to another aspect of the present invention, there is provided a method of building a roof structure, the structure having bridge members extending between support members such that end portions of the bridge members are received by openings in the support members and the end portions can be inhibited from being withdrawn from the openings, the bridge members supporting a safety barrier, the method comprising the step of:
providing an insulating layer defining insulation pockets on the safety barrier.
According to another aspect of the present invention, there is provided a method of building a roof structure, the method comprising the steps of:
extending a plurality of bridge members laterally between a plurality of adjacent support members such that end portions of the bridge members are received by openings in the support members and the end portions can be inhibited from being withdrawn from the openings;
supporting a safety barrier with the bridge members; and
supporting an insulating layer defining insulation pockets with the safety barrier.
According to another aspect of the present invention, there is provided an insulating layer including insulation pockets when used in a roof structure that has bridge members extending between support members, with end portions of the bridge members being received by openings in the support members and with the end portions being inhibited from being withdrawn from the openings, the bridge members supporting a safety barrier on which the insulating layer can be located.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more fully understood and put into practice, a preferred embodiment thereof will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a roof structure according to a preferred embodiment of the present invention;

FIG. 2 is a perspective view of a bridge member of the roof structure; and

FIG. 3 is an end view of the roof structure;

FIG. 4 is a perspective view of a telescopic bridge member of a roof structure in accordance with another embodiment of the present invention with parts separated;

FIG. 5 is a perspective view of the telescopic bridge member of FIG. 4 with parts engaged;

FIG. 6 is a top view of the telescopic bridge member of FIG. 5;

FIG. 7 is a side view of the telescopic bridge member of FIG. 5;

FIG. 8 is a bottom view of the telescopic bridge member of FIG. 5;

FIG. 9 is an end view of the telescopic bridge member of FIG. 5;

FIG. 10 is a partial perspective view of the telescopic bridge member of FIG. 5 engaging with a purlin; and

FIG. 11 is a side sectional view of alternate insulating material to be used in the roof structure of FIG. 1, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

Referring to the figures, a roof structure 20 according to a preferred embodiment of the present invention comprises a plurality of adjacent support members in the form of purlins 21. Purlins 21 are parallel to each other, and are spaced apart from each other at regular or irregular intervals.
Each purlin 21 is made from sheet metal, and has a Z-shaped profile comprising a lower portion in the form of a lower panel 22, an upper portion in the form of an upper panel 23, and a vertical intermediate portion in the form of an intermediate panel 24 which extends between the lower panel 22 and the upper panel 23, and which is perpendicular with respect to the lower panel 22 and the upper panel 23. A lip 25 extends upwardly from the lower panel 22, and is perpendicular with respect to the lower panel 22. A lip 26 extends downwardly from the upper panel 23, and is perpendicular with respect to the upper panel 23.
A plurality of T-shaped openings 27 are punched into the intermediate panel 24 of each purlin 21. Openings 27 are spaced apart from each other at regular intervals along the length of the purlins 21. FIG. 1 only shows one of the openings 27 in each of the purlins 21. Each opening 27 includes a first portion 28 and a second narrower portion 29 which adjoins the first portion 28.
A plurality of bridge members 30 are spaced apart from each other at regular intervals and extend laterally between each pair of adjacent purlins 21 such that the bridge members 30 are perpendicular with respect to the purlins 21.
Each bridge member 30 is made from sheet metal, and includes an intermediate portion 31 and a pair of end portions 32 which extend from the intermediate portion 31. Intermediate portion 31 includes a top panel 33 and a pair of side panels 34 which extend perpendicularly from the top panel 33. Each end portion 32 is provided by the top panel 33, and includes a head portion 35 and a narrower neck portion 36 which extends from the head portion 35.
The end portions 32 of the bridge members 30 are each received by the openings 27 in the purlins 21. The side panels 34 of each bridge member 30 are supported by the lip 25 of one of the purlins 21 which the bridge member 30 extends between.
In order to insert the end portion 32 of a bridge member 30 into one of the openings 27, the head portion 35 and the neck portion 36 of the end portion 32 are inserted into the first portion 28 of the opening 27 so that the neck portion 36 is located above the second portion 29 of the opening 27. The neck portion 36 is then lowered into the second portion 29. The width of the second portion 29 is such that the head portion 35 is inhibited from being withdrawn from the opening 27.
The end portion 32 is able to be removed from the opening 27 by firstly raising the end portion relative to the opening 27 so that the neck portion 36 is located in the first portion 28. The head portion 35 and the neck portion 36 are then able to be withdrawn from the first portion 28 of the opening 27.
Each opening 27 is able to receive an end portion 32 of two bridge members 30 as shown in FIGS. 1 and 3. The end portion 32 of one of the bridge members 30 which is received by a particular opening 27 overlies the other bridge member 30 which is received by that opening 27. In particular, the head portion 35 of the overlying end portion 32 lies on top of the top panel 33 of the other bridge member 30 which is received by the opening 27. The end portions 32 of the two bridge members 30 which are received by the opening 27 are secured together with fasteners which are in the form of 12×25 “Tek” screws 37.
A safety barrier 40 for preventing a person from falling off the roof structure 20 is secured relative to the bridge members 30 of the roof structure 20 as shown in FIGS. 1 and 3. Barrier 40 comprises a plurality of individual safety wires 41 which extend between adjacent bridge members 30. Wires 41 are secured to the bridge members 30 by wrapping or looping their ends around the bridge members 30 and then twisting the ends around the wires 41 as depicted in FIG. 1.
The bridge members 30 and the safety barrier 40 support an insulating layer which is provided by thermal insulation 42. Insulation 42 may be any suitable type of insulation. For example, insulation 42 may be fibreglass or wool insulation.
A roofing layer provided by one or more ribbed roof panels or sheets 50 is supported by the purlins 21 such that the sheets 50 rest on the upper panels 23 of the purlins 21. Roof sheets 50 and the insulation 42 are separated from each other by an air gap 60 which is 100 mm wide.
A method of building the roof structure 20 is now briefly described. The method comprises the steps of:
(i) extending a plurality of bridge members 30 laterally between a plurality of adjacent purlins 21 such that the end portions 32 of the bridge members 31 are received by the openings 27 in the purlins 21 such that the end portions 31 can be inhibited from being withdrawn from the openings 27;
(ii) supporting the safety barrier 40 with the bridge members 30;
(iii) supporting the insulating layer 42 with the safety barrier 40; and
(iv) supporting the roofing layer 50 with the purlins 21 such that the roofing layer 50 and the insulating layer 42 are separated from each other by the air gap 60.
Turning to FIG. 4, each bridge member 30 can be replaced by a telescopic bridge member 60 including two generally C-shaped body parts 62, 64 (see also FIG. 9). The bridge member 60 is substantially rigid and comprises an intermediate portion formed by the overlapping body parts 62, 64, and a pair of end portions 32 located at opposite ends of the intermediate portion. Each end portion 32 (as previously described) is adapted to be received by an opening 27 in a purlin 21 such that the end portion 32 can be inhibited from being withdrawn from the opening 27. The rigid bridge members 60 can be used to space a plurality of the purlins 21 apart from each other at regular intervals, and for maintaining the spacing between the purlins 21.
Each body part 62, 64 is of a similar construction. However, as can best be seen in FIGS. 5 to 8, body part 64 is dimensioned so as to be snugly slid within body part 62. Body part 64 defines a threaded fastening hole 66 for receiving a grub screw to fixedly fasten the movable parts 62, 64 together. In addition, one of the end portions 32 may define another fastening hole 68 in which a “Tek” screw 37 can be received when fastening end portions 32 of serially arranged bridge members 60 together.
Turning to FIG. 10, there is provided another purlin 70 with an intermediate panel 72. The purlin 70 is rotationally symmetric and defines a pair of symmetric openings 74 a, 74 b so that the purlin 70 has the same characteristics when mounted in either orientation, 180° apart. Each opening 74 defines a central portion 76 through which an end portion 32 is initially received. A pair of walls 78 taper downwardly to guide the neck portion 36 of the bridge member 60, and resiliently reciprocate to lock the bridge member 60 in a bottom recess 80 of the opening 74.
The bulk fibreglass or wool insulation 42 shown in FIG. 1 is comparatively difficult to install, and heavy which can cause the wires 41 of the safety barrier 40 to sag. Alternatively, using a thin and light-weight insulating layer 42 a air-cell insulation produced by Kingspan™, as shown in FIG. 11, reduces sagging of the safety barrier 40 and is comparatively simple to install being supplied on a roll. A comparatively larger air gap results, and using the insulating layer 42 a also produces a satisfactory thermal resistance value (Rvalue).
Turning to FIG. 11, the insulating layer 42 a includes insulation air pockets 90 which are arranged in a cellular array between a pair of highly reflective aluminium foil sheets 92 a, 92 b. The insulation pockets 90 typically contain sealed air or, in another embodiment, insulating foam.
A method of building the roof structure 20 using insulating layer 42 a is greatly simplified. The method involves providing the insulating layer 42 a on the safety barrier 40 from its roll.
Throughout the specification and the claims, unless the context requires otherwise, the term “comprise”, or variations such as “comprises” or “comprising”, will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers.
Throughout the specification and claims, unless the context requires otherwise, the term “substantially” or “about” will be understood to not be limited to the value for the range qualified by the terms.
It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth.
It will be clearly understood that, if a prior art publication is referred to herein, that reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.
The foreign priority application, Australian application 2013200319, filed Jan. 22, 2013, is incorporated by reference herein.

Claims

The claims defining the invention are as follows:

1. A roof structure comprising:

support members defining openings;

bridge members extending between the support members, end portions of the bridge members able to be received by the openings in the support members such that the end portions can be inhibited from being withdrawn from the openings;

a safety barrier supported by the bridge members; and

an insulating layer including insulation pockets and being supported by the safety barrier.

2. A roof structure as claimed in claim 1, wherein the insulation pockets are arranged in a cellular array between a pair of sheets.

3. A roof structure as claimed in claim 2, wherein the sheets are metallic foil sheets.

4. A roof structure as claimed in claim 3, wherein the sheets include reflective aluminium foil.

5. A roof structure as claimed in claim 1, wherein the insulation pockets are sealed air or foam pockets.

6. A roof structure as claimed in claim 1, wherein the insulating layer rests directly on the safety barrier.

7. A roof structure as claimed in claim 6, further including a roofing layer being supported by the support members, the roofing layer and the insulating layer being separated from each other by an air gap.

8. A roof structure as claimed in claim 1, wherein each bridge member is substantially rigid and comprises an intermediate portion, and a pair of end portions located at opposite ends of the intermediate portion.

9. A roof structure as claimed in claim 8, wherein each of the end portions includes a neck portion which extends from the intermediate portion and can receive a support member, and a head portion which extends from the neck portion and which is wider than the neck portion to inhibit withdrawal of the end portion from an opening.

10. A roof structure as claimed in claim 8, wherein the intermediate portion includes a main panel, and a pair of side panels extending from opposite sides of the main panel, the end portions being coplanar with the main panel.

11. A roof structure as claimed in any one of claims 8, wherein the intermediate portion is generally C-shaped.

12. A roof structure as claimed in claim 1, wherein each opening includes a first portion which allows the end portions of the bridge members to be inserted into and removed from the opening, and a second narrower portion which adjoins the first portion and which is able to inhibit the end portions from being withdrawn from the opening.

13. A roof structure as claimed in claim 12, wherein the openings of the support members are T-shaped and the support member is either a purl in or a rafter.

14. A roof structure as claimed in claim 12, wherein the profile of the support member includes a lower panel and an upper panel which are co-parallel, and an intermediate panel extending perpendicularly between the lower panel and the upper panel.

15. A roof structure as claimed in claim 1, wherein:

the bridge members supporting the safety barrier extend between lower portions of the support members;

each support member is a purlin, and the purlins can be pulled toward each other by the bridge members if sufficient downward force is applied to bend the bridge members;

each bridge member is telescopic so that its length can be varied; or

the end portions of the bridge members are T-shaped.

16. A method of building a roof structure, the structure having bridge members extending between support members such that end portions of the bridge members are received by openings in the support members and the end portions can be inhibited from being withdrawn from the openings, the bridge members supporting a safety barrier, the method comprising the step of:

providing an insulating layer defining insulation pockets on the safety barrier.

17. A method of building a roof structure, the method comprising the steps of:

extending a plurality of bridge members laterally between a plurality of adjacent support members such that end portions of the bridge members are received by openings in the support members and the end portions can be inhibited from being withdrawn from the openings;

supporting a safety barrier with the bridge members; and

supporting an insulating layer defining insulation pockets with the safety barrier.

18. A method of building a roof structure as claimed in claim 16, wherein the insulating layer includes a pair of metallic sheets between which the insulation pockets are located.

19. A method of building a roof structure as claimed in claim 16, further comprising the step of:

supporting a roofing layer with the support members such that the roofing layer and the insulating layer are separated from each other by an air gap.

20. A method of building a roof structure as claimed in any one of claim 16, wherein:

each bridge member is substantially rigid and comprises an intermediate portion, and a pair of end portions located at opposite ends of the intermediate portion, each end portion being adapted to be received by an opening in a support member of the roof structure such that the end portion can be inhibited from being withdrawn from the opening; and

each support member comprising a plurality of openings that are each adapted to receive an end portion of a bridge member such that the end portion of the bridge member can be inhibited from being withdrawn from the opening.