WO1994028266A1

WO1994028266A1 - Roofing element

Info

Publication number: WO1994028266A1
Application number: PCT/SE1994/000453
Authority: WO
Inventors: Ernst Kero
Original assignee: Plannja Ab
Priority date: 1993-05-21
Filing date: 1994-05-16
Publication date: 1994-12-08
Also published as: AU6810794A; SE501387C2; SE9301745D0; SE9301745L

Abstract

The present invention relates to a roofing element (1), particularly to be laid on supporting beams/primary beams (100) which extend in the direction of the pitch of the roof, wherein the roofing element (1) includes a top side, a bottom side, a front long-side and a rear long-side, and wherein the front long-side forms a bottom long-side as seen in the direction of roof pitch, and the rear long-side forms a top long-side as seen in the direction of roof pitch. The roofing element (1) includes an outwardly projecting lip (21) at its front long-side edge (20) this front lip (21) being located on the upper side of the roofing element. The roofing element (1) includes an outwardly projecting lip (31) on its rear long-side edge (30), this rear lip (31) being located on the underside of the roofing element. The roofing element (1) further includes a top sheet (10), a bottom sheet (13) and an insulating body (12) placed there between. The roofing element (1) also includes an upper stiffening (11) which is located immediately beneath the top sheet (10). The roofing element (1) further includes at least one beam (14, 15) whose height measurement essentially corresponds to the height measurement of the roofing element. The invention also relates to a method for mounting the inventive roofing element.

Description

ROOFING ELEMENT

The present invention relates to a roofing element according to the preamble of claim 1. The invention also relates to a method of mounting the roofing element.

Hitherto known roofing elements that are intended to be placed directly on primary beams which extend in the direction of roof pitch are comprised, for in¬ stance, of homogenous lightweight concrete elements or constructions comprised of wood and/or metal sheet, and may also include a separate insulating material. A common drawback with these known roofing elements is that the roof is not complete even when the roofing elements have been laid, but must be provided with a surface layer or with strips that cover the joins which extend transversally to the direction in which the roof is pitched. This makes the task of laying a roof a lengthy process and, among other things, good weather conditions are required in order to produce a roof of satisfactory quality.

The object of the present invention is to provide a specially designed roofing element which can be laid very advantageously directly onto beams which extend in the direction in which the roof is pitched for instance, and to provide a method for mounting the roofing element. These objects are achieved by virtue of the roofing element and the method having the characteristic features set forth in the following claims.

Given below are some of the many properties of the invention and the advantages afforded thereby.

The roofing element can be laid horizontally directly onto primary beams. The roofing element is self-supporting in both its longitudinal and transversal directions. The outer roof covering is integrated in the roofing element. The underside of the roofing element functions as an inner lining or covering.

Both outer and inner linings, or facings, are active parts of the supporting construction. Join overlaps are insensitive to tolerance deviations. The join overlap enables a perfect seal to be obtain¬ ed.

Holes can be made very easily for roof throughlets, lead-throughs, windows, smoke passageways, ventilation ducts and the like. The task of making holes in roofs is normally a very expensive and complicated task.

The roof can be initially laid very quickly, for instance with the aid.of a vehicle-mounted crane. The roofing elements can be screwed down in a later stage.

The roof is laid from the bottom and upwards, i.e. from the eaves to the purlin/ridge.

An upwardly protruding upper flange/upper lip on the lowermost roofing element is able to function as a surface on which gutters and the like can be secured. The underside of the roofing element can be readily secured to the eaves.

The flat upper surface of the roofing element and the configuration of the long-side overlap enables benefi- cial end-joins to be obtained with the aid, for in¬ stance, of a rubber fabric which will readily follow the junctions between adjacent roofing elements. Simple connection for ridge fittings. It is easy to obtain correct distances between up- per/outer and lower/inner seals such that both the outer seal and the inner seal (the diffusion seal) will be compressed to the extent desired. The outer seal may optionally be softer than the inner seal. The roofing element can be readily prefabricated in the factory and can be mounted quickly on the building site.

The roofing elements can be made relatively light in weight and can be produced in large sizes. Wide spans can be achieved.

The roofing element provides very large economical benefits.

Exemplifying embodiments of the invention will now be described with reference to the accompanying drawings, in which Figure 1 is a cross-sectional view of an inventive roofing element; Figures 2-5 are cross- sectional views of a number of alternative embodiments of the roofing element; Figure 6 is a vertical sec¬ tional view of a roof which is constructed with inven¬ tive roofing elements, said view been taken in the pitch -direction of the roof as shown by an arrow; Ficrure 7 is a cross-sectional view in larger scale of a long-side join between two adjacent roofing ele¬ ments; Figures 8 and 9 illustrate schematically modified corner sections of the roofing element shown in Figure 1; Ficrure 10 is a cross-sectional view of a roof ridge; Ficrure 11 illustrates schematically an end-join between two roofing elements; Ficrure 12 is a partial cross-sectional view of the end-join shown in Figure 11.

The roofing element 1 shown in Figure 1 includes a sheet-like upper lining in the form of a top sheet 10, for instance a surface-treated metal sheet, which is glued firmly to a stiffening sheet 11, for instance a sheet of particle board or plywood, which in turn is glued firmly to an insulating body 12 , for instance expanded polystyrene, cellular plastic, polyurethane or mineral wool. The insulating body 12 is also glued firmly to a bottom lining or covering sheet in the form of a bottom sheet 13, which is preferably com¬ prised of surface-treated sheet metal. The roofing element 1 also includes a front beam 14 and a rear beam 15, these beams being made of wood for instance and extending along the full length of the roofing element. The beams 14 and 15 contribute to the self-bearing properties of the roofing element 1 and prevent deformation of the insulation 12 of the roofing element.

The top sheet 10, the stiffening sheet 11, the insu- lating body 12 and the bottom sheet 13 also extend, of course, along the full length of the roofing element 1.

The roofing element l includes at its front long-side edge 20 an outwardly projecting upper lip or flange 21 which extends along the full length of the roofing element. The upper flange 21 is formed by an out¬ wardly projecting edge-part 22 of the stiffening sheet 11 and a part 23 of the top sheet 10 folded around the edge-part 22. The folded part 23 includes a sloping junction or transition part 24 and the fold 23 extends up to the beam 14, as will best be seen from Figure 7.

The roofing element l includes at its rear long-side edge 30 an outwardly projecting bottom lip or flange 31, which extends along the full length of the roofing element. The bottom flange 31 is formed by an out¬ wardly projecting edge-part 32 of a strip 16, which is conveniently glued to the underside of the beam 15 and to the bottom sheet 13, and a bottom-sheet part 33 which is folded around the edge-part 32. The fold 33 has a sloping junction or transition part 34 and the fold 33 extends up to the beam 15, as will best be seen from Figure 7. The strip 16 is made of plywood, for instance.

The roofing element 1 also includes a top seal 40 and a bottom seal 41 (see Figure 7) , these seals extending along the full length of the roofing element. The top seal 40 is either mounted on the underside of the top flange 21 or on the upper side of the top sheet 10 at its rear edge-part. The bottom seal 41 is mounted either on the upper side of the bottom flange 31 or on the underside of the bottom sheet 13, at the forward end-part of the bottom sheet. If considered benefi¬ cial, the seals 40 and 41 may have different dimen¬ sions and a different degree of hardness, and may even be made of mutually different materials.

Figure 2 illustrates an alternative embodiment of the roofing element 1, in which the front beam 14 has been omitted and the insulation 12 has been adapted to take the place of the front beam.

Figure 3 illustrates an alternative embodiment of the roofing element 1 in which both the front beam 14 and the rear beam 15 have been omitted. In the case of this embodiment, the strip 16 is replaced with a bottom stiffening sheet 17, for instance a sheet of particle board or plywood which extends across its width up to the front edge of the insulation 12. The bottom sheet 17 extends, of course, along the full length of the roofing element. As will be understood, the insulation 12 can be adapted to compensate for these changes.

Figure 4 illustrates an alternative embodiment of the roofing element 1 in which both the front beam 14 and the rear beam 15 have been omitted. The insulation 12 has, of course, been adapted to compensate for these changes. The bottom lip 31 is formed by a fold which optionally includes a strip and which also extends along the full length of the roofing element.

Figure 5 illustrates an alternative embodiment of the roofing element 1 in which the beams 14 and 15, the stiffening sheet 11 and the strip 16 have been exclud¬ ed, wherein the insulation 12 has, of course, been adapted to compensate for these changes. This very simple embodiment of the roofing element thus includes only the top sheet, the insulation and the bottom sheet and, of course, the necessary seals. It is also conceivable to configure the lips 21 and 31 without folds.

The exemplifying embodiments shown in Figures 1-5 may be applied in dependence of the qualifications of the insulation, among other things with regard to bearing capacity, and in dependence on the loads to be sus- tained by the roofing element. The distance between the primary beams/supporting beams is also of central significance in this context, of course. It will be understood that other embodiments are conceivable within the scope of the invention.

All of the afore described variants of the inventive roofing element, which are sandwich constructions, can be manufactured very easily and efficiently in the factory.

In the case of a particularly simple embodiment, the bottom lip 31 of the roofing element 1 can be omitted.

The sectional view of the roof illustrated in Figure 6 includes roofing elements 1 that have been laid di¬ rectly onto primary beams 100 and are supported by said beams. The arrow P shows the pitch direction of the roof.

The roof is laid in a direction from the eaves to the ridge of the roof and roofing elements l are subse¬ quently anchored to the primary beams 100 by means of fasteners in the form of screws 60 for instance. The screws 60 pass through the top flange 21 of an overly- ing roofing element 1 and through the rear beam 15 of an underlying roofing element 1, into screw engagement with the primary beams 100. Alternatively, anchoring of the rear edge of the roofing elements l can be effected with the aid of screws 51 that pass through the bottom flange 31 into screw engagement with the primary beams 100. The top flange 21 is anchored to underlying roofing elements by means of the requisite number of screws 62 which pass through the top flange and which have a length such as to screw into the rear beam 15 of an underlying roofing element 1. When necessary, screws 63 can also be applied from beneath, by inserting the screws through the bottom flange 31 and into the front beam 14 of an overlying roofing element 1.

The seals 40 and 41 are compressed as the roofing elements are screwed down, and the construction of the inventive roofing elements enables the correct dis¬ tance to be obtained readily between the top seal 40 and the bottom seal 41, so that the seals will be compressed in the desired manner.

The roofing element 1 lies directly on the primary beams 100 at its rear long-side, but indirectly at its front long-side, via the underlying roofing element 1. Figure 7 shows in detail a join between two mutually adjacent roofing elements 1.

Figure 8 illustrates the possibility of extending the bottom sheet 13 with an upwardly folding part 70 which is anchored to the vertical outer side of front beam 14, by means of nails or screws 71.

Figure 9 illustrates the possibility of extending the bottom sheet 13 with an upwardly folded part 72 which is anchored to the vertical outer side of the rear beam 15 by means of nails or screws 73.

The additional anchoring of the bottom sheet 13 shown in Figures 8 and 9 is beneficial from the aspect of fire safety.

Figure 10 illustrates schematically how a roof ridge can be formed with the aid of the inventive roofing elements 1. As shown, a covering plate 80 is placed between the mutually adjacent bottom flanges 31 and screwed firmly to the bottom flanges, via seals 81. The space between the beams 15 is filled with insulat¬ ing material 82, for instance mineral wool. The gap between the adjacent roofing elements 1 is covered with a ridge tile or ridge plate 83, and the ridge plate is screwed firmly to the upper sides of the roofing element 1, via sealing strips 84.

Figures 11 and 12 illustrate schematically how an end- join can be made between two roofing elements 1, wherein the space between the ends of the roofing elements is filled with an insulating material 90, for instance mineral wool. A sealing plate (not shown) is placed immediately above the primary beam 100 concerned. An elastic strap 91, made for instance of butyl rubber, is placed along the end-join, from the ridge to the eaves of the roof, this elastic strap 91 being clamped firmly to the upper sides of adjacent roofing elements 1, by screwing-down overlying strips 92. Sealing strips 93 are placed between the elastic strap 91 and the upper side of the roofing elements. The screw fasteners have been referenced 94.

The sloping transition part 24 (see Figure 12) of the top flange 21 makes it possible to achieve good, sealing connection of the seals 93 and the elastic strap 91. The elastic strap 91 permits the roofing elements 1 to move relative to one another. The insulating material 90 can be filled to excess, there¬ with to cause the elastic belt 91 to curve or bulge upwardly, if so desired.

The fasteners, whose heads are located on top of the roofing elements and are thus exposed to the weather, and wind, shall, of course, have a sealing washer placed beneath their heads.

As will be understood, the inventive roofing element is preferably dimensioned so as to be self-bearing in a direction perpendicular to the pitch of the roof and in a direction along the roof pitch, in other word the element shall be capable of supporting occurrent loads in the absence of support between the primary beams and also between their front and rear edges. The bottom flange at the rear edge and the top flange at the front edge play a central part in the load-bearing capacity of the longitudinal joins between the differ¬ ent roofing elements.

As will be understood, the beams 14 and 15 may be con¬ structed in many different ways and, with a view to saving energy, may be comprised of specially config¬ ured insulating beams, such as so-called masonite beams for instance. So-called profiled lightweight beams made of metal may also be used. These light¬ weight beams may include cut-outs/punch-outs with the intention of reducing the occurrence of cold bridges. When required, one or more additional beams (not shown) may be placed between the beams 14 and 15.

Naturally, the beams may be excluded when load condi¬ tions so permit.

It will also be understood that the insulation 12 can be varied in many ways, depending on the desired insulation properties of the roofing element, among other things.

It will also be understood that there is a wide scope within the actual inventive concept for variations with regard to the type of fasteners used and to the choice of materials for instance. It can be mentioned by way of example that the top sheet 10 and/or the bottom sheet 13 need not necessarily be made of metal but may conceivably be made of some other material, for instance they may be comprised of plastic laminates. The top sheet 10 and the bottom sheet 13 may also be integral with the insulation body 12. The beams prevent shear deformation of the insulating material and the sheets 10 and 13, and the beams may be glued and/or nailed/screwed to these sheets 10 and 13. If desired, all internal contact surfaces between the component parts of the roofing element may be glued.

The sheet 11 prevents load-initiated buckling of the top sheet 10. As before mentioned, the sheet 11 may be omitted when load conditions so permit. The top sheet 10 may also be provided with pattern-forming stiffening folds, either as an alternative or as a supplement to the stiffening sheet 11. If desired, a seal 75 ( see Figure 7) can be placed between the beams 14 and 15, alternatively between adjacent insu¬ lating bodies 12 when the roofing element does not include beams.

Naturally, the inventive roofing element can be pro- duced in any desired size, an example of a typical size being length 12m, width 1.2m and thickness 20 cm.

It will also be understood that the inventive roofing elements can be placed vertically if so desired, in which case the long sides of the roofing elements will extend in the direction of roof pitch.

The invention is therefore not restricted to the illustrated and described exemplifying embodiments thereof, since changes and modifications are conceiv¬ able within the scope of the following claims.

Claims

1. A roofing element which is particularly intended to be mounted on support beams/primary beams (100) which extend in the direction of the pitch of the roof, wherein the roofing element (1) includes a top side, a bottom side, a front long-side and a rear long-side, and wherein the front long-side forms a bottom long-side as seen in the direction of roof pitch and the rear long-side forms an upper long-side as seen in the direction of roof pitch, characterized in that the roofing element (1) further includes an outwardly projecting lip (21) on its front long-side edge (20) ; and in that said front lip (21) is located on the upper side of the roofing element.

2. A roofing element according to claim 1, characterized in that the roofing element (1) includes an outwardly projecting lip (31) on its rear long-side edge (30) ; and in that said rear lip (31) is located on the underside of the roofing element.

3. A roofing element according to claim 1 or 2, characterized in that the roofing element (1) includes a top sheet (10), a bottom sheet (13) and an insulating body (12) between said sheets.

4. A roofing element according to any one of claims 1-3, characterized in that the roofing element (1) includes a top stiffening sheet (11) which is located immediately beneath the top sheet (10) .

5. A roofing element according to any one of claims 1-4, characterized in that the roofing element (1) includes at least one beam (14,15); and in that the height measurement of the beam corresponds essentially to the height measurement of the roofing element.

6. A roofing element according to any one of claims 3-5, characterized in that the top sheet (10) includes a fold (23) which forms at least a part of the upper/front lip (21) ; and in that the bottom sheet (13) includes a fold (33) which forms at least a part of the lower/rear lip (31) .

7. A roofing element according to any one of claims 2-6, characterized in that the lower/rear lip (31) includes a section of a strip (16) or a bottom stiffening sheet (17) .

8. A roofing element according to any one of claims 4-7, characterized in that the top/front lip (21) includes a section (22) of the top stiffening sheet (11) .

9. A roofing element according to any one of claims 1-8 , characterized in that the upper side of the top/front lips (21) has a sloping transition part (24).

10. A method for mounting roofing elements according to any one of claims 1-9, said roofing elements (1) being particularly intended to be placed on primary beams/supporting beams (100) which extend in the direction (P) of the roof pitch, wherein the roofing elements include a top side, a bottom side, a front long-side and a rear long-side, and wherein the front long-side forms a bottom long-side as seen in the direction of roof pitch and the rear long-side forms a top long-side as seen in the direction of roof pitch, characterized by securing the rear long-sides of respective roofing elements with the aid of fasteners (60;61) such as screws or nails which extend through a bottom/rear lip (31) or through a rear part of a roofing element, such as a rear beam (15) for instance and into the primary beams/supporting beams (100); and by fastening the front long-sides of respective roof- ing elements with the aid of fasteners (60;62) , such as nails or screws, which extend through a top/front lip (21) and into a part of a roofing element (1) located therebelow as seen in the direction of roof pitch and overlapped by the top/front lip (21) .