WO1998037285A1

WO1998037285A1 - Roof module, building roof and methods for manufacturing and erection thereof

Info

Publication number: WO1998037285A1
Application number: PCT/SE1998/000249
Authority: WO
Inventors: Sten Engwall
Original assignee: Sten Engwall
Priority date: 1997-02-20
Filing date: 1998-02-12
Publication date: 1998-08-27
Also published as: SE9700601D0; AU6127298A; SE508578C2; SE9700601L

Abstract

The invention relates in a first aspect to a self-supporting roof module (1) for a building. In accordance with the invention, module (1) includes two continuous elements (10) that run in the cross direction of the roof. These extend along the entire width of the roof and along its contour in the cross direction. A layer of insulating material extends between the loadbearing elements (10). The invention also relates to a) a building roof built up of the invented modules, b) a method for manufacturing the roof module and c) a method for erecting a roof using such modules.

Description

ROOF MODULE, BUILDING ROOF AND METHODS FOR MANUFACTURING AND ERECTION THEREOF

The present invention relates in a first aspect to a roof module of the type set forth in the preamble to claim 1, in a second aspect to a roof-ridge module, in a second aspect to a building roof, in a fourth aspect to a method for manufacturing a roof module and in a fourth aspect to a method for erecting a building roof.

There is an urgent need to find ways to shorten and simplify the erection of roofs on buildings. Today, this is very time-consuming and is therefore relatively expensive. The disad- vantage is that it takes time for the roof to be fully finished, including the necessary insulation. Moreover, the building cannot be heated before insulation of the roof is completed without risk that, during winter, condensation will form on the inside of the roof.

There are several types of roof formulations such as saddle roofs, pent roofs, hipped roofs and so-called flat roofs. The aforesaid difficulties are encountered with all types of these roofs. A roof comprises a loadbearing structure such as roof trusses on which a roof-covering material is laid. The roof-covering can be made of wood on which, in turn, roofing tiles or metal roofing sheets are placed.

Insulation is laid between the roof trusses and beneath the roofing itself. The insulation, in turn, is covered with a suitable surface layer made of gypsum plasterboard, plywood, wood or the like.

In order to build a building roof in a more rational manner, it is previously known to make roof modules that can be connected together. See for example DE 40 25 639. These modules are flat and are not intended to cover the full width of the roof. Consequently, a troublesome jointing process is also required at the building site for this type of roof module. The purpose of the present invention is to eliminate the disadvantages associated with the erection of a building roof in accordance with conventional building techniques, thereby making possible significantly more rational and thus more economical construction of the roof part of the building.

In accordance with a first aspect of the invention, its purpose has been fulfilled by providing a self-supporting roof module of the type set forth in the preamble to claim 1 which includes the special characteristics set forth in the characterizing clause of this claim.

Due to the fact that the supporting element in the roof module extends along the entire width of the roof and the fact that the insulating material is supported by it, the module in its entirety can be placed on the already-erected walls where it comprises a complete section of the roof. This eliminates all need to erect roof trusses and then put the roof on them. Using these modules, the roof can be built extremely fast since, in principle, all that is needed is to lift the modules into place with a crane and then join the sections to each other. In the present application, the downward cross-direction of the roof is considered the extent of the roof that is perpendicular to the direction of the roof ridge, and said direction is thereby defined as the longitudinal direction. In accordance with this definition, the width of the roof is considered its dimension in the cross-direction. In accordance with a preferred embodiment of the roof module, the insulating material consists of cellular plastic, thereby making it possible to manufacture the module more rationally, especially if the cellular plastic is in the form of sheets.

Both of the loadbearing elements are preferably designed as U-beam sections oriented so that the web of the beam is vertical. A U-beam section has good loadbearing properties, and its flanges are well suited for joining to the insulating material.

In another preferred embodiment, one of the U-beam flanges protrudes into the insulating material while the other U-beam flange is located outside the surface of the insulating material. This provides a reliable joint with the insulating material and also prevents the U- beam, which is made of steel, from becoming a cold bridge. Alternatively, both of the U-beam flanges can protrude into the insulating material.

The module can be advantageously provided with external and/or internal cladding before being put in place on the building, and also with different types of elements intended for the building service systems such as electricity, air conditioning, fire alarms and antenna functions. This further reduces the time needed for construction. The module is well suited for prefabrication, and it thus comprises an important preferred aspect of the invention. Prefabrication makes possible rational industrial manufacturing of the modules and offers very substantial cost advantages.

The aforesaid and other preferred embodiments of the invented roof module are set forth in the claims that are dependent on claim 1. In a second aspect of the invention, its purpose has been fulfilled by providing a building roof made up of such modules in such a way that the advantages inherent in the invented modules are fully realized when the building is erected.

In a preferred embodiment of the roof, it is provided with longitudinal support rods that extend across several modules. These rods join the modules together and augment the loadbearing capacity of the roof in a simple, rational way.

Moreover, it is preferred that the loadbearing elements in the roof modules be designed so that they can support a load in direct tension carried by means of elements directed downwards from the roof. The structural advantages of the roof are utilized in this way to support and stabilize an intermediate floor slab in the building. In a third aspect, the purpose of the invention has been fulfilled by a method of manufacturing a roof module having insulating material in the form of cellular plastic sheets, wherewith a groove is made in the end-edges of the sheets, and the loadbearing elements are fitted into these grooves. Using this method, a roof module can be manufactured in a very short time.

Since factory-type production is possible using this method, it is a preferred embodiment of the invention. In a fourth and final aspect, the purpose of the invention has been fulfilled by having the invented method for erecting a building utilize the invented roof module, preferably in accordance with any of the preferred embodiments of said roof module.

The invention is explained in greater detail in the following detailed descriptions of its preferred embodiments which make reference to the attached drawings in which: Fig. 1 is a cross-section taken through a building having a roof that is in accordance with the invention.

Fig. 2 is a side view of the building shown in Fig. 1.

Fig. 3 is a perspective view of the building shown in Fig. 1.

Fig. 4 is a perspective view of a roof module that is in accordance with the invention. Fig. 5 is a section taken through a part of a roof module that is in accordance with the invention.

Fig. 6 is a section taken through a roof module that is in accordance with the invention.

Fig. 7 is a side view of a loadbearing element of a roof module that is in accordance with the invention. Fig. 8 is a perspective view of a part of the element shown in Fig. 7.

Fig. 9 is a section taken through a roof that is in accordance with an embodiment of the invention.

Fig. 10 is a section taken along line X-X in Fig. 9.

Fig. 11 is an end view of a roof module that is in accordance with the invention, shown during manufacturing.

Fig. 12 illustrates transportation of a roof module that is in accordance with the invention.

Figs. 13 and 14 illustrate, in cross-section, alternative embodiments of the invented roof module. Fig. 1 shows schematically a cross-section of a building, where roof module 1 appears in place on a building whose walls 2 and upper floor slab 3 are depicted in the figure. Roof module 1, as shown in the figure, has an angular design, i.e. it has a horizontal middle part 4 and a downward sloping part 5 on each side of the middle part. Roof ridge 6 is not a part of roof module 1. Instead, it comprises a separate unit that is placed above the middle part 4 of the roof module. The roof-ridge part can, as shown in Fig. 2, be made in one piece that extends throughout the entire length of the building. Fig. 2 also shows how the roof is made up of several of the invented roof modules 1 placed beside each other in the longitudinal direction of the roof.

Fig. 3 shows a perspective view of the roof in which one of modules 1 is covered with roofing tiles 7. Roofing tiles 7 or some other suitable roof-covering material can, in and of themselves, by laid in the conventional way, i.e. after the roof is in place. The invented module, however, makes it possible to lay the roof-covering material while roof module 1 is down on the ground before being lifted into place, thereby greatly simplifying the task of laying the roof. Alternatively, the modules can already have been provided with roof-covering material when delivered from the factory. Fig. 4 shows a perspective view of a part of two adjacent roof modules la, lb. Each roof module 1 consists of a number of cellular plastic sheets 8, 9 etc. placed between two loadbearing elements 10 that are designed as U-beams. The cellular plastic sheets 8 can thus, as illustrated in Fig. 4, be inserted between flanges 11 on U-beam 10, and in such case they will have the same thickness as the web of the U-beam. However, it is appropriate as shown in Fig. 5 to displace the sheets so that one flange

11a protrudes into cellular plastic sheet 8 while the other flange 1 lb lies somewhat outside. To accomplish this, a groove 12 is made in the end-edge of cellular plastic sheet 8, and flange 11a is inserted into said groove 12. This method prevents the U-beam from becoming a cold bridge. Each module is kept together by means of a number of tie-rods that are attached to the U-beams at both end-edges of the module. As shown by 15 in Fig. 5, the tie-rods can join the parts of the U-beams that lie outside cellular plastic sheets 8 or, alternatively, as shown by 14 they can extend through cellular plastic sheets 8. In the latter case, through-holes for the tie-rods are pre-drilled into the cellular plastic sheets.

As shown in Fig. 4, longitudinal support rods 16 can also be provided to pull together and hold together a number of roof modules in the finished roof. These can also run through pre-drilled holes in the cellular plastic material as shown in the illustration, or be located above or below it.

Fig. 6 shows a number of adjacent modules in cross-section where the U-beams, as shown in Fig. 5, are located partially on one side of cellular plastic sheets 9, in this case on the inside. The roof is clad on the outside with roofing tiles 7 and is provided on the inside with tie- rods 15, a layer of fire-retardant material 17, and gypsum plasterboard 18.

Fig. 7 shows one of the U-beams 10 that hold together each module and which comprise the loadbearing elements of roof. The U-beam follows the contour of roof 10 in cross-section, or more accurately the shape of the U-beam defines the roof contour. Each U-beam is made of relatively thin steel plate.

Fig. 8 shows in perspective a part of the U-beam, more particularly the part that is angled. As shown in the figure, the U-beam proportions provide a shallow and wide U-beam, i.e. web 13 is quite wide compared with the width of flanges 1 1. Since web 13 will be vertically oriented, this provides good loadbearing capacity.

At the place where the horizontal part of the U-beam and one of its downwardly sloping parts meet, it is joined together by means of a special jointing member 19 which is angled and has a cross-section that matches, in large part, that of the U-beam, i.e. it is designed so that it fits tightly onto the inside or outside of the U-beam. The jointing member is spot- welded to parts of the two U-beams.

Since a U-beam made of steel plate having the cross-section described above is preferable, it would seem evident that other suitable materials and other designs are possible for the loadbearing elements. Materials other than cellular plastic can, of course, be used as insulating material and in shapes other than sheets, even though the described embodiment is deemed preferable.

A roof made up of the described modules will be self-supporting and very stable. It is thus very suitable for use as a support which carries the floor slab located below it. Figs. 9 and 10 show how this can be realized. Fig. 9 is a cross-section taken through the upper part of a building having a roof that is in accordance with the invention. The cross section is taken precisely at the joint between two roof modules. Sheets 20 which extend from the roof are made of plywood, for example, and they extend down to intermediate floor slab 3, said sheets being anchored at both top and bottom. The plywood sheets stabilize intermediate floor slab 3 and can absorb a load in direct tension when the floor slab is loaded, and the self-supporting roof is strong enough to absorb said direct tensional load. This solution stabilizes intermediate floor slab 3, thereby reducing the elasticity of the floor without needing to rely on support from beneath by loadbearing partitions.

As shown in Fig. 10, plywood sheet 20 can extend up between two adjacent roof modules 1 and can be provided with a strip 21 that is supported by the respective upper flanges of the two adjacent U-beams 10. Other variants of anchorages for sheet 20 in the U-beams are conceivable. The figure also shows that sheet 20 is firmly anchored to floor slab 3 by means of, for example, screws 22.

The invented roof modules can be prefabricated advantageously at a factory, and each of the modules can thereby be easily turned in different directions while being handled (see Fig.

11 ) and supplemented if so desired with surface coatings and equipment for service systems.

Since the weight of a module is as low as 150 kg, it can be handled by as few as two persons. A minimum of manufacturing equipment is required and the manufacturing time is very short. In- factory prefabrication of the module is thus easy to implement in premises located close to the market. Several modules can be easily transported on a truck and trailer rig (see Fig. 12). The module can, of course, have a cross-sectional shape that deviates from what is shown in Fig. 1, as exemplified in Figs. 13 and 14.

Claims

1. Self-supporting roof module ( 1 ) for use in the roof of a building, said roof having a longitudinal direction and a cross direction, wherewith the roof has a cross-sectional contour that includes parts which form angles with each other, characterized in that the module (1) includes a) at least two continuous loadbearing elements (10) that run in the cross direction of the roof, extend along the entire width of the roof and extend along its cross-sectional contour thus forming parts that are angled with regard to each other and conform with the cross- sectional contour and b) a layer of insulating material (8) joined to the loadbearing elements (10).

2. Roof module in accordance with claim 1 for which the insulating material comprises cellular plastic sheets.

3. Roof module in accordance with claim 1 or 2 for which each module in the longitudinal direction of the roof is limited by two end-edges, wherewith loadbearing elements are arranged at each end-edge of the roof module and comprise U-beams (10).

4. Roof module in accordance with claim 3, for which the web (13) of each U-beam is arranged at right angles to the plane of the roof, and one flange (1 1 a) of each U-beam protrudes into insulating material (8) at a distance from one surface of the layer while the other flange (1 lb) is located outside the other surface of the layer.

5. Roof module in accordance with claim 3 for which the web (13) of each U-beam is arranged at right angles to the plane of the roof and the flanges of each U-beam protrude into insulating material (8) at a distance from the surfaces of the layer.

6. Roof module in accordance with claims 1 -5 for which continuous tie-rods (14, 15) that run in the longitudinal direction join said bearing elements (10) to each other.

7. Roof module in accordance with any of claims 1-6 for which the inside of roof module (1) is provided with a layer of fire-retardant material (17) and/or gypsum plasterboard (18) and has its outside clad with roof-covering material (7).

8. Roof module in accordance with any of claims 1-7 provided with elements intended for building service systems such as electricity, air conditioning, fire alarms and antenna functions.

9. Roof module in accordance with claims 1-8 for which roof module (1) has, in a vertical cross section, a central horizontal part (4) and, on each side of it, downward sloping parts (5).

10. Roof module in accordance with any of claims 1-9 made as a prefabricated unit.

11. Building roof characterized in that it is built up of roof modules ( 1 ) in accordance with any of claims 1-10.

12. Building roof in accordance with claim 11 for which the roof includes continuous support rods (16) that run in the longitudinal direction and extend across several modules (1).

13. Building roof in accordance with any of claims 1 1-12 for which said loadbearing elements (10) are provided with devices (21) that can be used to make joints with downwardly directed building elements (20) which carry a load in direct tension and are arranged to at least partially support an intermediate floor slab (3) in the building.

14. Method for manufacturing a roof module of the type set forth in any of claims 1-10 characterized in that the insulating material is supplied in the form of sheets, and in that a groove is made in each of the edges of the sheets that will form the end-edges of the module, and in that a loadbearing element is inserted into each groove, said loadbearing element having a shape that extends along the cross-sectional contour of the module thus forming parts that are angled with regard to each other.

15. Method in accordance with claim 14 for which manufacturing takes place in a factory.

16. Method for erecting a building roof characterized in that the roof is erected of roof modules in accordance with any of claims 1-10.