WO2015039666A1

WO2015039666A1 - Method for establishing a valley gutter and a valley gutter

Info

Publication number: WO2015039666A1
Application number: PCT/DK2014/050287
Authority: WO
Inventors: Jan Skovbjerg
Original assignee: Bygtjek A/S
Priority date: 2013-09-17
Filing date: 2014-09-17
Publication date: 2015-03-26
Also published as: DK178993B1; DK201670221A1

Abstract

The present invention concerns a method for establishing a valley gutter, wherein the valley gutter is of the kind used for draining water from roof and roofing underlay in roof constructions, typically between two roof surfaces, where the valley gutter at least one side at least includes and is made with a plate-shaped fixed base, and where on the fixed plate-shaped base there is arranged a first layer of a continuous water-tight web material. The invention further concerns a valley gutter for performing the method mentioned above. The new feature of a valley gutter according to the invention is that it includes that a second layer, namely a wearing layer, e.g. a metallic layer, is arranged upon the first layer, and where the second layer has substantially the same length as the first layer, and that the first as well as the second layer are laid from a rolled-up state and along the fixed plate-shaped layer.

Description

Method for establishing a valley gutter and a valley gutter Field of the Invention

The present invention concerns a method for establishing a valley gutter, wherein the valley gutter is of the kind used for draining water from roof and roofing underlay in roof constructions, typically between two roof surfaces, where the valley gutter at at least one side at least includes and is made with a plate-shaped fixed base, and where on the fixed plate-shaped base there is arranged a first layer of a continuous watertight web material with a first width and a first length, wherein the method includes at least the following steps:

- a second layer, namely a wearing layer, e.g. a metallic layer, is arranged upon the first layer, and where the second layer has substantially the same length as the first layer;

the first as well as the second layer are laid from rolled-up condition and along the fixed plate-shaped base;

- the first layer and the second layer are joined before laying; and the roofing underlay of the roof construction is joined with the first layer on projecting flanges, the flanges formed by the first layer being wider than the second layer and thus extending along the valley gutter;

fixing of the first layer to the fixed plate-shaped base is effected by mechanical fixation, e.g. by nails or staples, in projecting flanges along the roofing underlay,

The invention furthermore concerns a valley gutter for performing a method as indicated above, wherein the valley gutter is of the kind used for draining water from roof and roofing underlay in roof constructions, typically between two roof surfaces, where the valley gutter at at least one side at least includes and is made with a plate- shaped fixed base and a first layer of a continuous watertight web material with a first width and a first length, the valley gutter further including at least one second layer with a second width and second length, where the two layers are substantially coextensive in longitudinal direction, and where the width of the first layer is greater than the width of the second layer, and where the second layer is also a watertight web material. Description of Prior Art

It is commonly known that in different areas of the construction industry, and especially in connection with roof constructions, flashings of various kinds are applied. For example, it is known with flashings between a roof surface and a wall or a chimney and between two adjacent roof surfaces. Such a flashing is often termed "a valley gutter". In the following, the term "valley gutter" will be used about a flashing that can be between two roof surfaces but also about a flashing between a roof surface and a wall or similar, where the purpose of one or the other type of flashing is to prevent water from penetrating into the underlying structure.

In connection with increasing demands for insulation and tightness of building constructions, there are also heavier demands on as to how the various flashings are made between different building components, e.g. in the roof construction. Some types of roof coverings are mounted with a so-called roofing underlay the purpose of which being to prevent possible rain or drift snow that may enter under the roof covering from penetrating into the roof construction and/or the insulation material. In recent years, a number of different roofing underlay products and constructional solutions have been applied. Particularly the use of web products, i.e. materials on rolls with a suitable width have found their way to the European market. Mounting of these web products is done as a main rule along the common rafters, where the roofing underlay is fixed to the common rafters with a clamping strip also mounted along the rafters. The transverse roof battens are mounted upon these clamping strips, and finally the roof covering itself which is fixed to the battens in various ways.

In order to ensure that possible water on the roofing underlay and water on the roof surface are conducted to the base of the roof in a suitable way, there are several ways of establishing a valley gutter, though particularly one method is frequently used and which is recommended by various authorities. The said method is called "a depressed valley gutter" and is a solution where a fixed plate-shaped valley gutter bottom is provided at level with the top side of the rafters in longitudinal direction of the valley gutter. This is typically provided for by a cutout in the rafters or by adapting the valley gutter bottom between the rafters. Both of these methods are somewhat demanding but have the obvious advantage that it is allowable to continue the roofing underlay right out to the valley gutter, without any difference in level, where a glue joint is made between roofing underlay and the valley gutter/flashing. A second embodiment is, for that matter, a more traditional solution used for many years, and this solution is apparently still preferred among many of the construction workers performing the task. Like the first solution, this solution also consists of a fixed base of either plywood or a wide board. However, the difference is that the fixed base is mounted upon the rafters in longitudinal direction of the valley gutter. Along the external edge of this board is usually mounted a roof batten, and the roofing underlay is passed in over this construction and fixed along the batten with clamping strips.

By both types of valley gutter constructions, upon the fixed base there are mounted a web of roofing underlay, tarboard or similar, and outermost finally the actual flashing profile.

The outermost part of a valley gutter in contact with the weather, namely the "valley gutter tinplate", is typically made of aluminium or zinc or other suitable material. The prior art types of "valley gutter tinplate" is typically made of pieces with a length of one metre, why naturally there will always be a lot of transverse joints along a valley gutter with associated risk of ingression of water. Under the outermost part, the valley gutter tinplate, is therefore normally provided a continuous web from the base of the roof to the roof ridge and of the same material as the roofing underlay or of a bitumen- based roofing felt material, as mentioned above. The reason for using this layer is to ensure that if water should penetrate in under the outermost part, the valley gutter tinplate, it can be drained off upon this underlying layer.

Irrespective of the prior art solutions that are applied, the valley gutter is made up of several layers/parts, and the outermost part of the valley gutter itself is assembled in longitudinal direction and fixed with nails or screws to the fixed base. These nails or screws cannot be mounted without penetrating the underlying web, thereby increasing the risk of unwanted water penetrating into the roof construction itself. If water penetrates into the roof construction itself, water damage can occur and in the long run the woodwork will rot, but what is more serious is the risk of formation of mould fungus which is a direct health hazard to people using the building. Object of the Invention

It is the object of the invention to indicate a valley gutter and a method for establishing a valley gutter by which is achieved a rapid and easy mounting, and where at the same time is achieved a safe construction with a very limited risk of inadvertent ingression of water in the construction. At the same time, it is an object to indicate a solution where no joining has to be performed in longitudinal direction of the valley gutter.

Description of the Invention

The invention concerns, as mentioned in the introduction, a method for establishing a valley gutter, wherein the valley gutter is of the kind used for draining water from roof and roofing underlay in roof constructions, typically between two roof surfaces, where the valley gutter at at least one side at least includes and is made with a plate-shaped fixed base, and where on the fixed plate-shaped base there is arranged a first layer of a continuous water-tight web material with a first width and a first length.

The new feature of a valley gutter according to the invention is that the method at least includes the following steps:

a second layer, namely a wearing layer, e.g. a metallic layer, is arranged upon the first layer, and where the second layer has substantially the same length as the first layer;

the first as well as the second layer are laid from rolled-up condition and along the fixed plate-shaped base.

By a method according to the invention, a valley gutter can thus be built up with a traditional fixed plate-shaped base, and the other layers, namely a longitudinal watertight layer and a wearing layer possibly of metal, can subsequently be rolled out and secured on the fixed base. Hereby is achieved the obvious advantage that the valley gutter can be established with long lengths and in far the most cases in one long length without transverse joints as hitherto known. The first layer may advantageously be constituted by bitumen-based cardboard known from the roofing industry, and the wearing layer may advantageously be made of aluminium or of other suitable metal alloy.

In a variant of a method for establishing a valley gutter according to the invention, the method can include:

that the first layer and the second layer are laid at one and the same time from a rolled-up condition as respective layers are joined before laying.

By joining the first and the second layer before mounting on the fixed base, this operation can be performed in well-ordered and controllable conditions in suitable production facilities. The mentioned web materials, i.e. the first as well as the second layer, can therefore be joined from e.g. each their roll and subsequently rolled up in measured standard lengths or in lengths with special dimensions. When the web materials have been joined and rolled up, they can advantageously be packed in a suitable packing, e.g. in a cardboard tube with carrying handles. A construction worker can therefore carry a rolled-up valley gutter up to a roof ridge and there unpack and unroll either individual or joined layers down along the fixed plate-shaped base. It is then necessary to fix the laid webs of material to the base. The valley gutter is thus established in a hitherto unseen rapid, simple and not the least much better way as there are no joints transversely to the wearing layer as it has been until now. These transverse joints are due to the fact that the wearing layer is bent from metal plates with a relatively short length of one or two metres. The wearing layer according to the invention can be made e.g. of aluminium with a suitable thickness which can readily be rolled up in a suitable diameter.

- the roofing underlay of the roof construction is joined with the first layer on projecting flanges, the flanges formed by the first layer being wider than the second layer and thus extending along the valley gutter. The mentioned projecting flanges can be with any width, but if they have a width of e.g. 15 cm there is achieved possibility of a good and secure joint between roofing underlay and the first layer of valley gutter. When the valley gutter, or more accurately the part of the valley gutter consisting of the first layer with flanges and with the second layer, is rolled out, the task is only to fix it and to join the roofing underlay with the flanges and then mount the other parts in the roof construction.

By a method for establishing a valley gutter according to the invention, it is preferred that fixing of the first layer to the fixed plate-shaped base is effected by mechanical fixation, e.g. by nails or staples, in projecting flanges along the valley gutter.

By performing the fixing in these flanges, on the one hand it is ensured that the valley gutter is fixed and on the other hand that the fixing occurs in a material that can follow the movements of the constructions caused by temperature and due to wind action, etc. At the same time, the fixations of the roofing underlay are covered when disposed over the flanges. The risk of ingress of water is hereby reduced the most.

By a method for establishing a valley gutter according to the invention it is preferred that that the roofing underlay is fixed to the part of the first layer on the side of the valley gutter facing away from the fixed plane base, and where the first layer is wider than the second layer and is self-adhering.

By performing the fixing of the roofing underlay directly to the valley gutter by using the self-adhesive means of the valley gutter, a lot of time and work with mounting the valley gutter is saved as the construction workers do not need to remember additional materials such as tape, tarboard nails or similar, and tools such as hammer, pincers, scissors or similar are unnecessary for fastening the roofing underlay as well.

As mentioned in the introduction, the invention also concerns a valley gutter for performing a method as described above, wherein the valley gutter is of the kind used for draining water from roof and roofing underlay in roof constructions, typically between two roof surfaces, where the valley gutter at at least one side at least includes and is made with a plate-shaped fixed base and a first layer of a continuous watertight web material with a first width and a first length, the valley gutter further including at least one second layer with a second width and second length, where the two layers are substantially coextensive in longitudinal direction, and where the width of the first layer is greater than the width of the second layer, and where the second layer is also a watertight web material.

The new feature of a valley gutter according to the invention is that the valley gutter further includes that the second layer furthermore constitutes a wearing layer of metal and/or plastic, that the first layer at the side facing the fixed plane base includes an adhesive, and that the part of the first layer facing the side facing away from the fixed plane base and being wider than the second layer is self-adhering.

The two layers thus follow each other and there are no joints transversely of the valley gutter and thereby no risk also of water ingression. The roofing underlay can be fixed to the part of the first layer at the side facing away from the fixed plane base and which is wider than the second layer and self-adhering, and in addition a bird screen can be fitted on this self-adhering flange.

By a bird screen is meant e.g. a reliable strip upon which is provided one or more rows or mutually offset needle- or awl-shaped points that are long enough to extend from the mounting site on the valley gutter and up to the lower edge of the roof covering, which may be constituted by tiles, concrete, steel, asbestos cement or other form of roof covering. A valley gutter according to the invention can by certain types of roof covering also be used with bird screen without using a roofing underlay.

A valley gutter according to the invention may advantageously comprise that the first layer is joined by the second layer, e.g. via gluing, and where the first layer and the second layers are delivered as joined and rolled up and in a given length before mounting. Hereby is achieved possibility of mounting a valley gutter in one piece in a rapid and efficient way. If the first layer is a bitumen-based material this may advantageously be applied an adhesive at one side before joining with the valley gutter tinplate, namely the second layer which is covered by a protective film. In connection with joining the first and the second layer, the protective film is removed, and the second layer is simply mounted on the first layer and shortened to an appropriate length. However, it is also possible to apply a suitable adhesive on either one or the other of the two actual layers before they are joined. The function and operation of a valley gutter is not dependent on the joining between the two layer if only the joining is made in a suitable way.

A valley gutter according to the invention can advantageously be made such that the first layer is joined with the second layer, e.g. by gluing, and that the first layer has a width which is greater than the width of the second layer, where the first layer thus forms a projecting flange along and at least at one lateral side in relation to the second layer. Such a flange can be with a protective film and thereby be self-adhesive, whereby it becomes easy to secure the roofing underlay to the flanges/valley gutter. Such a protective film can be removed immediately before fixing the roofing underlay to the flange.

A valley gutter according to the invention may also include that the first layer on the side facing the fixed plane base includes an adhesive. The valley gutter is hereby fixed easily and accurately to the plane base on the rafter structure itself. This adhesive can be an adhesive corresponding to the adhesive as mentioned above and which is between the first and the second layer, though it can be a different type of adhesive as well. Moreover, it may be an adhesive covered by a protective film as mentioned above. However, it is also possible to apply the adhesive on the plane fixed base itself before mounting the valley gutter thereon.

In order to make the valley gutter according to the invention even more easy to mount, the valley gutter can be designed such that the second layer at the side facing away from the fixed plane base and away from the first layer includes a bending line in the form of an embossing or other kind of scoring of the bending line. By making such an embossing or scoring along the valley gutter tinplate, the former will act as a bending line, and when the valley gutter is rolled out, the scoring will ensure that the valley gutter is shaped according to the plane fixed base immediately at the unrolling thereof. Actually, it is so that if the first and the second layers are joined and an embossing or scoring along the second layer is performed, these layers will automatically be formed in relation to the fixed plane base as soon as they are rolled out. Such a scoring may in principle be a slight scoring made by a pointed object.

Production of a valley gutter according to the invention may advantageously be effected from a roll with the first layer and a roll with the second layer, where these layers are joined and subsequently rolled up as a finished and shortened valley gutter. During or in connection with joining of a first layer and a second layer, where both can advantageously be on each their roller prior to joining, such a scoring or embossing can easily be performed with a tool suited for the purpose during unrolling, between unrolling and rolling up, or immediately in connection with rolling up of the valley gutter. In case that the second layer - the valley gutter tinplate - is made of aluminium with a thickness between e.g. 0.5 and 1 mm, typically 0.6 mm, such an embossing/scoring only needs to be very modest, but the intended effect described above can occur.

A valley gutter according to the invention may also advantageously have the bending line include at least one beaded bend at the side of the second layer facing away from the fixed plane base as well as the first layer. As mentioned before, there is achieved the advantage of the embossing that the valley gutter is shaped according to the plane fixed base as soon as it is unrolled.

A valley gutter according to the invention may advantageously be a so-called double- sided valley gutter, that, is a valley gutter arranged/designed for application between two adjacently angled roof surfaces. This can e.g. be on a roof on an angularly built house or between a roof surface on the house itself and on an attic.

A valley gutter according to the invention may further have advantage of the second layer further including roof base embossings. The object of this is to mount this area of the valley gutter where the valley gutter bends up towards the gutter at the base of the roof, whereby are achieved the same advantages for this transition between the valley gutter and the base of the roof as achieved in other areas of application of the valley gutter, namely a rapid and easy mounting, and where at the same time is achieved a safe construction with a very limited risk of inadvertent ingression of water into the construction. At the same time it is an object to indicate a solution where no joining has to be performed in longitudinal direction of the valley gutter and therefore not for the part of the valley gutter hereby including the base of the roof either.

A valley gutter according to the invention may advantageously have the roof base embossings run in direction from the bending line of the second layer and towards the at least one side edge of the second layer. The embossings may advantageously be straight lines, an evident possibility for traditional building constructions, but if different conditions call for it the embossings can have a different shape as well.

In addition, a valley gutter according to the invention may advantageously have the roof base embossings provided with a spacing which is greater towards the at least one side edge of the second layer than the spacing towards the bending line of the second layer. As a valley gutter usually is mounted such that the cross-section of the valley gutter assumes a V-shape, and as the transition from the valley gutter to the base of the roof entails a bend in direction of the pointed end of the V-shape, the part of the valley gutter material located farthest from the point of the V-shape will be upset the most. The material can be more readily be pressed/upset by such roof base embossings and thereby "fit in place" without using several parts and joints in the material.

In principle, the invention concerns a valley gutter by the metre which can be mounted in one work operation and in full length. The valley gutter can include a support layer, - a first layer, typically of tarboard and additionally a top layer - a second layer of metal, e.g. of aluminium. The valley gutter can be delivered in rolled-up condition and is unrolled, typically from the roof ridge and down along the prepared base on the rafter structure, but may as well be mounted from the base of the roof and unrolled up along the plane fixed base, depending on the actual conditions in connection with the valley gutter in question. The valley gutter is fixed e.g. by nailing along the edge only provided with tarboard as the wearing layer/aluminium layer does not extend right out to the edge. Also, this edge can be made with adhesive such that the roofing underlay can be fixed directly to the edge of the valley gutter. At the ends of the valley gutter there may also be a given length of tarboard/support layer that can be mounted across the roof ridge and/or down to the gutter in order to ensure perfect tightness. Such an excessive length of the first layer can e.g. be 30 to 80 cm, but it can obviously be adapted according to need or even be ordered exactly to the desired dimensions.

A complete valley gutter according to the invention typically weighs less than 20 kg and may thus be handled without using advanced lifting tools, and first of all it is without joints and thereby without risk of leaks. It is also more rapid to mount than the current ones which are built up of several parts in longitudinal direction.

Short Description of the Drawing

The invention is described in more detail with reference to the drawing, wherein: Fig. 1 shows parts of a roof construction with a valley gutter.

Fig. 2 shows a cross-section of a roof construction with a valley gutter.

Fig. 3 shows a rolled-up valley gutter including a first and a second layer.

Fig. 4 shows a valley gutter including roof base embossings.

Fig. 5 shows an example of the final mounting of a valley gutter at the base of the roof.

List of designations

1 roof construction

2 roof tiles

3 batten

4 clamping strip

5 roofing underlay

6 valley gutter

7 plane fixed base

8 a first layer

9 a second layer

10 self-adhering flange

11 package

12 embossing, bending line, beaded bend 13 roof base embossing

14 valley gutter corner

In the explanation of the Figures, identical or corresponding elements will be provided with the same designations in different Figures. Therefore, no explanation of all details will be given in connection with each single Figure/embodiment.

Detailed Description of Embodiments of the Invention

In Fig. 1 is seen a roof construction 1 - partially open - for a clearer view of specific details. Here appears a roof covering of tiles 2 arranged on battens 3. The battens 3 are mounted upon clamping strips 4 that fix the roofing underlay 5 to not shown common rafters. At the centre of Fig. 1 is seen the valley gutter 6 which is here built up with a plane fixed base 7 disposed in level with the roofing underlay 5, and thus is part of the so-called depressed valley gutter 6. Upon the plane fixed base 7 there is arranged a first layer 8, here in the form of a bituminous product, and upon the latter a second layer 9, here in the form of an elongated aluminium plate with a thickness of 0.6 mm. At the centre of the elongated aluminium plate 9 appears a marking corresponding to where the plate 9 is bent. As seen on Fig. 1, the first layer 8 is wider than the second layer 9, and thus a self-adhering flange 10 extend at either side of the second layer 9 between the not shown roof ridge and roof base. The roofing underlay can be fixed to this flange and in the shown embodiment the roofing underlay extend further in over the second layer 9 itself.

At the area where the first layer 8 is wider than the second layer 9, a bird screen can also be mounted on the part of the self-adhering flange 10 at the area where the roofing underlay is not or does not need to be fastened.

Fig. 2 shows a second view, namely a cross-sectional view of a valley gutter 6 according to the invention. Here, the details shown in Fig. 1 appear as well.

Fig. 3 shows a package 11 consisting of a first layer 8 of tarboard and a second layer 9 of aluminium which together with a plane and fixed base 7 constitute a valley gutter 6. At the centre and longitudinally of the second layer 9 is seen a broken line 12 which here indicates an embossing/scoring that causes the valley gutter to adapt itself, so to say, from the plane condition shown here to an angular shape corresponding to the plane fixed base 7, as shown in Figs. 1 and 2. The package 11 is delivered rolled-up and ready to be transported to e.g. the roof ridge for unrolling on a plane fixed base 7 as shown in Figs. 1 and 2.

Fig. 4 shows a valley gutter 6 including roof base embossings 13 made with the object of mounting and adapting this area of the valley gutter 6 at the point where the valley gutter 6 bends up towards the gutter.

The broken line 12 on Fig. 3 is shown on Fig. 4 as an embossing 12 where the embossing 12 is made as a beaded bend 12 at least at the side of the second layer 9 facing away from the fixed plane base 7 (not shown on this Figure) as well as from the first layer 8. It is possible to make a beaded bend 12 at both sides of the second layer 9, an option making the valley gutter 6 more flexible.

Fig. 5 shows an example of final mounting of a valley gutter 6 at the base of the roof, and where the valley gutter 6 is further terminated by a valley gutter corner 14. The Figure has the object of showing the approximate distance from the end of the valley gutter 6 to the base of the roof and thereby the roof base embossings 13.

Claims

1. A method for establishing a valley gutter, wherein the valley gutter is of the kind used for draining water from roof and roofing underlay in roof constructions, typically between two roof surfaces, where the valley gutter at at least one side at least includes and is made with a plate-shaped fixed base, and where on the fixed plate- shaped base there is arranged a first layer of a continuous water-tight web material with a first width and a first length, wherein the method includes at least the following steps:

- the first layer and the second layer are joined before laying;

the roofing underlay of the roof construction is joined with the first layer on projecting flanges, the flanges formed by the first layer being wider than the second layer and thus extending along the valley gutter;

fixing of the first layer to the fixed plate-shaped base is effected by mechanical fixation, e.g. by nails or staples, in projecting flanges along the valley gutter,

characterised in

that the roofing underlay is fixed to the part of the first layer on the side of the valley gutter facing away from the fixed plane base, and where the first layer is wider than the second layer and is self-adhering.

2. A valley gutter for performing a method according to claim 1, wherein the valley gutter is of the kind used for draining water from roof and roofing underlay in roof constructions, typically between two roof surfaces, where the valley gutter at at least one side at least includes and is made with a plate-shaped fixed base and a first layer of a continuous watertight web material with a first width and a first length, the valley gutter further including at least one second layer with a second width and second length, where the two layers are substantially coextensive in longitudinal direction, and where the width of the first layer is greater than the width of the second layer, and where the second layer is also a watertight web material, characterised in that the second layer furthermore constitutes a wearing layer of metal and/or plastic, that the first layer at the side facing the fixed plane base includes an adhesive, and that the part of the first layer facing the side facing away from the fixed plane base and being wider than the second layer is self-adhering.

3. A valley gutter according to claim 2, characterised in that the first layer is joined by the second layer, e.g. via gluing, and where the first layer and the second layers are delivered as joined and rolled up and in a given length before mounting.

4. A valley gutter according to any of claims 2 and 3, characterised in that the first layer is joined with the second layer, e.g. by gluing, and that the first layer has a width which is greater than the width of the second layer, where the first layer thus forms a projecting flange along and at least at one lateral side in relation to the second layer.

5. A valley gutter according to any of claims 2 to 4, characterised in that the second layer at the side facing away from the fixed plane base and away from the first layer includes a bending line in the form of an embossing or other kind of scoring of the bending line.

6. A valley gutter according to claim 5, characterised in than the bending line includes at least one beaded bend at the side of the second layer facing away from the fixed plane base as well as the first layer.

7. A valley gutter according to any of claims 2 to 6, characterised in that the valley gutter is double-sided.

8. A valley gutter according to any of claims 2 to 7, characterised in that the second layer furthermore includes roof base embossings.

9. A valley gutter according to claim 8, characterised in that the roof base embossings run in direction from the bending line of the second layer and towards the at least one side edge of the second layer.

10. A valley gutter according to any of claims 8 to 9, characterised in that the roof base embossings have a spacing which is greater towards the at least one side edge of the second layer than the spacing towards the bending line of the second layer.