U.S. patent application number 11/023005 was filed with the patent office on 2005-05-19 for modular green roof system, apparatus and methods, including pre-seeded modular panels.
Invention is credited to Mischo, Donald J..
Application Number | 20050102921 11/023005 |
Document ID | / |
Family ID | 27396599 |
Filed Date | 2005-05-19 |
United States Patent
Application |
20050102921 |
Kind Code |
A1 |
Mischo, Donald J. |
May 19, 2005 |
Modular green roof system, apparatus and methods, including
pre-seeded modular panels
Abstract
A modular green roof system includes modular panels (10)
providing a surrounded space suitable for supporting live plant
growth and adapted for installing onto a roof deck in side-by-side
positioning while allowing water flow on the roof thereunder. The
panels are filled with growing medium and pre-seeded prior to
delivery to the roof site, and delivered in either a preserved
condition or a germinated condition. The panels are adapted for
interconnecting to adjacent panels, and for connection to an edge
finishing/edge termination system (46) and support structure to
enable provision of non-panel areas of the green roof, and
above-panel structures.
Inventors: |
Mischo, Donald J.;
(Janesville, WI) |
Correspondence
Address: |
KEITH FRANTZ
401 WEST STATE STREET
SUITE 200
ROCKFORD
IL
61101
|
Family ID: |
27396599 |
Appl. No.: |
11/023005 |
Filed: |
December 27, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11023005 |
Dec 27, 2004 |
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09908881 |
Jul 18, 2001 |
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6862842 |
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60218889 |
Jul 18, 2000 |
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60219063 |
Jul 18, 2000 |
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60219457 |
Jul 18, 2000 |
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Current U.S.
Class: |
52/79.1 |
Current CPC
Class: |
A01G 9/033 20180201 |
Class at
Publication: |
052/079.1 |
International
Class: |
E04H 001/00; E04H
003/00; E04H 005/00; E04H 006/00 |
Claims
1. A method of constructing a modular green roof system comprising
the steps of: (A) providing (i) a plurality of panels each having a
bottom and sides extending upwardly therefrom to define a
surrounded space for receiving green roof materials, the bottom of
the panels being formed with drain holes and being shaped to permit
water to flow thereunder, and (ii) a plurality of covers each
having a top and sides extending downwardly therefrom, (B) planting
growable green roof materials in the panels; (C) germinating the
green roof materials in the panels; (D) positioning said covers
onto said panels over the germinated green roof materials; (E)
stacking and connecting first ones of said panels onto the covers
positioned on second ones of said panels in a manner to prevent
sliding therebetween; (F) delivering the planted, stacked, panels
to a roof site; and (G) positioning the panels onto the roof; (H)
preserving the planted, germinated panels in a non-growing
condition prior to said delivering step.
2. The method of claim 1 further comprising the step of preserving
the planted, germinated panels in one of a dried condition and a
frozen condition prior to said delivering step.
3. A method of constructing a modular green roof system comprising
the steps of: (A) providing a plurality of panels each having a
bottom and sides extending upwardly therefrom to define a
surrounded space for receiving green roof materials, the bottom of
the panels being formed with drain holes and being shaped to permit
water to flow thereunder, (B) planting growable green roof
materials in the panels, (C) preserving the green roof materials in
the panels in a non-growing condition in one of a dehydrated state
and a frozen state, (D) delivering the filled panels to a roof
site, and (E) positioning the panels onto the roof.
4. The method of claim 3 in which said preserving step includes
sealing the green roof materials in the panels.
5. The method of claim 3 further comprising the step of germinating
the growable green roof materials in the panels prior to said
preserving step.
6. The method of claim 3 further comprising the step of connecting
the panels on the roof to one of (i) adjacent panels, (ii)
intermediate members, and (iii) edge termination members.
7. The method as defined in claim 3 further comprises the steps of
(F) providing a plurality of connectors, (G) positioning the
connectors to the tops of said panels in a manner to prevent
sliding therebetween, and (H) stacking first ones of said panels
onto the connectors positioned on second ones of said panels in a
manner to prevent sliding therebetween.
8. The method as defined in claim 7 in which said connectors are
provided with horizontal perimeter portions adapted to support the
bottoms of said second ones of said panels.
9. The method as defined in claim 8 in which said horizontal
perimeter portions are provided in a form including a generally
planer horizontal plate adapted to support the bottoms of said
second ones of said panels.
10. A method of constructing a modular green roof system comprising
the steps of: (A) providing (i) a plurality of panels each having a
bottom and sides extending upwardly therefrom to define a
surrounded space for receiving green roof materials, the bottom of
the panels being formed with drain holes and being shaped to permit
water to flow thereunder, and (ii) a plurality of drip irrigation
lines, (B) filling the panels with growing medium suitable to
support growable green roof materials in the panels, (C)
positioning the drip irrigation lines in the panels on the growing
medium, (D) delivering the filled panels with the drip irrigation
lines to a roof site, (E) positioning the panels onto the roof in
side-by-side relation, and (F) connecting the drip irrigation lines
of proximate panels together.
11. A method of constructing a modular green roof system comprising
the steps of: (A) providing a plurality of panels pre-planted with
green roof materials, (B) positioning said panels in side by side
relation in a bounded area on the roof to establish a bounded
modular green roof area on the roof, and (C) establishing a bounded
non-modular green roof area on the roof, the modular and
non-modular green roof areas having at least one common boundary,
and
12. The method of claim 11 further comprising the step of (D)
providing an edge transition system at said common boundary between
said modular and non-modular green roof areas.
13. The method of claim 12 in which said edge transition system
comprises elongated edge termination members (i) connected to the
panels at said common boundary and extending therefrom to proximate
the roof, and (ii) providing lateral support for said non-modular
area along said common boundary.
14. The method of claim 11 further comprising the step of (D)
interconnecting adjacent panels to one another after said
positioning step.
15. A method of constructing a modular multi-level green roof
system comprising the steps of: (A) providing first and second
plurality of panels pre-planted with green roof materials, (B)
positioning said first plurality of pre-planted panels in side by
side relation to establish a first modular green roof area at a
first height, (C) positioning said second plurality of pre-planted
panels in side by side relation to establish a second modular green
roof area at a second height.
16. The method of claim 15 in which each of said first plurality of
panels includes a bottom resting on the roof and sides extending
upwardly therefrom to said first height, and each of said second
plurality of panels includes a bottom resting on the roof and sides
extending upwardly therefrom to said second height.
17. The method of claim 15 in which said first and second modular
green roof areas having at least one common boundary, said method
further comprising the steps of (D) providing an edge transition
system at said common boundary between said first and second
modular green roof areas.
18. The method of claim 17 in which said edge transition system
comprises an elongated edge termination member extending between
said first and second heights between the edges of adjacent panels
at said common boundary.
19. The method of claim 18 in which said edge transition system
comprises an elongated edge termination member extending from the
taller of said first and second heights to proximate the roof.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a divisional of and claims the filing
date benefit of U.S. patent application Ser. No. 09/908,881, filed
Jul. 18, 2001, which application claims the benefit of U.S.
Provisional Patent Applications Ser. No. 60/218,889 filed Jul. 18,
2000, Ser. No. 60/219,063 filed Jul. 18, 2000, and Ser. No.
60/219,457 filed Jul. 18, 2000.
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT
DISC
[0002] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of Invention
[0005] The present invention relates generally to green roof
systems, also known as roof landscaping systems and roof gardens,
that are suitable for supporting live plant growth on building
roofs.
[0006] More particularly, the invention relates to modular green
roof systems, and methods and apparatus for use therewith.
[0007] 2. Background Art
[0008] Briefly, prior green roof systems typically comprise several
layers of materials suitable to support vegetation on a roof. These
layers are typically supplied in bulk or earthen rolls that are
rolled into position on the roof.
[0009] Common types of vegetation used in green roof systems
include herbs, grasses, mosses, wild plants and flowers, and other
types of perennials.
[0010] A typical prior green roof system includes at least (i) a
waterproofing membrane laid over the roof or roof supporting
structure, (ii) based on the roof grade, a layer over the
waterproofing membrane of one of: (a) a drainage layer and an
overlaying blanket of root growth protection material (for a grade
of approximately 2 to 5 degrees), (b) a root growth protective
fleece (for a grade of approximately 6 to 10 degrees), and (c) a
substrate fixing or erosion control blanket including root growth
protection (for a grade of approximately 10 to 20 degrees); (iii) a
layer of mineral wool or other substrate for water retention, and
(iv) a top layer of vegetation growing in a fiber fleece or other
suitable growing medium.
[0011] Other green roof designs include additional layers of
various materials for various roof protection and vegetation growth
support purposes.
[0012] It is believed that prior green roof systems of the above
general type were first used in Europe approximately 20 years ago.
Since that time, use of similar and derivative green roof systems
has become common in many parts of Europe on commercial,
institutional, industrial, and residential buildings, and interest
in green roof systems is growing in the United States.
[0013] The advantages typically attributed to green roof systems
include extending the roof service life; reducing heating and
cooling energy costs; conserving and utilizing valuable commercial
space; reducing runoff from roof surfaces; and increasing property
values.
[0014] However, inspection of such prior systems also reveal the
following disadvantages:
[0015] the prior systems are relatively expensive and are difficult
to install, typically requiring the need for and assistance of a
specially trained consultant;
[0016] the systems are not designed to be installed over an
existing functional roof without the necessity of reroofing;
[0017] thus, a complete new waterproofing membrane must typically
be installed before the green roof system can be used on existing
buildings, resulting in additional costs;
[0018] since the green roof materials are delivered in bulk or
earthen rolls, design freedom is limited, alternating designs of
plants are not easily incorporated in the design of the green
roof;
[0019] terracing or variations of surfaces are also not easily
accomplished; and changing of the design layout after installation
requires removal and destruction of the effected area and
replanting with the new design;
[0020] selection of pre-growing plants in the upper fiber fleece is
typically limited to low-growing plants, mosses, etc., since the
fleece is supplied to the roof in rolls;
[0021] selection of pre-grown plants available is further typically
limited because: the need to maintain the plants in the growing
state prior to shipment results in additional costs; the demand
must be estimated in advance of the installation season in order to
have the pre-grown plants ready; and such estimates are typically
conservative in order to prevent overstocking and spoilage if not
used during that season; and
[0022] maintenance and repair to the roof is difficult and
expensive; if a leak develops in the roof membrane, or if other
maintenance or repair is required, the entire green roof, or at
least large portions of the green roof, must be removed to locate
and repair the leak or accomplish the desired maintenance; the
removed green roof must then be replaced and replanted.
[0023] Thus, it is clear there is a need for new and improved green
roof systems which:
[0024] are less expensive and more easily installed than prior
green roof systems;
[0025] can be installed over existing roofing materials on existing
buildings, thus eliminating the need and associated cost to install
completely new roofing membranes or systems prior to installation
of the green roof;
[0026] provide for substantially enhanced design flexibility and
freedom, including;
[0027] the ability to change the design layout of the green roof
after initial installation, and
[0028] the ability to be used either as a standalone system, or in
combination with prior green roof systems
[0029] as an original green roof layout and design including both
prior systems and systems in accordance with the present invention,
and
[0030] to enable repair of a prior green roof such as when a
portion of the prior green roof has been removed for repairs of the
building roof deck, to eliminate the current need to re-install the
entire prior green roof systems after such removals or repairs;
and
[0031] permit ease of access to desired portions of the roof for
maintenance and repair without the need to destroy and then replace
large portions of the green roof.
SUMMARY OF THE INVENTION
[0032] The general aim of the present invention is to provide new
and improved green roof systems, and methods and apparatus
therefore--to address the above-identified disadvantages of prior
green roof systems and achieve the advantages and benefits flowing
from addressing the above-identified needs thereof.
[0033] More particularly, it is an objective of the invention to
provide a modular green roof system comprising pre-seeded modular
panels having a surrounded space suitable for supporting live plant
growth and adapted for installing onto an existing roof deck in
side-by-side positioning while allowing water flow on the roof
thereunder.
[0034] The panels are filled with growing medium and pre-seeded
prior to delivery to the roof site, and delivered in either a
preserved condition or a germinated condition, and are adapted for
packaging, shipping and delivery in either condition. In preferred
embodiments, the panels are also provided with a watering system to
assist in supporting the growing plants therein.
[0035] The panels are further adapted for, and associated apparatus
and methods are provided for, interconnecting to adjacent panels,
connection to an edge finishing/edge termination system and a
support structure, and lifting and positioning into place on the
roof, or removing from the roof, without disturbing adjacent
panels.
[0036] Consequently, the pre-seeded modular panels of the invention
are more easily installed than prior green roof systems. The
pre-seeded modular panels enhance design-layout flexibility by
enabling provision of a greater selection of growing and
non-growing materials for the green roof system without concern for
spoilage, enabling the growing materials to include those requiring
greater soil depth than is available in prior green roof systems,
and enabling the panels to be rearranged after installed. These
aspects allow the designer or architect to select a broad variety
of various colored or height plants to be incorporated within the
system. In addition, the panels can be filled with proper growing
soil composition for optimal growth potential for each pre-planted
species, the panels can be alternately filled with any desired or
decorative material such as gravel or concrete for walkways, and
the filled panels can be used to achieve a desired weight for
desired ballast required for loose-laid membrane roof such as of at
least approximately 10-12 lb./sq. ft.
[0037] In combination with the edge termination/edge finishing
system and support structure, the panels enable provision of
multi-level terracing of the green roof, provision of bounded areas
for uses such as a water pond, a field planted area, walkway areas,
and putting greens, provision of above-panel structures, and other
elements to the designer's imagination. The modular panels also
provide for ease of repair of the roof structure by simply removing
the necessary panels, thus eliminating the need to destroy a
substantial portion of the installed green roof as with prior green
roof systems.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 is a top diagrammatic view of a modular green roof
system in accordance with and incorporating the unique aspects of
the present invention.
[0039] FIG. 2 is a perspective view of a green roof system
including multi-level terracing.
[0040] FIG. 3 is perspective view of a modular panel incorporating
certain unique aspects of the invention, and suitable for use in a
modular green roof system according to the invention.
[0041] FIG. 4 is a side view of the panel of FIG. 3 and showing the
panel pre-seeded in accordance with the invention.
[0042] FIG. 5 is fragmentary top view taken substantially along the
line 5-5 of FIG. 4.
[0043] FIG. 6 is fragmentary view taken substantially along the
line 6-6 of FIG. 4.
[0044] FIGS. 7A and 7B are fragmentary views showing adjacent
modular panels connected together as installed on a roof with
alternate closure/connector strips.
[0045] FIGS. 8 and 9 are views similar to FIG. 7 but showing
alternate apparatus connecting the adjacent panels.
[0046] FIG. 10 is a view similar to FIG. 7 but showing a water line
and riser of an installed watering system.
[0047] FIG. 11 is a top view of the panel flanges of FIG. 10 but
showing the flanges separated for illustrative purposes.
[0048] FIG. 12 is a view similar to FIG. 11 but showing the
watering system components as installed in connection with the
alternate panel connector of FIG. 8.
[0049] FIG. 13 is a fragmentary perspective view of an alternate
panel incorporating integral provisions for a watering system.
[0050] FIG. 14 is an enlarge fragmentary view of a panel edge
system in accordance with another aspect of the invention.
[0051] FIG. 15 is a fragmentary cross-sectional view showing
construction details of one embodiment of a non-modular area of the
green roof, and more particularly, showing a pond area such as
generally indicated in FIG. 1.
[0052] FIGS. 16 and 17 are top and side fragmentary views,
respectively, of a support connected to the modular panels/edge
system framework and adapted to support an above-roof
framework.
[0053] FIG. 18 is a fragmentary side view showing a walkway
supported by the panel edge system to provide access to planted
areas of the green roof.
[0054] FIG. 19 is a side view of edge termination system suitable
for multi-level terracing as generally shown in FIG. 2.
[0055] FIG. 20 is a perspective view of a panel and cables adapted
to assist in raising and lowering the panel from the roof.
[0056] FIG. 21 is an enlarged fragmentary view of the panel and
cable shown in FIG. 20.
[0057] FIG. 22 is a perspective view of an installed green roof and
showing a panel being lifted from a predetermined location on the
roof deck without disturbing previously installed panels
surrounding and adjacent to the predetermined location.
[0058] FIG. 23 is a perspective view of an above-roof temporary
framework adapted for assisting in installation, removal and moving
of filled panels.
[0059] FIGS. 24 and 25 are side views of alternate frameworks
suitable for assisting is installation, removal and moving of
filled panels.
[0060] FIG. 26 is a perspective view of an alternate above-ground
structure supported be the framework of the green roof system.
[0061] FIG. 27 is a view similar to FIG. 26 of an alternate
above-ground structure in the form of a walkway.
[0062] FIG. 28 is a view similar to FIG. 15 of an alternate bounded
non-modular area of the green roof system.
[0063] FIG. 29 is an enlarged side view illustrating certain
aspects of pre-seeding, preserving and shipping of modular
panels.
[0064] FIG. 30 in an enlarged fragmentary side view illustrating
certain aspects of shipping panels with larger pre-growing
plants.
[0065] FIG. 31 is a view of a panel provided with alternate
flexible, interconnectable, drip-irrigation lines which may be used
for both pre-growing prior to delivery to the roof site, and which
may be interconnected connected at the roof site.
[0066] While the invention is susceptible of various modifications
and alternative constructions, certain illustrated embodiments have
been shown in the drawings and will be described below in detail.
It should be understood, however, that there is no intention to
limit the invention to the specific forms disclosed, but on the
contrary, the intention is to cover all modifications, alternative
constructions, and equivalents falling within the spirit and scope
of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0067] Brief Description of Modular-Design Green Roof System
[0068] The present invention relates to a modular-design green roof
system that is uniquely adapted to provide versatility of design
with a broad range of design layout possibilities, while
simultaneous providing for ease of installation and maintenance,
and repairs to both the green roof and the underlying roof
structure or roof deck of the building on which the green roof is
installed.
[0069] Green roof systems of the present invention include
pre-seeded modular pans or containers herein generally referred to
as "panels" adapted to provide both green and non-green areas on
the roof deck, and certain associated apparatus adapted to provide
for design freedom and ease of installation, maintenance and
repairs. Preferred systems also include apparatus for releasably
connecting the modular panels together, and edge termination; for
ease of maintenance and repair of the underlying roofing structure
and replacement of the modular panels, for defining the boundaries
of the green roof areas provided by the modular panels and
optionally providing bounded non-green roof areas such as for
ponds, walkways, putting greens and other desired structures or
uses.
[0070] Briefly, filled panels are arranged on a roof deck in a
desired aesthetic design layout such as illustrated in FIG. 1 in
which the numbers associated with each panel 10 represent
characteristics of the panels and/or the green roof--panel fill
materials.
[0071] The panels can be of different heights and depths, and
planted with various sedum, foliage, or perennials to provide for
various "green" areas for a desired visual effect. Alternately, and
in addition, the panels can be filled with decorative and/or
functional materials such as gravel, decorative rocks, mulch or
other materials to provide for "non-green" areas.
[0072] In accordance with the invention, the panels are pre-filled
and pre-planted, i.e., pre-seeded, such that the pairs of numbers
associated with each panel shown in FIG. 1 may represent, for
example, the (i) height of the panel and (ii) the type and/or color
of plant in the panel. This provides substantial design freedom and
ease of layout design from a selection of pre-planted pre-designed
modular units. Preferred embodiments include provision for
releasably connecting the modular panels together, and edge
termination systems. The interconnecting panels provide for, among
other things, assisting in maintaining the panels in place on the
roof, for ease of maintenance and repair of the underlying roofing
structure and for ease of replacement of the modular panels. The
edge termination systems provide for, among other things, defining
the boundaries of the green roof areas provided by the modular
panels, and optionally providing bounded non-green (non-growing)
roof areas such as for ponds, walkways, putting greens and other
desired structures or uses.
[0073] Design versatility of the present invention is further
illustrated in FIG. 1 wherein the green roof includes a ponded area
12, and in the multi-level green roof embodiment shown at 14 in
FIG. 2, both of which are discussed further below.
[0074] Modular Panels
[0075] In accordance with one aspect of the invention, modular
panels are provided that are adapted for filling with a growing
medium and supporting plant life, and are suitable for placing
directly onto a roof deck in a modular green roof system.
[0076] As discussed further below, the panels optionally include a
cover, or are configured for accepting a cover, and/or for
temporarily connecting together for storage and transportation of
pre-filled panels prior to installation, and/or for temporary
storage and stacking during repairs to the roof.
[0077] One embodiment of a modular panel suitable for use in
accordance with the present invention is the panel 10 shown in
detail in FIGS. 3-6.
[0078] In this instance, the panel 10 is vacuum formed, molded or
otherwise shaped modular panel made from high-strength plastic,
HDPE (high density polyethylene), recycled rubber or any moldable
material suitable to achieve cost effective manufacture, sufficient
strength and rigidity for the panel size, and a desired durability
and long life.
[0079] The panels are formed in modular sizes convenient for
handling such as between approximately one and one-half to eight
inches deep, and up to 16 square feet surface area, or otherwise as
desired. One convenient size for certain roofs and greenery, and
for manual handling is a pan measuring approximately 2 feet by 4
feet. The preferred shape of the panels is generally rectangular so
that the panels cooperate with each other and/or additional
apparatus discussed below, to generally cover the roof when viewed
from above.
[0080] The sides 16 and bottom 18 of the panel 10 shown are formed
with reinforcing ribs 20 (see FIGS. 5 and 6) to achieve additional
strength and rigidity for a given wall thickness.
[0081] A waffle design on the under side of the bottom 18, such as
defined by criss-crossing ribs or flow passages 22 extending along
the underside of the panel, or other downwardly facing voids, for
lowered feet portions (not shown) to raise the floor of the panel
above the roof, allow multi-directional free water flow and
drainage on the roof deck under the panel.
[0082] Drain holes 24 formed through the bottom 18 of the panel 10
provide water drainage of soil mass or other contents in the panel.
The size and number of drain holes in this area can be varied to
provide the ideal amount of moisture content for the various types
of plants and soil.
[0083] Drain ports or holes 24A formed in the sides of the panels
10 are placed to assure run off therethrough in the event the water
level in the panel rises to the height of these holes, thereby
providing a control for the total weight of the panels during
periods of excessive rainfall.
[0084] Optional grooves 30 are formed along the bottom of the panel
10 to assist in installation and removal of filled panels as
discussed further below.
[0085] The sides 16 of the panel 10 are preferably tapered to allow
for ease of removal from the vacuum mold, and for additional
reasons discussed below, are preferably sized for clearance in the
neighborhood of between approximately 1 to 2 inches between sides
of adjacent panels when in side-by-side relation.
[0086] Flanges 26 may be formed in a desired configuration along
the upper edge portions of the panel 10 for cooperation with
adjacent panels, and/or connecting and termination arrangements
discussed below. Advantageously, flanges provide the panel with
additional stiffness, to assist in maintaining the panel shape when
moving filled panels.
[0087] A webbing or netting 28 is placed on the bottom of the panel
10 prior to filling with the growing medium to prevent root growth
into and through the drain holes 24 and onto the roof deck below
the panel.
[0088] As will be apparent, alternate modular panel embodiments,
adapted for filling with either a decorative fill, or a growing
medium and plant life, and including alternate construction and
flange or edge details, are also suitable for use in the green roof
system of the present invention as contemplated herein.
[0089] Accordingly, a green roof system can be quickly and easily
installed with the use of such modular panels by covering the roof,
or the desired portion of the roof, with panels in side by side or
abutting relation, the panels being filled with desired growing and
non-growing green roof materials.
[0090] Advantageously, the larger, heavier filled panels provide
the ballast that is necessary for a conventional loose-laid
membrane roof in a modular manner to permit ease of removal for
inspection of and repair to the membrane.
[0091] Interconnecting Modular Panels
[0092] In preferred embodiments, modular panels are provided for
releasably connecting together. Such an arrangement is useful in
providing a cohesive green roof system, and is particularly useful
in connection with shallow, relatively light panels to prevent high
wind from lifting the panels from the roof deck.
[0093] In carrying out this aspect of the invention, in the
embodiments shown, apparatus is provided for releasably connecting
the flanges of adjacent panels together. Alternately, for example,
for panels without flanges, the sides of adjacent panels may be
connected directly together.
[0094] One embodiment of panel/flange connector is shown in the
drawings in FIG. 7A as a closure strip 32 in the form of an
elongated, extruded plastic or aluminum strip comprising an outer
face 34 sized to overlap the outer edge portions of the flanges 26
of adjacent panels, and a pair of laterally spaced leg portions 36
and associated bent knee portions 38 extending downwardly from the
outer face 34 and cooperating to cover or seal off the void between
the adjacent panels. An alternate closure strip 32B shown in FIG.
7B is provided with sharp prongs that are inserted through the
flanges of adjacent panels to connected the panels together.
[0095] In an alternate embodiment shown in FIG. 8, adjacent panels
are connected with a closure strip 40 such as a molded plastic or
treated wood strip, and suitable fasteners such as the butterfly
type threaded fastener 42 to secure the flanges 26 of the adjacent
panels to the closure strip.
[0096] A second alternate connector is shown in FIG. 9 connecting
modified flanges 26A. In this instance, the adjacent flat flanges
are positioned overlapping one another, and are connected with
fasteners such threaded screws 44. As discussed further below, in
the event of connecting the flanges in an overlapping manner, the
flanges are preferably relatively flexible or resilient such that
the panel with the flange under the other may be removed from the
roof without the need to remove the panel having the flange on
top.
[0097] Persons skilled in the art will appreciate alternate
connectors or fasteners may be used for releasably connecting
adjacent panels together, with the edge details or flanges of the
panels being modified for use therewith. By way of non-limiting
examples, in alternate embodiments not shown, the panels are
provided with releasable, snap-together interlocking flanges for
connecting adjacent panels, apparatus is provided for connecting
parts of adjacent panels other than with the flanges or upper edges
of the panels, or holes are provided in the adjacent panels for the
use of cable ties and other flexible connectors to tie the panels
together.
[0098] Watering System
[0099] To provide for ease of maintenance of the green roof system,
the panels are preferably provided with interconnecting watering
apparatus connected to one or more water supply lines.
Conveniently, a water supply line 64 is optionally provided,
running in the approximately 1 to 2 inch clearance provided between
adjacent tapered panels such as shown in FIGS. 10 and 12, with
pressurized irrigation risers 66 extending upwardly through the
overlapped flanges 26A of the adjacent panels, or, for example,
through the closure strip 40 (FIG. 12) for periodic watering of the
plant life in the green roof system. In this instance, one or both
of the overlapping flanges 26A are notched (such as shown in FIG.
11 wherein the flanges are shown separated for illustrative
purposes) for the riser to extend therethrough.
[0100] Advantageously, such internal watering arrangements provide
additional design freedom since they are easily adapted for use
with specific green roof design layouts, such as with the alternate
edge systems.
[0101] An alternate panel 160 molded with integral water line and
riser receiving locations is shown in FIG. 13. In this instance,
the panel is molded with a pop-out opening 166 sized to receive the
riser or standard sprinkler head 168 which is then connected to a
T-connector 170 for joining with water line hoses 164 running in
cylindrical or curved indentations 162 molded in the sides of the
panel.
[0102] In another alternate embodiment shown in FIG. 31, the panels
are provided with flexible, interconnectable, drip-irrigation lines
172.
[0103] Edge Finishing/Green Roof Termination System
[0104] In accordance with yet another aspect of the invention, the
panels are adapted for use with edge finishing/edge termination
systems are provided for connecting to and/or cooperating with the
panels to define the various boundaries of the green roof system.
Such edge finishing is adapted for decorative effect at the
boundaries, and/or for functional purposes including supporting the
flanges or panels, or connection between the panels and/or other
structures as discussed further below. Briefly, the edge finishing
is of a suitable, durable, decorative and/or structural material
and configuration for cooperation with the modular panels to define
the boundaries of the green roof system.
[0105] In carrying out this aspect of the invention, in the
embodiments shown, termination detail is provided in the form of an
edge finishing--facing material adapted for connection to the
flanges of the panels.
[0106] In the preferred embodiments shown in the drawings,
dimensional lumber or composite extruded or other material beam is
provided for the termination/facing material to define the
boundaries of the green roof system. Such boundaries include outer
boundaries, inner boundaries of enclosed areas, and transition
boundaries of the green roof system. FIG. 14 illustrates one
embodiment of termination or edge detail using a facing material in
the form of a structural beam, dimensional lumber or composite
extrusion 46 to finish off the exposed edges of panels located
along the boundaries of the green roof system. In this instance,
the dimensional lumber or composite extrusion 46 is standing on its
lower edge on the roof (not shown), and is located under, shaped
for, and connected to the flange 26 for positioning and support
thereof. As shown in FIGS. 17 and 18, alternate flange-supporting
and/or edge systems will be adapted for the specific flange
configuration with which they are connected to and/or used
with.
[0107] Persons skilled in the art will also appreciate that
alternate edge finishing/edge termination systems will be provided
within the scope of the present invention. By way of non-limiting
example, in an alternate embodiment not shown, the outer and inner
boundaries of the green roof system are defined by decorative
facing material shaped for slipping over the flanges or exposed
edges of the modular panels, the facing being sized to extend
downwardly to the roof deck.
[0108] Multi-Level Green Roof
[0109] As previously mentioned and shown in FIG. 2, the present
invention contemplates a green roof capable of multi-level
terracing. This is accomplished with the use of panels of different
depths and intermediate, boundary transition edge finishing systems
therebetween.
[0110] Advantageously, the ability of the system to accommodate the
use of panels of different height also permits the growth of
various planted material which may not be suitable for growth in
prior green roof systems. In particular, the modular panels and
associated apparatus of the present invention enable, for example,
provision of plants requiring substantial depth of soil or other
growth medium.
[0111] In carrying out this aspect of the invention,
interconnecting, boundary termination facing material such as
described above comprises suitable height transition apparatus and
accommodates multi-level terracing in a visually appealing
manner.
[0112] In particular, one method of transitioning between panels of
different heights with the dimensional lumber/composite extrusion
edge system described above is shown in detail in FIG. 19. In this
instance, the edge pieces 46A and 46B are secured under associated
flanges 26A of adjacent panels of different heights, and are tied
together with nails 48. Block 50 is optionally provided for
additional lateral support at the base of the edge termination
pieces.
[0113] In an alternate embodiment edge system, a facing material is
connected between the flanges of the adjacent panels of different
height to cover the exposed side portions of the taller panel.
[0114] Additional Modular Components and Bounded Areas
[0115] The present invention also contemplates and accommodates
additional modular components and bounded areas--providing for
additional design freedom and flexibility. The following are
illustrative of a few such additional components and bounded areas,
and edge finishing/edge termination systems associated
therewith.
[0116] Alternate Decorative or Functional Fills
[0117] As previously mentioned, the modular panels 10 may be filled
with decorative gravel, concrete or other non-green materials for
decorative purposes, or functional purposes such as to provide
walkways through the green roof.
[0118] For example, in one embodiment, a walkway is provided with
panels of a height less than the surrounding panels filled with,
for example, growing greenery, with suitable edge support and edge
finishing or height transition system provided such as previously
described, and/or as illustrated in FIG. 19.
[0119] In an alternate embodiment, the walkway is provided in
panels of the same height as surrounding panels, but which may be
partially filled with a light-weight "filler" under the walkway
material to reduce the weight of the filled panel if desired.
[0120] Pond Area
[0121] Additional design flexibility is available through the
unique ability of green roof systems of the invention to include
ponded areas such as indicated in FIG. 1 with the use of an
internal boundary edge finishing system.
[0122] The details of one embodiment of a pond area 52 is shown in
FIG. 15. In this instance, the water is contained in a loose-laid
membrane 54, such as made from flexible EPDM, that is surrounded by
panel termination dimensional lumber/composite extrusion 46 and is
secured between the flanges 26 and the lumber/extrusion; with
wooden strip 58 provided for additional lateral support. To insure
positive omni-directional drainage on the roof deck, the membrane
is laid over a grid work of material such as round river rock 56,
to allow drainage under the membrane. Such an arrangement may be
adapted for a permanent ponded area purely for aesthetic purposes
when provided with a water supply and associated apparatus, or
alternately for a collection area for natural rain water, such as
to be optionally re-used in watering the green roof system.
[0123] Other Non-Modular Areas
[0124] Use of the edge termination system with the panels 10 to
create other non-modular areas of the roof deck provides yet
additional flexibility in the design of the green roof system.
[0125] For example, in an alternate arrangement shown in FIG. 28,
an edge-termination/membrane-enclosed area similar to the ponded
area discussed above is used for field planted material to
compliment the modular system. In this instance, the membrane 54A
is perforated at 88 for drainage, and is lined with anti-root
fabric 150 to prohibit growth of roots through the membrane and
into the waterways provided on the roof deck. Rather than rounded
stone, the membrane shown is supported on and the waterways of the
roof are provided by a molded plastic sheet 152 having spaced
frusto-conical supports provided with additional drain holes
154.
[0126] With suitable edge finishing, the green roof system can be
arranged to provide for other, either fully or partially enclosed
areas on the roof deck for other uses and purposes. Advantageously,
this arrangement is suitable for use in combination with installed
green roof systems of prior designs. As a result, the modular green
roof systems of the present invention can be used as a replacement
for portions of prior systems such as in the event a portion of the
prior green roof is removed for repair of the underlying roof
structure. Partially enclosed areas may also include the irregular
edge areas of the roof deck.
[0127] Support Framework for Additional Decorative and Functional
Add-On Structures
[0128] Preferred green roof systems hereof are also provided with a
support framework, structure or anchoring system to support add-on
components suitable for use for decorative and/or functional
purposes to compliment the modular and non-modular aspects of the
green roof system.
[0129] Additional or add-on components may be temporary structures
such as maintenance walkways or apparatus to assist in installation
or removal of filled panels, or they may be semi-permanent
structures such as bridges 84 (FIG. 27), trellises, sun shades, sun
or weather type gazebos, fabric canopies 72 (FIG. 26) and other
desired above-panel structures that are maintained in the installed
green roof system.
[0130] In carrying out this aspect of the invention, one embodiment
of a suitable framework or support structure is provided by the
dimensional lumber/composite extrusion edge joining system
described above. In this instance, the lumber or extrusion 46 is
connected under panel flanges (e.g., 26, 26A) as necessary for
support of the desired additional structures, with the structures
being secured to the edge framework as required.
[0131] Alternately, for example, the support framework includes
spaced support plates molded in or secured to the top section of
the panels, or secured to the support lumber/extrusion 46 if used
therewith, the support plates being adapted for cooperation with
the add-on components to provide support thereof. In the embodiment
shown in FIGS. 16 and 17, support plates in the form of corner
gussets 60 are provided with vertically extending openings 62 sized
to receive support poles 70 of the add-on components.
[0132] Roof Deck and Green Roof Maintenance and Repair
[0133] Advantageously, green roof systems of the present invention
are uniquely adapted for ease of maintenance and repair of both the
green roof system itself and the underlying roof deck structure
Bridge
[0134] Access/Walkway Panels
[0135] As illustrated in FIGS. 17 and 18, in green roof systems
that include intermediate boundary, panel edge support systems such
as the dimensional lumber/composite extrusion edge systems
described above, access to the planted areas is provided using the
strength of the panel edge support system with a bridge or plank
150, or other bridging mechanism (see e.g., FIG. 27) that is laid
over the modular panels and supported by the panel edge support
system. The walkways or bridges may include provision to maintain
alignment on the panels such as with brackets 152 (FIG. 18). Such
walkways can be temporary or permanent to provide walkways for
elevated access to the planted areas without disturbing them.
[0136] Movement of Filled Panels
[0137] In accordance with another aspect of the invention,
apparatus is provided for lifting and moving individual filled
panels, for installation of the green roof system with pre-seeded
or pre-planted panels, and for lifting, removing and replacing
individual filled panels from an installed green roof, without the
need to disturb surrounding panels.
[0138] Advantageously, such a non-progressive arrangement, i.e.,
the ability to lift and move panels from the installed green roof
without the need to disturb adjacent panels, permits access to
portions of the underlying roof deck such as for repair or periodic
maintenance or access to drain openings without the need to tear-up
and destroy large sections of the green roof as with prior green
roof systems, and provides the ability to change the green roof
design after its initial installation by simply rearranging or
replacing desired panels.
[0139] More particularly, the modular panels are adapted to connect
to and cooperate with an above-panel support and transport
framework for lifting and moving thereof.
[0140] Panel Lifting and Moving Apparatus
[0141] In carrying out this aspect of the invention, the modular
panels are provided with grabbing or gripping apparatus adapted to
facilitate being lifted vertically upwardly so as to not disturb
adjacent panels.
[0142] In one embodiment, the panels are provided with lifting
hooks, handles, openings or like structure or devices sized to
connect to or receive an extension member adapted to extend
upwardly to the above-roof support framework.
[0143] The extension member can be either a flexible member such as
a strap, rope, cable or like carrying and support apparatus, a
rigid extension member, a jointed rigid member, or a combination
thereof such that the member is adapted for connection between the
panels and the above-roof support framework and to lift and support
the panels therefrom.
[0144] In the embodiment shown in FIGS. 3-4, 20 and 21, the panels
10 are provided with relatively deep grooves 30 formed extending
along the bottom of the panel 10, and a flexible cable or strap 80
extends underneath the panel through the grooves. The top of the
strap is provided with eyelets 82, hooks or other apparatus
suitable for connecting to the above-roof support framework. Such
straps or cables can either be permanently positioned under the
panels before they are installed onto the roof deck, or fed through
the groove prior to lifting the panel. Thus, the filled modular
panels can, among other things, be lifted out of the field for
access to roof deck in the surrounded area such as indicated at 86
in FIG. 22. Alternately, enclosed grooves or tunnels can be formed
along the bottom and extending up the sides of the modular panels
to facilitate threading the lifting strap therethrough.
[0145] Optional spreader bars 84 are installed across the top of
the panels, connected between opposite sides of the panel, and
generally aligned with the straps 80, prior to lifting or transport
of the panels. The spreader bars prevent the panel from collapsing
inwardly onto itself due to the weight of the fill in the panel in
the event the design of the panel presents such a possibility. For
smaller panels, the spreader bar is also sized to carry the weight
of the panel such that the panels can be manually carried with the
bar attached.
[0146] Supporting Framework
[0147] The above-roof framework includes apparatus for connecting
to the extension members, lowering and raising the panels after
connection thereto, and transporting the panels from one location
to another on the roof.
[0148] FIG. 23 illustrates a framework 90 comprising vertical legs
92 supported with feet 94 and/or in stationary support brackets
such as brackets 60, top rails 96 supported on the legs 92,
cross-beams 98 releasably connected at 100 to the straps 80, and
apparatus for raising and lowering the filled panels and sliding or
rolling the raised panels along the rails 96 for repositioning as
indicated by arrow A-A.
[0149] FIG. 24 illustrates the support rails 98 slipped through the
loops 82 such as for use in the rail system of FIG. 23, or simply
comprising an alternate framework of spaced parallel rails for
manually raising and carrying the filled panels.
[0150] FIG. 25 illustrates another alternate framework 104 with
castors or wheels to assist in transporting the filled panels. With
such arrangement, the rails 98 may be adapted for manually raising
the panel and then connection to the framework, or the rails may be
permanently connected, with panel raising and lowering apparatus,
and with the wheels adapted for rolling in grooves such as formed
in the top of the lumber/extrusion edge support systems discussed
above.
[0151] Advantageously, such arrangements for lifting and moving
filled panels provides for freedom of design of the entire green
roof system, including being able to install the green roof system
without covering or enclosing the entire roof deck area with a
fully seeded or planted area of prior green roof systems, allowing
the design of the installed green roof system to be changed as
required or desired, and to be able to cooperate with prior green
roof systems so as to provide fully seeded and planted area(s) of
prior systems in combination with areas of the modular system
hereof such as interspaced therewith or around the perimeter.
[0152] Pre-Seeding of Modular Panels
[0153] In accordance with yet another aspect of the invention, the
modular panels 10 are pre-filled with suitable growing medium 110
(see e.g., FIG. 29) and pre-planted with sedum, shrubbery,
perennials, foliage and/or other green roof vegetation or plants
112 in accordance with one of several alternate methods, or
alternately pre-filled with non-growing decorative materials.
[0154] In the case of plant materials, the panels are either
pre-planted and then suitably preserved until shipped for
installation into a green roof system, or pre-planted, germinated,
and maintained in a growing condition until needed.
[0155] Advantageously, pre-planted preserved panels can be prepare
well in advance of when they will be needed, and then stocked and
maintained in a preserved condition for as long as desired. This
permits additional selection and quantities of green roof materials
to be available during the green roof installation season without
concern for spoilage since unused preserved panels can be simply
maintained until the next season.
[0156] To obtain pre-planted panels in a preserved state, ready for
installation, the panels are filled with sanitized dry earth or
other suitable growing medium 114, pre-seeded with sedum or other
perennial seed, and maintained in a dry state to preclude
germination.
[0157] Alternately, for example, the plants in the panels may be
germinated and pre-grown in a greenhouse, and as they reach the
appropriate growth for the geographic area in which they are to be
located, and frozen as would occur during the normal winter cycle
for perennials of such type. The frozen pre-grown panels are then
cryogenically preserved until shipped for installation into a green
roof system.
[0158] Cryogenically preserving pre-grown panels offers the unique
ability to stock a selection of "ready to grow" materials without
the need to maintain growing plants and the expense associated
therewith. Thus, a greater selection can be prepared in advance,
without concern for additional costs of maintenance or spoilage if
not used within a specific time period.
[0159] Advantageously, the growing medium used in the modular
panels may also include the same types of materials used in prior
green roof systems such as pre-cut mats of mineral wool or water
retention substrate, and pre-cut mats of pre-seeded fiber fleece.
Thus, manufacturers and suppliers or prior green roof systems are
able to also supply and realize the benefits of modular green roof
systems in accordance herewith using many of the same
materials.
[0160] Storage of Pre-Planted Modular Panels
[0161] In keeping with the invention, the pre-planted panels 10 are
stored in a manner suitable for preserving the plants therein.
[0162] For example, pre-planted pre-growing panels can be stored in
a greenhouse, maintaining the growing condition of the plants until
shipped to an installation site. Such storage can be provided on
shelves, or if provided with covers suitable to permit exposure to
light, watering and air circulation, the panels can be stored in
stacks.
[0163] In the case of pre-planted panels that are preserved in a
non-growing state, the panels are optionally sealed by vacuum
packing, with a complete vacuum liner 120 (FIG. 29) such as of
approximately 6-8 mil thickness surrounding the entire panel. This
vacuum packed package 122 is then either dry or cryogenically
preserved to prohibit any or further growth, and to protect from
contamination, moisture, and sunlight (if provided with a
sun-blocking film). The panels are then maintained ready for
shipment and placement as desired at the job site with an assured
pre-seeded type of foliage or growth that would match and be
identified by alphanumeric characteristics such as generally
indicated by the pairs of numbers shown in FIG. 1. The advantages
of such pre-planting and pre-packaging includes the simplicity and
freedom of green roof system design. And the cryogenically
preserved panels assure growth within a relatively short time
assuming the green roof is installed during the warmer months.
[0164] Shipping of Pre-Planted Modular Panels
[0165] The pre-seeded panels are also adapted for ease of shipment
to the installation site with provision of covering, stacking and
banding the stacked panels together. To this end, and if not
provided previously such as for purposes of storage, stacking for
shipment may be provided for with a rigid cover or separator 130
such as made from a plywood board, rigid composite extrusion or
other suitable rigid material, pre-cut to size, and placed over the
panels (see FIG. 29). An edge extrusion 132, shaped and sized for
cooperation between the upper portion of the lower panel and/or its
cover (e.g. 130), and the lower portion of the adjacent upper
panel, is secure between the stacked panels to prevent the panels
from slipping relative to one another. This allows the panels to be
stacked and secured or banded together for shipping. Alternately, a
molded rigid cover may be provided with an integrally molded edge
extension, or integrally molded pattern configured to interlock
with, for example, the grooves 30 or the waffle design of the
bottom of the panel stacked thereon.
[0166] Shipping of panels with plants 136 or other items that
extend above the top of the panel 10 requires the use of a rigid
cover with a "bubble" sized to protect the plants during shipment.
FIG. 30 illustrates one particularly advantageous arrangement for
preparing such pre-planted panels for shipment. In this instance,
the shipping lid is an empty panel 10 which is turned upside down
onto the filled panel, with the edges of the panels temporarily
secured together as indicated at 138. Also shown in FIG. 30 is a
rigid separator board 140 between the stacked panels with an edge
extrusion 142 fastened to secure the stacked panels from sliding
during shipment. Alternately, in contemplation of using empty
panels as shown to protect contents of filled panels, the lower
portions of the panels are molded with connector receiving
indentations or openings adapted for receiving temporary shipping
connectors that would secure the "top" of an inverted panel with
the bottom of the upright panel stacked thereon. In view of the
disclosure hereof, those skilled in the art will appreciate
numerous variations and other methods suitable for use in
pre-filling, planting, and otherwise preparing the modular panels
for use in green roof systems according to the invention.
[0167] From the foregoing, it will be apparent that the present
invention brings to the art new and improved green roof system and
associated methods therefor, including uniquely configured
pre-seeded modular panels and associated apparatus for use
therewith.
* * * * *