U.S. patent application number 11/130352 was filed with the patent office on 2005-12-29 for steel roofing panel support.
Invention is credited to Smith, Gary Edward.
Application Number | 20050284068 11/130352 |
Document ID | / |
Family ID | 26861522 |
Filed Date | 2005-12-29 |
United States Patent
Application |
20050284068 |
Kind Code |
A1 |
Smith, Gary Edward |
December 29, 2005 |
Steel roofing panel support
Abstract
A steel roofing panel support system is disclosed herein. The
system generally includes a support element positioned on a roof
surface, the support being configured to support at least a portion
of a steel roof panel to be placed thereon. The support element may
be cut from a block of expanded polystyrene such that the support
is substantially wedge-shaped. A support element as disclosed
herein may also be used in installations of steel panels over
existing wood shakes or other roof surfaces.
Inventors: |
Smith, Gary Edward;
(Huntington Beach, CA) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE
CA
92614
US
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Family ID: |
26861522 |
Appl. No.: |
11/130352 |
Filed: |
May 16, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11130352 |
May 16, 2005 |
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10165601 |
Jun 7, 2002 |
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6907701 |
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60296579 |
Jun 7, 2001 |
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Current U.S.
Class: |
52/506.01 |
Current CPC
Class: |
E04D 13/1693 20130101;
E04D 3/30 20130101; E04D 13/1681 20130101 |
Class at
Publication: |
052/506.01 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. A device for use with steel roofing panels and a roof surface
comprising: a support element configured to be disposed between a
roof surface and a steel roofing panel, said support element having
substantially flat upper and lower surfaces.
2. The device of claim 1, wherein the support element is
substantially wedge-shaped
3. The device of claim 1, wherein the support element is made of
expanded polystyrene.
4. The device of claim 3, wherein the support element is cut from a
larger block of polystyrene using a hot wire.
5. The device of claim 1, wherein the support element is configured
to underlie a plurality of roof panels.
6. A roofing system comprising: a steel roof panel; a roof surface;
a support element disposed between said roof panel, and said roof
surface; wherein said support element is not conformed to a shape
of the steel roof panel.
7. The roofing system of claim 6, wherein the support element is
made of expanded polystyrene.
8. The roofing system of claim 7, wherein the support element is
cut from a larger block of polystyrene using a hot wire.
9. The roofing system of claim 6, wherein the support element is
configured to underlie and support a plurality of roof panels.
10. The roofing system of claim 6, wherein the support element
comprises a quadrilateral wedge shape.
11. A roofing system comprising: a steel roof panel; a roof
surface; a wedge-shaped support element having a flat upper
surface, and disposed between said roof panel, and said roof
surface.
12. The roofing system of claim 11, wherein the support element is
substantially wedge-shaped.
13. The roofing system of claim 11, wherein the support element is
made of expanded polystyrene.
14. The roofing system of claim 13, wherein the support element is
cut from a block of polystyrene.
15. The roofing system of claim 11, wherein the roof surface
comprises previous roofing tiles.
16. The roofing system of claim 15, further comprising: a plurality
of strips disposed vertically on the tiles; horizontal battens
secure to the top of the strips; a riser disposed between the
strips, and underlying the horizontal battens.
17. A roofing system comprising: a steel roof panel; a roof
surface; means for supporting a central portion of said panel on
said roof surface.
18. The roofing system of claim 17, further comprising: existing
roof tiles; a plurality strips disposed vertically on the tiles;
horizontal battens secure to the top of the strips; a riser
disposed between adjacent strips, and underlying the horizontal
battens.
19. The roofing system of claim 18, wherein the means for
supporting comprises a wedge of expanded polystyrene.
20. The roofing system of claim 17, wherein the roof panel
comprises a corrugated shape.
21. The roofing system of claim 17, wherein the means for
supporting a roof panel underlies a plurality of roof panels.
22. A method of assembling a roof covering, comprising: providing a
steel roof panel; providing a wedge-shaped support element; placing
said support element on a roof surface; placing said panel on said
support element; securing said panel and said support element to
the roof surface.
23. The method of claim 22, wherein the support element underlies a
plurality of roof panels.
24. The method of claim 22, wherein the roof surface comprises a
plurality of existing roof tiles, the method further comprising the
steps of: placing a plurality of strips vertically over a plurality
of roof tiles; placing a riser between adjacent strips; placing
horizontal battens over said strips and said riser.
25. The method of claim 22, wherein the support element is cut from
a block of expanded polystyrene.
26. The method of claim 22, wherein the support element provides a
thermal resistance rating of at least 4.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No.
10/165,601, filed Jun. 7, 2002, which claims priority under 35
U.S.C. .sctn.119(e) to U.S. Provisional Application 60/296,579,
filed Jun. 7, 2001.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates generally to roofing products,
and more specifically, to a roof panel support that allows
individuals to walk on a steel panel roof without permanently
deforming the steel panels.
[0004] 2. Description of the Related Art
[0005] Steel panel is a common roofing material for use on new
construction as well as re-roofing installations over existing wood
shake roofs. It is very popular for its lightweight, yet
weatherproof properties as well as its ease of installation. The
thin, lightweight nature of the steel panel allows it to be easily
and cost-effectively installed on new construction, or over
existing wood shake. An example of a steel roofing panel is
described in U.S. Pat. No. 4,932,184 to Waller.
[0006] In a typical installation, 2.times.2 inch wood strips are
attached horizontally to the roof to act as battens on which the
front of the steel panels will rest. Raising the front of the steel
panel in this way creates a space between the roofing surface and
the underside of the roofing panel. Unfortunately, due to the
thinness of the steel panels, they tend to bend and permanently
deflect when the roof is walked on. In addition to being unsightly,
damaged steel roofs may not provide adequate water drainage or
weather protection.
[0007] Some attempts have been made to provide custom-shaped
supports underneath the steel panel. These supports are molded to
exactly match the profile of the roofing panels. The cost of the
molds required are typically quite substantial and in some cases,
too expensive to justify the use of such supports. Such molded
supports also have the limitations that they are only compatible
with the specific panel for which they were designed. Additionally,
such conforming supports tend to be somewhat difficult to install
due to the difficulty in ensuring that the supports are aligned
with the panels.
SUMMARY
[0008] The present roof panel support recognizes the desirability
of being able to walk on a steel panel roof with confidence that
the steel panels will not be permanently bent or otherwise damaged.
The present roof panel support satisfies the need for a steel roof
panel support element that is compatible with a broad range of
steel roof panels, is adjustable during installation, allows
individuals to walk confidently on a steel panel roof without
damaging the panels, and provides thermal insulation.
[0009] In one embodiment, a support element is preferably
wedge-shaped to provide support under as much of the steel panel as
possible, while remaining as inexpensive as possible. The
wedge-shaped support element is preferably made of expanded
polystyrene so that it is lightweight, durable, semi-compressible,
fire safe, inexpensive and easy to manufacture and install. Steel
roof panels placed on the wedge-shaped support elements are
preferably supported slightly above the next lower course of steel
panels.
[0010] Support elements are preferably independent of the steel
roof panels. Individual support elements can be mass-produced for
use with different, but similar, kinds of steel panel.
Additionally, during installation the steel roof panels can be
adjusted forward or backward with respect to the support element in
order to increase or decrease the head lap of the steel panels.
Support elements that are not attached to steel panels, and have a
uniform quadrilateral or triangular cross-sectional shape, are more
cost effective in terms of packaging and delivery than combined
structures.
[0011] In another embodiment, support elements may be used in
steel-panel installations over existing roofing surfaces. When a
steel-panel system is installed over an existing roofing surface
such as wood shakes, a wood framework is laid over the roofing
surface. Typically, 1.times.4 inch wood strips are run vertically
up the roof, and the 2.times.2 inch battens run horizontally as in
a new installation. In order to use support elements to support the
steel panels, the space between the 1.times.4 strips must be
filled. This may be accomplished by using a riser (typically
3/4-inch), or by increasing the dimensions of the support element.
Risers to be used in accordance with the present invention are also
preferably made of expanded polystyrene so that they are
lightweight, durable, semi-compressible, fire safe, inexpensive and
easy to manufacture and install.
[0012] One of the preferred methods for installing steel roof panel
supports comprises placing a support element on a roofing surface,
placing a steel roof panel over the support element, and securing
the steel roof panel to the roofing surface.
[0013] For purposes of summarizing the invention and the advantages
achieved over the prior art, certain objects and advantages of the
invention have been described herein above. Of course, it is to be
understood that not necessarily all such objects or advantages may
be achieved in accordance with any particular embodiment of the
invention. Thus, for example, those skilled in the art will
recognize that the invention may be embodied or carried out in a
manner that achieves or optimizes one advantage or group of
advantages as taught herein without necessarily achieving other
objects or advantages as may be taught or suggested herein.
[0014] All of these embodiments are intended to be within the scope
of the present invention herein disclosed. These and other
embodiments of the present invention will become readily apparent
to those skilled in the art from the following detailed description
of the preferred embodiments having reference to the attached
figures, the invention not being limited to any particular
preferred embodiment(s) disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Having thus summarized the general nature of the invention,
certain preferred embodiments and modifications thereof will become
apparent to those skilled in the art from the detailed description
herein having reference to the figures that follow, of which:
[0016] FIG. 1 is a side section view of a steel panel roofing
system incorporating support elements;
[0017] FIG. 2A is a perspective view of the roofing system of FIG.
1;
[0018] FIG. 2B is a front section view of an alternate roofing
system of FIG. 1;
[0019] FIG. 3A is a section view of a steel panel roofing system
installed over an existing shake roof and incorporating support
elements;
[0020] FIG. 3B is a perspective view of a frame structure for use
in installing a steel panel roofing system as in FIG. 3A;
[0021] FIG. 4 is a perspective view of one embodiment of a support
element;
[0022] FIG. 5 is a perspective view of an alternative embodiment of
a support element;
[0023] FIG. 6 is perspective view illustrating a method of packing
support elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] In an embodiment as shown in FIGS. 1 and 2, a steel roof
panel support element 14 fits between steel roof panels 16 and a
roofing surface 12 to provide support for the steel roof panels 16.
Preferably, a support element 14 is wedge-shaped to provide support
under as much of the steel panel 16 as possible. The support
element 14 is preferably made of expanded polystyrene so that it is
lightweight, durable, semi-compressible, fire safe, inexpensive and
easy to manufacture and install. Alternatively, the support element
14 may be made of other materials such as foam, rubber, plastic,
wood, or any other material which provides sufficient support when
used as described herein.
[0025] FIG. 1 illustrates a typical installation of a steel roof
panel 16 with a support element 14 having preferred features and
advantages on a newly-constructed roof. In a typical installation
on a new roof, battens 20 are preferably attached to the roof
horizontally in a manner consistent with the particular steel roof
panels to be used. Support elements 14 are then placed on the
roofing surface 12 such that the larger dimension of the wedge
shape is adjacent to the next lower batten 20a, and the short side
of the support element 14 is adjacent to the next higher batten
20b. A roof panel is then placed over the support elements 14 and
attached to the roofing surface using nails or other method known
in the art. Embodiments of the roof panel support vary depending on
the type of support elements 14 and steel roof panels 16 used.
[0026] The steel roof panel 16 may be placed so that it is in
contact with, and rests completely on, the support element 14.
Alternatively, the steel panel 16 may be placed so that it rests on
the support element 14 and the roofing surface 12, or in another
method, the steel roof panel 16 may be placed so that it rests on a
support element 14 and the next lower batten 20a. In still another
embodiment, the steel roof panel 16 may be placed so that it rests
on the roofing surface 12, the support element 14, and both the
upper and lower battens 20a and 20b, respectively.
[0027] Preferably, the steel roof panels 16 are placed over the
support elements 14 and then secured to the roofing surface using
roofing nails. In a preferred method of installation, the nail
passes through both the steel roof panel 16 and the support element
14 and into the roofing surface 12 to secure the steel panel 16. In
another preferred method, the nail passes through the steel panel
16 and into the roofing surface 12 and the weight of the steel
panel 16 as well as the location of the battens 20 act to secure
the support element 14. One method of installing support elements
14 for use with steel roof panels 16 includes positioning a second
support element 14 in a horizontal row next to a first support
element 14, leaving a gap between the sides of the two support
elements 14 to facilitate water drainage down the roof.
[0028] In FIGS. 2A and 2B, a steel roof panel support system 10 is
shown covering a portion of a roof. The roofing surface 12 has
battens 20 attached horizontally along the roof. These battens are
typically 2.times.2 wood strips, however they may comprise other
materials and sizes as known to those skilled in the art.
Wedge-shaped roof panel support elements 14 are shown resting on
the roofing surface 12. A steel roof panel 16 is shown resting on a
roof panel support element 14.
[0029] Support elements 14 are preferably arranged in rows and
preferably rest directly on the roofing surface 12. A support
element 14 in a row is preferably one or two inches away from the
next support element 14 in the row, although support elements 14
may be arranged on a roofing surface 12 with little or no space
between them.
[0030] The steel roof panels 16 are preferably secured in place
using nails appropriate for use with steel roof panels 16. The
nails may pass through both the steel roof panel 16 and the support
element 14. In other embodiments, the nails may only pass through
the steel roof panels 16. Support elements 14 are preferably
independent of the steel roof panels 16 in that the support
elements 14 are not necessarily formed integrally with, nor
attached directly to a steel roof panel. Support elements 14 are
also typically independently shaped from steel roof panels in order
to allow a support element to be used with a variety of steel roof
panels. During installation, steel roof panels 16 can be adjusted
forward or backward with respect to an independent support element
14 in order to increase or decrease the amount of overlap 38 of the
steel panels 16.
[0031] With reference now to FIGS. 3A and 3B, support elements may
be used in steel-panel installations over existing roofing surfaces
such as wood shakes 22. Typically, when a steel-panel system is
installed over an existing roofing surface, a wood framework such
as that shown in FIG. 3B, is laid over the existing wood shakes 22.
In a standard installation of steel panels over existing roofing,
wood strips 21 (typically 1.times.4 inch nominal) are run
vertically up the roof to support the horizontal battens 20
(typically 2.times.2 inch). The use of the 1.times.4 inch vertical
strips creates a space 25 which is about 3/4" larger than the
similar space created in an installation on new construction. Thus
in order to use support elements 14 to support the steel panels 16
above existing roofing material, the extra space 25 created by the
wood strips 21 must be filled. This may be accomplished either by
an appropriately sized (typically 3/4-inch) riser 24, or by
increasing the dimensions of the support elements 14 to fill the
extra space. Risers 24 to be used in accordance with the roof panel
support are also preferably made of expanded polystyrene so that
they are also lightweight, durable, semi-compressible, fire safe,
inexpensive and easy to manufacture and install.
[0032] Installation of steel roof panels with support elements over
an existing roof is generally very similar to installation over new
construction with the added steps of attaching the wood framework
and placing risers on the roof surface before placing the support
elements on the risers and subsequently placing steel roofing
panels on the support elements. The steel panels are then
preferably secured using nails or other method know to those
skilled in the art. Those skilled in the art will recognize that
risers, support elements and steel panels may also be installed
over asphalt, ceramic, or any other roofing surface over which
steel roofs may be installed.
[0033] FIGS. 4 and 5 show steel roof panel support elements 14
having desired features and advantages. Support elements 14 are
preferably independent of steel roof panels 16. Individual support
elements 14 can be mass-produced for use with different, but
similar, kinds of steel roof panels. Commercially available steel
panels are available in a variety of shapes. For example, some
steel panels have a scalloped cross-section, some are corrugated,
and some have irregularly shaped cross-sections. Suitable steel
roofing panels are manufactured by such companies as Gerard Roofing
Technologies, MCA Roofing, and Tasman Roofing.
[0034] A support element having features and advantages of the
present roof panel support is preferably substantially
"wedge-shaped" as shown in FIG. 4. This wedge-shape has been shown
to sufficiently support a variety of shapes of steel roof panels
16, regardless of the shape of the roof panel 16. The support
element 14 shown in FIG. 4 has a quadrilateral cross-section 50.
Alternatively, a support element may have a substantially
triangular cross-section 40 as shown in FIG. 5.
[0035] The wedge-shaped supports with flat upper surfaces have been
shown to adequately support steel roof panels despite contacting
only the lowest-extending points of the panels. Field tests were
performed in which steel roofing panels 16 manufactured by Tasman
Roofing supported by a support element 14 were walked on. These
tests indicate that with support elements 14 under the roof panels
16, roof panels 16 may deflect substantially but will not yield
(i.e., will not permanently deflect). Thus, when a person walks
along a steel roof, the steel panels 16 supported by support
elements 14 may deflect initially, but will return to their
original shape without damage or permanent denting.
[0036] The support element 14 is preferably made of expanded
polystyrene foam. The support elements 14 are preferably cut from a
large block of expanded polystyrene with a hot wire. Suitable foam,
for example, is 1 lb. density foam manufactured by Insulfoam, Inc.
Support elements manufactured in this way, are very inexpensive.
The thickness and properties of the polystyrene are preferably such
that support elements 14 do not have a negative effect on a roof's
fire rating, and provide a thermal resistance rating (R-value) of
about 4 to about 6.
[0037] The width 44 and the height 46 of the support element 14
will vary depending on the specific installation requirements. The
height 46 at the front end 48 of the support element 14 is
preferably the same height or slightly smaller (about {fraction
(1/16)}.sup.th inch smaller) than the height of the battens 20.
Alternatively, the support element 14 may be taller than the height
of the batten 20. The width 44 of the support element 14 is
preferably such that that its bottom surface 58 covers a majority
of the roofing surface 12 directly below the corresponding steel
roof panels 16. The width 44 of the support element 14 is also
preferably such that its top surface 56 contacts a majority of the
surface of the downward-protruding portions 70 (FIG. 2a) under the
corresponding steel roof panels.
[0038] A steel roof panel support element 14, with a rectangular or
triangular cross section 40 may be designed to be compatible with
steel roof panels such as those manufactured by Tasman, Inc., which
are approximately 52.5" long, 14.5" wide, and made of about 26
gauge steel. The front end portion of the steel roof panel 16 may
be formed such that it may overlap a lower course of steel panels
16, as shown in FIGS. 1-3. Of course, those skilled in the art will
recognize that a variety of steel roof panels may also be used with
supports as described herein.
[0039] A steel roof panel support element 14 designed to be
compatible with such a steel panel could be 48" long 42, 12" wide
44, and preferably tapers from 1.5625" at the tall side 46 to about
0.5625" at its short side 62. Those skilled in the art will
recognize that other sizes may be used depending on the needs of
the specific installation and the size of the steel roofing panels
16 to be used. In such an arrangement, a steel panel 16 could be
placed over the support element 14 such that the bottom surface 58
of the support element 14 would be covering a majority of the
roofing surface 12 directly below the steel roof panel 16. As best
seen in FIG. 2a, for a steel roof panel with a non-flat cross
section, the downward-protruding portions 70 of the lower surface
of the steel roof panel would be in contact with the top surface 56
of the support element 14. A majority of the surface area of the
downward-protruding portions 70 of the steel roof panel 16, that is
not contacting the battens 20 or in contact with the roofing
surface 12, would be supported by the support element 14.
[0040] FIG. 6 illustrates a preferred packaging assembly 52 of
steel roof panel support elements 14. A number of support elements
14 are shown arranged into a bundle 52. The support elements 14 are
preferably stacked in an alternating fashion such that each
overlaying support element 14 is turned 180.degree. relative to the
adjacent elements 14 stacked thereby. The support elements 14 are
preferably bound with a plastic wrap 54 or some other method of
binding. In another preferred embodiment, the support elements 14
are packaged in bags. Support elements 14 that are independent of
steel roof panels are more cost effective in terms of packaging and
delivery than combined structures.
[0041] Although certain preferred embodiments and examples have
been described herein, it will be understood by those skilled in
the art that the present inventive subject matter extends beyond
the specifically disclosed embodiments to other alternative
embodiments and/or uses of the invention and obvious modifications
and equivalents thereof. Thus, it is intended that the scope of the
present inventive subject matter herein disclosed should not be
limited by the particular disclosed embodiments described above,
but should be determined only by a fair reading of the claims that
follow.
* * * * *