U.S. patent application number 11/415182 was filed with the patent office on 2007-11-15 for method and system for installation of diverse exterior sheathing components of buildings.
This patent application is currently assigned to Huber Engineered Woods LLC. Invention is credited to Federico R. Cecilio, Sherry S. Walker.
Application Number | 20070261340 11/415182 |
Document ID | / |
Family ID | 38683787 |
Filed Date | 2007-11-15 |
United States Patent
Application |
20070261340 |
Kind Code |
A1 |
Cecilio; Federico R. ; et
al. |
November 15, 2007 |
Method and system for installation of diverse exterior sheathing
components of buildings
Abstract
A method and system is provided for facilitating the proper
installation and ease of inspection therefor of a sheathed building
structure having a sheathing system comprising diverse sheathing
units to be used for roofing and sidewalls thereof which
incorporates a visual signaling system to ensure proper panel
selection and installation.
Inventors: |
Cecilio; Federico R.;
(Athens, GA) ; Walker; Sherry S.; (Salisbury,
NC) |
Correspondence
Address: |
Carlos Nieves, Esq.;Huber Engineered Woods LLC
c/o J.M. Huber Corp.
333 Thornall Street
Edison
NJ
08837
US
|
Assignee: |
Huber Engineered Woods LLC
Charlotte
NC
|
Family ID: |
38683787 |
Appl. No.: |
11/415182 |
Filed: |
May 2, 2006 |
Current U.S.
Class: |
52/311.1 |
Current CPC
Class: |
E04B 2001/741 20130101;
E04D 13/00 20130101; E04B 1/762 20130101; E04F 13/10 20130101 |
Class at
Publication: |
052/311.1 |
International
Class: |
E04F 15/00 20060101
E04F015/00 |
Claims
1. A method for facilitating the proper installation and ease of
inspection therefor of a sheathed building structure incorporating
a sheathing system comprising diverse sheathing units to be used
for roofing and sidewalls thereof, comprising: providing a
plurality of roofing panels each having a first water-resistant
major surface having a visually observable first panel color, and a
plurality of sidewall panels each having a second water-resistant
major surface having a visually observable second panel color which
is visually different from the first panel color, wherein the first
and second panel colors are correlated to a common panel parameter
category selected from the group consisting of panel load strength,
panel surface slip resistance, and panel fastening pattern, wherein
the roofing panels have a first panel parameter amount or pattern
as applicable for the common panel parameter category that is
different from a second panel parameter amount or pattern as
applicable for the common panel parameter category for the sidewall
panels; selecting, by a building structure assembler, the roofing
panels with visual reference to the first panel color; attaching,
by the building structure assembler, the selected roofing panels to
rafters forming part of an underlying first supporting structural
frame portion of a building frame, wherein the first
water-resistant major surface of each roofing panel faces outward;
selecting, by the building structure assembler, the sidewall panels
with visual reference to the second panel color; attaching, by the
building structure assembler, the selected sidewall panels to wall
frame forming part of a second supporting structural portion of
said building frame, wherein the second water-resistant major
surface of each sidewall panel faces outward.
2. A method according to claim 1, further comprising providing the
building structure assembler access to a medium before the
assembler selects the roofing panels, wherein the medium visually
displays an image of a representative building structure properly
sheathed with the sheathing system in which the first panel color
of the roofing panels is visible exclusively on a representative
roof of said representative building structure displayed in the
image, and the second panel color of the sidewall panels being
visible exclusively on representative exterior sidewalls of said
representative building structure displayed in the image.
3. A method according to claim 2, wherein the medium is selected
from the group consisting of a printed document, a still
photograph, an electronic digital camera image, a cellular phone
transmitted image, a computer-displayed still image, a videotape, a
CD video, internet-delivered streaming video, internet webpage
information, a television broadcast, and an image printed directly
on the roofing and sidewall panels.
4. A method according to claim 1, wherein the first and second
panel colors correlate to different panel load strengths of the
respective roofing and sidewall panels.
5. A method according to claim 1, wherein the first and second
panel colors correlate to different surface slip resistances of the
respective roofing and sidewall panels.
6. A method according to claim 1, wherein the first and second
panel colors correlate to different fastening patterns for the
respective roofing and sidewall panels.
7. A method according to claim 1, wherein said outward-facing
surface of said roofing panels further comprises a first fastening
pattern comprising a pattern of colored indicia having a first
fastening pattern color that is visibly distinct from the first
panel color of said outward-facing surface of said roofing panels
and said second panel color of said outward-facing sidewall
panels.
8. A method according to claim 1, wherein said outward-facing
surface of said sidewall panels further comprises a second
fastening pattern comprising a pattern of colored indicia having a
second fastening pattern color that is visibly distinct from the
second panel color of said outward-facing surface of said sidewall
panels, said first panel color of said outward-facing roofing
panels, and said first fastening pattern color.
9. A method according to claim 1, wherein said providing step
comprises production and delivery of said roofing and sidewall
panels to a building structure assembler.
10. A method according to claim 1, wherein said providing step
comprises a building structure assembler obtaining the roofing
panels and sidewall panels from a building materials retailer.
11. A method according to claim 1, further comprising, prior to
said providing step, packaging said roofing panels as respective
first bundled units in combination with first exterior packaging
displaying a first exterior packaging color, and packaging said
sidewall panels as respective second bundled units in combination
with second exterior packaging displaying a second exterior
packaging color, wherein the first and second exterior packaging
colors visually differ from each other, and the first and second
exterior packaging colors each substantially corresponds to the
respective first and second panel colors, respectively, effective
to provide a visual cue to a warehouse inventory manager, a
building materials supplier, and/or building structure assembler
regarding the roofing or sidewall panel contents associated with
packaged bundled units of building panels combined with either the
first or second exterior packaging.
12. A method according to claim 1, wherein proper installation of
the roofing and sidewall panels is confirmed by visual comparison
of the sheathed building structure with the image displayed in the
medium.
13. A method according to claim 1, wherein the first panel color is
displayed on at least about 50% of the total outward surface area
of the roofing panels and the second panel color is displayed on at
least about 50% of the total outward surface area of the sidewall
panels.
14. A method according to claim 1, wherein the first panel color is
displayed on at least about 90% of the total outward surface area
of the roofing panels and the second panel color is displayed on at
least about 90% of the total outward surface area of the sidewall
panels.
15. A method according to claim 1, further comprising seaming tape
applied to seams located between adjacent assembled roofing panels
and between assembled sidewall panels on the building
structure.
16. A method according to claim 1, wherein the sidewalls are
attached to the second supporting structural frame portion in an
orientation that is substantially vertical relative to a plane of a
base of the building structure, and the roofing panels are attached
to said first supporting structural frame portion in a non-parallel
inclined orientation relative to the plane of the base of the
building structure.
17. A method according to claim 1, wherein the roofing panels are
assembled in a first quilt pattern forming a substantially
continuous flat roof surface atop the first supporting structural
frame portion, and the sidewall panels are assembled in a second
quilt pattern forming a substantially continuous flat sidewall
surface on the second supporting structural frame portion.
18. The building product of the method of claim 1.
19. A system facilitating the proper installation and ease of
inspection therefor of a building structure incorporating a
sheathing system comprising diverse sheathing units to be used for
roofing and sidewalls thereof, comprising: a first packaged bundle
of first sheathing panel units which each having a first
water-resistant major surface having a visually observable first
panel color, said first packaged bundle having first exterior
packaging displaying a first packaging color corresponding to said
first panel color; a second packaged bundle of second sheathing
panel units which each having a second water-resistant major
surface having a visually observable second panel color, said
second packaged bundle having second exterior packaging displaying
a second packaging color corresponding to said second panel color,
wherein the second panel color is visually different from the first
panel color, and wherein the first and second panel colors are
correlated to a common panel parameter category selected from the
group consisting of panel load strength, panel surface slip
resistance, and panel fastening pattern, wherein the first
sheathing panels have a first panel parameter amount or pattern as
applicable for the panel parameter category that is different from
a second panel parameter amount or pattern as applicable for said
panel parameter category for the second sheathing panels; a medium
visually displaying an image of a representative building structure
properly sheathed with the sheathing system in which the first
panel color of the first sheathing panels being visible exclusively
on a representative roof of said representative building structure
displayed in the image, and the second panel color of the second
sheathing panels being visible exclusively on representative
exterior sidewalls of said representative building structure
displayed in the image.
20. A system according to claim 19, wherein the first panel color
is displayed on at least about 50% of the total outward surface
area of the roofing panels and the second panel color is displayed
on at least about 50% of the total outward surface area of the
sidewall panels.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a method and system for installing
diverse exterior sheathing components of buildings.
BACKGROUND OF THE INVENTION
[0002] The roof of a residential or commercial building is
typically constructed by attaching several roofing panels to the
rafters of an underlying supporting structural frame; the panels
are most often placed in a quilt-like pattern with the edge of each
panel generally aligned with the edges of adjacent panels so as to
form a substantially continuous flat surface atop the structural
frame.
[0003] However, small gaps along the edges of adjoining roofing
panels remain after roof assembly, which over time change in size
as the panels expand and contract. Because the roofing panels are
typically installed days or even weeks before shingles are
installed, it is important to have a panel system that minimizes
leakage resulting from exposure to the elements until such time as
the roof is completed. To prevent water from leaking through the
gaps between panels, it is commonly practiced in the industry to
put a water-resistant barrier layer on top of the roofing
panels.
[0004] The building construction industry has used water-resistive
materials before shingle installation, primarily in the form of
felt paper. While this provides protection against water
penetration, it has the disadvantage of being difficult and
time-consuming to install because the paper or felt must be first
unrolled and spread over the roof surface and then secured to the
panels. The felt paper is vulnerable to the weather. Strong wind,
rain, and other events weaken the felt paper; often this barrier
fails to maintain its ability to shed bulk water, and must be
re-installed prior to shingle installation. Sometimes, the damaged
barrier layer is not repaired prior to shingle installation and the
home owner is left with an inferior roof.
[0005] Wall construction similarly involves installation of a
weather-resistive barrier before siding installation in the form of
felt or housewrap. Same as roof installation, this involves an
extra step of unrolling the felt or housewrap, attaching to the
panels with staples or button cap nails, cutting and folding at
fenestration openings such as windows and doors. These are
difficult to install, since housewrap typically comes in nine foot
wide rolls, which can be difficult to maneuver on a scaffold,
especially during high-wind conditions. Poor installation of the
housewrap leads to problems that are difficult to detect until they
cause serious damage. For instance, a housewrap can trap water
between itself and the sheathing over which it is installed. This
situation can cause mold and rot.
[0006] Roofing panels and wall panels used in building construction
often have significantly different performance requirements from
one another. Panel requirements are often specified differently for
roofing and wall panels by state and/or local applicable building
codes, ordinances, requirements, standards, etc. Many jurisdictions
also currently require inspections of both roofing and wall
sheathing as part of the building permit process.
[0007] Sheathing panels having different thicknesses and/or
different imprinted fastening regimens are often present and
available for use on building sites. These panels also often are
made with generally similar wood composite materials, such as
plywood or oriented strand board (OSB). Panel thickness is one of
the most often used variables which is adjusted by panel
manufacturers to adjust panel performance ratings. Absent careful
time-consuming measurements, these differences in panel thicknesses
are often imperceptible. However, there is a risk that the design
of the structure under construction may be compromised and/or fail
inspection in the event diverse paneling used for roofing and wall
sheathing was interchanged. Moreover, after the building is
assembled, a building inspector has not been able to readily
determine and detect if appropriate types of panels were properly
selected and used in constructing the entire respective roof and
wall sheathing systems.
[0008] As will become apparent from the descriptions that follow,
the invention addresses these needs as well as provides other
advantages and benefits.
SUMMARY OF THE INVENTION
[0009] This invention relates to a method and system for
facilitating the proper installation and ease of inspection
therefor of a sheathed building structure having a sheathing system
comprising diverse sheathing units to be used for roofing and
sidewalls thereof which incorporates a visual signaling system to
ensure proper panel selection and installation.
[0010] In one embodiment, the method comprises providing a
plurality of roofing panels each having a first water-resistant
major surface having a visually observable first panel color, and a
plurality of sidewall panels each having a second water-resistant
major surface having a visually observable second panel color which
is visually different from the first panel color. The first and
second panel colors are correlated to a common panel parameter
category selected from the group consisting of panel load strength,
panel surface slip resistance, and panel fastening pattern, wherein
the roofing panels have a first panel parameter amount or pattern
as applicable for the common panel parameter category that is
different from a second panel parameter amount or pattern as
applicable for the common panel parameter category for the sidewall
panels. A building structure assembler selects the roofing panels
with visual reference to the first panel color, and attaches the
selected roofing panels to rafters forming part of an underlying
first supporting structural frame portion of a building frame,
wherein the first water-resistant major surface of each roofing
panel faces outward. A building structure assembler also selects
the sidewall panels with visual reference to the second panel color
and attaches the selected sidewall panels to wall frame forming
part of a second supporting structural portion of the building
frame, wherein the second water-resistant major surface of each
sidewall panel faces outward.
[0011] This invention aids building structure assemblers and
inspectors in readily and accurately differentiating between
roof-grade paneling with integrated water-resistive barriers and
wall-grade paneling with integrated water-resistive barriers. In
this manner, it makes it possible to ensure that the roofing and
wall paneling, as installed on the building by assemblers, meets
the applicable sheathing performance requirements. For example, the
method of the present invention allows for accurate selection
between diverse panel supplies on site such that the paneling as
installed meets the applicable roof or wall sheathing performance
requirements, such as load requirements, fastening schedule, and
surface slip resistance. This invention thus makes it possible to
overcome differences in language, level of education and literacy
at a building site, since it is commonly known in the building
industry that there routinely exist huge differences in these areas
amongst building crews. The color scheme system, as presented and
applied herein, provides a universal communication mode which
visually communicates information to builders and building
inspectors so that they can readily identify and distinguish
between different types of paneling off or on the building.
[0012] In a further embodiment, the building structure assembler is
provided access to a medium before the assembler selects the
roofing panels, wherein the medium visually displays an image of a
representative building structure properly sheathed with the
sheathing system in which the first panel color of the roofing
panels is visible exclusively on a representative roof of the
representative building structure displayed in the image, and the
second panel color of the sidewall panels being visible exclusively
on representative exterior sidewalls of the representative building
structure displayed in the image. The builder references the medium
or media before selecting and assembling the roofing and wall
sheathing. In yet another embodiment, proper installation of the
roofing and sidewall panels is confirmed by visual comparison of
the sheathed building structure with the image displayed in the
medium. For example, a building site manager or building inspector
can reference the medium or media when inspecting the roofed and
walled building. In a particular embodiment, the medium is selected
from the group consisting of a printed document, a still
photograph, an electronic digital camera image, a cellular phone
transmitted image, a computer-displayed still image, a videotape, a
CD video, internet-delivered streaming video, internet webpage
information, a television broadcast, and an image printed directly
on the roofing and sidewall panels.
[0013] In another further embodiment, the outward-facing surface of
the roofing panels further comprises a first fastening pattern
comprising a pattern of colored indicia having a first fastening
pattern color that is visibly distinct from the first panel color
of the outward-facing surface of the roofing panels and the second
panel color of the outward-facing sidewall panels. Also, the
outward-facing surface of the sidewall panels may further comprise
a second fastening pattern comprising a pattern of colored indicia
having a second fastening pattern color that is visibly distinct
from the second panel color of the outward-facing surface of the
sidewall panels, the first panel color of the outward-facing
roofing panels, and the first fastening pattern color.
[0014] In another embodiment, the roofing and side panels are
provided via production and delivery of the roofing and sidewall
panels to a building structure assembler, such as located at a
building site or building materials storage site therefor.
Alternatively, the roofing and sidewall panels may be provided by a
building structure assembler obtaining the roofing panels and
sidewall panels from a building materials retailer.
[0015] In another embodiment, prior to providing the panels to a
building structure assembler, the roofing panels are packaged as
respective first bundled units in combination with first exterior
packaging displaying a first exterior packaging color, and the
sidewall panels are packaged as respective second bundled units in
combination with second exterior packaging displaying a second
exterior packaging color, wherein the first and second exterior
packaging colors visually differ from each other, and the first and
second exterior packaging colors each substantially corresponds to
the respective first and second panel colors, respectively,
effective to provide a visual cue to a warehouse inventory manager,
a building materials supplier, and/or building structure assembler
regarding the roofing or sidewall panel contents associated with
packaged bundled units of building panels combined with either the
first or second exterior packaging.
[0016] In another embodiment, the first panel color is displayed on
at least about 50%, particularly at least about 90%, of the total
outward surface area of the roofing panels and the second panel
color is displayed on at least about 50%, particularly at least
about 90%, of the total outward surface area of the sidewall
panels.
[0017] The difference in color provided between the roofing and
wall sheathing panels may be any visually-discernible difference in
colors that can be perceived by the human eye. Preferably, the
color choices are at least two colors apart on the color wheel so
that a builder or inspector can readily visually distinguish the
roof-grade from wall-grade panels. The two colors preferably may
differ from each other in the range between a color diad to
complementary colors. The two colors may vary from one another in
terms of hue, lightness, saturation, tint, tone, shade and/or
value.
[0018] In another embodiment, a seaming tape is applied to seams
located between adjacent assembled roofing panels and between
assembled sidewall panels on the building structure. The sidewalls
are attached to the second supporting structural frame portion in
an orientation that is substantially vertical relative to a plane
of a base of the building structure, and the roofing panels are
attached to the first supporting structural frame portion in a
non-parallel inclined orientation relative to the plane of the base
of the building structure. In a particular embodiment, the roofing
panels are assembled in a first quilt pattern forming a
substantially continuous flat roof surface atop the first
supporting structural frame portion, and the sidewall panels are
assembled in a second quilt pattern forming a substantially
continuous flat sidewall surface on the second supporting
structural frame portion.
[0019] Building products of methods of the present invention are
also encompassed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a block diagram of a method for facilitating the
proper installation and ease of inspection therefor of a sheathed
building structure incorporating a sheathing system comprising
diverse sheathing units to be used for roofing and sidewalls in
accordance with an embodiment of the present invention.
[0021] FIG. 2 is a perspective view of building constructed with
panelized roofing and wall sheathing assembled using color schemed
panels according to a method of the present invention.
[0022] FIGS. 3 and 4 illustrate roof and wall panels, respectively,
with respective integral fastening guides imprinted on their outer
surfaces.
[0023] FIG. 5 is a modified rendition of the Color Wheel, within
the constraints of black and white illustration, showing the
relative locations of primary, secondary and tertiary colors with
applicable labeling.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] As used herein, a "color" may be a primary color (a color
that cannot be made as a combination of any other colors), a
secondary color (a color created from a combination of two primary
colors), a tertiary color (a combination of three colors that are
primary or secondary) or other intermediates, or black, and
includes earth colors. A "color wheel" refers to a traditional
color wheel (see, e.g., FIG. 5), such as a Johannes Itten color
wheel, based on the RYB model (red/yellow/blue) with secondary
colors of orange, green, and violet (purple), and tertiary colors
comprising combinations of primary and secondary colors (i.e.,
yellow-orange, red-orange, red-violet, blue-violet, blue-green,
yellow-green). A "color diad" or "diadic color scheme" is one using
two colors that are two colors apart on the color wheel (e.g., red
and orange). A "complementary color scheme" is one that uses colors
or hues that are directly across from each other on the color wheel
(e.g., blue and orange). "Hue" is the name of the color itself, the
dominant wavelength of light or the choice of pigment. "Lightness
(brightness)" is the lightness or darkness of the color, the amount
of light reflected or transmitted. "Saturation" is the level of
white, black or grey, ranges from neutral to brilliant (pastel to
full color). "Tint" is base color plus white. "Tone" is base color
plus grey. "Shade" is base color plus black. "Value" is how light
or dark a color is.
[0025] As used herein, "wood" is intended to mean a cellular
structure, having cell walls composed of cellulose and
hemicellulose fibers bonded together by lignin polymer. "Wafer
board" is intended to mean panels manufactured from reconstituted
wood wafers bonded with resins under heat and pressure. By "wood
composite material" it is meant a composite material that comprises
wood and one or more other additives, such as adhesives or waxes.
Non-limiting examples of wood composite materials include oriented
strand board ("OSB"), waferboard, particleboard, chipboard,
medium-density fiberboard, plywood, and boards that are a composite
of strands and ply veneers. As used herein, "flakes" and "strands"
are considered equivalent to one another and are used
interchangeably. A non-exclusive description of wood composite
materials may be found in the Supplement Volume to the Kirk-Othmer
Encyclopedia of Chemical Technology, pp. 765-810, 6th sup. edition.
As used herein, "structural panel" is intended to mean a panel
product composed primarily of wood which, in its commodity end use,
is essentially dependent upon certain mechanical and/or physical
properties for successful end use performance such as plywood. A
non-exclusive description may be found in the PS-2-92 Voluntary
Product Standard.
[0026] The following describes preferred embodiments of the present
invention which provides a method for selecting and installing
panels for panelized roofing and wall sheathing systems that
facilitates proper selection, installation and inspection amongst
diverse panels used in the construction. The method is suitable for
use in the construction of residential and commercial
buildings.
[0027] Referring to FIG. 1, the block diagram describes a sequence
of steps for implementing a building method 100 of the present
invention. In Steps 1001a, 1001b, a plurality of roofing panels is
provided having a water-resistant major surface having a visually
observable first panel color ("Color 1"), and a plurality of
sidewall panels also is provided having a water-resistant major
surface having a visually observable second panel color ("Color
2"), which is visually different from the first panel color. The
first and second panel colors are correlated to a common panel
parameter category selected from the group consisting of panel load
strength, panel surface slip resistance, and panel fastening
pattern, wherein the roofing panels have a first panel parameter
amount or pattern as applicable for the common panel parameter
category that is different from a second panel parameter amount or
pattern as applicable for the common panel parameter category for
the sidewall panels.
[0028] The selection of contrasting colors for Color 1 and Color 2
involves choosing colors that will be easily distinguished by
unskilled or skilled workers for installation and inspection, and
that will appropriately maintain that distinction. The first panel
color is displayed on at least about 50%, particularly at least
about 90%, of the total outward surface area of the roofing panels
and the second panel color is displayed on at least about 50%,
particularly at least about 90%, of the total outward surface area
of the sidewall panels. Color 1 and Color 2 can be provided as a
continuous coat across the entire exposed outer face of the given
panel (approx. 100% coverage), or, alternatively, it may be
provided in pattern form or discontinuously on the exposed outer
face with a neutral colored background area on the same face of the
panel relative. For example, Color 1 and Color 2 could be imprinted
or coated on the outer surface in the form of a pattern of colored
logos, geometric shapes (e.g., stripes, circles, etc.), patterns
(e.g., plaid), and so forth, on a white or other neutral colored
background different from Color 1 and Color 2.
[0029] The difference in color provided between the roofing and
wall sheathing panels may be any visually-discernible difference in
colors that can be perceived by the human eye. Preferably, the
color choices are at least two colors apart on the color wheel so
that a builder or inspector can readily visually distinguish the
roof-grade from wall-grade panels. The two colors preferably differ
from each other in the range between a color diad to complementary
colors. For example, referring to FIG. 5, Color 1 could be
Yellow-Orange and Color 2 could be Yellow-Green. Alternatively, for
example, Color 1 could be Red-Orange and Color 2 could be
Blue-Green, and so forth. It will be appreciated that shades of the
twelve hues indicated in FIG. 5 also can be used, which are not
shown due to limitations of black and white illustration, but will
be understood by those familiar to the pigment arts and the like.
The two colors may vary from one another in terms of hue,
lightness, saturation, tint, tone, shade and/or value.
[0030] The visually-discernible color difference between Color 1
and Color 2 also can be expressed as different respective Pantone
color numbers. For instance, Color 1 of the roof sheathing products
may be selected to be Pantone 167U, while Color 2 of the wall
sheathing products may be selected to be Pantone 576U. Other color
combinations based on visually-different colors having different
respective Pantone numbers also may be used in selecting the
roofing and wall panel colors.
[0031] The visually-discernible color difference between Color 1
and Color 2 also can be expressed quantitatively, such as with the
CIE L*a*b* Color Scale. In one aspect, the first and second panel
colors have differing respective total color difference values,
.DELTA.E*; differing respective chroma values, .DELTA.C*; and/or
differing respective hue angle values, .DELTA.H*; based on CIE
L*a*b* Color Scale measurements taken on the panels using a
Hunterlab color measurement instrument that correlate to
visually-different colors. For example, the roofing panels may be
designed in this alternate embodiment to have a .DELTA.E*.sub.Color
1 value that quantitatively differs from the .DELTA.E*.sub.Color 2
value of the wall panel in an amount that correlates to
visually-perceptible differences between Color 1 and Color 2.
Similarly, differences in .DELTA.C* and/or .DELTA.H* values can be
provided as between roofing panel Color 1 and wall panel Color 2
that correlate to visually-perceptible differences between Color 1
and Color 2.
[0032] In step 1002a, a builder selects the roofing panels with
visual reference to the first panel color. In step 1003a, the
builder then attaches selected roofing panels to rafters forming
part of an underlying first supporting structural frame portion of
a building frame with the first water-resistant major surface of
each roofing panel facing outward. Alternatively, in step 1003a,
the builder selects the sidewall panels with visual reference to
the second panel color. In step 1003b, the builder attaches the
selected sidewall panels to wall frame forming part of a second
supporting structural portion of the building frame with the second
water-resistant major surface of each sidewall panel faces outward.
In step 1004, the paneled structure is inspected by the builder or
building inspector by reference to the panel colors observed at the
roof and sidewalls of the building.
[0033] The builder is trained to correlate color with type of
panel. For example, in step 1000a or alternatively step 1000b, the
builder is provided access to a medium displaying a building
structure image to the builder that indicates the proper color
scheme of the roofing and wall panels relative to each other. The
builder can reference that image before selecting and assembling
the roof panels and wall panels on the building frame to ensure and
confirm proper placement of the respective different types of
panels. The medium also may be used for post-construction
inspections of the paneled building. The medium may be printed or
electronic. It must be in a format useful to communicate color
differences. The medium may be selected from the group consisting
of a printed document (e.g., a brochure, flyer, etc.), a still
photograph, an electronic digital camera image, a cellular phone
transmitted image, a computer-displayed still image, a videotape, a
CD video, internet-delivered streaming video, internet webpage
information, a television broadcast, and an image printed directly
on the roofing and sidewall panels, or combinations of these.
[0034] The method of this invention for installing roof and wall
sheathing having an integrated water-resistive barrier minimizes
builder crews' potential mistake of interchanging panels for the
intended application by providing visual cues as a visually
distinct color for the overlay of roof sheathing panels and a
different color for the overlay of wall sheathing panels. It also
allows building structure assemblers and inspectors to readily and
accurately differentiate between roof-grade paneling with
integrated water-resistive barriers and wall-grade paneling with
integrated water-resistive barriers. In this manner, it makes it
possible to ensure that the roofing and wall paneling, as installed
on the building by assemblers, meets the applicable sheathing
performance requirements. This invention makes it possible to
overcome differences in language, level of education and literacy
at a building site, since it is commonly known in the building
industry that there routinely exist huge differences in these areas
amongst building crews. The color scheme system, as presented and
applied herein, provides a universal communication mode which
visually communicates information to builders and building
inspectors so that they can readily identify and distinguish
between different types of paneling off or on the building.
[0035] FIG. 2 illustrates a building product 101 assembled with a
method of the present invention. Building 101 includes a panelized
roof sheathing construction system 10 and panelized wall sheathing
system 110 having a plurality of panels 20 and 120, respectively,
attached to a building frame structure 102 including rafters 116
and wall frame 115, in substantially abutting relationship. The
differently angled imaginary diagonal lines d1 and d2 included in
the depictions of roofing panels 20 and wall panels 120,
respectively, denote differently colored outer surfaces
therebetween.
[0036] Referring still to FIG. 2, the roofing panels 20 have an
inward-facing surface 22, an outward facing surface 24 displaying
"Color 1", and at least one peripheral edge. Surfaces 22 are major
panel surfaces facing the space enclosed by the sheathing, and
surfaces 24 are major panel surfaces on the opposite sides of the
respective panels that face away from the enclosed space. Also, the
roofing system 10 preferably includes a plurality of
water-resistant sealing means 40, each of the means 40 sealing at
least one of the joints 25 between the adjacent panels 20. The wall
panels 120 have an inward-facing surface 121 (i.e., a major panel
surface that faces the building space enclosed by the sheathing),
and an outward facing surface 122 (i.e., a major panel surface that
faces away from the enclosed building space) displaying "Color 2",
and have at least one peripheral edge. The roofing system 10 also
preferably includes water resistant barrier layers adhesively
secured to at least one of the surfaces of the panels 20.
[0037] The wall sheathing system 110 preferably includes a
plurality of water-resistant sealing means 140, each of the means
140 sealing at least one of the joints 127 between the adjacent
panels 120. The wall sheathing system 110 also preferably includes
water resistant barrier layers adhesively secured to at least one
of the surfaces of the panels 120.
[0038] In meeting load design requirements, builders often utilize
7/16 inch, 1/2 inch, 5/8 inch, 23/32 inch, or other suitable
thickness panels for roof construction. 7/16 inch paneling requires
either a closer rafter spacing or use of H-clips to prevent
buckling, deflection and misalignment between panel edges, whilst
utilizing 1/2 inch panels allow for wider rafter spacing as well as
eliminate the need for H-clips due to its higher load capacity.
Structural wall sheathing on the other hand typically will have
either 7/16 inch or 1/2 inch thickness, although the 7/16 inch
thickness paneling often is typically adequate to meet wall
sheathing requirements and thus is usually used. However, when the
present invention is not used, the panels may be easily mixed up in
the job site when 1/2 inch panels are required for roofing and 7/16
inch panels are needed for wall sheathing, and the like. For
example, the present invention eliminates the risk of 7/16 inch
"wall" panels being used for a roof construction having 1/2 inch
thickness structural load design or requirement.
[0039] As illustrated in FIGS. 3 and 4, fastening schedules between
roof and wall installation typically differ due to differences in
the building code and installation practices. The fastening
locations are indicated at sites 31 in FIG. 3 and at sites 32 in
FIG. 4. As common with the panel suppliers to the building
industry, manufacturers provide fastening guide patterns to make it
easier, faster and more convenient for the building crew to install
roof and wall sheathing. However, all the current arts utilize
printing on the engineered wood panel itself, be it in the form of
plywood or oriented strand board (OSB). Felt and housewrap are
installed after sheathing installation, and hence do not come with
a fastening or nailing pattern.
[0040] Printing fastening schedules on the surface of the overlay,
or more specifically, the weather-resistive barrier has the
downside of using a wall fastening schedule on a roof and
vice-versa, the design from a loading, wind-resistance,
wind-uplift, wall racking and a host of other factors are different
for roof and wall construction. Hence, there exists the possibility
that a builder will follow a fastening schedule not for its
intended use. For example, as illustrated in FIGS. 3 and 4, there
is a basic difference between roof and wall, i.e., roof sheathing
are typically installed horizontally relative to the rafters,
whilst wall sheathing can be installed vertically or horizontally.
Utilizing a fastening guide design for a different application will
result in compromising the structural integrity of the building.
The method of the present invention makes it possible for builders
to readily differentiate between roofing and wall panels based on
the color scheme.
[0041] In a further embodiment, the outward-facing surface of the
roofing panels can be provided a fastening pattern imprinted as a
pattern of colored indicia in a color that is visibly distinct from
the color of the host panel and the panel color of the wall panels.
Similarly, the outward-facing surface of the wall panels can be
provided a fastening pattern imprinted as a pattern of colored
indicia in a color that is visibly distinct from the color of its
host panel, the color of the roofing panels as well as the color of
the fastening pattern on the roofing panels.
[0042] Another difference that commonly exists between roofing and
wall panels is in slip resistance requirements. A panel product
used in the roof typically will have more stringent requirements in
terms of slip resistance than the sidewalls because builders
typically walk on roofing construction panels during construction
of the roof. The color scheme used in the present invention also
can be used to aid workers in readily differentiating more skid
resistant panels from less skid resistant ones.
[0043] Other advantages of using a visual-based instruction aid in
building construction in accordance with the present invention also
include the following: mistake-proof building sheathing
construction based on visual aids is provided; contractors can show
the benefits and advantages of "mistake-proofing" to buyers during
the construction process, creating a higher confidence level of
having a more robust/safer dwelling place; lumberyards, home
building supply retailers, inventory and supply chain systems, can
more easily differentiate not only the panel colors, but also
packaging of the panels that would carry the same visual aid
differentiation, resulting in a more efficient sales and
distribution process and lowering the probability of shipping
similar panels by mistake for roof vs. wall applications. Also, the
building inspection process will be improved in both ease and
accuracy regarding building roofing and sheathing inspections.
Also, while new products in the construction industry typically
require considerable communication and training, the visual-based
differentiation system based on color as used in the inventive
method allows a significantly simpler and easier opportunity for
building inspectors to differentiate and ensure that the proper
materials are installed for roof versus wall applications when they
go around the construction sites.
[0044] Although not limited thereto, and aside from the color
feature thereof, structural panels with built-in waterproof
surfaces that may be used for panelized roof sheathing and
panelized wall sheathing systems used in methods of the present
invention, include those described, for example, in U.S. Published
Pat. Appln. Nos. US2005/0229504 A1, US2005/0229524 A1, and
US2005/0257469 A1, which descriptions are incorporated herein by
reference. Also, panel seaming means (such as tape, laminate,
caulk, foam, spray, putty, mechanical means, or any other suitable
sealing mechanism used to seal the joints or seams between
adjoining panels), panel tongue-and-groove fasteners, and
panel-to-frame fastening systems, and the like, which may be used
in the assembly of panelized roofing and wall systems in methods of
the present invention, also are generally described, for example,
in these '504, '524 and '469 published patent publications, which
are incorporated herein by reference. The roofing panels are
suitable for use behind numerous exterior finishes for roofs such
as shingles, metal, and tile, and the wall panels are suitable for
use behind numerous exterior finishes, such as siding, brick, lap
siding, vinyl, and the like. As will be appreciated, the roofing
and wall sheathing systems as installed in methods of the present
invention ordinarily will be inspected before such exterior
finishes are applied. It will be appreciated that the outer
surfaces of the roofing and wall panels described therein will be
modified for purposes of the present invention to further include
color schemes in accordance with embodiments of the present
invention. For instance, the outer surfaces of the roofing and wall
panels may provided with an appropriate color by any suitable
technique such as painting, coating, or overlaying a substrate
panel with pigmented or colored paper or a pigmented or colored
synthetic plastic film, and so forth, using any conventional or
otherwise suitable technique for providing a colored major surface
thereon.
[0045] While the invention has been particularly described with
specific reference to particular process and product embodiments,
it will be appreciated that various alterations, modifications and
adaptations may be based on the present disclosure, and are
intended to be within the spirit and scope of the present invention
as defined by the following claims.
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