U.S. patent number 3,763,605 [Application Number 05/268,157] was granted by the patent office on 1973-10-09 for roofing system and method of application.
This patent grant is currently assigned to Wyndham J. Freeman Ltd.. Invention is credited to Wyndham J. Freeman.
United States Patent |
3,763,605 |
Freeman |
October 9, 1973 |
ROOFING SYSTEM AND METHOD OF APPLICATION
Abstract
A roofing system characterized in that it employs a first
loading or insulating coat of asphaltic cement and a suitable inert
insulating material preferably an igneous, glassy, siliceous or
micaceous rock such as vermiculite (exfoliated), pearlite (popped)
or the like applied to and covering a roof deck, a waterproof
membrane applied over said first loading coat and extending at
least substantially to the edges thereof, and a second loading coat
of asphaltic cement and a suitable inert insulating material
preferably an igneous, glassy, siliceous or micaceous rock such as
vermiculite (exfoliated), pearlite (popped) or the like applied
over said waterproof membrane.
Inventors: |
Freeman; Wyndham J. (Downsview,
Ontario, CA) |
Assignee: |
Wyndham J. Freeman Ltd.
(Downsview, Ontario, CA)
|
Family
ID: |
23021732 |
Appl.
No.: |
05/268,157 |
Filed: |
June 30, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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205219 |
Dec 6, 1971 |
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Current U.S.
Class: |
52/58; 52/408;
52/94; 156/71 |
Current CPC
Class: |
E04D
13/1415 (20130101); E04D 13/155 (20130101); E04D
11/02 (20130101); E04D 7/00 (20130101) |
Current International
Class: |
E04D
13/15 (20060101); E04D 7/00 (20060101); E04D
13/155 (20060101); E04D 11/00 (20060101); E04D
11/02 (20060101); E04D 13/14 (20060101); E04d
001/36 () |
Field of
Search: |
;52/58,302,94,408,411,748 ;156/71 ;161/160,236 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Perham; Alfred C.
Parent Case Text
This application is a continuation-in-part of U.S. Patent
application Ser. No. 205,219, filed Dec. 6, 1971 and now abandoned.
Claims
I claim:
1. In a roofing system, a roof deck, a first loading coat of
asphaltic cement and an igneous rock aggregate applied to and
covering said roof deck, a waterproof membrane applied over said
first loading coat and extending at least substantially to the
edges thereof, and a second loading coat of asphaltic cement and an
igneous rock aggregate applied over said waterproof membrane.
2. A roofing system as claimed in claim 1 in which said aggregate
is selected from exfoliated vermiculite and popped pearlite.
3. A roofing system as claimed in claim 2 in which said waterproof
membrane is formed of asphalt impregnated and coated sheeting.
4. A roofing system as claimed in claim 3 in which said sheeting is
provided on its upper surface with a coating of abrasive particles
in interlocking relation with said second loading coat.
5. A roofing system as claimed in claim 3 in which the edges of
said waterproof membrane are turned upwardly to define a waterproof
tank within said upturned edges.
6. A roofing system as claimed in claim 3 in which at the edges of
said roof deck said first and second loading coats with said
waterproof membrane embedded therebetween are extended upwardly to
define a waterproof tank within said upturned edges.
7. A roofing system as claimed in claim 3 in which said edges of
said waterproof membrane are extended beyond said first loading
coat and are turned upwardly and inwardly to envelop the edges of
said second loading coat.
8. In a roofing system, a roof deck, a first loading coat resistant
to water penetration but permitting migration of water vapour such
as to prevent vapour pressure build-up applied over and covering
said deck, a moisture and water vapour proof membrane applied over
said loading coat and in intimate contact therewith, said moisture
and vapour proof membrane extending at least substantially to the
edges of said first loading coat, and a second loading coat
resistant to water penetration but permitting migration of water
vapour such as to prevent vapour pressure build-up applied over and
in intimate contact with said moisture and waterproof membrane,
said first and second loading coats being formed of asphaltic
cement and igneous rock aggregate.
9. A roofing system as claimed in claim 8 in which said aggregate
is selected from exfoliated vermiculite and popped pearlite.
10. A roofing system as claimed in claim 9 in which said moisture
and water vapour proof membrane comprises asphalt impregnated and
coated sheeting.
11. A roofing system as claimed in claim 10 in which said sheeting
is provided on its upper surface with a coating of abrasive
particles in interlocking relation with said second loading
coat.
12. A roofing system as claimed in claim 9 in which the edges of
said waterproof membrane are turned upwardly to define a waterproof
tank within said upturned edges while leaving the periphery of said
first loading coat exposed for the lateral escape of any water
vapour present in said first loading coat beneath said tank prior
to the application of said water and moisture proof membrane.
13. A roofing structure as claimed in claim 9 in which the edges of
said waterproof membrane are extended beyond said first loading
coat and are turned upwardly to envelop the edges of said second
loading coat while leaving the periphery of said first loading coat
exposed for the lateral escape of any water vapour present in said
first loading coat prior to the application of said membrane.
14. A roofing structure as claimed in claim 9 in which said first
and second loading coats comprise an intimate mixture of asphaltic
cement and aggregate in the proportions of about 4 gallons of
asphaltic cement to about 4 cubic feet of aggregate.
15. A roofing structure as claimed in claim 9 having a surface
protective layer applied over said second loading coat.
16. A method of applying a roofing system to a roof deck comprising
applying a first layer of hot intimately mixed asphaltic cement and
igneous rock aggregate to the roof deck and compacting said layer
to form a first loading coat having a substantially smooth upper
surface, applying a water and vapour proof membrane over said first
loading coat while eliminating air pockets therebeneath, then
applying a second layer of hot intimately mixed asphaltic cement
and igneous rock aggregate over said water and vapour proof
membrane.
17. A method as claimed in claim 16 in which said igneous rock
aggregate is selected from exfoliated vermiculite and popped
pearlite.
18. A method of applying a roofing system as claimed in claim 17 in
which the asphaltic cement and aggregate are mixed in the
proportion of about 4 gallons of asphaltic cement to about 4 cubic
feet of aggregate.
19. A method as claimed in claim 16 in which said membrane is
turned upwardly at the edges to define a water and vapour proof
tank overlying said roof deck.
20. A method as claimed in claim 16 in which said membrane is
extended beyond the edges of said loading coats and turned upwardly
to envelop the edge of said second loading coat.
21. A method as claimed in claim 16 in which said waterproof
membrane comprises as asphalt impregnated and coated sheeting and
said sheeting is applied by mopping with hot asphalt.
Description
FIELD OF THE INVENTION
This invention relates to improvements in roofing and the
installations thereof and more particularly to a novel roofing
system for waterproofing and insulating the main roof structure of
buildings of all types, which incorporate roof decks.
BACKGROUND OF THE INVENTION
There have been innumerable built-up roofing systems proposed for
use on roof decking in the prior art but no entirely satisfactory
roofing system has heretofor been devised. In such prior art
roofing, the attempt to render the roofing impervious to water is
frequently nullified by the very means such as nails intended to
hold the roofing in place, which pierce or puncture the roofing.
Often, too, the roofing punctured by the assembly of other
equipment on the roofing or by the dropping thereon of heavy
objects such as masonry objects or the like during work in progress
on and around the roofing.
Even where great care is taken to minimize or to prevent actual
piercing or puncturing of present roofing systems, such systems
almost invariably contain some moisture particles which under
changing ambient conditions on either side of the roofing build up
pressure and effect blistering and ridging of the roofing and in
time the rupture of the intended water proofing barriers to render
such roofing pervious to water.
Another difficulty with present roofing is that it is adversely
affected when rain falls on the components during application or
when application is made in cold weather. Still again, many of the
present roofing systems are totally unsuitable for tropical
climates.
BRIEF DESCRIPTION OF THE INVENTION
According to the present invention, the above problems are overcome
by first applying to the roof deck a first protective insulating or
loading layer of an asphaltic cement or bitumen and a suitable
inert insulating material preferably an igneous, glassy, siliceous
or micaceous rock such as vermiculite (exfoliated), pearlite
(popped) or the like, over which is applied a waterproof membrane
and over which in turn is applied a second protective or loading
coat of asphaltic cement or bitumen and a suitable insulating
material as referred to above. Thereafter any desired protective or
decorative roof surfacing may be applied. Preferably the waterproof
membrane comprises asphalt saturated and coated sheeting to provide
for intimate bonding with the asphalt-insulating material loading
coats. Also, preferably, but not necessarily, the waterproof
membrane is extended beyond the first loading coat and is turned
upwardly to envelop the surrounding edge of the second loading
coat. The system according to the invention thus provides a
waterproof membrane barrier or core member isolated against
physical damage from all external sources, between two loading
coats of asphaltic cement or bitumen and insulating material which
in themselves provide for lateral passage of vapours which normally
cause pressure build-ups. Thus the loading coats also protect the
waterproof membrane from physical damage from all internal
sources.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a broken-away, part-elevational, part-vertical sectional
view of a roofing system according to the invention, applied to a
concrete deck.
FIG. 1A is an enlarged broken-away vertical sectional view of the
loading coats and centre core membrane of the roofing system of
FIG. 1.
FIG. 2 is a view similar to FIG. 1 but showing the system applied
to a steel decking and omitting the surface wearing course.
FIG. 3 is a view similar to FIG. 1 but showing a modified roofing
system arrangement in which the centre core membrane is returned
inwardly to envelop the edge of the roofing thereabove.
FIG. 4 is again a view similar to FIG. 1 but showing a further
arrangement in which the centre core membrane terminates at the
edge of the roof.
DETAILED DESCRIPTION OF THE DRAWINGS
Referring first to FIG. 1, there is shown applied over the roof
decking D a first layer or coat 1 which is formed of asphaltic
cement or bitumen and an aggregate of a suitable inert insulating
material preferably an igneous, glassy, siliceous or micaceous rock
such as vermiculite (exfoliated), pearlite (popped) or the like.
Applied over this layer 1 is a centre core membrane 2 whose
essential requirement is that it must be moisture and vapour
impervious. This layer 2 may conveniently and economically be
formed from asphalt saturated and coated felted sheet material in
order to achieve an intimate surface contact or bond with the layer
1. Applied over and in intimate contact with the centre core
membrane 2 is a second layer 3 of asphaltic cement or bitumen and
again an aggregate of a suitable inert insulating material
preferably an igneous, glassy, siliceous or micaceous rock such as
vermiculite (exfoliated), pearlite (popped) or the like.
These layers 1, 2 and 3 form the basic roofing system of the
invention over top of which the desired wearing or decorative
roofing courses, canting and flashing may be applied. The layers 1
and 3 of asphaltic cement or bitumen and exfoliated vermiculite,
popped pearlite or the like aggregate may be considered as roof
insulating or loading coats which serve the additional essential
function of isolating and protecting the moisture and vapour proof
centre core membrane 2. Each of the coats 1 and 3 forms an
essentially waterproof layer in the sense that water will not
percolate therethrough. At the same time, as illustrated in FIG.
1A, each coat comprises a lens or honeycomb system made up of
cementitiously coated insulating aggregate particles 20, bonded
together by the asphaltic cement or bitumen. Thus, as indicated by
the arrows 21, each coat will allow the migration therethrough of
moisture vapour created by the vapourizing of any moisture trapped
within the layers under the effects of temperature variations
internally and externally of the roofing. In this way the invention
precludes any moisture trapped in the insulating or loading coats 1
and 3 from effecting a pressure build-up at the surfaces of the
centre core membrane 2 which would cause rupture thereof. Instead,
the moisture is free to migrate through the lower loading coat 1
laterally beneath the centre core membrane to escape at the edges
of the roofing or in the case of the upper loading coat 3,
laterally and upwardly away from the membrane 2 where it will cause
no impairment to the moisture imperviousness of the roofing. Thus
the loading coats 1 and 3 not only physically isolate the membrane
2 from damage by external forces but they insulate the membrane by
virtue of their insulating honeycomb structure from the effects of
temperature and humidity extremes, as well as eliminating all
potential pressure build-up by entrapped moisture therewithin.
Preferably, as shown in FIG. 1, the centre core membrane 2 is
turned upwardly at the edge as at 2' around the periphery thereof
to in effect form a tank having side walls 2' and a bottom wall 2.
This tank ensures any migration of moisture vapour which may be
present in the upper loading coat 3 from migrating around the
centre core membrane 2 at the edges thereof. However, if adequate
roof edge flashing is provided the upturned edge 2' of the centre
core membrane 2 may be omitted, as more particularly illustrated in
FIG. 4.
FIG. 1 illustrates one particular example of a surface protecting
or wearing coat and flashing arrangement. As illustrated, applied
over top of the second loading coat 3 is a wearing course membrane
4 preferably comprising asphalt saturated felting which will
intimately bond with the asphaltic cement or bitumen and aggregate
structure of the coat 3. The wearing course membrane 4 extends to
beneath the cant 5 which may conveniently comprise an asphalt
coated and saturated fibre or wood structure, the upturned edge 2'
of the centre core membrane extending upwardly between the cant 5
and the outer wall W.
Applied over the cant 5 and the upper ends of the upturned loading
coats 1 and 3 and the centre core membrane 2 is a layer 6 of an
asphalt plastic cement supporting and anchoring an under flashing
membrane 7 which again may be asphalt impregnated and coated
felting. A second layer 8 of asphalt plastic cement is applied over
the under-flashing membrane 7 and above the second asphalt plastic
cement layer is a metal counter flashing 9.
The general area of the roofing system as illustrated in FIG. 1 is
covered by roof aggregate 11 which may be anchored in asphalt 10
applied over the wearing course membrane 4. It will be appreciated
of course that any form of decorative surface finish may be
utilized in place of the roof aggregate. In accordance with the
invention, the roofing is applied by first applying the first
insulating and loading coat 1 while hot. The exfoliated vermiculite
popped pearlite or the like aggregate and the asphaltic cement or
bitumen may be mixed in approximately the proportions of 1 bag (4
cubic feet) of aggregate to 4 gallons (40 pounds) boiling asphaltic
bitumen or cement heated to a temperature not exceeding
450.degree.F. Such asphaltic cement or bitumen for warmer climates
should be such as to have a fairly high softening point, e.g. about
200.degree.F and a very suitable material in such cases is Canadian
Standards Association Specification No. A 123-7, type 3. For colder
climates, the asphaltic cement may have a lower softening point.
The mixture may be conveniently heated in a paddle type mixing
machine until thoroughly mixed and is applied while hot to the
decking D to provide a layer having a fairly even surface. The
thickness at this stage of application should be approximately
one-fourth inch thicker than the desired finished thickness (e.g. 1
inch). This applied layer is consolidated by means of tampers or
heated rollers in preparation for the application of the centre
core vapour proof membrane 2.
A very satisfactory centre core membrane is provided by a 40 pound
ply sheet of asphalt impregnated and coated felt sheeting provided
on the upper surface thereof, as illustrated in FIG. 1A, with a
coating 200 of silica, sand, or other abrasive particles. The
sheeting or membrane 2 should be applied snooth and free from air
pockets, wrinkles, fishmouths, prominent lap joints or tears. The
sheeting 2 may be conveniently applied by mopping down with hot
asphalt. Over top of the centre core membrane 2 the second loading
coat 3 is applied while hot. This second layer should be applied to
a depth of approximately one-fourth inch thicker than the required
total consolidated finished thickness of the roofing and after
applied, should be tamped or consolidated as in the case of the
first loading coat. By the provision of the mineral particle
coating 200, a keying effect is provided which assists in anchoring
the second loading coat during the rolling or consolidation thereof
and forms a mechanical lock therewith.
The wearing course membrane 4 may then be applied over top of the
second loading coat and may be united thereto by hot (boiling)
asphaltic cement. Various other constituents may then be installed
including the protective asphalt bound aggregate 11, the cant 5,
the asphalt plastic cement (steam refined) layers 6 and 8, and the
flashing members 7 and 9.
The utilization of the two loading coats and centre core membrane
provide a very lightweight compactible insulating roofing structure
and because the first loading coat is applied as a hot flowable
spread, it can be applied over all forms of roof deck systems and
will flow into and fill all surface irregularities in such systems.
Since the basic roofing system is comprised of the layers 1 to 3
and these layers are applied as, or with the use of, hot flowable
material having temperatures up to about 450.degree.F, the ambient
climatic temperature has no appreciable effect on their
application. Thus the roofing system can be applied in extremely
hot or cold weather. Further, the inherent inertness of the
insulating and protecting coatings 1 to 3 render the roofing system
highly adaptable to tropical climates when the asphaltic cement
chosen has a sufficiently high softening point as mentioned
above.
As previously explained, each of the layers 1 and 3 provides for
the migration of moisture which may initially be present to prevent
vapour pressure build-up and enables the roofing system to be
installed in damp or wet weather without concern regarding
entrapping moisture within the layers.
It will be understood that the system also allows the roofing to be
graded to falls and contours in the roof to ensure positive roof
drainage simply by controlling the spreading of the spreadable
layers 1 and 3.
As mentioned, because of the spreadability of the loading coats 1
and 3, the roofing system is adaptable to all types of roof deck
arrangements and FIG. 2 illustrates the application of the
invention to a steel decking D' which has a corrugated steel
decking 100 supported on crossbeams 101 carried on main structural
I beams 102. In FIG. 2, all protective or decorative roof surfacing
structures have been omitted. It will be seen from FIG. 2 that the
first loading coat 1 completely fills the grooves of the corrugated
decking 100 to provide an additional strengthening and stiffening
effect.
FIG. 3 shows a modified roofing arrangement in which the roofing
system of the invention is applied to a steel decking D' similar to
that illustrated in FIG. 2. In this case, however, the centre core
membrane 2 is not only turned up at the edges of the roofing but is
turned inwardly at 2" to enclose the membrane 4' which again may
comprise asphalt impregnated and coated felt layers. It will be
understood that the inturned edges 2" of the centre core membrane 2
will be anchored to the asphalt impregnated and coated wearing
course layer 4' by asphaltic cement and it may be further anchored
by being placed under the cant 5' over which is applied a mastic
flashing 7' which extends beneath a metal flashing 9' carried by a
roof facing block 103. Located between the mastic flashing 7' and
the cant 5' in place of the asphaltic plastic cement used in the
arrangement of FIG. 1 is a layer of asphalt impregnated and coated
felt flashing 6'.
FIG. 4 illustrates a further arrangement in which the centre course
membrane 2 terminates at the edge of the roofing and a metal
termination strip 104 is utilized to contain the roofing edge and
is turned upwardly to extend beneath the metal counter flashing 9".
Again the roof is provided with a cant 5", a wearing course
membrane 4" overlying the cant and covered by a steam refined
asphaltic plastic cement 7", and the main body of the roofing
system is covered by aggregate 11".
It will be understood that the several arrangements of roofing
systems according to the invention shown are illustrative only and
variations in the nature of the decking to which the roofing system
is applied, the canting, flashing and surface details, may be made
within the spirit of the invention and without departing from the
scope of the appended claims.
* * * * *