Twist resistant roof structure

Abstract

The present invention relates to a roof structure comprising support members. Depth locators are provided for fastening to the support members to locate a desired depth of bridge members. The bridge members extend between the support members at the desired depth. A safety barrier is provided for being supported by the bridge members. Each depth locator may include a folded sheet bracket which advantageously resists twisting when fastened to the support members with a threaded depth locator fastener driven by a rattle gun.

Claims

1. A roof structure comprising: support members; depth locators configured to be fastened to the support members to locate a desired depth of bridge members; the bridge members configured to extend between the support members at the desired depth; and a safety barrier configured to be supported by the bridge members, wherein each depth locator includes a back configured to align with a vertical wall of a respective support member, the back being in substantial contact with the vertical wall when the depth locator is fastened to the respective support member, and wherein each depth locator includes a lip configured to align with a roof of a support member.

2. A roof structure as claimed in claim 1, wherein each depth locator includes a folded sheet bracket which advantageously resists twisting when fastened to the support members with a threaded depth locator fastener driven by a rattle gun.

3. A roof structure as claimed in claim 1, wherein each depth locator includes a pair of flanges extending from either side of the back.

4. A roof structure as claimed in claim 3, wherein the pair of flanges are configured to receive one of the bridge members.

5. A roof structure as claimed in claim 3, wherein the back and the support member define co-incident holes for receiving a depth locator fastener.

6. A roof structure as claimed in claim 5, wherein the depth locator fastener includes a bolt.

7. A roof structure as claimed in claim 3, wherein the structure further includes a pair of bridge fasteners extending through the flanges to fasten a bridge member to a depth locator.

8. A roof structure as claimed in claim 7, wherein each bridge fastener includes a rivet.

9. A roof structure as claimed in claim 1, wherein a safety barrier is supported by the bridge members and an insulating layer rests directly on the safety barrier.

10. A roof structure as claimed in claim 1, further including a supported roofing layer.

11. A roof structure as claimed in claim 10, wherein the roofing layer and the insulating layer are separated from each other by an air gap.

12. A roof-structure depth-locator for configured to be fastened to a support member to locate a desired depth of a bridge member, the depth-locator including: a back configured to align with a vertical wall of the support member, the back being in substantial contact with the vertical wall when the depth locator is fastened to the support member, and a lip configured to align with a roof of a support member.

13. A method of building a roof structure, the method comprising the steps of: (i) extending bridge members between adjacent support members at a desired depth located by depth locators fastened to the support members; and (ii) supporting a safety barrier with the bridge members, wherein each depth locator includes a back configured to align with a vertical wall of a respective support member, the back being in substantial contact with the vertical wall when the depth locator is fastened to the respective support member, and wherein each depth locator includes a lip configured to align with a roof of a support member.

14. A method of building a roof structure as claimed in claim 13, the method comprising: (iii) supporting an insulating layer with the safety barrier.

15. A method of building a roof structure as claimed in claim 14, the method further involving: (iv) supporting a roofing layer with the support members such that the roofing layer and the insulating layer are separated from each other by an air gap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The features of the invention believed to be novel and the elements characteristic of the invention are set forth with particularity in the appended claims. The figures are for illustration purposes only and are not drawn to scale. The invention itself, however, both as to organization and method of operation, may best be understood by reference to the detailed description which follows taken in conjunction with the accompanying drawings in which:

(2) FIG. 1 is a perspective view of a roof structure;

(3) FIG. 2 is a perspective view of a bridge member of the roof structure; and

(4) FIG. 3 is an end view of the roof structure;

(5) FIG. 4 is a perspective view of a telescopic bridge member of another roof structure with parts separated;

(6) FIG. 5 is a perspective view of the telescopic bridge member of FIG. 4 with parts engaged;

(7) FIG. 6 is a top view of the telescopic bridge member of FIG. 5;

(8) FIG. 7 is a side view of the telescopic bridge member of FIG. 5;

(9) FIG. 8 is a bottom view of the telescopic bridge member of FIG. 5;

(10) FIG. 9 is an end view of the telescopic bridge member of FIG. 5;

(11) FIG. 10 is a partial perspective view of the telescopic bridge member of FIG. 5 engaging with a purlin; and

(12) FIG. 11 is a perspective view of an alternative roof structure in accordance with an embodiment of the present invention;

(13) FIG. 12a is a side sectional view of the roof structure of FIG. 11;

(14) FIG. 12b is a front perspective view of a depth locator of the roof structure of FIG. 11;

(15) FIG. 12c is a rear perspective view of a depth locator of the roof structure of FIG. 11; and

(16) FIG. 12d is a perspective view of a purlin support member of the roof structure of FIG. 11.

DESCRIPTION OF THE EMBODIMENT(S)

(17) Referring to the figures, a roof structure 20 comprises a plurality of adjacent support members in the form of purlins 21. Purl ins 21 are parallel to each other, and are spaced apart from each other at regular or irregular intervals.

(18) Each purlin 21 is made from sheet metal, and has a Z-shaped profile comprising a lower portion in the form of a lower panel 22, an upper portion in the form of an upper panel 23, and a vertical intermediate portion in the form of an intermediate panel 24 which extends between the lower panel 22 and the upper panel 23, and which is perpendicular with respect to the lower panel 22 and the upper panel 23. A lip 25 extends upwardly from the lower panel 22, and is perpendicular with respect to the lower panel 22. A lip 26 extends downwardly from the upper panel 23, and is perpendicular with respect to the upper panel 23.

(19) A plurality of T-shaped openings 27 are punched into the intermediate panel 24 of each purl in 21. Openings 27 are spaced apart from each other at regular intervals along the length of the purlins 21. FIG. 1 only shows one of the openings 27 in each of the purlins 21. Each opening 27 includes a first portion 28 and a second narrower portion 29 which adjoins the first portion 28.

(20) A plurality of bridge members 30 are spaced apart from each other at regular intervals and extend laterally between each pair of adjacent purlins 21 such that the bridge members 30 are perpendicular with respect to the purlins 21.

(21) Each bridge member 30 is made from sheet metal, and includes an intermediate portion 31 and a pair of end portions 32 which extend from the intermediate portion 31. Intermediate portion 31 includes a top panel 33 and a pair of side panels 34 which extend perpendicularly from the top panel 33. Each end portion 32 is provided by the top panel 33, and includes a head portion 35 and a narrower neck portion 36 which extends from the head portion 35.

(22) The end portions 32 of the bridge members 30 are each received by the openings 27 in the purlins 21. The side panels 34 of each bridge member 30 are supported by the lip 25 of one of the purlins 21 which the bridge member 30 extends between.

(23) In order to insert the end portion 32 of a bridge member 30 into one of the openings 27, the head portion 35 and the neck portion 36 of the end portion 32 are inserted into the first portion 28 of the opening 27 so that the neck portion 36 is located above the second portion 29 of the opening 27. The neck portion 36 is then lowered into the second portion 29. The width of the second portion 29 is such that the head portion 35 is inhibited from being withdrawn from the opening 27.

(24) The end portion 32 is able to be removed from the opening 27 by firstly raising the end portion relative to the opening 27 so that the neck portion 36 is located in the first portion 28. The head portion 35 and the neck portion 36 are then able to be withdrawn from the first portion 28 of the opening 27.

(25) Each opening 27 is able to receive an end portion 32 of two bridge members 30 as shown in FIGS. 1 and 3. The end portion 32 of one of the bridge members 30 which is received by a particular opening 27 overlies the other bridge member 30 which is received by that opening 27. In particular, the head portion 35 of the overlying end portion 32 lies on top of the top panel 33 of the other bridge member 30 which is received by the opening 27. The end portions 32 of the two bridge members 30 which are received by the opening 27 are secured together with fasteners which are in the form of 1225 Tek screws 37.

(26) A safety barrier 40 for preventing a person from falling off the roof structure 20 is secured relative to the bridge members 30 of the roof structure 20 as shown in FIGS. 1 and 3. Barrier 40 comprises a plurality of individual safety wires 41 which extend between adjacent bridge members 30. Wires 41 are secured to the bridge members 30 by wrapping or looping their ends around the bridge members 30 and then twisting the ends around the wires 41 as depicted in FIG. 1.

(27) The bridge members 30 and the safety barrier 40 support an insulating layer which is provided by thermal insulation 42. Insulation 42 may be any suitable type of insulation. For example, insulation 42 may be fiberglass or wool insulation.

(28) A roofing layer provided by one or more ribbed roof panels or sheets 50 is supported by the purlins 21 such that the sheets 50 rest on the upper panels 23 of the purlins 21. Roof sheets 50 and the insulation 42 are separated from each other by an air gap 60 which is 100 mm wide.

(29) A method of building the roof structure 20 is now briefly described. The method comprises the steps of:

(30) (i) extending a plurality of bridge members 30 laterally between a plurality of adjacent purlins 21 such that the end portions 32 of the bridge members 31 are received by the openings 27 in the purlins 21 such that the end portions 31 can be inhibited from being withdrawn from the openings 27;

(31) (ii) supporting the safety barrier 40 with the bridge members 30;

(32) (iii) supporting the insulating layer 42 with the safety barrier 40; and

(33) (iv) supporting the roofing layer 50 with the purlins 21 such that the roofing layer 50 and the insulating layer 42 are separated from each other by the air gap 60.

(34) Turning to FIG. 4, each bridge member 30 can be replaced by a telescopic bridge member 60 including two generally C-shaped body parts 62, 64 (see also FIG. 9). The bridge member 60 is substantially rigid and comprises an intermediate portion formed by the overlapping body parts 62, 64, and a pair of end portions 32 located at opposite ends of the intermediate portion. Each end portion 32 (as previously described) is adapted to be received by an opening 27 in a purlin 21 such that the end portion 32 can be inhibited from being withdrawn from the opening 27. The rigid bridge members 60 can be used to space a plurality of the purlins 21 apart from each other at regular intervals, and for maintaining the spacing between the purlins 21.

(35) Each body part 62, 64 is of a similar construction. However, as can best be seen in FIGS. 5 to 8, body part 64 is dimensioned so as to be snugly slid within body part 62. Body part 64 defines a threaded fastening hole 66 for receiving a grub screw to fixedly fasten the movable parts 62, 64 together. In addition, one of the end portions 32 may define another fastening hole 68 in which a Tek screw 37 can be received when fastening end portions 32 of serially arranged bridge members 60 together.

(36) Turning to FIG. 10, there is provided another purlin 70 with an intermediate panel 72. The purlin 70 is rotationally symmetric and defines a pair of symmetric openings 74a, 74b so that the purlin 70 has the same characteristics when mounted in either orientation, 180 apart. Each opening 74 defines a central portion 76 through which an end portion 32 is initially received. A pair of walls 78 taper downwardly to guide the neck portion 36 of the bridge member 60, and resiliently reciprocate to lock the bridge member 60 in a bottom recess 80 of the opening 74.

(37) According to an embodiment of the present invention, there is provided a roof structure 20 as shown in FIG. 11. Like reference numerals refer to like features previously described.

(38) The roof structure 20 includes support members in the form of purlins 21. Depth locators 500 are fastened to the purlins 21 to locate a desired depth of bridge members 30 and therefore insulation 42. The bridge members 30 extend between the purlins 21 at the desired depth. A mesh safety barrier 40 is supported by the bridge members 30.

(39) Each depth locator 500 is in the form of a folded sheet bracket which advantageously resists twisting when fastened to the purlins 21 with a threaded depth locator bolt 502 (i.e. fastener) driven by a rattle gun. Steel fabricators have rattle guns on hand and can readily drive the bolts 502 which are tightened with nuts that can induce twisting.

(40) Each depth locator 500 includes an upper lip 504 for aligning with the horizontal roof of the purlin 21. Each depth locator 500 further includes a back 506 for aligning with the vertical wall of the purlin 21, and a pair of flanges 508 extending from either side of the back 506. The flanges 508 receive a bridge member 30 that is located at the base of the depth locator 500 which is desired depth of bridge members 30. Not only does the depth locator 500 resist the twisting when tightening the bolts 502, but the base of the flanges 508 also provide the desired depth of bridge members 30 and therefore insulation 42.

(41) The structure 20 further includes a pair of bridge rivets 510 (i.e. fasteners) extending through respective flanges 508 to fasten the bridge member 30 to a depth locator 500 (see also FIG. 12a).

(42) The depth locator backs 506 of the two depth locators 500 shown in FIGS. 12b and 12c, and the purlin 21 shown in FIG. 12d sandwiched there-between, define three co-incident holes 512 for receiving the depth locator bolt 502.

(43) Throughout the specification and the claims, unless the context requires otherwise, the term comprise, or variations such as comprises or comprising, will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers.

(44) Throughout the specification and claims, unless the context requires otherwise, the term substantially or about will be understood to not be limited to the value for the range qualified by the terms.

(45) It will be appreciated by those skilled in the art that variations and modifications to the invention described herein will be apparent without departing from the spirit and scope thereof. The variations and modifications as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as herein set forth.

(46) It will be clearly understood that, if a prior art publication is referred to herein, that reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.