Fastening Arrangements for a Metal Roof
20180023300 ยท 2018-01-25
Inventors
Cpc classification
E04D1/2918
FIXED CONSTRUCTIONS
E04D2001/3438
FIXED CONSTRUCTIONS
E04D1/29
FIXED CONSTRUCTIONS
E04D2001/3423
FIXED CONSTRUCTIONS
E04D1/265
FIXED CONSTRUCTIONS
E04D2001/3482
FIXED CONSTRUCTIONS
E04D2001/3494
FIXED CONSTRUCTIONS
E04D1/34
FIXED CONSTRUCTIONS
International classification
E04D1/34
FIXED CONSTRUCTIONS
Abstract
Metal roofing includes metal roof-covering sheets or tiles having apertures along longitudinal end edges for coupling a pair of the sheets in an overlapping condition. One fastening arrangement comprises a fastener having a shaft extending in a longitudinal direction and fastening features at longitudinally spaced positions along the shaft. The fastening features may comprise a fastening peg or an opening receiving a fastening member therethrough. The pegs and openings may be combined in such a manner that at least two of the features cooperate with the apertures of the respective sheet in opposing transverse directions so as to longitudinally offset the apertures in the overlapping condition. Another fastening arrangement comprises a roof-covering sheet locating fastenings pegs which are spaced inward of the apertures in a longitudinal direction of the sheet so as to form the longitudinal offset between the respective sets of apertures.
Claims
1. A fastener for coupling a pair of metal roof-covering sheets of a metal roofing system in an overlapping condition, each one of the roof-covering sheets having at least one aperture at or adjacent a longitudinal end edge of the respective roof-covering sheet that is overlapped, the fastener comprising: a shaft extending in a longitudinal direction for residing between the pair of the metal roof-covering sheets; at least one fastening peg at or adjacent one longitudinal end of the shaft that extends therefrom in a transverse direction so as to pass through the at least one aperture of one of the metal roof-covering sheets in the overlapping condition; at least one fastening feature carried on the shaft at a position longitudinally spaced from said at least one fastening peg for cooperation with the at least one aperture of the other one of the metal roof-covering sheets in a manner so as to longitudinally offset the apertures of the pair of metal roof-covering sheets in the overlapping condition.
2. The fastener according to claim 1 wherein said at least one fastening feature comprises at least one opening passing through the shaft in the transverse direction for receiving at least one respective fastening member through said at least one opening and said at least one aperture of said another one of the metal-roof-covering sheets.
3. The fastener according to claim 1 wherein said at least one fastening feature comprises at least one additional peg extending from the shaft in an opposite transverse direction to the at least one fastening peg so as to pass through the at least one aperture of said another one of the roof-covering sheets in the overlapping condition.
4. The fastener according to claim 1 wherein each fastening peg has a threaded tip receiving a respective threaded fastening element thereon so as to secure said one of the metal roof-covering sheets sheet between the shaft and the respective fastening element.
5. The fastener according to claim 3 wherein the at least one fastening peg and the at least one additional peg each both have a threaded tip receiving a respective threaded fastening element thereon so as to secure a respective one of the roof-covering sheets between the shaft and the respective fastening element.
6. The fastener according to claim 3 wherein the at least one fastening peg is located at or adjacent a first end of the shaft and the at least one additional peg comprises a pair of pegs that extend in a common second transverse direction from the shaft at or adjacent a second end of the shaft for engaging one of the pair of the roof-covering sheets so as to resist swiveling between the pair of the roof-covering sheets in the overlapping condition, the common second transverse direction of the pair of pegs being opposite to the transverse direction of the fastening peg.
7. The fastener according to claim 1 in combination with the pair of metal roof-covering sheets, which reside on a peaked roof having a peak at an upper end of the roof and a roof end edge at a lower end of the roof which is downstream of the upper end, the pair of metal roof-covering sheets being arranged in an overlapping condition in which an upper one of the roof-covering sheets partially overlaps a lower one of the roof-covering sheets, which is downstream of the upper roof-covering sheet; wherein the shaft of the fastener is disposed between the pair of the roof-covering sheets, the fastening peg passes through one of the apertures of the upper and lower roof-covering sheets, and the other of the upper and lower roof-covering sheets is fastened to the at least one fastening feature through another one or more of the apertures in the other of the upper and lower roof-covering sheets to thereby couple the upper and lower roof-covering sheets together in a manner offsetting said one of the apertures from said another one or more of said apertures along a slope of the peaked roof so as to resist fluid leaks between the roof-covering sheets.
8. The fastener according to claim 2 in combination with the pair of metal roof-covering sheets and the respective fastening member for each opening in the shaft, wherein the pair of metal roof-covering sheets reside on a peaked roof having a peak at an upper end of the roof and a roof end edge at a lower end of the roof which is downstream of the upper end, the pair of metal roof-covering sheets being arranged in an overlapping condition in which an upper one of the roof-covering sheets partially overlaps a lower one of the roof-covering sheets, which is downstream of the upper roof-covering sheet; and wherein the shaft of the fastener is disposed between the pair of the roof-covering sheets, the fastening peg passes through one of the apertures in one of the upper and lower roof-covering sheets, and the at least one respective fastening member is driven through another one or more of the apertures in the other one of the roof-covering sheets at the at least one opening in the shaft to thereby couple the upper and lower roof-covering sheets together in a manner offsetting said one of the apertures from said another one or more of the apertures along a slope of the peaked roof so as to resist fluid leaks between the roof-covering sheets.
9. The combination of claim 8 wherein said one of the apertures through which the fastening peg passes through is located in the upper one of the roof-covering sheets, and the at least one respective fastening member at the one or more openings in the shaft is driven into a roof deck of the peaked roof through said another one or more apertures, which are located in the lower one of the roof-covering sheets.
10. The combination of claim 8 wherein the respective fastening member for each opening in the shaft is a nail.
11. The fastener of claim 3 in combination with the pair of metal roof-covering sheets, which reside on a peaked roof having a peak at an upper end of the roof and a roof end edge at a lower end of the roof which is downstream of the upper end, the pair of metal roof-covering sheets being arranged in an overlapping condition in which an upper one of the roof-covering sheets partially overlaps a lower one of the roof-covering sheets, which is downstream of the upper roof-covering sheet; wherein the shaft of the fastener is disposed between the pair of the roof-covering sheets, the fastening peg passes through one of the apertures in one of the upper and lower roof-covering sheets, and the at least one additional peg passes through another one or more apertures in the other of the upper and lower roof-covering sheets, thereby coupling the upper and lower roof-covering sheets together in a manner offsetting said one of the apertures from said one or more other apertures along a slope of the peaked roof so as to resist fluid leaks between the roof-covering sheets.
12. The combination of claim 7 wherein said one of the apertures in said one of the upper and lower roof-covering sheets is in the upper roof-covering sheet, said another one or more apertures is located in the lower roof-covering sheet, and said one of the apertures in the upper roof-covering sheet is located downstream of said another aperture in the lower roof-covering sheet.
13. The fastener according to claim 3 wherein said at least one additional peg is longer than the fastening peg.
14. The combination according to claim 11 wherein said another one or more apertures through which the at least one additional peg passes are found in the lower roof-covering sheet, and the at least one additional peg passes through a roof deck of the pitched roof so as to secure the roof-covering sheets thereto.
15. The combination of claim 7 wherein the roof-covering sheets comprise an offset grid pattern simulating an appearance of asphalt shingles in an installed condition on the roof.
16. The fastener according to claim 1 wherein said at least one fastening feature comprises at least one nailing spike extending from the shaft for driving of said spike into a roof deck through the at least one aperture of said another one of the roof-covering sheets in the overlapping condition.
17. A metal roof-covering sheet for covering a roof in an overlapping condition with another metal roof-covering sheet which has at least one aperture at or adjacent a longitudinal end edge thereof that is overlapped in said overlapping condition, the metal roof-covering sheet comprising: a sheet body having opposing longitudinal end edges of which at least one is overlapped in the overlapping condition; at least one aperture for receiving a respective fastening member therethrough to secure the sheet body during installation on the roof, said at least one aperture being located at or adjacent said one of the longitudinal end edges for overlapping; at least one fastening peg extending transversely from the sheet body at a location spaced longitudinally of said at least one aperture for passing through the at least one aperture of the another metal roof-covering sheet so as to longitudinally offset the apertures of said sheet body and said another metal roof-covering sheet in the overlapping condition.
18. The metal roof-covering sheet of claim 17 in combination with said another metal roof-covering sheet, wherein said metal roof-covering sheets reside on a peaked roof having a peak at an upper end of the roof and a roof end edge at a lower end of the roof which is downstream of the upper end, said metal roof-covering sheets being arranged in an overlapping condition in which an upper one of the metal roof-covering sheets partially overlaps a lower one of the metal roof-covering sheets which is downstream of the upper one of the metal roof-covering sheets, one of the upper and lower metal roof-covering sheets having the fastening peg thereof received through a respective aperture of the other of the upper and lower metal roof-covering sheets in a manner offsetting said respective aperture from the at least one aperture of said one of the upper and lower roof-covering sheets along a slope of the peaked roof.
19. The metal roof-covering sheet according to claim 16 wherein said at least one fastening peg is located inward of said at least one aperture in a longitudinal direction of the sheet body so as to locate the at least one aperture of said another metal roof-covering sheet longitudinally inward of said at least one aperture of the sheet body.
20. A method of producing a metal covering sheet for use in metal roofing for covering a roof, the metal covering sheet having a peripheral edge delimiting an inner surface for facing inwardly toward the roof and an opposing outer surface, the method comprising: providing the metal covering sheet; forming in the outer surface of said covering sheet an offset grid pattern simulating an appearance of asphalt shingles in an installed condition on the roof.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0064] Preferred embodiments of the invention will now be described in conjunction with the accompanying drawings in which:
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[0078] In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION
[0079] Referring to
[0080] Generally speaking, the roof has a peak at an upper end of the roof and a roof end edge at a lower end of the roof which is downstream of the peak or upper end of the roof. Especially in residential applications, the roof is sloped downwardly from the peak to the roof end edge. Note that the downstream direction and an opposing upstream direction are respectively indicated at D and U.
[0081] The fastener 100 or 100 comprises a shaft 102 extending in a longitudinal direction of the fastener. The fastener includes a plurality of fastening pegs 104 and 106 respectively located at longitudinally spaced position on the shaft 102. Regardless of the specific number of fastening pegs, at least two of the fastening pegs extend from the shaft in opposite transverse directions. Typically, the fastenings pegs are respectively located at or adjacent first and second ends 102A and 102B of the shaft so as to be closer to one end than the other. Consequently, the fastener overall is zig-zag shaped in transverse side view.
[0082] Furthermore, in the illustrated embodiment, each fastening peg has a threaded tip 108 as schematically shown in
[0083] In the first embodiment, the fastener 100 has two fastening pegs 104 and 106. One fastening peg is located at each of the first and second ends 102A, 102B of the shaft.
[0084] In the second embodiment, the fastener 100 has three fastening pegs 104, 106A, and 106B. Two of these (those being 106A, 106B) are located at or adjacent the second end 102B of the shaft and which extend in a common one of the transverse directions from the shaft 102. The reason for having a pair of the fastening pegs will become apparent later.
[0085] In one arrangement (irrespective of either one of the two illustrated embodiments), the fastening pegs may be sufficiently long so that the fastening pegs can pass through a roof deck 4 or support frame of the roof 1. Thus, the fastener 100 or 100 and the roof-covering sheets 101 which the respective fastener couples together may be secured to the roof deck 4.
[0086] Turning our attention to the roof-covering sheets, in the illustrated embodiment each roof-covering sheet 101 is rectangular in shape. However, in other embodiments, the roof-covering sheets may be of different shapes and also of different sizes (between applications) so long as the roof-covering sheets may be positioned in a manner so as to fully cover the roof. Each roof-covering sheet comprises at least one row of apertures 112 along each longitudinal end edge 101A, 101B of the respective roof-covering sheet. In one arrangement of the roof-covering sheet (not shown), the roof-covering sheet has one row of apertures along each longitudinal end edge so as to be suited for cooperation with the fastener 100 of the first embodiment as in
[0087] With the above structure of the roof-covering sheets in mind, the roof-covering sheets 101 are arranged to be coupled in an overlapping condition better shown in
[0088] As known in the art, the roof-covering sheets 101 are typically corrugated so as to have ridges running longitudinally of the roof-covering sheets which form protrusions on an outer surface 114 of the respective roof-covering sheet and recessed grooves on an inner surface 115 of the respective roof-covering sheet which faces the roof deck. Thus, roof-covering sheets disposed side-by-side, that is transverse to the upstream or downstream directions of the roof U or D, can be overlapped in the side-by-side direction to reduce relative side-to-side movement between each pair of side-by-side roof-covering sheets.
[0089] In the illustrated embodiment, the outer surface 114 of the roof-covering sheet, which is delimited by a peripheral edge 116 thereof, comprises an offset grid pattern simulating an appearance of asphalt shingles in an installed condition on the roof. In the illustrated embodiment, the grid pattern is formed by stamping the roof-covering sheet 101 with the offset grid pattern using a machine such as a stamping press. Thus, the roof-covering sheets may appear like asphalt shingles from afar, which may be desirable given the popularity of asphalt shingles especially in residential roofing applications.
[0090] In use, the roof-covering sheets 101 are typically installed starting at or adjacent the lower end of the roof. Then, successive roof-covering sheets are installed in a direction upstream, that is, towards the upper end or peak of the roof. Within each pair of roof-covering sheets, the fastening pegs 106 or 106A, 106B of the respective fastener at the second end 102B thereof are inserted through the apertures 112 of the lower roof-covering sheet 101L. The apertures 112 of the lower roof-covering sheet, which will be used for coupling to the upper roof-covering sheet 101U, are oriented at an upstream end of the lower roof-covering sheet. The fastener is oriented such that the fastening peg 104 extending upwardly in a position ready to receive the upper roof-covering sheet 101U is located downstream D of the fastening pegs 106 or 106A, 106B inserted into the lower roof-covering sheet 101L. Note that the fastening pegs passing through the lower roof-covering sheet may also be inserted through the roof deck 4 if this arrangement is chosen. The fastening elements 110 are then inserted onto the tips 108 of the fastening pegs at the second end of the shaft so as to secure the lower roof-covering sheet 101L along its thickness between the shaft 102 of the respective fastener and the fastening element 110. When the fastening pegs are inserted through the roof deck 4 as shown in
[0091] The upper roof-covering sheet 101U is disposed, in the overlapping condition, onto the lower roof-covering sheet 101L as viewed in the direction transverse to the roof deck. Within the respective pair of the roof-covering sheets, the apertures 112 of the upper roof-covering sheet through which the fastening peg 104 at the first end 102A of the shaft passes are consequently located downstream D of the apertures of the lower roof-covering sheet 101L through which the fastening pegs 106 or 106A, 106B at the second end 102B of the shaft pass. Similarly to a process of fastening of the lower roof-covering sheet, the upper roof-covering sheet 101U is disposed along its thickness at a location on the respective fastening peg 104 at the first end of the shaft between the shaft 102 and the fastening element 110 received on the tip 108 so as to be secured between the shaft and fastening element. This process of partially overlaying or overlapping roof-covering sheets in the direction upstream and fastening each pair of roof-covering sheets disposed in the overlapping condition in the upstream direction continues until the roof between the lower and upper ends thereof is covered.
[0092] During installation of the roof-covering sheets in the overlapped condition coupled to one another by the fastener 100 or 100, a sealant material 118 such as sealing tape is laid along an upstream or upper longitudinal edge 101B of the lower roof-covering sheet that is subsequently covered by the respective upper roof-covering sheet. The sealant runs parallel to the longitudinal edges of the roof-covering sheets, but is applied suitably close to the upstream longitudinal edge 101B of the lower roof-covering sheet so as to be spaced upstream from both the exposed or free longitudinal edge 101A of the upper roof-covering sheet 101A and the downstream set of apertures in the upper roof-covering sheet that lie adjacent this exposed longitudinal edge 101A. The sealant material fills an entirety of the gap that is created between the roof-covering sheets 101 by the presence of the fastener's shaft 102 between them. The spacing of the sealant material upstream from the free longitudinal end edge 101a at or near the covered longitudinal edge 101B of the lower roof-covering sheet may be such that the sealant is transversely inline with the shaft 102. In this instance, the sealant material 118 may be discontinued at each fastener 100 or 100 so as to be disposed only in areas of the gap that resides between adjacent fasteners, as shown in
[0093] Thus, the overall metal roofing system described herein seeks to overcome the potential problem of leakage in traditional metal roofs. The fasteners 100 or 100 are shaped so that the apertures 112 of overlapping roof-covering sheets 101U, 101L are offset or misaligned. More specifically, the fasteners 100 or 100 are oriented in an installed condition as better shown in
[0094] In another arrangement of the fastener 100 or 100, the fastening pegs 106, 106A, or 106B that are adjacent the second end 102B of the shaft and which pass through the lower roof-covering sheet 101L may comprise tapered ends such that the fastening pegs are arranged to be driven into a roof deck 4. The tapered fastening pegs may be driven with a tool such as with a hammer, for example. This arrangement is suited for an existing roof in which an underside of the roof deck 4 may not be readily accessed from a topside of the roof thus inhibiting installation of threaded fastening elements 110 such as nuts on ends of the fastening pegs which are at the second end 102B.
[0095] Further embodiments of the fastener are illustrated in
[0096] Thus, the openings 120 in the shaft 102 and the fastening pegs 104 and 106 or 106A, 106B all define fastening features of the various forgoing embodiments of the fastener for cooperation with the apertures 112 in the roof-covering sheets.
[0097] Referring to
[0098] Since various modifications can be made in my invention as herein above described, and many apparently widely different embodiments of same made, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.