GB2261229A - Insulating roofing - Google Patents
Insulating roofing Download PDFInfo
- Publication number
- GB2261229A GB2261229A GB9120931A GB9120931A GB2261229A GB 2261229 A GB2261229 A GB 2261229A GB 9120931 A GB9120931 A GB 9120931A GB 9120931 A GB9120931 A GB 9120931A GB 2261229 A GB2261229 A GB 2261229A
- Authority
- GB
- United Kingdom
- Prior art keywords
- panels
- roofing
- structure according
- core
- water
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000004794 expanded polystyrene Substances 0.000 claims abstract description 11
- 239000004568 cement Substances 0.000 claims abstract description 10
- 239000011248 coating agent Substances 0.000 claims abstract description 5
- 238000000576 coating method Methods 0.000 claims abstract description 5
- 238000009413 insulation Methods 0.000 abstract description 15
- 238000004078 waterproofing Methods 0.000 description 14
- 239000012528 membrane Substances 0.000 description 12
- 239000010410 layer Substances 0.000 description 7
- 239000000463 material Substances 0.000 description 7
- 239000003365 glass fiber Substances 0.000 description 5
- 229920006327 polystyrene foam Polymers 0.000 description 5
- 239000011150 reinforced concrete Substances 0.000 description 5
- 239000000758 substrate Substances 0.000 description 5
- 239000012774 insulation material Substances 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 239000004576 sand Substances 0.000 description 4
- 238000010521 absorption reaction Methods 0.000 description 3
- 239000004567 concrete Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 239000011521 glass Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000011159 matrix material Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 229910052902 vermiculite Inorganic materials 0.000 description 3
- 239000010455 vermiculite Substances 0.000 description 3
- 235000019354 vermiculite Nutrition 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 239000000919 ceramic Substances 0.000 description 2
- UHZZMRAGKVHANO-UHFFFAOYSA-M chlormequat chloride Chemical compound [Cl-].C[N+](C)(C)CCCl UHZZMRAGKVHANO-UHFFFAOYSA-M 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000011065 in-situ storage Methods 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 238000002834 transmittance Methods 0.000 description 2
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000011398 Portland cement Substances 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 239000011151 fibre-reinforced plastic Substances 0.000 description 1
- 229910052500 inorganic mineral Inorganic materials 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 239000011707 mineral Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 230000019612 pigmentation Effects 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 238000003908 quality control method Methods 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 125000006850 spacer group Chemical group 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/16—Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
- E04D13/1606—Insulation of the roof covering characterised by its integration in the roof structure
- E04D13/1662—Inverted roofs or exteriorly insulated roofs
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D11/00—Roof covering, as far as not restricted to features covered by only one of groups E04D1/00 - E04D9/00; Roof covering in ways not provided for by groups E04D1/00 - E04D9/00, e.g. built-up roofs, elevated load-supporting roof coverings
- E04D11/02—Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Roof Covering Using Slabs Or Stiff Sheets (AREA)
Abstract
A roofing structure especially for tropical climates in which it provides good heat insulation comprises a plurality of roofing panels 1 each comprising a lightweight insulating core 8, for example of high density expanded polystyrene, and a rigid, self-supporting coating 9, for example of glass-reinforced cement, around the core, the panels being disposed in edge- to-edge abutment and being spaced from (4) and supported on a substantially water-impermeable roofing surface 5, 6, 7. <IMAGE>
Description
IMPROVEMENTS RELATING TO ROOFING SYSTEMS
This invention relates to roofing systems and is particularly concerned with insulating roofing systems.
In tropical climatic conditions, buildings require some form of insulation against heat from the sun. The conventional flat reinforced concrete roofs of commercial, industrial and to a certain extent residential buildings are subject to maximum exposure as they sit on a horizontal plane. In certain countries, building plans are subject to guidelines and regulations imposed by the authorities and the thermal transmittance of roofs has to meet required values as dictated by the authorities. Therefore some kind of insulation material will have to be incorporated into the roofing design in order to comply with the requirements. In the selection of a proper insulation material, its compatibility with the substrate, the water-proofing membrane and the function of the roof itself must be considered.Due partly to the limited availability of suitable insulation materials for the roof, it is difficult to strike a balance between on the one hand, good thermal insulation properties, resistance to wear and lightweight and on the other hand water-proofness, cost-effectiveness and ease of application.
In accordance with the invention, there is now provided a roofing structure including a plurality of roofing panels each comprising a lightweight insulating core and a rigid, self-supporting coating around the core, the panels being disposed in edge-toedge abutment and being spaced from and supported on a substantially water-impermeable roofing surface.
The roofing panels used according to the invention are preferably manufactured from materials which find wide use in the construction industry and whose properties and characteristics are already well documented. For example, the lightweight insulating core is preferably of high density expanded polystyrene which finds wide use throughout the construction industry as an insulating material and is already manufactured in large quantities and is therefore relatively low in cost. Alternatively, the lightweight insulating core may be of other foamed or expanded plastics materials, such as foamed polyurethane, or of glass or mineral fibres, if necessary suitably treated to render them selfsupporting. Similarly, the coating around the core can be of a wide variety of structural materials but is preferably of a cementitious nature, for example glass-reinforced cement.Alternatively, it can be of plastics materials, especially fibre reinforced plastics materials.
The panels may be of any convenient shape or size to achieve their purpose and to enable their safe and rapid transport and manoeuvrability on site. For example, the panels may be of rectangular or hexagonal shape, but are preferably rectangular. In use, the panels are disposed on a water-proofing finish on the structural roof surface to form a continuous roofing surface, but are spaced from the water-proofing finish to permit rainwater which will percolate between the panels, to run off. Such spacing may be from 2 to 10 mm but is preferably approximately 5 mm, and may be achieved by arranging the corners of rectangular panels, for example, on suitable spacers. This arrangement has the additional advantage of maintaining the under-surface of the panels out of contact with the water-proofing finish to prevent rupture of the latter.
The roofing system of this invention can be considered to be an adaptation of the inverted roof system in that the insulation layer is situated above the water-proofing membrance to offer protection against U-V and weathering exposure. The significant difference is that thermal insulation is provided for example in a preferred and especially straightforward embodiment of the invention, by expanded high-density polystyrene foams encased all round with a skin of glass reinforced cement in the form of a lightweight panel. The panels are placed directly over the waterproofing membrance with a slight clearance of about 5 mm for example, to allow drainage of surface run-offs, resting on padded footings on four corners of the panels to cushion their weight and prevent puncture of the membrance.Depending on the thickness of the structural roof slab, the thickness of the insulating panels may be varied during factory production to ensure compliance with the existing thermal transmittance value requirement. The versatility of the glass reinforced concrete skin offers a wide variety of finishes including moulded patterns and the usage of colour pigments to create an aesthetic appeal over the entire roof.
In general, the advantages of the insulating panels outweigh those associated with conventional roofing systems and may be summarised as follows: (a) Thermal insulation value
With the core made of expanded polystyrene foam,
the insulation value of the panels ranks among
the best when the weight factor is considered.
Expanded polystyrene of density 16 kg/m3 has a
K-value (thermal conductivity - W/m deg K) of
0.035 compared to vermiculite plastering of
density 640 kg/m3 at K-value of 0.202 and
concrete of density 2400 kg/m3 and K-value of
1.442.
(b) Compatibilitv with substrate-water-proofinq membrance
As the panels are pre-casted and placed on site,
the problem of compatibility with either the
substrate or the water-proofing layer is totally
avoided. In conventional roofing systems in
which the insulation layer is cast on site
directly on top of the substrate or the
membrance, differential stressing at the
interface of the layers can cause cracks to occur
resulting in delamination of the insulation from
the base.
(c) Water absorption and retention
Conventional warm-roof systems require the water
proofing membrance to be laid over the insulation
layer; this is a common system adopted widely in
practice in tropical countries. The insulation
materials specified for such systems are usually
lightweight screeds of either vermiculite cement
or air-entrained concrete. Being cast in-situ
and being cementitious in nature, the screed
normally requires a curing period of 14 days. In
tropical climatic conditions, heavy showers of
rain can occur throughout the year and the
exposed insulation screed may be saturated during
a downpour.Due to the absorption and retention
of such moisture by exfoliated vermiculite or the
entrapment of moisture within the pores of air- entrained screed, the drying out period may be
excessively prolonged and if the water-proofing
membrance is to be laid over the insulation
screed before it has completely dried, problems
with blistering of the membrane occur with
damaging results. With the insulating panels of
the invention, the polystyrene core is protected
by the GRC skin which because of its density will
exclude most of the moisture. As pre-cast
panels, curing occurs in the factory thus saving
time on the construction site. In this system,
the membrance will be laid directly over cast
reinforced concrete and due to the much higher
density of the concrete, water absorption if any
is kept to a minimum.
(d) Protection of water-proofing membrane
As in the inverted roofing system, with the
insulation placed above the water-proofing
membrane, the surface temperature of the membrane
will be kept fairly constant since the insulating
panels will act as a thermal screen. This will
in turn minimise damage to the membrane due to
cyclic thermal stressing. The panels also
protect the membrane against damaging U-V
radiation and surface erosion by wind and
rainwater and therefore a lower performance (and
less costly) water-proofing membrane may be used.
(e) Trafficability
The GRC skin on the insulating panels is
sufficiently thick to resist all forms of foot
traffic and also includes limited wheel-based
traffic such as pallet-trucks and wheelbarrows,
for example. The panels are also suitable for
use in roof-gardens and car-park decks subject to
filing the area first with a layer of sand before
placement of the panels. It should be noted that
the water-proofing membrane must be able to
resist ponding when used in the above situations.
(f) Aesthetic finishing
The insulating panels may be moulded and coloured
to form decorative patterns to improve the
aesthetic finish of the roofs. Due to the
versatility of the GRC encasement, the finish may
be in the form of tiles, ceramics or granolithic
without the common problems of such tiles
without the common problems of such tiles
delaminating in the conventional case-in-situ
screeding method because of differential thermal
movement of the substrate.
(g) Maintenance of roof
Since the panels are relatively light and can be
lifted up quite easily, the water-proofing
membrane may be inspected and any damages
repaired without great difficulty.
The invention will now be described in greater detail by way of example only with reference to the accompanying drawings, in which:
Figs. l(a), l(b) and l(c) are top, bottom and side views of a roofing panel; and
Fig. 2 is a cutaway perspective view of a roofing system according to the invention.
Referring first to Figs. l(a), l(b) and l(c) of the drawings, there is shown a roofing panel generally designated 1. The panel shown is in the form of a 600 mm square slab having a thickness of approximately 40 mm. Its top surface 2 has been formed to represent a tiled finish. Its bottom surface 3 is provided with pads 4 of synthetic rubber material at each corner, which serve to support the panel on a roof surface.
A roofing system according to the invention is shown in Fig. 2. It comprises a reinforced concrete roof slab 5 some 150 mm thick which supports a 50 mm sand/cement screed 6 applied to give a slight fall to provide water run-off. On the screed 6 there is a water-proof membrane 7 which may be a plastics sheet or, preferably, a liquid-applied material which has been allowed to dry and cure. It is on to this waterproof membrane 7 that the insulating panels 1 have been applied, standing on the pads 4. As can be seen in Fig. 2, the panel itself consists of a core 8 of 25 mm expanded polystyrene foam coated on both sides and on all edges with a 7 mm thick skin layer 9 of glassreinforced cement.
In the arrangement depicted in Fig. 2, the complete roof structure will have a thermal conductivity of approximately 0.85 W/mOK.
The following technical specifications apply to the major components of the insulating panels, namely the GRC skin and the expanded polystyrene foam core.
Due to the versatility of the GRC, the specifications can be adjusted to suit the overall requirement of the finished product in line with its intended usage, i.e.
for heavy traffic roofs the glass fibre contents may be increased to give better tensile strength.
1. GRC specifications
(a) Cement
Ordinary Portland cement (OPC) to BS 12.
(b) Sand
Fine clean river sand free of excessive silt
of particle size in the range of 150 pm to
1 mm.
(c) Glass Fibres
Alkali-resistant (AR) glass fibres for
example those supplied under the trade name
Cem-FIL which are pre-cut chopped strands of
12 to 25 mm length.
(d) Matrix ratio
Aggregate/cement ratio - 0.25 or more
Glass fibre ratio - 3% to 6% by
weight
Modified by suitable acrylic polymers for
workability and improved strength.
(e) Density
Dry density approximately 1800 to 2000
kg/m3.
(f) Thermal conductivity
"K" value - 0.3 W/m deg K (g) Method of placement
Using pre-mix method with chopped fibres
incorporated in the fluid matrix and mixing
at low-shear to distribute the fibres in all
directions to produce a random three
dimensional orientation of the fibres in the
composite.
2. Expanded Polystyrene Foams
(a) Density
Ranging from 16 kg/m3 to 32 kg/m3 depending
on usage of roof.
(b) Compressive strength
Approximately 50 KN/m2 to 250 KN/m2
(c) Thermal conductivity
K value - 0.028 to 0.035 W/m deg K
(d) Grade
Self-extinguishing expanded polystyrene EPS
to BASF F 321/F 412.
3. Desiqn of panels
1. Suitable dimensions are as follows:
(a) Lengths
Available either as 600 mm x 600 mm or
750 mm x 750 mm.
(b) Thickness of core (EPS)
Minimum thickness of 25 mm. Increment in 5
mm up to 40 mm depending on insulation value
to be achieved.
(c) Thickness of GRC skin
All round thickness to be minimum 7 mm thick
and may be extended to 12 mm for heavy
loading requirement or special finishing,
e.g. granolithic trowel finishing.
(d) Available decorative finishing
The versatility of the GRC skin offers a
wide variety of decorative finishing to be
incorporated into the design of the panels
and colour pigmentation may be added to
enhance the effect. Ceramic or mosaic tiles
may be trowelled onto the panels during
fabrication, thus saving time and ensuring
quality control at manufacturing standard
when compared to site application.
The panels will generally be manufactured by the pre-mix method whereby the pre-cut chopped strands of glass fibres will be mixed into the cement/sand fluid matrix and poured into a vibrating mould to form the required shape and thickness. Normal curing or accelerated steam curing may then be carried out.
Polymer modification with an acrylic resin may be part of the mix to improve its theology Standard quality checks on the panels will be based on the normal testing of GRC including hardness/impact and tensile breaking tests.
The insulating panels used according to the invention offer many advantages over the components of conventional roofing systems, in particular savings both in terms of time and money. The roofing system incorporates a protective layer together with a thermal insulation core to be installed over the screed/reinforced concrete substrate in a simple onestep installation without any cumbersome "wet works" on site.
Claims (7)
1. A roofing structure including a plurality of roofing panels each comprising a lightweight insulating core and a rigid, self-supporting coating around the core, the panels being disposed in edge-toedge abutment and being spaced from and supported on a substantially water-impermeable roofing surface.
2. A structure according to claim 1, wherein the cores of the panels are of high density expanded polystyrene.
3. A structure according to claim 1 or claim 2, wherein the coating around the cores of the panels is of glass-reinforced cement.
4. A structure according to any one of claims 1 to 3, wherein the panels are rectangular.
5. A structure according to any one of claims 1 to 3, wherein the panels are hexagonal.
6. A structure according to any one of claims 1 to 5, wherein the panels are supported at their corners on spacing members which are supported on the roofing surface.
7. A roofing structure according to claim 1, substantially as hereinbefore described with reference to Figures 1 and 2 of the accompanying drawings.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB9120931A GB2261229A (en) | 1991-10-02 | 1991-10-02 | Insulating roofing |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB9120931A GB2261229A (en) | 1991-10-02 | 1991-10-02 | Insulating roofing |
Publications (2)
Publication Number | Publication Date |
---|---|
GB9120931D0 GB9120931D0 (en) | 1991-11-13 |
GB2261229A true GB2261229A (en) | 1993-05-12 |
Family
ID=10702313
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB9120931A Withdrawn GB2261229A (en) | 1991-10-02 | 1991-10-02 | Insulating roofing |
Country Status (1)
Country | Link |
---|---|
GB (1) | GB2261229A (en) |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1009983A (en) * | 1960-12-08 | 1965-11-17 | Karl Meyer | Insulating panels and securing means therefor |
US3830687A (en) * | 1972-08-04 | 1974-08-20 | Dyna Shield Inc | Flame retardant and fire resistant roofing material |
WO1981002601A1 (en) * | 1980-03-10 | 1981-09-17 | Selvaagebygg As | A building construction element and a method for the production thereof |
US4320605A (en) * | 1979-11-14 | 1982-03-23 | Scientific Applications Incorporated | Insulation panel |
US4348841A (en) * | 1979-05-18 | 1982-09-14 | Bridgestone Tire Co., Ltd. | Outer heat insulating structure on a building roof |
-
1991
- 1991-10-02 GB GB9120931A patent/GB2261229A/en not_active Withdrawn
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1009983A (en) * | 1960-12-08 | 1965-11-17 | Karl Meyer | Insulating panels and securing means therefor |
US3830687A (en) * | 1972-08-04 | 1974-08-20 | Dyna Shield Inc | Flame retardant and fire resistant roofing material |
US4348841A (en) * | 1979-05-18 | 1982-09-14 | Bridgestone Tire Co., Ltd. | Outer heat insulating structure on a building roof |
US4320605A (en) * | 1979-11-14 | 1982-03-23 | Scientific Applications Incorporated | Insulation panel |
WO1981002601A1 (en) * | 1980-03-10 | 1981-09-17 | Selvaagebygg As | A building construction element and a method for the production thereof |
Also Published As
Publication number | Publication date |
---|---|
GB9120931D0 (en) | 1991-11-13 |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |