A ROOF, WALL OR FAÇADE STRUCTURE
A roof, wall or façade structure suitable for new flat or pitched roofs, or renovation or reconstruction thereof, to a kit of parts for constructing, reconstructing or renovating a roof, wall or façade structure and a method for constructing or reconstructing a roof, wall or façade structure.
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This invention relates to a roof, wall or façade structure suitable for flat or pitched roofs, or renovation or reconstruction thereof, to a kit of parts for constructing, renovating or reconstructing a roof, wall or façade structure and a method for constructing, renovating or reconstructing a roof, wall or façade structure.
Roofs such as standing seam roofs, or alternative panel-type roofs, are flexible systems that are being used around the world for creating new buildings and also for renovation. When designing and creating a new building the versatility of the standing seam system, such as the Kalzip® standing seam system as supplied by Kalzip GmbH, allows complex structures including curved and/or tapered geometry to be covered.
In renovations however, the existing building dictates to a large extent the options for a replacement roof. This usually involves a lot of improvising by the renovators and this improvisation sometimes results in defective or untidy work which may, in time, lead to leakage, failure or unaesthetically looking constructions.
It is therefore an object of this invention to provide a system for renovating roof, wall or façade structures which is easy to install, quick to install, and to install without risking defective or untidy renovated structures.
It is also an object to provide a system for renovating roof, wall or façade structures with a minimum of different parts.
It is also an object to provide a system for renovating roof, wall or façade structures which uses a minimum of different parts which can moreover be made to fit easily, reproducibly and tidily.
One or more of these objects is reached by a roof, wall or façade structure comprising:
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- a retaining element (A) having a head section (1) for engaging at least one building sheet (B) of a roof, wall or façade, by flanging a free end (9) of the building sheet (B) over the head section (1), a base section (3) spaced from the head section, and a connecting member (2) fixedly connecting the head section (1) and the base section (3), and
- a supporting rail (C) comprising a first profile section (4) for detachably receiving and holding the base section (3) of the retaining element (A) and a second profile section (5), wherein the base section (3), when positioned in the first profile section (4) is rotatable relative to the supporting rail (C) around the axis perpendicular to the supporting rail between a first position at which the base section (3) is freely detachable from the first profile section (4) of the supporting rail (C) and a second position at which the base section (3) is secured in the first profile section (4) of the supporting rail (C), the rotation enabling the alignment of the longitudinal axis of the head section (1) of the retaining element (A) with the free end of the building sheet fixed to the head section (1), and
- a mounting element (D) comprising a head portion (6) for receiving and holding the second profile section (5) of the supporting rail (4), a foot portion (7) spaced from the head portion (6) for mounting the mounting element (D) on a roof, wall or façade substructure (E) and a connecting portion (8) connecting the foot portion (7) and the head portion (6), wherein the supporting rail (C) is rotatable around its longitudinal axis when held by the head portion (6) of the mounting element(D) to enable alignment of the longitudinal axis of the head section (1) of the retaining element (A) with the inclination of the wall, roof or façade.
In a preferred embodiment the head section (1) is elongate. Elongate within the context of this invention has its usual meaning, i.e. the head section is longer than it is wide, as seen from above, and the head section is longer than it is high, as seen from the side. By means of non-limiting examples: a torpedo or zeppelin shape is such an elongate shape.
The invention will first be explained in more detail in reference to a standing seam roof, but as demonstrated herein below the invention can be applied equally well using alternative panel-type roofs. It should therefore be noted that the explanation given herein below for the standing seam roof is not intended to be limited to it.
The invention is embodied in a standing seam roof, wall or façade structure comprising:
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- a retaining element (A) having an elongate head section (1) for engaging at least one building sheet (B) of a standing seam roof, wall or façade, by flanging a free end (9) of the building sheet (B) over the elongate head section (1), a base section (3) spaced from the elongate head section, and a connecting member (2) fixedly connecting the elongate head section (1) and the base section (3), and
- a supporting rail (C) comprising a first profile section (4) for detachably receiving and holding the base section (3) of the retaining element (A) and a second profile section (5), wherein the base section (3), when positioned in the first profile section (4) is rotatable relative to the supporting rail (C) around the axis perpendicular to the supporting rail between a first position at which the base section (3) is freely detachable from the first profile section (4) of the supporting rail (C) and a second position at which the base section (3) is secured in the first profile section (4) of the supporting rail (C), the rotation enabling the alignment of the longitudinal axis of the elongate head section (1) of the retaining element (A) with the free end of the building sheet flanged, or to be flanged, over the elongate head section (1), and
- a mounting element (D) comprising a head portion (6) for receiving and holding the second profile section (5) of the supporting rail (4), a foot portion (7) spaced from the head portion (6) for mounting the mounting element (D) on a roof, wall or façade substructure (E) and a connecting portion (8) connecting the foot portion (7) and the head portion (6), wherein the supporting rail (C) is rotatable around its longitudinal axis when held by the head portion (6) of the mounting element(D) to enable alignment of the longitudinal axis of the elongate head section(1) of the retaining element (A) with the inclination of the wall, roof or façade.
The basis for the roof, wall or façade structure according to the invention is formed by three major components A, C and D in addition to the roof sheet B, which is a known standing seam roof sheet or sheets of the Kalzip® FC Rainscreen or steproof type, generally referred to as click-type systems. By means of example, and not limited to these, reference is made to the standing seam panels of the Kalzip system which are provided in varying profile widths, straight, tapered and/or curved and in different seam heights. The three major components are formed by a retaining element A, a supporting rail C and a mounting element D. The retaining element A has an head section 1 for engaging at least one building sheet B of a standing seam roof, wall or fa↑ade, by flanging a free end of the building sheet B over the head section (see
The base section 3 of a retaining element A is mounted in a first profile section of a supporting rail C. The base section possesses the functionality of a bayonet catch in that it can be inserted into the first profile section in a first position and be taken out again, but after insertion of the base section into the first profile section in a first position and rotation of the retaining element around the axis perpendicular to the supporting rail to a second position, the retaining element is secured in the profile section. In this second position the retaining element can still be moved freely along the length of the supporting rail, but the retaining element cannot be taken out without first rotating it back to the first position. The movement of the retaining element along the length of the supporting rail and the rotatability of the retaining element in the first profile section to choose a favourable second position with regard to the orientation and location of the standing seams of the building sheet allows easy installation. When the retaining element is in the right place and the desired second position, the retaining element may be fixed in place, if required, for example by a fixing element, such as a screw or small protrusions on the lower surface of the base section 3 of the retaining element A to increase the friction between the base section and the upper part of the supporting rail C, thereby preventing further movement, wobble, rattle and rotation of the base section in the first profile. The supporting rail is also provided with a second profile section 5 congruent with the head portion of mounting element D, so that the head portion can hold the supporting rail in place. The holding in place may be the result of a clamping force exerted by the second profile section on the head portion of mounting element, or the result of a fixing element, such as a screw, which secures the second profile section, and thus the supporting rail C, to the mounting element D. The second profile section is shaped such that it allows a rotation around the head portion of mounting element so that the inclination of the retaining elements in the first profile section can be adapted to the desired inclination of the standing seams, and thus of the wall, roof or fagade. The mounting element is secured to the building.
As mentioned hereinabove, the invention is not only suitable in constructing, renovating or reconstructing roofs, walls or facades using standing seam panels, but also with other types of roof and wall panels, such as the Kalzip® FC Rainscreen system or a steproof system as depicted in
In a preferred embodiment the head of the retaining element is elongate, so as to enable a larger contact area in (in case of the standing seam roof type) or with (in case of the click-type roof) the flanges of the building sheets. This geometry of the head prevents the occurrence of tension in the building sheet when the sheet thermally expands or shrinks, because the elongate head allows movement of the flanged sheet over the head.
In order for the flanges of the standing seam building sheets to move as easily as possible over the elongate head section of the retaining element during installation of the structure, the head section comprises a middle section which is substantially of constant cross-section along its longitudinal axis and two partially dome-shaped end sections 1a and 1c, one at either end. The simplest shape of the middle section would be cylindrical or substantially cylindrical. This could be described as a torpedo like shape, when seen from the side as in
In a preferred embodiment of the invention the head section also has a torpedo like shape in a top view (i.e. perpendicular to the side view of
The inventors found that retaining elements wherein the elongate head section comprises a middle section which has substantially the same shape in cross-section along its longitudinal axis and two dome-shaped end sections, but wherein the size of the cross-section of the middle section is not constant, has advantages in some cases. An example of such a middle section is the case where the diameter of the middle section increases starting at the end of the first dome section towards a maximum diameter in the middle of the middle section, and decreases again towards the other dome section, comparable to the shape of the ‘Hindenburg’ airship (without the tailfins). This shape means that there is a smaller contact area between the seams and the head section, which has benefits in some cases. The location of the maximum diameter may be in the middle of the middle section, but it may also be nearer one end section.
In a preferable embodiment the length of the connecting portion 8 of the mounting elements D is variable. This allows the distance between the head portion 6 and the foot portion 7 of the mounting element to be adapted to a desired distance when constructing the roof, wall or façade structure. After determining the desired distance the length of the connecting portion is fixable to keep the desired distance between the head portion and the foot portion 7 after construction. This way it is possible to increase or decrease the inclination of a structure by progressively adapting the distance between the head portion and the foot portion of the mounting elements. This also allows installers to compensate for local differences in height of the building onto which the roof, wall or façade is to be mounted. In a preferable embodiment the connecting portion has an adjustable length e.g. by having two or more telescoping segments translatable longitudinally relative to each other to adjust the length of the connecting portion. Upon selecting the desired length of the connecting portion the length can be fixed by one or more fixing elements, such as screws.
In another embodiment of the invention the connecting portion 8 of the mounting elements D is provided in the form of a length of profile or tube to which the head portion 6 and the foot portion 7 are attached. In this embodiment the head and foot portion are standardized parts which are designed to be attachable to the connecting portion on the installation site. This allows each mounting element D to have a bespoke length by cutting the length of the connecting portion 8 to the desired length, preferably on the building site, but elsewhere if required. The profile or tube can be cut to length from a long length.
In an embodiment of the invention the foot portion 7 is provided with inclination means 11 to allow the mounting element D to be mounted to a substructure in a direction which is not perpendicular to the substructure. In particular when the substructure is inclined at a different angle than the renovated roof, it is important that the mounting elements are mounted in a substantially vertical direction to direct the forces acting on the roof to the substructure. It is particularly beneficial if the foot portion is also provided with the potential to rotate the mounting element around its longitudinal axis so that orientation of the head portion is facilitated.
Preferably the inclination means are provided in the form of a ball-and-socket joint. These ball-and-socket joints allow movement in all directions and also allow rotation. It is preferable that the ball part of the joint 12 is fixed to the connecting portion, and the socket part 13 is fixed to the substructure. Preferably the ball part is designed such that it can be fixed to the connecting portion. The socket part is fixed to the substructure, and a pad 15 may be provided between the socket part and the substructure, e.g. for thermal insulation. An insert piece 14 may be provided in the socket part to complete the socket or the socket may be an integral part of the socket part. The parts 13 and 14 can be produced from the same materials and by the same method. Part 14 may be produced form a suitable polymer like polyamide or the like.
The inventors found that a maximum inclination angle of 20° of the ball-and-socket joint is adequate for most cases. More preferably the maximum angle is 15°. The ball-and-socket joint allows a 360° rotation along the longitudinal axis of the mounting element D.
In an embodiment of the invention the head portion 6 of the mounting element D is provided in the form of a separate element that can be fixed to the upper end of the connecting portion. Preferably the head portion is designed in such a way that it can be fixed to the connecting portion at a selected position, where the position depends on the desired length of the entire mounting elements D. This flexibility enables the installers to work with a degree of tolerance in the length of the connecting portion, and also allows correction of unexpected deviations in the flatness of the substructure without having to cut a new connecting portion. The function of the head portion is to hold the supporting rail C in the right position and orientation.
When providing the mounting element with the ball-and-socket joint it is preferable that the ball part and the socket part remain unconnected. This means that the socket part can be mounted to the substructure with care and precision. The mounting element can then be inserted into the socket, for instance sideways, through a hole which is sufficiently large to allow the ball, which may be flattened on both side edges to facilitate this (see
It is preferable that after erecting the mounting element with the ball-and-socket joint and rotating it in the desired direction, that the mounting element is fixed in this position by securing means 18 provided in the ball-and-socket joint.
In cases where the old substructure is horizontal the ball-and-socket joint may not be needed because as depicted in
In an embodiment the retaining elements A are produced by die-casting. Although the retaining elements could, in principle, be produced by extrusion and cutting to length, the inventors found that it is preferable to produce the retaining elements by die-casting or equivalent production processes. This type of production allows the head sections to have the dome-shaped end sections. It also allows the connecting member to be constructed with weight-saving holes, stiffening ribs and, if so desired, with a non-constant width of the connecting member for instance so as to be smaller at the base section and wider at the elongate head section.
The material from which the retaining elements are produced preferably consist of die-cast metal, such as zinc or a zinc alloy, aluminium or an aluminium alloy, or a suitable die-cast polymer such as polyamide or glass-fibre reinforced polyamide. The retaining elements may also be produced by 3D-printing from a suitable material, either off site, or on site.
In a preferable embodiment the supporting rail C consists of an extruded profile, either from a suitable metal, such as aluminium or aluminium alloys, or a suitable polymer, such as polyamide, or a roll-formed material such as (galvanized) steel or aluminium. This allows the profile to be produced at standard lengths, which can be made to fit on the building site, with a minimum of loss of material, and a minimum of logistical issues. The supporting rails may also be produced by 3D-printing from a suitable material, either off site, or on site.
The mounting element D, preferably comprises or consists of a metal such as (galvanized) steel or aluminium or a polymer, preferably polyamide, and may be produced by die-casting or 3D-printing from a suitable material. The 3D-printing may be carried out off site or on site.
In the embodiment where the mounting element D comprises a tubular connecting part 8 and add-on head portions 6 and foot portions 7, the tubular connecting part may be an extruded profile, either from a suitable metal, such as aluminium or aluminium alloys, or a suitable polymer, such as polyamide, or a roll-formed material such as (galvanized) steel or aluminium. This allows the part to be produced at standard lengths, which can be made to fit on the building site, with a minimum of loss of material, and a minimum of logistical issues. The add-on head portions 6 and foot portions 7 may be produced by die-casting. This type of production allows the head portions and foot portions to have intricate shapes to produce the ball and socket joints 12, 13 and 14. It also allows the parts to be provided with weight-saving holes, stiffening ribs and, if so desired, with a different wall thickness as and when desired. In the examples and the figures the cross section of the connecting part is square with grooves at either sides, rendering the cross section H-shaped. However, the cross section may also be circular or any other suitable shape with a groove at either side.
The material from which the add-on head portions and foot portions are produced preferably consist of die-cast metal, such as zinc or a zinc alloy, aluminium or an aluminium alloy, or a suitable die-cast polymer such as polyamide or glass-fibre reinforced polyamide. The parts may also be produced by 3D-printing from a suitable material, either off site, or on site.
According to a second aspect, the invention is also embodied in a kit of parts for constructing or reconstructing a roof, wall or façade structure according to any one of claims 1 to 13 comprising one or more retaining elements A, one or more supporting rails C and one or more mounting elements D. The kit of parts may also comprise one or more building sheets B suitable for forming a roof, wall or façade of the standing-seam type or the click type.
Using this kit of parts the construction, reconstruction or renovation of a roof, wall or façade can be achieved according to the description and figures.
According to a third aspect, the invention is also embodied in a method of constructing, reconstructing or renovating a roof, wall or façade structure using the kit of parts according to the invention.
The method using this kit of parts allows the construction, reconstruction or renovation of a roof, wall or façade to be achieved according to the description and figures. The invention will now be further explained by means of the following, non-limitative drawings:
This way it is possible to increase or decrease the inclination of a structure by progressively adapting the distance between the head portion and the foot portion of the mounting elements.
It is noted that the figures show structures with a standing seam roof. It should be noted that for use of the invention with another type of panel such as the FC-rainscreen or steproof the only change that is needed is the head section 1 of the retaining element A.
Claims
1. A roof, wall or façade structure comprising:
- a retaining element having a head section for engaging and holding at least one building sheet of a roof, wall or façade, a base section spaced from the head section, and a connecting member fixedly connecting the head section and the base section, and
- a supporting rail comprising a first profile section for detachably receiving and holding the base section of the retaining element and a second profile section, wherein the base section, when positioned in the first profile section is rotatable relative to the supporting rail around the axis perpendicular to the supporting rail between a first position at which the base section is freely detachable from the first profile section of the supporting rail and a second position at which the base section is secured in the first profile section of the supporting rail, the rotation enabling the alignment of the longitudinal axis of the head section of the retaining element with the flanged edges of the building sheet, and
- a mounting element comprising a head portion for receiving and holding the second profile section of the supporting rail, a foot portion spaced from the head portion for mounting the mounting element on a roof, wall or façade substructure and a connecting portion connecting the foot portion and the head portion, wherein the supporting rail is rotatable around its longitudinal axis when held by the head portion of the mounting element to enable alignment of the longitudinal axis of the elongate head section of the retaining element with the inclination of the wall, roof or façade.
2. The roof, wall or façade structure according to claim wherein the head section of the retaining element is elongate for engaging at least one building sheet of a standing seam roof, wall or façade, by flanging a free end of the building sheet over the elongate head section.
3. The standing seam roof, wall or façade structure according to claim 1, wherein the head section of the retaining element is elongate for engaging at least one building sheet of a standing seam roof, wall or façade, by flanging a free end of the building sheet over the elongate head section, a base section spaced from the elongate head section, and a connecting member fixedly connecting the elongate head section and the base section.
4. The roof, wall or façade structure according to claim 1, wherein the retaining element is moveable in the longitudinal direction of the first profile section to adjust the position of the retaining element with respect to the free end of the building sheet.
5. The roof, wall or façade structure according to claim 2 comprising one or more retaining elements wherein the elongate head section comprises a middle section and two dome-shaped end sections.
6. The roof, wall or façade structure according to claim 2 comprising one or more retaining elements wherein the elongate head section comprises a middle section and two dome-shaped end sections, and wherein the diameter of the middle section is not constant.
7. The roof, wall or façade structure according to claim 1, comprising one or more mounting elements wherein the length of the connecting portion of the mounting elements is variable to allow the distance between the head portion and the foot portion to be adapted to a desired distance when constructing the roof, wall or façade structure, and wherein the length of the connecting portion is fixable to keep the desired distance between the head portion and the foot portion after construction.
8. The roof, wall or façade structure according to claim 7 comprising one or more mounting elements wherein the connecting portion of the mounting elements comprises a telescoping section, wherein one part of the telescoping section is fixedly attached to the head portion, and wherein another part of the telescoping section is fixedly attached to the foot portion.
9. The roof, wall or façade structure according to claim 1 wherein the retaining element is fixedly connected to the supporting rail in the second position.
10. The roof, wall or façade structure according to claim 1, comprising one or more retaining elements produced by die-casting.
11. The roof, wall or façade structure according to any one of the preceding claims comprising one or more retaining elements consisting of die-cast metal, such as zinc or a zinc alloy, or a suitable polymer such as polyamide or glass-fibre reinforced polyamide.
12. The roof, wall or façade structure according to claim 1 wherein one or more of the mounting elements D comprise a tubular connecting portion, a head portion releasably fixed thereto on one end, and a foot portion releasably fixed thereto on the other end.
13. The roof, wall or façade structure according to claim 1, wherein the supporting rail and/or the mounting element comprise metal or a polymer.
14. The kit of parts for constructing or reconstructing a roof, wall or façade structure comprising one or more retaining elements, one or more supporting rails and one or more mounting elements the retaining elements, supporting rails and mounting elements being according to any one of claim 1, the kit of parts optionally also comprising one or more building sheets for forming a roof, wall or façade.
15. The method of constructing or reconstructing a roof, wall or façade structure using the kit of parts according to claim 14 comprising the steps of securing one or more mounting elements to a building by fixing the foot portion to a building, providing one or more supporting rails and positioning the second profile section of the supporting rail over the head portion of the mounting element for holding the supporting rail in place, mounting the base section of one or more retaining elements in the first profile section of the supporting rail, providing at least one building sheet, wherein the head sections of retaining elements engage and hold the at least one building sheet.
16. The roof, wall or façade structure according to claim 5, comprising one or more retaining elements wherein the middle section is substantially rotationally symmetric along its longitudinal axis.
17. The roof, wall or façade structure according to claim 6, wherein the middle section is substantially rotationally symmetric along its longitudinal axis.
18. The roof, wall or façade structure according to claim 1, wherein one or more of the mounting elements D comprise a tubular connecting portion, a head portion releasably fixed thereto on one end, and wherein the foot portion comprises a ball-and-socket joint.
19. The roof, wall or façade structure according to claim 1, wherein the supporting rail and/or the mounting element comprise steel, aluminium or polyamide.
20. The roof, wall or façade structure according to claim 1, wherein the supporting rail and/or the mounting element consist of metal or aluminium or a polymer.
21. The roof, wall or façade structure according to claim 1, wherein the supporting rail and/or the mounting element consist of steel, aluminium or polyamide.
Type: Application
Filed: Dec 21, 2016
Publication Date: Dec 27, 2018
Applicant: KALZIP GMBH (Koblenz)
Inventors: Mario KENDA (WEILERSWIST), Horst Ewald SCHMITT (KELBERG), Bruce Edward William PORTEOUS (WALDBREITBACH), Ferdinand Johannes Leonardus KARLAS (ARNHEM)
Application Number: 16/060,743