Abstract: Processes for making algaecidal roofing granules are disclosed. In one aspect, the disclosure provides a method includes providing composite nanoparticles comprising algaecidal nanoparticles and a carrier material; coating granule cores with the coating material to form a coating layer having an exterior surface; and applying the composite nanoparticles to the exterior surface of the coating layer to provide the algaecidal nanoparticles at exterior surfaces of the algaecidal roofing granules. In another aspect of the disclosure, a method includes dispersing composite nanoparticles in a coating material, the composite nanoparticles including a carrier material and algaecidal nanoparticles, then coating the granule cores with the coating material to form a coating layer; and curing the coating layer, the cured coating layer providing algaecidal nanoparticles at exterior surfaces of the algaecidal roofing granules.

Abstract: A roof rock spreader has a rock hopper and a motive drive system. An optical system detects areas already treated and areas still in need of treatment. Location aware sensors detect present location and speed of travel. A control system determines proper application paths and locations, and controls application of roof rock to provide an even and consistent layer. When the rock hopper empties, the roof rock spreader will move to a refill location. A laser alignment system detects and confirms proper hopper positioning prior to automated refill. During the refilling procedure, wheel load sensors monitor hopper fill. Rock hopper refill may be limited, to accommodate gross vehicle weight limitations of a particular roof. A communication system provides remote viewing through the optical system or other camera to confirm proper function, provides remote emergency shut-off, and enables a plurality of like spreaders to work in unison.

Abstract: A shingle includes a substrate having an asphalt coating on a top surface of the substrate and on a bottom surface of the substrate. A surface layer of granules is embedded in the asphalt on the top surface of the substrate. A backdust layer of particles is embedded in the asphalt on the bottom surface of the substrate. A sealant is disposed on the backdust. A hydrophobic material is applied to the sealant.

Abstract: Solar reflective roofing granules include a binder and inert mineral particles, with solar reflective particles dispersed in the binder. An agglomeration process preferentially disposes the solar reflective particles at a desired depth within or beneath the surface of the granules.

Abstract: A converted reverse ballasted roof system is provided including a structural roof beam. Insulation is positioned upwardly adjacent the structural roof beam, and a first waterproofing membrane is arranged upwardly adjacent the first waterproofing membrane. A weighted cover board is disposed upwardly adjacent the first waterproofing membrane and a second waterproofing membrane is installed upwardly adjacent the weighted cover board. The first water proofing membrane and the second waterproofing membrane substantially seal the weighted cover board.

Abstract: A method includes providing a production line configured for continuous fabrication of polymer or predominantly polymer roofing boards by setting and expansion of precursor materials on a conveyor. A first polymer or predominantly polymer material foam precursor is dispensed to the production line, and allowed to rise and at least partially set to form a foam core layer for an insulation board, the foam core layer for the insulation board having a first density. A second polymer or predominantly polymer material foam precursor is dispensed to the production line and allowed to rise and set to form a core layer for a cover board, the foam core layer for the cover board having a second density greater than the first density. The combined thickness of the foam core layer for the insulation board and the core layer for the cover board is set by constraining the expansion of the combined foam precursors using a downstream forming conveyor disposed above the rising foam precursors.

Abstract: The disclosed principles provide a roofing product and related methods of manufacturing having antimicrobial properties. The antimicrobial properties are provided by an antimicrobial delivery system including antimicrobial materials compounded, e.g., mixed together and melted, with polymeric materials. The antimicrobial delivery system is applied to roof covering material during the production process. The roof covering material may be sheets, shingles, panels, or roll stock.

Abstract: Roofing granules include a core having an average ultraviolet transmission of greater than sixty percent and an average near infrared reflectance of greater than sixty percent and a UV coating layer on the exterior surface. The coating provides UV opacity, while the core provides near infrared reflectance.

Abstract: The invention relates to biocidal granules composed of a mineral core coated with at least one porous inorganic layer including at least one organic compound capable of limiting or preventing the growth of microorganisms, in particular of algae. The invention also relates to a sol-gel process for the preparation of the biocidal granules and to the use of these biocidal granules in building materials, in particular shingles and siding coatings.

Abstract: Compositions useful in pesticidal applications include water, a copper complex and an alpha olefin sulfonate surfactant. Additional components can be included in such formulations including one or more additional surfactants, and one or more penetrating agents.

Abstract: A method for distributing granules may include transporting a hopper along a roof while releasing granules through a valve of the hopper, thereby depositing a line of granules on the roof. Another method for distributing granules may include adjusting a valve of a container mounted on a cart, depositing a predetermined width of the granules though the valve onto the roof while driving the cart along a roof, and covering a seam between adjacent sheets of roofing material with the granules. A device for depositing granules on a roof may include a hopper, and a valve, where granules stored in the hopper flow directly through the valve to the roof in response to gravity when the valve is at least partially opened, and where the flow of the granules is not assisted by an agitator, an auger, or air pressure.

Abstract: A method of waterproofing or damp proofing a protected member having a surface with a sulfur-extended plastomer asphalt binder composition uses a sulfur-extended plastomer asphalt binder composition that includes elemental sulfur, a plastomer and an asphalt binder. The method includes the steps of combining the plastomer with the asphalt binder maintained at a plastomer mixing temperature such that an intermediate asphalt binder mixture forms, and combining elemental sulfur with the intermediate asphalt binder maintained at a sulfur mixing temperature such that the sulfur-extended plastomer asphalt binder composition forms. The method also includes the step of applying the sulfur-extended plastomer asphalt binder composition to the surface of the protected member such that the sulfur-extended plastomer asphalt binder composition contacts, adheres to and forms a layer upon the surface of the protected member. The asphalt binder composition is applied at a temperature no greater than 150° C.

Abstract: A method of waterproofing or damp proofing a protected member having a surface with a sulfur-extended elastomer asphalt binder composition uses a sulfur-extended elastomer asphalt binder composition that includes elemental sulfur, an elastomer and an asphalt binder. The method includes the steps of combining the elastomer with the asphalt binder maintained at an elastomer mixing temperature such that an intermediate asphalt binder mixture forms, and combining elemental sulfur with the intermediate asphalt binder maintained at a sulfur mixing temperature such that the sulfur-extended elastomer asphalt binder composition forms. The method also includes the step of applying the sulfur-extended elastomer asphalt binder composition to the surface of the protected member such that the sulfur-extended elastomer asphalt binder composition contacts, adheres to and forms a layer upon the surface of the protected member. The asphalt binder composition is applied at a temperature no greater than 145° C.

Abstract: A method of manufacturing a granule coated asphaltic article comprising the steps of applying liquid asphalt to a reinforcing sheet to create an asphaltic sheet, the asphaltic sheet having a top surface and a bottom surface; bending the asphaltic sheet to form an arcuate top surface of the sheet; and applying a coating of granules over the arcuate top surface of the asphaltic sheet.

Abstract: An asphalt-based sheet roofing material includes capsules on its upper surface. When struck, as by hailstones, the capsules break to release a film forming fluid that spreads over the surface to heal the damage created by the hailstones.

Abstract: The retention of roofing granules on bituminous roofing products is enhanced by providing an adherent material in the interstices between the exterior surface of the roofing granules and the exposed upper surface of the base sheet.

Abstract: A process for preparing roofing granules includes forming kaolin clay into green granules and sintering the green granules at a temperature of at least 900 degrees Celsius to cure the green granules until the crystalline content of the sintered granules is at least ten percent as determined by x-ray diffraction.

Abstract: According to one embodiment, a method for pressing roofing granules into a roofing membrane may include providing a roofing membrane and applying roofing granules atop a surface of the membrane. The method may also include adjusting a position of a second roller relative to a first roller so as to vary an amount of contact between the membrane and the first roller and pressing the roofing granules into the membrane via the first roller. In some embodiments, a line speed of the membrane may be determined and a contact value may be calculated based on the line speed of the membrane. The contact value may represent an effective amount of contact between the membrane and the first roller. The position of the second roller may be adjusted so that the amount of contact between the membrane and the first roller corresponds to the effective amount of contact.

Abstract: A system for coating a surface comprises providing a source of amorphous metal, providing ceramic particles, and applying the amorphous metal and the ceramic particles to the surface by a spray. The coating comprises a composite material made of amorphous metal that contains one or more of the following elements in the specified range of composition: yttrium (?1 atomic %), chromium (14 to 18 atomic %), molybdenum (?7 atomic %), tungsten (?1 atomic %), boron (?5 atomic %), or carbon (?4 atomic %).

Abstract: Algae-resistant roofing granules are formed by extruding a mixture of mineral particles and a binder to form porous granule bodies, and algaecide is distributed in the pores. Release of the algaecide is controlled by the structure of the granules.

Abstract: According to one embodiment, a method for pressing roofing granules into a roofing membrane may include providing a roofing membrane and applying roofing granules atop a surface of the membrane. The method may also include adjusting a position of a second roller relative to a first roller so as to vary an amount of contact between the membrane and the first roller and pressing the roofing granules into the membrane via the first roller. In some embodiments, a line speed of the membrane may be determined and a contact value may be calculated based on the line speed of the membrane. The contact value may represent an effective amount of contact between the membrane and the first roller. The position of the second roller may be adjusted so that the amount of contact between the membrane and the first roller corresponds to the effective amount of contact.

Abstract: A method for distributing granules may include transporting a hopper along a roof while releasing granules through a valve of the hopper, thereby depositing a line of granules on the roof. Another method for distributing granules may include adjusting a valve of a container mounted on a cart, depositing a predetermined width of the granules though the valve onto the roof while driving the cart along a roof, and covering a seam between adjacent sheets of roofing material with the granules. A device for depositing granules on a roof may include a hopper, and a valve, where granules stored in the hopper flow directly through the valve to the roof in response to gravity when the valve is at least partially opened, and where the flow of the granules is not assisted by an agitator, an auger, or air pressure.

Abstract: A process for preparing roofing granules includes forming kaolin clay into green granules and sintering the green granules at a temperature of at least 900 degrees Celsius to cure the green granules until the crystalline content of the sintered granules is at least ten percent as determined by x-ray diffraction.

Abstract: A roofing granule can include a material including a transition metal carbonate; a mixed metal carbonate, wherein at least one metal within the mixed metal carbonate includes a transition metal; a first metal carbonate and a second metal compound, wherein the first and second metals are different metal elements; a third metal carbonate and silica; or any combination thereof. A process of forming a roofing granule can include providing a base particle having pores, and infiltrating a fluid into the pores of the base particle, wherein the fluid includes a carbonate. The process can further include reacting the carbonate with a metal compound within the base particle to form a metal carbonate, wherein the roofing granule comprises a material that includes the metal carbonate.

Abstract: Algae-resistant roofing shingles are formed by extruding a mixture of mineral particles and a binder to form porous granule bodies, and algaecide is distributed in the pores to provide alqae-resistant granules, which are subsequently applied to roofing shingles. Release of the algaecide is controlled by the structure of the granules.

Abstract: A method of fabricating a roof-covering element out of molded cellulose impregnated with bitumen for roofing. In a first step, an element, preferably of cellulose, is made by hot compression molding in a mold, in a second step, once the element has a dry matter content of at least 60% when extracted from the mold, the element is covered in a pigmented varnish and dried, and in a third step, once the element has a dry matter content of at least 98%, the element is impregnated with hot bitumen. Specific operating conditions are given. The covering elements include in particular a ridge side portion, a ridge cap, a ridge-covering kit, a fillet or curb, and a hip.

Abstract: A method of manufacturing a granule coated asphaltic article comprising the steps of applying liquid asphalt to a reinforcing sheet to create an asphaltic sheet, the asphaltic sheet having a top surface and a bottom surface; bending the asphaltic sheet to form an arcuate top surface of the sheet; and applying a coating of granules over the arcuate top surface of the asphaltic sheet.

Abstract: Bitumen-impregnated cellulose fiber sheets include on one of their main surfaces, an adhesive primer layer, and, deposited on this adhesive primer layer, a fireproof coating including expandable graphite. In a preferred embodiment of the invention, the expandable graphite has a trigger temperature lower than 300° C. and the layer of expandable graphite corresponds to a dry matter basis weight of 80 to 140 g/m2. The sheets have a fire resistance fulfilling in particular the European Standard EN 13 501-5. They are mainly intended to be used as covering material, and in particular, as roof covering material.

Abstract: A bio-based adhesive and method of making the adhesive replaces or serves as additives for asphalt, sealant, and polymers such as styrene-butadiene-styrene and atactic polypropylene in the manufacture of building or paving materials. The method includes steps of forming a mixture of oil comprising fatty acids group and optionally a powdered material; maintaining the oil-to-powdered-material weight ratio in the mixture between 1 to 0.00001 and 1 to 20; heating the mixture to a reaction temperature greater than 55 degrees Centigrade; maintaining the reaction temperature until the oil is polymerized; and, injecting air into the mixture while polymerizing the oil. The adhesive of this method comprises a renewable polymer and the powdered material.

Abstract: A method of manufacturing a granule coated asphaltic article is disclosed. The method includes applying molten asphalt to a reinforcement to create an asphaltic sheet, the asphaltic sheet having a top surface and a bottom surface. Next, the asphaltic sheet is bent to form an arcuated top surface of the sheet. The method concludes by applying a plurality of granules to the arcuated top surface of the asphaltic sheet.

Abstract: An asphalt-based sheet roofing material includes capsules on its upper surface. When struck, as by hailstones, the capsules break to release a film forming fluid that spreads over the surface to heal the damage created by the hailstones.

Abstract: This invention relates to various methods of improving the energy efficiency and utility of roofs typically of the flexible membrane granulated type including shingles and roll roofing using a series of generally continuous curved surfaces although is applicable to all types of roofing including metal, concrete, and clay roofing products. Further, this invention relates to a spacer apparatus used to effect several methods of improving the utility and efficiency of roofing of this class.

Abstract: A method of manufacturing roofing shingles is provided. The method includes the step of coating a continuously supplied shingle mat with roofing asphalt to make an asphalt-coated sheet. The asphalt-coated sheet has at least one prime portion and at least one headlap portion. The thickness of the asphalt-coated sheet is varied by passing the asphalt coated sheet through compression rollers configured to compress the asphalt-coated sheet and form a formed sheet such that the prime portion of the formed sheet has a first thickness and the headlap portion has a second thickness, different from the first thickness. The formed sheet is passed under a film applicator configured to supply a film to the headlap portion thereby forming a filmed sheet. Granules are applied to the filmed sheet to form a granule-covered sheet such that granules do not adhere to the headlap portion. The granule-covered sheet is cut into shingles.

Abstract: A coating composition useful for building materials products, especially roofing surfaces, is provided. The coating composition provides durable exterior protection to surfaces that it applied to, and it has reflective properties. The coating composition includes a mixture of a polymeric binder, a polymeric carrier and a pigment. The pigment is present in the coating composition in amount that is capable of providing a coating that has an initial energy efficiency rating greater than or equal to 0.65 for a low-sloped roof, or an initial energy efficiency greater than or equal to 0.25 for a steep-sloped roof.

Abstract: A roofing and/or siding system having an improved average resulting reflectivity. The roofing and/or siding system is at least partially coated with a plurality of granules. At least one layer of paint is applied to the roofing and/or siding system to increase the resulting reflectivity of the roofing and/or siding system.

Abstract: The present invention relates to roofing materials for roofs, sidewalls and other exterior surfaces exposed to the weather such as, but not limited to, asphaltic and non-asphaltic roofing materials, wherein color coated metal flakes cover up to 100% of the weathering surface of the roofing materials. The metal flakes are coated with a colored coating material by fluidizing the flakes in an air stream, spraying pressurized air and colored coating material, and curing the coated metal flakes. The present invention also relates to methods of making roofing materials.

Abstract: Algae-resistant roofing shingles are prepared with granules are formed by coating mineral particles with a clay-silicate binder including a metal oxide algaecide and small organic particles. When the particles are heated to cure the binder, the organic particles pyrolyse to form pores in the coating. Release of the algaecide is controlled by the structure of the granules.

Abstract: A process for forming algae-resistant roofing shingles comprises producing algae-resistant granules, and adhering the granules to a shingle stock material. The algae-resistant roofing granules are produced by a process that includes coating mineral particles with a clay-silicate binder including a metal oxide algaecide and small organic particles. The particles are heated to cure the binder, and the organic particles pyrolyse to form pores in the coating. The release of the algaecide is controlled by the structure of the granules.

Abstract: A shingle layer of shingle is provided having an increased thickness adhesive coating on at least a portion of its rear surface, with granules embedded therein, with the granules being of a size range that is larger than the fine particles normally applied to the rear surface of a shingle layer.

Abstract: An apparatus for applying granules onto an asphalt-coated sheet includes a granule applicator positioned above an asphalt-coated sheet moving in a machine direction. The granule applicator deposits granules into contact with the asphalt-coated sheet along a contact line substantially perpendicular to the machine direction, thereby defining a granule-coated sheet. A granule deflector plate engages the granule-coated sheet downstream of the contact line such that the granule deflector plate rides on the granules of the granule-coated sheet.

Abstract: A solar heat-reflective roofing product includes a base sheet, and solar heat-reflective roofing granules on top of the base sheet. The granules have a base particle with a flake-like geometry covered by a uniform coating layer. The coating layer has a thickness of at least one mil and includes a coating binder and at least one solar heat-reflective pigment. The solar heat-reflective pigment provides a solar heat reflectance of greater than 70 percent to the granules and the roofing product. Roofing products including roofing shingles and roofing membranes are described.

Abstract: Roofing material with an irregular surface and tailored radiation properties and tailored aesthetic properties in separate directions, simultaneously. This provides enhanced thermal performance in the sun direction and aesthetically pleasing visual appearance from viewing directions.

Abstract: A method of making a laminated shingle is provided. The method includes coating a shingle mat with roofing asphalt to make an asphalt-coated sheet, adhering a reinforcement member to a portion of the asphalt-coated sheet, covering the asphalt-coated sheet, and optionally covering the reinforcement member, with granules to make a granule-covered sheet, dividing the granule-covered sheet into an overlay sheet and an underlay sheet, wherein the overlay sheet has a tab portion normally exposed on a roof and a headlap portion normally covered-up on a roof, the headlap portion having a lower zone adjacent the tab portion and an upper zone adjacent the lower zone, and wherein the reinforcement member is adhered to the lower zone of the headlap portion and laminating the overlay sheet and the underlay sheet to make the laminated shingle.

Abstract: An adhesive product and method of making the product replaces asphalt in the manufacture of roofing shingles. The method comprises steps of forming a mixture of oil comprising fatty acids and a powdered catalyst operable to catalyze the polymerization of the oil; maintaining the oil to powdered catalyst weight ratio in the mixture between 1 to 0.01 and 1 to 4.9; heating the mixture to a reaction temperature greater than 100 degrees Centigrade; maintaining the reaction temperature for at least five minutes; and, injecting air into the mixture while maintaining the reaction temperature. In making a roofing shingle, the method includes additional steps of: applying the heated mixture to a fiberglass mat sheet from an upstream roll to form a tacky coated strip; and, adding a layer of granules to the tacky coated strip. The adhesive material of this method comprises polymerized oil and the powdered catalyst.

Abstract: A system and associated method applies a fluid to a surface. In particular, the system applies a roof surface covering to an existing roof location of a building. The system includes a pump for providing a pressurized source of fluid, a fluid conduit for extending from the pump to the roof location and delivering the fluid to the roof location, and an applicator device for applying the delivered fluid to the roof location to provide a portion of the applied roof surface. The system also includes a granule supply device for proving loose granules, a granule conduit for extending from the granule supply device to the roof location and delivering the loose granules to the roof location, and a dispenser for dispensing the loose granules onto the applied fluid on the roof location to provide another portion of the applied roof surface. The pump may be a peristaltic pump and the fluid does not directly engaging any surface of the pump. The applicator device may include a roller.

Abstract: Roofing shingles have a top surface, a bottom surface, a headlap portion, and a bead of tab sealant that is configured to bond to an underlying shingle when the shingle is applied on a roof. The tab sealant has a thickness that causes it to extend beyond a face of the bottom surface of the shingle. The headlap portion has a depression extending horizontally across the shingle when shingle is applied to the roof, the depression being spaced from a top edge of the shingle by a distance that will allow the depression to be aligned with the tab sealant of a complementary shingle when the shingles are assembled in complementary pairs, back to back in a bundle.

Abstract: A method of applying a powder coating composition during manufacture of modified bitumen roll roofing membranes, is provided. The coating composition is heat activated providing greater adherence to surfaces that it applied to, and greater reflective properties. The coating that has an initial energy efficiency rating greater than or equal to 0.65 for a low-sloped roof, or an initial energy efficiency greater than or equal to 0.25 for a steep-sloped roof.

Abstract: A shingle blank comprises a substrate coated with an asphalt coating and having an upper surface and a lower surface, the upper surface configured to include a first prime region and a second prime region. The first prime region is substantially covered by prime granules having a first overall visual effect and the second prime region is substantially covered by prime granules having a second overall visual effect different from the first overall visual effect. The shingle blank is capable of being divided into individual cap shingles that can be applied to a roof ridge or hip, with the cap shingles including both the first and second prime regions, thereby enabling the cap shingles to be installed in an overlapping manner on the hip or ridge with either the first or the second prime colors being exposed.

Abstract: A system for manufacturing a granule covered roofing shingle includes establishing at least two sources of granules. A standardized process for manufacturing granules having a standardized appearance is then established, wherein a color of the granules from one of the sources of granules is substantially identical to the color of the granules from the others of the sources of granules, thereby defining at least one standardized granule color. Granules of the standardized granule color are then manufactured according to the standardized process. The manufactured granules are transported to at least one shingle manufacturing facility, and granule covered roofing shingles are then manufactured using the manufactured granules of the standardized granule color.

Abstract: Algae-resistant roofing granules are formed by extruding a mixture of mineral particles and a binder to form porous granule bodies, and algaecide is distributed in the pores. Release of the algaecide is controlled by the structure of the granules.