Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of insulation boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of insulation boards includes polyisocyanurate foam having a first polyisocyanurate foam density. Each of the plurality of cover boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of cover boards includes polyisocyanurate foam having a second polyisocyanurate foam density greater than the first polyisocyanurate foam density.

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: 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: According to one aspect, a roofing system comprises a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation. Each of the plurality of insulation boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of insulation boards comprises polyisocyanurate foam having a first polyisocyanurate foam density. The roofing system further comprises a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of cover boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of cover boards comprises polyisocyanurate foam having a second polyisocyanurate foam density greater than the first polyisocyanurate foam density. The greater polyisocyanurate foam density provides for a compressive strength to resist deformation.

Abstract: According to one aspect, a roofing system comprises a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation. Each of the plurality of insulation boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of insulation boards comprises polyisocyanurate foam having a first polyisocyanurate foam density. The roofing system further comprises a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of cover boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of cover boards comprises polyisocyanurate foam having a second polyisocyanurate foam density greater than the first polyisocyanurate foam density. The greater polyisocyanurate foam density provides for a compressive strength to resist deformation.

Abstract: According to one aspect, a roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation. Each of the plurality of insulation boards includes a first polyisocyanurate foam having a first foam density. The roofing system further includes a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of cover boards includes a second polyisocyanurate foam having a second foam density, and the second foam density is greater than the first foam density. Each of the insulation boards and cover boards may have a facer on at least one major surface. The second foam density may be selected to provide the cover boards with a compressive strength to resist deformation.

Abstract: According to one aspect, a roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation. Each of the plurality of insulation boards includes a first polyisocyanurate foam having a first foam density. The roofing system further includes a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of cover boards includes a second polyisocyanurate foam having a second foam density, and the second foam density is greater than the first foam density. Each of the insulation boards and cover boards may have a facer on at least one major surface. The second foam density may be selected to provide the cover boards with a compressive strength to resist deformation.

Abstract: A method includes dispensing a first polymer or predominantly polymer material foam precursor and allowing the precursor to rise and at least partially set to form a foam core layer for an insulation board, the foam core layer having a first density. The method further comprises dispensing a second polymer or predominantly polymer material foam precursor and allowing the second precursor to rise and set to form a core layer for a cover board, the core layer for the cover board having a second density greater than the first density. The second foam precursor may include polyisocyanurate. The method may also include feeding facer materials over the precursors to form facers on the core layers. Such insulation boards and cover boards may be cut to length and installed on a roof.

Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each insulation board includes a foam material that includes polyisucyanurate, the foam material having a first density. Each cover board includes a material including polyisocyanurate, the material having a second density greater than the first. The roofing system may further include a waterproofing membrane adapted for overlying the cover boards. The insulation boards and cover boards may include facers on top or bottom surfaces.

Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each insulation board includes a polymer foam material having a first density. Each cover board includes a material including polyisocyanurate, the material having a second density greater than the first. The foam material of the insulation boards may include, for example, polystyrene, polyurethane, or a phenolic material. The insulation boards and cover boards may include facers on top or bottom surfaces.

Abstract: A cover board composite for overlying insulation of a roofing system includes a high-density core layer that is at least predominantly of a polymer material, a facer overlying and bonded to a bottom major surface of the core layer, and a reinforcement interposed between the facer and the bottom major surface of the core layer to coincide with a fastener pattern for securing the cover board composite to a roof deck and increase a per-fastener wind-uplift pull through rating for the cover board composite.

Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each insulation board includes a foam material that includes polyisocyanurate or polyurethane, the foam material having a first density. Each cover board includes a material including polyisocyanurate or polyurethane, the material having a second density greater than the first. The roofing system may further include a waterproofing membrane adapted for overlying the cover boards. The insulation boards and cover boards may include facers on top or bottom surfaces.

Abstract: A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each insulation board includes a foam material that includes polyisocyanurate or polyurethane, the foam material having a first density. Each cover board includes a material including polyisocyanurate or polyurethane, the material having a second density greater than the first. The roofing system may further include a waterproofing membrane adapted for overlying the cover boards. The insulation boards and cover boards may include facers on top or bottom surfaces.

Abstract: A roofing system includes a layer of insulation boards overlying a roof deck, and a layer of cover boards overlying the insulation boards. The insulation boards include a polyisocyanurate or polyurethane foam material that has a first density. The cover boards include a polyisocyanurate or polyurethane material that has a second density. The second density is greater than the first. The roofing system may also include a waterproofing membrane overlying the cover boards.

Abstract: A process for forming a reinforced product suitable for use as a roofing material is provided, comprising: (a) providing a composition comprising a matrix material; and (b) extruding the composition with an extruder to form a reinforced product, wherein a plurality of fibers is combined with the matrix material prior to or during the extrusion step. Also provided is a process for forming a reinforced product suitable for use as a roofing material, comprising: (a) forming a first layer comprising a first matrix material; (b) providing a plurality of fibers on the first layer; (c) forming a second layer comprising a second matrix material, above the plurality of fibers; and (d) combining the plurality of fibers with the first matrix material and/or the second matrix material, to form a reinforced product.

Abstract: Provided is a method of mixing a modified bitumen composition and feeding one or more polymeric materials to an extruder, together with asphalt fed at more than one location along a length of the extruder. Improved mixing and elimination of asphalt melting in the production of rolled goods and other products is improved.

Abstract: A cover board composite for overlying insulation of a roofing system includes a high-density core layer that is at least predominantly of a polymer material, a facer overlying and bonded to a bottom major surface of the core layer, and a reinforcement interposed between the facer and the bottom major surface of the core layer to coincide with a fastener pattern for securing the cover board composite to a roof deck and increase a per-fastener wind-uplift pull through rating for the cover board composite.

Abstract: A roofing system includes a layer of insulation boards overlying a roof deck, and a layer of cover boards overlying the insulation boards. The insulation boards include a polyisocyanurate or polyurethane foam material that has a first density. The cover boards include a polyisocyanurate or polyurethane material that has a second density. The second density is greater than the first. The roofing system may also include a waterproofing membrane overlying the cover boards.

Abstract: A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 4 lbs/ft3 and 25 lbs/ft3. A prefabricated roofing panel composite includes the cover board and an insulation board that has a low-density polymer or predominantly polymer material foam core layer preferably having a density less than 2.5 lbs/ft3. The cover board may have a waterproofing membrane forming the top major surface of the cover board. When making the roofing panel composite, the low-density foam core layer of the insulation board may be formed with the high-density core layer of the cover board being currently or subsequently formed over and bonded to a top major surface of the low-density foam core layer in the same operation or preformed insulation boards may be fed into a production line with the high-density core layer of the cover board being formed over and bonded to top major surfaces of the low-density foam core layers of the insulation boards.

Abstract: Self-adhering flashing cap strip and end lap connector cap sheet assemblies include a reinforcing layer encapsulated within self-adhering bitumen. The bottom major surfaces of the flashing cap strips and the connector end lap cap sheets are formed by the self-adhering bitumen and the top major surfaces of the flashing cap strips and the connector end lap cap sheets have lateral edge portions formed by the self-adhering bitumen and a coated central portion that extends between the lateral edge portions. The flashing cap strips are used to interconnect cap sheets at roof surface intersections in the formation of waterproof roofing layers and the connector end lap sheets are used to connect lengths of cap sheets at the job site.