Abstract: A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 6 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 having a density less than 6 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: A prefabricated cover board has a high-density polymer or predominantly polymer material core layer having a density between 6 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 having a density less than 6 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: 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: 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 roofing membrane with improved edge flexibility comprises a base reinforcement layer having a width W, a top reinforcement layer bonded to the base reinforcement layer, and a matrix coating the top reinforcement layer bonded to the base reinforcement layer. The top reinforcement layer has a width of about 80%±10% of width W. The matrix comprises one or more materials selected from the group consisting of bitumen, modified bitumen, one or more polymeric materials, and mixtures thereof.

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.

Abstract: A self-adhered roof system includes a plurality of waterproof self-adhering base sheets that are self-adhered by watertight bonds to underlying and overlying layers of the roof system and, preferably, waterproof fire-retardant cap sheets that are adhered to an underlying layer formed of the self-adhering base sheets. Base sheet assemblies that each include a base sheet with release sheets overlying its bottom and top major surfaces and, preferably, fire-retardant cap sheet assemblies that each include a fire-retardant cap sheet with release sheets overlying its bottom major surface and a selvage edge portion of its top major surface are utilized to form the self-adhered roof system. The self-adhering base sheets may be used with cap sheets other than fire-retardant cap sheets and with other roof components.

Abstract: A roofing membrane temperature indicator is provided for preventing the installation of a roofing membrane or roofing membranes at a temperature below a minimum recommended installation temperature for the roofing membrane(s) and/or a minimum recommended installation temperature for the roofing membrane(s) for a particular installation procedure. The membrane temperature indicator is visibly associated with the roofing membrane(s) and includes a thermochromic indicator having a first color at temperatures below a designated temperature and a second color visibly different from the first color at and above the designated temperature. The designated temperature at which the color of the membrane indicator changes is at or above a minimum recommended installation temperature for the roofing membrane(s) and/or a minimum recommended installation temperature for the roofing membrane(s) for a particular installation procedure.

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.

Abstract: A roofing component adhering assembly includes a bitumen layer having first and second major surfaces and at least a first release sheet substantially coextensive with the first major surface of the bitumen layer. The first release sheet is separable from the first major surface of the bitumen layer so that the bitumen layer of the roofing component adhering assembly can be used to adhere together overlapping surfaces, such as end and/or lateral edge portions, of first and second roofing components. The roofing component adhering assembly is especially well suited for adhering surfaces together where one of the surfaces is a granule surface, such as an end edge portion of a cap sheet. Preferably, styrene-butadiene-styrene modified bitumen is used to form the bitumen layer.

Abstract: A cap sheet for cold-applied adhesive roof installations includes a reinforcement mat saturated with and encapsulated within SBS modified bitumen. Bitumen layers above and beneath the mat have top and bottom major surfaces. The top surface of the top bituminous layer has a first edge portion extending inward from and along a first lateral edge. The bottom surface of the bottom bituminous layer has a second edge portion extending inward from and along a second lateral edge. The bitumen in the edge portions is a pressure-sensitive adhesive that is covered by release liners for protection prior to installation. When the cap sheets are installed, the release liners are removed from the edge portions and overlapping edge portions of the cap sheets are pressed and adhesively bonded together to immediately form effective watertight, weather-secure seams.

Abstract: A roofing component adhering assembly includes a bitumen layer having first and second major surfaces and at least a first release sheet substantially coextensive with the first major surface of the bitumen layer. The first release sheet is separable from the first major surface of the bitumen layer so that the bitumen layer of the roofing component adhering assembly can be used to adhere together overlapping surfaces, such as end and/or lateral edge portions, of first and second roofing components. The roofing component adhering assembly is especially well suited for adhering surfaces together where one of the surfaces is a granule surface, such as an end edge portion of a cap sheet. Preferably, styrene-butadiene-styrene modified bitumen is used to form the bitumen layer.

Abstract: A roofing component adhering assembly includes a bitumen layer having first and second major surfaces and at least a first release sheet substantially coextensive with the first major surface of the bitumen layer. The first release sheet is separable from the first major surface of the bitumen layer so that the bitumen layer of the roofing component adhering assembly can be used to adhere together overlapping surfaces, such as end and/or lateral edge portions, of first and second roofing components. The roofing component adhering assembly is especially well suited for adhering surfaces together where one of the surfaces is a granule surface, such as an end edge portion of a cap sheet. Preferably, styrene-butadiene-styrene modified bitumen is used to form the bitumen layer.

Abstract: A cap sheet for cold-applied adhesive roof installations includes a reinforcement mat saturated with and encapsulated within SBS modified bitumen. Bitumen layers above and beneath the mat have top and bottom major surfaces. The top surface of the top bituminous layer has a first edge portion extending inward from and along a first lateral edge. The bottom surface of the bottom bituminous layer has a second edge portion extending inward from and along a second lateral edge. The bitumen in the edge portions is a pressure-sensitive adhesive that is covered by release liners for protection prior to installation. When the cap sheets are installed, the release liners are removed from the edge portions and overlapping edge portions of the cap sheets are pressed and adhesively bonded together to immediately form effective watertight, weather-secure seams.