ROOF CLIP FOR STANDING SEAM ROOF

Disclosed are elongate roof clips for fixedly attaching standing seam roof panels to a roof. The elongate roof clips provide improved resistance to uplift. Also provided are methods for securing roof panels in a standing seam roof, kits comprising the elongate roof clips, and an improved roof system.

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Description
CROSS REFERENCE TO RELATED APPLICATIONS

This claims priority to U.S. Provisional Patent Application No. 61,221,322 filed Jun. 29, 2009, which is incorporated herein by reference, in its entirety.

FIELD OF THE INVENTION

This relates to roof clips, and more particularly to roof clips for use with standing seam roofing.

BACKGROUND OF THE INVENTION

Sheet or panel roofing, such as metal panel roofing, is known in the art, and provides many benefits including protection from the elements, and a generally attractive appearance and architectural appeal. One common type of panel roof is the standing seam roof. Proper seams are important to the structure and integrity of such roofs, including allowing the roof to accomplish its primary protective functions. The standing seam roof features panels with flanges on each opposing long edge, typically one flange being longer than the other, i.e. each panel has one shorter flange and one longer flange on the opposite edge. Standing seams are formed between adjacent panels wherein an upwardly extending flange at an edge of one panel is folded over an adjacent, generally shorter, flange on an edge of an adjoining panel. By interlocking the roof panels in this manner to form seams, a proper seal is provided to keep out the elements (e.g. rain, snow), which can not penetrate the standing seams. However, when subjected to certain external forces, e.g., high winds (either sudden gusts, or sustained winds, such as storm winds), roof panels seamed with standing seams are prone to lifting from the underlying substrate on which the panels are positioned. Roof clips are therefore used to adequately secure the panels or sheets to the underlying roof structure. These roof clips secure the panel to the roofs substructure. Preferably, the roof clips are not visible when the roof is complete, i.e. they are installed to portions of the roof panels that are not apparent in the finished roof, or to a covered portion of the standing seam.

A variety of roof clips are known in the art. Two of the most common roof clips are nearly universal in application: fixed clips, and sliding or floating clips. Floating clips generally are fixedly secured to the underlying structure at one portion, and then a slidable portion of the clip is attached to the covered portion of the standing seam. The floating clip, with its movable parts, allows for certain limited relative movement of the roof panels, e.g. expansion and contraction, building movement, and the like. Fixed roof clips, on the other hand, lack any moving parts, and are fixedly attached to both the support structure and the roof panels. Other less common types of roof clips are available that feature more complicated designs, or specialty designs that are only compatible with particular roof panel system specifically designed to receive such specialty clips.

The invention disclosed herein provides improved roof clips for us with panel roofs, including standing seam roofs.

SUMMARY OF THE INVENTION

The inventor has surprisingly discovered that an elongate roof clip with an improved design featuring a length that is substantially longer than previously known clips provides unexpected advantages, such as easier and faster installation, as well as improved resistance to lifting forces, e.g. as measured for example by the UL 580 Standard entitled “Tests for Uplift Resistance of Roof Assemblies.” The roof clips provided herein can range from about 18 inches to 10 feet or more in length. Preferred clips have a length that is at least one-third to one-half of the length of the roof panels being used, and more preferably, substantially the same length as the roof panels used. The clips may be of any known type, including floating clips, but are generally of the fixed clip type.

In a first aspect of the invention, provided are elongate roof clips, of the fixed clip type, for use with panel roofs. The clips comprise a substantially flat elongate base member preferably having a plurality of attachment-receiving holes or openings therein for allowing the base member to be fixedly secured to a roof substructure element, such as a purlin, joist, sheathing, or other known roof structure, using one or more attachments means, such as screws, bolts, rivets, nails, pins, or the like. Presently preferred embodiments of the clip feature an elongate roof-engaging base member with holes provided, for example by punching or predrilling during manufacture.

The clip further comprises an elongate roof panel-receiving channel which is capable of receiving at least a portion of a seam flange provided on a roofing panel. The roof panel-receiving channel and base member are connected via and on opposing sides and opposite ends of a web or backbone member of the roof clip. Preferably, in use, the backbone member is positioned substantially normal to the roof structure to which the base member is secured. The base member, like the roof panel that the clip secures, will preferably lie substantially parallel to the underlying roof structure, and the roof panel receiving channel will lie on top of one of the roof panel flanges, and under the adjacent roof panel flange. Thus, it is preferable in practice, that the roof clip is at least partially not visible, or more preferably, not visible, in the finished roof, as each clip is preferably hidden by the next roof panel, i.e. the panel having a flange that goes on top of the clip.

In another aspect of the invention, methods of securing roof panels are provided, wherein each roof panel is secured using less than three clips per standing seam. In one embodiment, a single fixed clip that extends substantially the entire length of the panel is used. The method of securing seams in a panel roof comprises the steps of fixedly securing a base member portion of an elongate fixed roof clip having a length greater than 18″ and allowing the roof panel receiving channel of the first roof clip to receive a first upward flange of a first roof panel and creating a standing seam by adding a second panel adjacent to and oriented in the same direction as the first panel, said second panel having a second upward flange for creating a standing seam by folding said second upward panel over the receiving channel of the elongate fixed roof clip and first upward flange thereby creating the standing seam between the first and second panels. In a preferred embodiment, the elongate roof clip comprises a base member, and a panel-receiving interconnected by a backbone or web member, and disposed on generally opposite ends and opposite sides thereof.

In yet another aspect of the invention, a kit for installing sheet or panel roofing is provided. The kit provides together in a single package, or together in separate packages, at least one elongate fixed roof clip having a length greater than 18 inches and a plurality of attachment means such as screws, bolts, rivets, nails, pins or the like for attaching a base member of the roof clip to a roof structure in connection with installing panels. The kit can optionally provide instructions for use of the roof clip, along with additional information useful to the installer or purchaser. The elongate roof clip provided with the kit is preferably a roof clip comprising a base member, and a panel-receiving interconnected by a backbone or web member, and disposed on generally opposite ends and opposite sides thereof.

In a further aspect of the invention, a system for roofing is provided, the system comprising roof panels including flanges for making standing seams, roof clips comprising elongate roof clips of the type described herein, having a length that is at least about one-third the length of the roof panels. Optionally, the system includes a plurality of attachment means, such as screws, bolts, rivets, nails, pins, or the like. The system is useful for quickly constructing standing seam roofs that provide improved resistance to uplift due to wind conditions.

These and other aspects of this disclosure will be more fully described, along with further details of how to make and use them, with reference to the drawings and detailed description that follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides a partial view of an elongate fixed roof clip showing the base member, including a plurality of opening for receiving the attachment means, the panel-receiving channel, and the backbone member.

FIG. 2 provides an end profile view of an elongate clip.

FIG. 3 depicts a profile view of the 1½″ mechanical seal panel used in testing.

FIG. 4 depicts a partial top view of an elongate clip showing the base member with a set of attachment openings. The backbone member is not visible from this perspective.

FIG. 5 is an elevation view of a portion of an elongate clip with the roof panel-receiving channel apparent at the top of the backbone member. The base member is not visible from this perspective.

FIG. 6 shows a profile view of the continuous clip used in the uplift resistance testing.

FIG. 7 shows a profile view of the construction of the standing seam for the field panel in comparison with that of the corner panels. Note the use of additional sealant for use in conjunction with the corners.

FIG. 8 shows the layout for the structural members for a 10′×10′ roof used for testing the elongate roof clip for uplift resistance.

FIG. 9 shows the layout of the sheathing, felt, and barrier for the 10′×10′ roof used for testing the elongate roof clip for uplift resistance.

FIG. 10 shows the layout for the field decking. The cut away view shows the location and placement of the continuous clips under the panels. The location of the test frame for the UL 580 Standard is indicated by the dashed square.

 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Disclosed herein are elongate roof clips with an improved design featuring a length that is substantially longer than previously known clips provides unexpected advantages, such as easier and faster installation, as well as improved resistance to lifting forces, e.g. as measured for example by the UL 580 Standard entitled “Tests for Uplift Resistance of Roof Assemblies.” The roof clips provided here can range from about 18 inches to 10 feet or more in length. Preferred clips have a length that is substantially the same length as the roof panels being used. The clips may be of any known type, including floating clips but are generally of the fixed clip type.

In one aspect of the invention, provided are elongate roof clips, of the fixed clip type, for use with panel roofs. These clips are sometimes referred to herein as ‘continuous’ clips, in contrast with existing clips which are short in comparison, having lengths typically of two or three inches. The clips comprise a substantially flat elongate base member preferably having a plurality of attachment-receiving holes or openings therein for allowing the base member to be fixedly secured to a roof substructure element, such as a purlin, joist, sheathing, or other known roof structure, using one or more attachments means, such as screws, bolts, rivets, nails, pins, or the like. Presently preferred embodiments of the clip feature an elongate roof-engaging base member with holes provided, for example by punching or predrilling during manufacture.

Further description of the improved roof clip will be facilitated by reference to the Figures. FIG. 1 depicts a partial view of an elongate fixed roof clip 20 showing the base member 22, including a plurality of openings 24 for receiving the attachment means 26, the panel-receiving channel 28, and the backbone member 30. As can be seen, the elongate roof clip 20 comprises a base member 22 for securing the clip 20 to the roof or roof assembly 100 (not shown).

The base member 22 is generally substantially flat and elongate and preferably has a plurality of attachment-receiving holes or openings 24 therein for allowing the base member 22 to be fixedly secured to a roof substructure element 102 (not shown), such as a purlin, joist, sheathing, or other known roof structure, using one or more attachments means 26, such as screws, bolts, rivets, nails, pins, or the like. Presently preferred embodiments of the clip 20 feature an elongate roof-engaging base member 22 with holes 24 provided, for example, by punching or predrilling during manufacture.

The clip 20 further comprises an elongate roof panel-receiving channel 28 capable of receiving at least a portion of a seam flange 12, 14 provided on a roofing panel 10 (not shown). The roof panel-receiving channel 28 and base member 22 are connected via, and disposed on opposing sides and opposite ends of a web 30 or backbone member 30 of the roof clip 20. Preferably, in use, the backbone member 30 is positioned substantially normal to the roof structure 100 to which the base member 22 is secured. The base member 22, like the roof panel 10 that the clip 20 secures, will preferably lie substantially parallel to the underlying roof structure 100, and the roof panel receiving channel 28 will lie on top of one of the roof panel flanges 12, 14, and under the adjacent roof panel flange 12, 14. Thus, it is preferable in practice, that the roof clip 20 is at least partially not visible, or more preferably, not visible, in the finished roof 200 (not shown), as each clip 20 is preferably hidden by the next roof panel 10 (not shown), i.e. the panel 10 having a flange 12, 14 that goes on top of the clip 10 and obscures it from view in the completed roof 200.

As described above, the base member 22 and roof panel-receiving channel 28 are disposed on opposite sides 34a,b of the backbone member 30. Each of the base member 22 and the panel-receiving channel 28 are also disposed on opposite ends 32a,b of the backbone member 30.

It should be noted that the relative dimensions of the various components of the roof clip 20 can vary according to need. The overall length (l) of the roof clip 20 is preferably at least 18″ to 3′, and has been described herein above. The other dimensions can also vary. For example, the base member 22 can be any width (See ‘w’ in FIG. 4) or thickness dimension required. In one embodiment, the base member 22 extends about 1.0 inches from the backbone member 30. In other embodiments, the base member 22 could be longer or shorter as required or preferred, provided the resulting clip 20 passes the required structural tests, and/or meets the required structural strength/uplift resistance standards, such as UL 580, TAS 125, or the like.

The backbone member 30 can again be of any convenient dimension. The embodiment of roof clip 20 exemplified comprised a backbone member that was 1.625 inches. However, the height of the backbone member can range from less than 1 inch, to greater than 2 inches, with the only limitation being that the overall roof clip 20 must accommodate the height of the standing seam for which it is used. See ‘h’ in FIG. 5.

The receiving channel 28 typically comprises at least first and second portions 29a,b to define the channel 28, generally along with at least a portion of the backbone member 30. As with the other components of the roof clip 20, the first and second portions 29a,b of the panel-receiving channel 28 are of any convenient or useful width or thickness. In the exemplified embodiment, the first portion 29a of the receiving channel 28 was 0.5 inches, and the second portion 29b of the receiving channel 28 was 0.25 inches. The dimensions of first and second portions 29a,b of the receiving channel 28 are limited only by the ability to complement the shape of the standing seem, or meet the requirements for uplift resistance.

The overall shape of the roof-panel receiving channel 28 exemplified is substantially a rectangle (with one open side). Deviations from this shape are of course possible. Other shapes for the panel receiving channel are contemplated herein and compatible with the roof clip 20 described herein. For example, a more generally U-shape is defined by the panel-receiving channel in some embodiments. The receiving channel is conveniently adapted to the needs of the panel flange/standing seam geometry.

Generally, the thickness of all of the components of the roof clip 20 is the same in a given embodiment. For example, the thickness of the base member 22 or other portions can conveniently be the same as any standard sheet metal such as 18-26 gauges. In the embodiment exemplified below, roof clips were made from 24 ga galvanized steel. Preferably the roof clip is manufactured from a single, continuous piece of metal, with an absence of any welds, joints or the like. In yet other embodiments, one or more components of the roof clip 20 may be thicker than others, or such component as the base member 22, backbone member 30, or other portion may be reinforced. Such reinforcement can occur either through the inclusion or presence of thicker material for one or more components, or through the use of reinforcing structure. Reinforcing structures for use with roof clips, including use of one or more ribs, angled portions or other strengthening or reinforcing structures are known in the art.

While the roof clip 20 described for the embodiment above is constructed of galvanized steel. In other embodiments, the material from which the roof clip is made can be nongalvanized steel, stainless steel, or other sheet metal, including aluminum, or other metal, and any alloy, with the only limitation being that the roof clip 20 must be sufficiently structurally strong as discussed above, according to standard tests such as UL 580 or TAS 125. In various embodiments, the thickness is 18, 20, 22, 24, 26 ga material. One or more portions can be thicker as described above, but for greatest ease of manufacture and cost efficiency, the roof clip 20 is preferably constructed of uniform thickness. In other embodiments, the clip 20 and or roof panels 10 may comprise one or more plastics, polymeric materials, or reinforced plastics and/or polymeric materials. An example of such materials that has already proven useful for roof clips is nylon such as DuPont's Zytel® nylon, particularly where reinforced with glass, such as fiberglass. Such clips can be thermoformed or injection molded.

With further reference to the figures, FIG. 2 provides an end profile view of an elongate clip 20. The presence of the base member 22 and roof panel-receiving channel 28 on opposing sides 32a,b and opposing ends 34a,b of the backbone member 30 is apparent in this view. In the embodiment depicted, the base member 22 is offset from the backbone member 30 by a first offset angle 36 that is preferably about 90 degrees. Similarly, the roof panel-receiving channel 28 is offset from the backbone member 30 by a second offset angle 36 that is preferably about 90 degrees. In various embodiments the first and second offset angles 36, 38 can vary from 90 degrees before and/or after installation. Generally, the base member 22 will be offset from a standard backbone member 30 by substantially 90 degrees, except where there is a structural reason for altering the first offset angle 36. In embodiments where the backbone member 30 features some altered structural element, the offset angle 26 may also vary to accommodate the structure of the backbone member 30. The receiving channel may be offset from the backbone member 30 by any offset angle 38 that accommodates the panel flanges 12, 14. Thus, it is possible in some embodiments, that the receiving channel 28 will be offset from the backbone member 30 by, for example, by an acute angle.

With yet further reference to the figures, FIG. 3 depicts a profile view of the 1½″ mechanical seal panel 10 used in testing. The panel 10 shown is representative of the types of panels that are used with standing seam roofs. The panel 10 shown is constructed of 24 ga material, and provides 16″ of coverage. Such panels can be of any suitable dimensions and provide more or less coverage, but typically such coverage may be dictated by the roof substructure, such as the spacing of roof joists or the like. A first flange 12, and second flange 14 are seen at the edges of the panel 10. As can be seen, the flanges are complementary, and when overlapped the flange 14 can be wrapped around a flange 12 of an adjacent roof panel 10, so as to form a standing seam that is weather tight. The dimensions a (width of panel), b, b′ (height of first and second upward flanges, respectively) c, c′ (width of first portion of first and second upward flanges, respectively) d (width of second portion of second upward flange) can all be varied to create panels of varying geometries. The exemplified panel 10 also features structural reinforcements in the form of stiffening ribs 16.

FIG. 4 depicts a partial top view of an elongate clip 20 showing the base member 22 with a set of attachment openings 24. The backbone member 30 is not visible from this perspective. The letter w denotes the width of the base member. FIG. 5 shows an elevation view of a portion of an elongate clip 20 with the second portion 29b of the roof panel-receiving channel 28 apparent at the top of the backbone member 30. The base member 22 is not visible from this perspective, nor is the first portion 29a of the panel-receiving channel 28. The letter h denotes the height of the backbone member.

Attachment openings 24 may be spaced at any convenient and structurally useful distance (e) and pattern. Depicted openings may be in sets of two openings spaced about two inches on center (2″ O.C.), with such sets of openings 24 every six to twelve inches apart along the length of the base member 30. It will be apparent to one of skill in the art that the openings 24 can be made more or less frequent depending on the requirements of a particular application, e.g. likely maximal uplift forces to be faced in that application. The skilled artisan will also appreciate that the openings 24 need not completely uniformly distributed along the base member 22, but may be varied in frequency along the length of the base member 22. For example, the ends of the roof clip 20 may comprise more or less openings 24, and openings can be spaced individually or in sets of 2, 3, etc.

In connection with the openings 24, attachment means 26 are used to fixedly attach the roof panel 10 to the roof 100 or its substructure 110, such as sheathing, joists, etc. Attachment means 26 are selected based on the particular application of the roof clips 10. In the exemplified roof clips 20, #10 pancake screws, one inch in length, were used. Considerations in selecting the attachments means 26 will of course include the speed and ease of installation, the material of which the clip 20 is made, the material or structure to which the clip 20 is being attached, the potential uplift resistance required for the application, building code requirements, availability, cost, etc. Generally preferred attachment means 26 are screws for most applications. Also useful are bolts, nails, pins, rivets, and the like.

With yet further reference to the figures, FIG. 6 shows a profile view of the continuous clip 20 used in the uplift resistance testing exemplified herein. As with FIG. 2, the location of the base member 22 and the panel-receiving channel 28 on opposing sides and ends of the backbone member 30 are evident. The dimensions of the components of the exemplified embodiment are as follows: base member 22, 1.5 inches; backbone member 30, 1.625 inches; first portion 29a of panel-receiving channel 28, 0.5 inches; second portion 29b of panel-receiving channel 28, 0.25 inches.

FIG. 7 shows a profile view of the construction of the standing seam 18 for the field roof panel 10 in comparison with that of the corner panels 10. As can be seen, the first flange 12 of a first roof panel 10 is secured to the roof 100 by one or more attachment means 26 passed through the roof clip 20 with also overlaps the first flange 12. A second flange 14 of a second (adjacent) roof panel 20 is then overlapped over both the roof clip 20 and the first flange 12. The second flange 14 is then folded around the first flange 12 and the roof clip 20 to form the standing seam 18. Note the use of additional sealant 19 for use in conjunction with the standing seams 18 for the corner panel 10 application.

FIG. 8 shows the layout for the structural members 110 for a 10′×10′ roof 100 used for testing the elongate (continuous) roof clip 20 for uplift resistance. In the exemplified embodiment, the structural members 110 are 2×12 Southern Pine planks used as joists. The dashed line denotes the test device 115 for applying the uplift forces.

With further reference to the figures, FIG. 9 shows the layout of the roof substructure 120 including sheathing 122, felt paper 124, and fire barrier 126 for the 10′×10′ roof 100 used for testing the elongate roof clip 20 for uplift resistance. The plywood sheathing 122 was attached to the joists 110 with 8d×2½″ galvanized common nails, placed 4″ O.C. at the perimeter and 6″ O.C in the field. The felt paper 124 was attached with roofing nails. The felt paper 124 was overlapped 2″ between adjacent sheets, and 4″ on endlaps. The fire barrier 126 used was VERSASHIELD®.

FIG. 10 (a) shows the layout for the field decking of the roof panels 10. The cut away portion 150 shows the location and placement of the continuous roof clips 20 under the panels 10. The location of attachments means 26 is indicated. Attachment means were one inch long #10 pancake screws used in sets of two screws set 1.5 inches O.C., with sets separated 12 inches O.C, continuous. The location of the test frame 115 for the UL 580 Standard is indicated by the dashed square. The small inset FIG. 10 (b) shows the location and construction of the standing seam 18 for the field panels 10 using the continuous roof clips 20 under the panels 10.

In another aspect of the invention, methods of securing roof panels 10 are provided, wherein each roof panel 10 is secured using less than three elongate clips 20 per roof panel 10 or standing seam 18. In particular, the method for securing seams 18 in a panel roof 10 comprises the following steps:

a) providing a roof clip 20 comprising a base member 22, and a roof panel-receiving channel 28 interconnected by, and disposed on opposing ends 32a,b and sides 34a,b of a backbone member 30 therebetween; wherein said base member 22 is adapted for fixedly attaching the roof clip 20 to at least one portion of a roof substructure 110, and said roof panel-receiving channel 28 is adapted for receiving at least a first upward flange 12 on an edge of roof panel 10 for forming a standing seam 18; said roof clip 20 having a length that is at least one-third the length of the roof panels 10 used;

b) fixedly securing the base member 22 to a portion of the roof substructure 110 and allowing the roof panel-receiving channel 28 to receive a first upward flange 12 of a first roof panel 10; and

c) creating a standing seam 18 by folding a second upward flange 14 of a second roof panel 10 adjacent to and oriented in the same direction as the first roof panel 10, over the panel receiving channel 28 of the elongate fixed roof clip 20 and first upward flange 12 of the first roof panel 10;

thereby creating and securing the standing seam 18 between the first and second panels 10; wherein no more than three such roof clips 20 may be used for each roof panel 10 so secured.

In another embodiment, the method comprises the steps of

a) fixedly securing a base member portion 22 of an elongate fixed roof clip 20 having a length greater than 18″ and allowing the roof panel-receiving channel 28 of the first roof clip 20 to receive a first upward flange 12 of a first roof panel 10; and

b) creating a standing seam by adding a second roof panel 10 adjacent to and oriented in the same direction as the first roof panel 10, said second roof panel 10 having a second upward flange 14 for creating a standing seam 18 by folding said second upward panel 14 over the receiving channel 28 of the elongate fixed roof clip 20 and first upward flange 12 thereby creating the standing seam 18 between the first and second panels 10.

In one embodiment, the elongate roof clip 20 comprises a continuous base member 22, and a panel-receiving channel 28 interconnected by a backbone or web member 30, and disposed on generally opposite ends 32a,b and opposite sides 34a,b thereof; wherein no more than clips are used per standing seam.

While two or three roof clips 20 may be used per panel 10 section, in a presently preferred embodiment, a single ‘continuous’ fixed clip 20 that extends substantially the entire length of the panel is used. In one embodiment, the roof clip 20 has a length that is about 120 inches, or a length that is substantially the same as the roof panel 10 used to create the standing seam 18. In another embodiment, the base member 22 comprises a plurality of openings 24 for receiving said attachment means 26.

The methods provide faster and easier installation, and surprisingly, despite only using a small number of clips 20 (compared to the traditional practice of using a plurality of small fixed clips) the completed roof is more resistant to uplift forces, as determined by standard tests, such as the UL 580 Standard, or TAS 125 of the Florida Building Code.

In yet another aspect of the present invention, a kit for installing sheet or panel roofing is provided. The kit provides together in a single package, or together in separate packages, at least one elongate fixed roof clip 20 having a length greater than 18″ and a plurality of attachment means 26 such as screws, bolts, rivets, nails, pins or the like for attaching a base member 22 of the roof clip 20 to a roof structure 100 or substructure 100, in connection with installing panels 10 in a standing seam-type roof. In one embodiment, the kit comprises a) a roof clip 20 comprising a base member 22, and a roof panel-receiving channel 28 interconnected by, and disposed on opposing ends 32a,b and sides 34a,b of a backbone member 30 therebetween; wherein said base member 22 is adapted for fixedly attaching the roof clip 20 to at least one portion of a roof substructure 110, and said roof panel-receiving channel 28 is adapted for receiving at least a first upward flange 12 on an edge of roof panel 10 for forming a standing seam 18; said roof clip 20 having a length of at least 18 inches; and b) a plurality of attachment means 26 for fixedly securing the roof clip 20 to a roof substructure 110. In one embodiment, the base member 22 comprises a plurality of openings 24 for receiving said attachment means 26.

The kits can optionally include at least one roof panel 10, and/or instructions for use of the roof clip 20, along with additional information useful to the installer or purchaser, such as information about uplift resistance, or standards testing for roof panels. The elongate roof clip 20 provided with the kit is preferably a roof clip 20 comprising a base member 22, and a panel-receiving channel 28 interconnected by a backbone 30 or web member 30, and disposed on generally opposite ends 32a,b and opposite sides 34a,b thereof. In various embodiments, the length of the roof clip 20 is at least 3 feet, at least 5 feet, or at least 120 inches.

In a further aspect of the invention, a system for roofing is provided, the system comprising at least one roof panel 10 including flanges 12, 14 for making standing seams 18, roof clips comprising elongate roof clips 20, having a length that is at least about one-third the length of the roof panels. In one embodiment, the roof clip 20 comprises a base member 22, and a roof panel-receiving channel 28 interconnected by, and disposed on opposing ends 32a,b and sides 34a,b of a backbone member 30 therebetween; wherein said base member 22 is adapted for fixedly attaching the roof clip 20 to at least one portion of a roof substructure 110, and said roof panel-receiving channel 28 is adapted for receiving at least a first upward flange 12 on an edge of roof panel 10 for forming a standing seam 18; said roof clip 20 having a length of at least 18 inches.

Optionally, the system includes a plurality of attachment means 26, such as screws, bolts, rivets, nails, pins, or the like. In one embodiment, the base member 22 comprises a plurality of openings 24 for receiving said attachment means 26. The system is useful for quickly constructing standing seam roofs that provide improved resistance to uplift due to wind conditions. In a preferred embodiment, the length of the roof clip is substantially the same as that of the roof panels used for the standing seam roof.

The foregoing has described several embodiments of the roof clips 20 provided herein, as well as methods of making and using the clips 20 in the construction of standing seam roofs, and kits comprising the roof clips. These and other aspects of the invention will become clearer through the examples provided below.

EXAMPLES

Previously, it was considered that using a plurality of relatively short and independent roof clips in standing seam roofs provided the maximum benefits in terms of uplift resistance and ease of installation. This practice has been the industry standard for decades. Standard roof clips are commercially available in lengths of 2″, 3″, and 6″. It was considered that longer roof clips would be more difficult, time-consuming, and cumbersome to install. Further, it was believed that the failure of roof due to uplift would be less likely with a plurality of clips because even if an area of a seam failed, the plurality of remaining clips would suffice to secure the roof panels as well as possible. Under actual tests conditions, it was surprisingly discovered that elongate (or ‘continuous’) clips were actually able to resist lifting forces up to 228.5 psf when used for field panels and 273.5 psf in corner panel installation. Further, failure of panels installed with the continuous clips did not occur until 243.5 psf, and 288.5 psf for field panels and corner panels, respectively. Such results were more than sufficient to satisfy the requirements of the UL 580 Standard, as well as the State of Florida's more stringent TAS 125 Maximum Combined Sustained Pressure test. Further, it has also been determined that the continuous clips, which are substantially longer than previously known clips, provide other unexpected advantages, for example they were actually easier to install and resulted in faster panel roof installation,

The uplift resistance tests were conducted as follows:

Two specimens of 120 inch (length) elongate roof clips were submitted to an independent test laboratory for testing in March 2009. The roof clips were used in conjunction with a test installation of 1½ inch mechanical standing seam roofing panels. The roof deck was 120 inches (wide)×120 inches (long).

Each test assembly comprised a 120″×120″ roof structural frame fabricated from nominal 2×10 inch wood rafters, with intermediate rafters spaced 24″ on center (o.c.). This test assembly was sheathed with a single layer of ½″ structural CDX plywood (min 15/32″ thick).

The metal roof system was attached directly to the surface of the roof deck. The testing laboratory was certified under Miami-Dade County, Florida Building Code, IAS, AAMA, WDMA, and the Texas Department of Insurance. The laboratory was also Keystone Certified. The tests were conducted by a Professional Engineer certified in Florida.

Tables 1, 2, and 3 provide descriptions of the members, components, and accessories used for the structural support frame and the metal roof system, and other materials, respectively.

TABLE 1 Structural Support Frame Members Item Description Perimeter Support (4) - C12 × 20.7 A36 C-Channels Frame Intermediate Rafters (6) - 2″ × 12″ (nominal) Southern Yellow Pine timber planks spaced at 24″ o.c. Plywood Substrate A single layer of ½″ CDX Plywood (min 15/32″) was utilized across the entire surface of this sample. Each sheet of plywood spanned and attached to a minimum of three (3) rafters.

TABLE 2 Metal Roof System Components Overall Coil Description Cross-Section Material Length 1½″ mechanically- ½″ × 16.5″ × ASTM A653-97 20″ seamed panel, 16.5″ 24-Ga. grade C galvanized Coverage steel Clips 120″(long) × 1½″ ASTM A653-97 N/A wide × 1⅝″ (tall) grade C galvanized w/ ¼″ × 1⅝″ (tall) w/ ¼″ return flap steel

TABLE 3 Accessories for Roof Assembly Item Description Felt Paper 30# Asphalt-saturated organic paper (ASTM D226) meeting type II requirements. Felt Barrier A single layer of VersaShield ® was applied across the entire surface of this sample.

The test lab verified the test specimen construction in accordance with FIGS. 3, 4, 5, 6, 7, 8, 9 and 10. Table 4 provides the specimen construction materials and fastening materials for the 1½″ mechanical standing seam panel used for testing.

TABLE 4 Construction Using Continuous Roof Clip Specimens Description Location Location Fastener Type Spacing Plywood Sheathing to Perimeter 8d × 2″ galvanized ring shank common nails  4″ o.c. Structural Support Field 8d × 2″ galvanized ring shank common nails  6″ o.c. Frame Felt Paper 30# Perimeter 0.120″ × 1¼″ galvanized annular ring shank  6″ o.c. Field roofing nails with 32-ga tin caps with a 6″ 12″ o.c. overlap between adjacent sheets of felt paper. Staggard VersaShield ® A single layer of VersaShield ® with 3″ laps was laid loosely across the top of the felt paper. 0.120″ × 1¼″ galvanized annular ring shank roofing nails were used as necessary to hold sheets in place Field Panel Panel to Each roof panel was mechanically attached to the plywood Specimen #1 Frame using a continuous clip. This clip was held in place with a single row of #10 × 1″ pancake screws fastened down to the roof frame (2) screws 1½″ apart @12″ on center. Corner Panel Each roof panel was mechanically attached to the plywood Specimen #2 using a continuous clip. This clip was held in place with a single row of #10 × 1″ pancake screws fastened down to the roof frame (2) screws 1½″ apart @6″ on center. Panel to Panel The Adjacent metal roof panels were connected to each other using a hand held seamer that facilitated a 90 degree angle. Specimen #2 (Corner) had a continuous bead of Bostick Chem-Caulk between the mechanical seam. Specimen #1 (Field) had no sealer between the mechanical seam Roof Panel Ends Each roof panel was attached to the plywood using a single row of #10 × 1″ pancake screws (5) screws per panel at 3″ on center max. Roof Panel Each partial roof panel cut edge was attached to the plywood using a single Side Edge row of #10 × 1″ pancake screws at 4″ on center, 5″ max. indicates data missing or illegible when filed

Because Florida construction has been subjected in recent years to extreme conditions, e.g. hurricane and other storms providing challenges to construction methods, Florida Building Codes have been revised and provide a good standard for construction materials and techniques. Thus, the tests were conducted to certify the performance of the elongate (or continuous) roof clips under the requirements of e.g., the Florida Building Code. The summary of the test results for performance under the Florida Building Code TAS 125-04 entitled “Standard Requirements for Metal Roofing Systems” are shown in Table 5. TAS 125 encompasses the UL 580 Standard within its requirements.

TABLE 5 Results for tests under the TAS 125-04 Standard Test Method Conclusion Specimen #1 (Corner) TAS 125 (UL-580) PASS (Class 30, 60, and 90) TAS 125 228.5 psf Maximum Combined Sustained Pressure TAS 125 243.5 psf Combined Failure Pressure Specimen #2 (Corner) TAS 125 (UL-580) PASS (Class 30, 60, and 90) TAS 125 273.5 psf Maximum Combined Sustained Pressure TAS 125 288.5 psf Combined Failure Pressure indicates data missing or illegible when filed

It should be noted that Table 5 provides the results for Specimen 1, which was a “field panel” installation, and Specimen 2, a “corner panel” installation.

Tests were conducted according the sequence as shown in Table 6. For each specimen, tests were conducted based on UL 580 Class 30, 60, and 90, respectively, after which, the optional UL 1897 Standard test was conducted.

TABLE 6 UL Tests Test Specimen Test Specimen #1 (Field) #2 (Corner) 1. UL-580 Class 30 Test 1. UL-580 Class 30 Test 2. UL-580 Class 60 Test 2. UL-580 Class 60 Test 3. UL-580 Class 90 Test 3. UL-580 Class 90 Test 4. UL-1897 (optional 4. UL-1897 (optional    per TAS 125    per TAS 125) indicates data missing or illegible when filed

UL-580 Test Results:

The individual test results for the test specimens are presented in the following Tables. During the testing, a single layer of 2 ml flat polyethylene film was applied across the entire surface of the plywood in order to seal against air leakage. This plastic film contacted all surfaces of the panels and or clips and did not interfere with air passage to the sample or the movement of adjacent parts. Tables 7, 8, and 9 provide the test load data for Specimens tested under Class 30, 60, and 90, respectively.

Subsequent to the completion of Phase 5 of the Class 90 test sequence, the test specimens were subjected to additional static uplift pressures. Continuation of the test to increased pressure levels was option of the manufacturer, and not expressly required by the Building Code or the UL Standard. The results for these optional “failure” tests are provided in Tables 10 and 11 for the field Specimen (1) and the corner Specimen (2), respectively.

No signs of failure were noticed during class 30, 60, and 90 of the UL-580 test. No failures were observed in any components of the roof system or in any of the fasteners used to attach the roof system to the prepared structural roof frame.

The highest combined pressure Specimen 1 successfully resisted for 1 minute was 228.5 psf. The field specimen failed while attempting to resist a sustained combined pressure of 243.5 psf. For Specimen 2, the highest combined pressure the test specimen successfully resisted for 1 minute was 273.5 psf. Specimen 2 failed while attempting to resist a sustained combined pressure of 288.5 psf.

TABLE 7 Results for Specimen 1, Class 30 Data Test Positive Negative Test Duration Pressure Pressure Test Phase (min) (psf) (psf) Status 1 5 0.0 16.2 PASS 2 5 13.8 16.2 PASS 31 60 13.8 8.1-27.7 PASS 4 5 0.0 24.2 PASS 5 5 20.8 24.2 PASS 1Cyclic stage with 8-12 seconds per cycle.

TABLE 8 Results for Specimen 1, Class 60 Data Test Positive Negative Test Duration Pressure Pressure Test Phase (min) (psf) (psf) Status 1 5 0.0 32.3 PASS 2 5 27.7 32.3 PASS 31 60 27.7 16.2-55.4 PASS 4 5 0.0 40.4 PASS 5 5 34.6 40.4 PASS 1Cyclic stage with 8-12 seconds per cycle.

TABLE 9 Results for Specimen 1, Class 90 Data Test Positive Negative Test Duration Pressure Pressure Test Phase (min) (psf) (psf) Status 1 5 0.0 48.5 PASS 2 5 41.5 48.5 PASS 31 60 41.5 24.2-48.5 PASS 4 5 0.0 56.5 PASS 5 5 40.5 56.5 PASS 1Cyclic stage with 8-12 seconds per cycle.

TABLE 10 Results for Specimen 1: Load Sequence, Pressure Duration, Negative, Positive and Combined Pressures Negative Positive Combined Test Pressure Pressure Pressure Pressure Phase Duration (psf) (psf) (psf) Status 1 1 min. 30.0 48.5 78.5 PASS 2 1 min. 45.0 48.5 93.5 PASS 3 1 min. 60.0 48.5 108.5 PASS 4 1 min. 75.0 48.5 123.5 PASS 5 1 min. 90.0 48.5 138.5 PASS 6 1 min. 105.0 48.5 153.5 PASS 7 1 min. 120.0 48.5 168.5 PASS 8 1 min. 135.0 48.5 183.5 PASS 9 1 min. 150.0 48.5 198.5 PASS 10 1 min. 165.0 48.5 213.5 PASS 11 1 min. 180.0 48.5 228.5 PASS 12 1 min. 195.0 48.5 243.5 FAIL

TABLE 11 Results for Specimen 1: Load Sequence, Pressure Duration, Negative, Positive and Combined Pressures Negative Positive Combined Test Pressure Pressure Pressure Pressure Phase Duration (psf) (psf) (psf) Status 1 1 min. 30.0 48.5 78.5 PASS 2 1 min. 45.0 48.5 93.5 PASS 3 1 min. 60.0 48.5 108.5 PASS 4 1 min. 75.0 48.5 123.5 PASS 5 1 min. 90.0 48.5 138.5 PASS 6 1 min. 105.0 48.5 153.5 PASS 7 1 min. 120.0 48.5 168.5 PASS 8 1 min. 135.0 48.5 183.5 PASS 9 1 min. 150.0 48.5 198.5 PASS 10 1 min. 165.0 48.5 213.5 PASS 11 1 min. 180.0 48.5 228.5 PASS 12 1 min. 195.0 48.5 243.5 PASS 13 1 min. 210.0 48.5 258.5 PASS 14 1 min. 225.0 48.5 273.5 PASS 15 1 min. 240.0 48.5 288.5 FAIL

There have been described and exemplified herein a number of embodiments of an elongate roof clip, along with methods for making and using the roof clips, as well as kits and roof systems comprising the roof clips. The specific embodiments provided were primarily selected to illustrate the features of the roof clips to the understanding of the skilled artisan. Such a skilled artisan will appreciate that various modifications and alterations can be made to the specific embodiments exemplified, and that such modification and alterations are within the intended scope of the invention as defined in the appended claims.

Claims

1. An elongate roof clip for use with a standing seam-type roof, the clip comprising a base member, and a roof panel-receiving channel interconnected by, and disposed on opposing ends and sides of a backbone member therebetween; wherein said base member is adapted for fixedly attaching the roof clip to at least one portion of a roof substructure, and said roof panel-receiving channel is adapted for receiving at least a first upward flange on an edge of roof panel for forming a standing seam; said roof clip having a length of at least 18 inches.

2. The roof clip of claim 1 wherein the base member comprises a plurality of openings, each opening for receiving an attachment means for fixedly securing said base member to a portion of the roof substructure.

3. The roof clip of claim 2 wherein said attachment means is a screw, a bolt, a rivet, a nail, or a pin.

4. The roof clip of claim 1 wherein the base member and the roof panel-receiving channel are each displaced from the backbone member at an offset angle that is substantially a right angle.

5. The roof clip of claim 1 wherein when the base member is fixedly attached to the roof substructure, the backbone is situated substantially normal to the roof substructure.

6. The roof clip of claim 1 wherein the roof panel-receiving channel comprises first and second portions, which together with at least a portion of the backbone member, define a substantially rectangular space with one open side; wherein said first portion is connected to the backbone member and approximately 90 degrees offset therefrom, and said second portion is connected to the first portion and approximately 90 degrees offset therefrom.

7. The roof clip of claim 6 having a length of at least 3 feet, wherein the base member is about 1-2 inches wide, the backbone is about 1-2 inches high, the first portion of the panel-receiving channel is about 0.375-0.625 inches wide, and said second portion is about 0.2-0.675 inches wide.

8. The roof clip of claim 7 wherein the base member is about 1.5 inch wide; the backbone is about 1.625 inches high, the first portion of the panel-receiving channel is about 0.5 inches wide, and said second portion is about 0.25 inches wide.

9. The roof clip of claim 1 or claim 8 that has a length of about 120 inches.

10. The roof clip of claim 1 having a length that is substantially the same as the roof panel with which it is used.

11. A method for securing seams in a panel roof comprising the steps of:

a) providing a roof clip comprising a base member, and a roof panel-receiving channel interconnected by, and disposed on opposing ends and sides of a backbone member therebetween; wherein said base member is adapted for fixedly attaching the roof clip to at least one portion of a roof substructure, and said roof panel-receiving channel is adapted for receiving at least a first upward flange on an edge of roof panel for forming a standing seam; said roof clip having a length that is at least one-third the length of the roof panels used;
b) fixedly securing the base member to a portion of the roof substructure and allowing the roof panel-receiving channel to receive a first upward flange of a first roof panel; and
c) creating a standing seam by folding a second upward flange of a second roof panel adjacent to and oriented in the same direction as the first roof panel, over the panel receiving channel of the elongate fixed roof clip and first upward flange of the first roof panel;
thereby creating and securing the standing seam between the first and second panels;
wherein no more than three such roof clips may be used for each roof panel secured.

12. The method of claim 11 wherein the roof clip has a length that is about 120 inches, or a length that is substantially the same as the roof panel used to create the standing seam.

13. A kit for creating a standing seam between at least two roof panels, said kit comprising together in a single package, or together in separate packages:

a) a roof clip comprising a base member, and a roof panel-receiving channel interconnected by, and disposed on opposing ends and sides of a backbone member therebetween; wherein said base member is adapted for fixedly attaching the roof clip to at least one portion of a roof substructure, and said roof panel-receiving channel is adapted for receiving at least a first upward flange on an edge of roof panel for forming a standing seam; said roof clip having a length of at least 18 inches; and
b) a plurality of attachment means for fixedly securing the roof clip to a roof substructure.

14. The kit of claim 13 further comprising instructions for use of the roof clip, and optionally, at least one roof panel for use with a standing seam roof.

15. The kit of claim 12 wherein the base member has a plurality of opening therein for receiving the attachment means.

16. The kit of claim 15 wherein the roof clip has a length that is about 120 inches, or a length that is substantially the same as the roof panel used to create the standing seam.

17. A roofing system comprising at least two roof panels, each such panel including first and second flanges for making standing seams; a plurality of elongate roof clips, each clip having a length that is at least about one-third the length of the roof panels;

said roof clip comprising a base member, and a roof panel-receiving channel interconnected by, and disposed on opposing ends and sides of a backbone member therebetween; wherein said base member is adapted for fixedly attaching the roof clip to at least one portion of a roof substructure, and said roof panel-receiving channel is adapted for receiving at least a first upward flange on an edge of roof panel for forming a standing seam.

18. The system of claim 17 further comprising a plurality of attachment means.

19. The system of claim 17 wherein the base member comprises a plurality of openings for receiving said attachment means.

20. The system of claim 17 useful for constructing standing seam roofs that provide improved resistance to uplift due to wind conditions compared to a standing seam roof constructed with two or three inch length fixed clips.

Patent History
Publication number: 20100326000
Type: Application
Filed: Jun 25, 2010
Publication Date: Dec 30, 2010
Applicant: Value Metal, Corp. (Homestead, FL)
Inventor: Israel Jacob Garcia (Homestead, FL)
Application Number: 12/823,431
Classifications
Current U.S. Class: Fastener Or Anchor At Juncture (52/520); Assembled In Situ-type Anchor Or Tie (52/698); Anchor, Bond, Etc. (52/745.21); Engaging Folded Section Of Strip Or Facing (52/545)
International Classification: E04D 1/34 (20060101); E04B 1/38 (20060101);