SELF-ADHERED TERMINATION BAR

Abstract

A method of installing a self-adhered termination bar over a roofing system membrane positioned against a vertical surface, such as, for example, a parapet wall. The method includes positioning a termination bar having a pre-applied adhesive layer on a vertical surface having a single-ply membrane secured thereto. The self-adhered termination bar is initially secured to the membrane solely by the adhesive layer provided thereon. Mechanical fasteners are then driven through apertures in the self-adhered termination bar and into the structure to permanently secure the termination bar in place. The self-adhered termination bar allows the installation process to be performed by a single person.

Description

This application claims the benefit of U.S. Provisional Application Serial No. 61/260,109 filed on Nov. 11, 2009, which is incorporated herein by reference.

FIELD OF THE INVENTION

One or more embodiments of the present invention relate to a termination bar having an adhesive on one surface. More particularly, the termination bar may be provided with an adhesive layer and a release paper positioned over the adhesive layer. In other embodiments of the invention, a method of installing roof flashing is provided, the method including using a self-adhering termination bar to secure the flashing to a vertical surface.

BACKGROUND OF THE INVENTION

The construction industry commonly uses single ply membranes to provide a waterproof barrier on flat or low-slope roofs. It is prohibitively expensive and difficult to produce and transport a single membrane that is sized to cover an entire roof surface, thus, a plurality of individual membranes are provided and oriented in an overlapping arrangement. The overlapping portions, or splices, of these individual membranes must be secured together to ensure that the plurality of membranes form a single waterproof surface. In addition, the outer edges of the membranes adjacent to the roof edge must be sealed in some manner (e.g. to the roof substrate or to a roof edge surface) to ensure that water does not intrude beneath the membranes.

In many cases a parapet wall exists at one or more edges of the roof on which the roof membrane is provided, particularly in the case of flat roofs. In order to prevent leakage of the roofing system it is necessary to seal the edges of the membranes to the parapet wall. For example, a strip of flashing may be secured to the membrane edges adjacent to the parapet wall, the flashing extending vertically up the parapet wall and being secured thereto. The flashing may be secured to the membranes by an adhesive, by heat welding, or by other known methods of creating a water-tight seam. The flashing is secured to the vertical surface of the parapet wall by fasteners, adhesives, and/or other known methods. In many cases, a termination bar is provided to secure the flashing to the parapet wall. The termination bar is an elongate bar, typically made of metal, with a plurality of apertures. Mechanical fasteners are provided through the apertures of the termination bar and extend into the parapet wall, thereby further securing the flashing to the parapet wall along the length of the termination bar. A sealant may then be provided at the uppermost vertical edge of the flashing to create a water-resistant seal.

Conventional methods of securing roof flashing to a parapet wall using a termination bar are labor intensive, and therefore time consuming and expensive. Typically, two installers are required for the installation of the termination bar: one to hold the termination bar in place against the vertical surface, and another to drive the mechanical fasteners into the parapet wall. It is difficult for a single installer to perform both functions because the termination bar is prone to shift and slide down the surface as the installer drives the mechanical fasteners into the parapet wall.

Thus, there exists a need in the art for a termination bar that requires less labor during installation. Further, there exists a need for a method of installing a termination bar to reduce the labor required.

SUMMARY OF THE INVENTION

One or more embodiments of the present invention provide a termination bar for use in a single-ply membrane roofing system, the termination bar including an elongate body having a planar surface; a lip extending from an edge of the body away from the planar surface; a plurality of apertures through the elongate body; and an adhesive layer on the planar surface of the body, the adhesive layer adapted to temporarily secure the body to a vertical surface.

One or more embodiments of the present invention also provide a method of installing a termination bar over a roofing system membrane that is positioned against a vertical surface of a structure protruding from the roof surface, the method including: positioning a termination bar having an adhesive layer on a vertical surface having a single-ply membrane secured thereto, the termination bar being secured to the membrane solely by adhesive properties of the adhesive layer; and driving mechanical fasteners through apertures in the termination bar and into the structure to permanently secure the termination bar in place.

One or more embodiments of the present invention also provide a method of installing roof flashing on a vertical surface of a structure protruding from a roof surface, the method comprising: adhering one longitudinally extending edge of the flashing to a roofing membrane; adhering the other longitudinally extending edge of the flashing to a vertical surface of the structure protruding from the roof surface; positioning a termination bar having an adhesive layer on the vertical surface of the structure over the flashing, wherein the termination bar is held in place on the flashing solely as a result of the adhesive properties of the adhesive layer; and driving mechanical fasteners through apertures in the termination bar and into the structure to permanently secure the termination bar in place.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational perspective view of a roof membrane assembly including a self-adhered termination bar positioned on a roof having a parapet wall projecting therefrom;

FIG. 2 is a sectional view showing the self-adhered termination bar of FIG. 1 secured to roof edge flashing and a parapet wall by mechanical fasteners; and

FIG. 3 is a perspective view of the self-adhered termination bar having a pre-applied adhesive and a release liner and adapted to be secured to an edge flashing.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring now to FIG. 1, a membrane assembly is shown, and is generally indicated by the numeral 10. Membrane assembly 10 includes at least one membrane 12 that may be waterproof and weather-resistant. In the embodiment depicted in FIG. 1, two membranes 12 are shown. In one or more embodiments, the membrane may be fabricated from a thermosetting material. In other embodiments, the membrane may be fabricated from a thermoformable material. In one or more embodiments, the membrane may be EPDM based. In other embodiments, the membrane may be TPO based. In these or other embodiments, the membrane may be flexible and capable of being rolled up for shipment. In one or more embodiments, the membrane may include fiber reinforcement.

Membranes 12 are joined at a lap seam, generally indicated by the numeral 14. Lap seam 14 adjoins adjacent edges of membranes 12 to form a continuous watertight seal. Lap seam 14 may be formed by any method known to those skilled in the art for adjoining overlapping membranes. In one or more embodiments, lap seam 14 may be created using a solvent based primer and adhesive applied to the adjacent edges of the membrane 12. In other embodiments, lap seam 14 may be created using a primer and a double-sided adhesive tape applied to the adjacent edges of the membranes 12. In still other embodiments, lap seam 14 may be created using pre-applied primer and/or adhesive provided on the edges of the membranes 12. In yet other embodiments, lap seam 14 may be created by heat welding the edges of adjacent thermoformable membranes.

Membrane assembly 10 may be installed on flat or low-slope roofs. In one or more embodiments, the roof includes a parapet wall 16 on at least one of the edges thereof. Parapet wall 16 may be provided as a safety feature to prevent unwanted falls over the edge of a building, or it may be provided as an aesthetic feature of the building. Membranes 12 are secured to the roof substrate, and may be so secured by any mechanism or method known in the art, including, for example, adhesives or mechanical fasteners. Membrane assembly 10 may also be sealed against parapet wall 16 in order to prevent water from travelling down the parapet wall and beneath membranes 12.

In one or more embodiments, membranes 12 are positioned to overlap and travel up parapet wall 16 (not shown in Figures). In these embodiments, membranes 12 have an overlapping portion that may be adhered to parapet wall 16 in the same manner in which membranes 12 are adhered to the roof substrate. In other embodiments, such as that depicted in FIG. 1, a strip of flashing 18 is provided along an outer edge of membranes 12. Flashing 18 is secured to membrane 12 along a first longitudinal edge 20 to form another lap seam, generally indicated by the numeral 22. Lap seam 22 may be created by any method known to those skilled in the art as discussed above with respect to lap seam 14. An overlapping portion of flashing 18 is positioned against parapet wall 16 and is therefore oriented vertically. In one or more embodiments, overlapping portion 24 may be secured to parapet wall 16 by an adhesive.

Termination bars 26 are secured to parapet wall 16 over overlapping portion 24 of flashing 18. Termination bars 26 are elongate strips adapted to receive mechanical fasteners therethrough into parapet wall 16 to further secure overlapping portion 24 of flashing 18 to the wall. In one or more embodiments, termination bars 26 may be made of a metal. In other embodiments, termination bars 26 may be made of a plastic or composite material. In a preferred embodiment, termination bars 26 are made of aluminum.

An exemplary termination bar 26 is shown in FIGS. 2 and 3. Termination bar 26 includes a longitudinally extending planar portion 30, which may also be referred to as body 30. In one or more embodiments, termination bar 26 may include a top flange 32 and a bottom flange 34 extending generally perpendicular from planar portion 30. In one or more embodiments, a plurality of apertures 36 are provided in planar portion 30 of termination bar 26. Apertures 36 are adapted to receive mechanical fasteners 38 therethrough. Mechanical fasteners 38 pass through overlapping portion 24 of flashing 18 and into parapet wall 16 to anchor termination bar 26 to the parapet wall.

In one or more embodiments, termination bar 26 may have a length of between approximately 2 and 20 feet, in other embodiments between approximately 5 and 15 feet, and in still other embodiments, a length of approximately ten feet. In one or more embodiments, termination bar 26 may have a width of between approximately 0.2 and 3.0 inches, in other embodiments between approximately 0.5 and 2.0 inches, and in still other embodiments, a width of approximately 1.6 inches.

In one or more embodiments, planar portion 30 of termination bar 26 may have a thickness of between approximately 0.50 and 1.0 inches, in other embodiments between approximately 0.8 and 0.9 inches, and in still other embodiments, a thickness of approximately 0.87 inches.

In one or more embodiments, apertures 36 may be evenly spaced along the longitudinal length of termination bar 26. In these or other embodiments, apertures 36 may be spaced from one another along the longitudinal length of termination bar 26 by a distance of between approximately 2.0 inches and 5.0 inches, in other embodiments by a distance of between approximately 2.5 inches and 4.5 inches, and in still other embodiments by a distance of between approximately 3.5 inches and 4.0 inches.

Termination bar 26 includes an adhesive layer 40 on a surface of planar portion 30 opposite flanges 32 and 34. It is contemplated that any known adhesive may be used, and practice of the present invention is not limited by the adhesive selected. In one or more embodiments, adhesive layer 40 may be provided in the form of an adhesive tape. The term adhesive tape is used herein to refer to a substantially planar adhesive layer with or without a backing, which is consistent with the meaning of the term in the art of roofing systems. For example, the adhesive tape may be a pressure sensitive planar extrudate that is adhered on one surface to planar portion 30, and may have a second planar surface adapted to secure termination bar 26 to another surface (e.g. parapet wall). In one or more embodiments the adhesive tape may be generally the same width as termination bar 26. In other embodiments, the adhesive tape may have a width that is less than the width of termination bar 26.

The adhesive tape may include those that are conventional in the art, including those that have EPDM and/or butyl rubber. Useful adhesive tapes are disclosed in U.S. Pat. Nos. 6,120,869; 5,888,602; 5,859,114; 5,733,621; 5,612,141; 5,563,217; 5,545,685; 5,504,136; 4,932,171; 4,849,268; and 4,657,958, which are incorporated herein by reference. Useful tapes are commercially available, including those available under the trade names PLIOSEAL™ (Ashland) or 510™ (Adco) or 505™ (Adco).

In one or more embodiments, a release liner 42 may be provided over adhesive layer 40. Release liner 42 may include a thin film that the adhesive strip may form a temporary bond with, but which bond can be readily broken by applying minimal tension. In one or more embodiments, the release liner may include a paper or cellulosic structure coated with a polymeric coating, and therefore it may be referred to as release paper 42. In other embodiments, the release liner may include a polymeric extrudate or film; for example, the release liner may include a polyester or polyolefin (e.g., polypropylene) film. Release liner 42 may advantageously provide protection to adhesive layer 40 during storage or shipment, and may remain in place until it is desired to mate adhesive layer 40 to overlapping portion 24 of flashing 18.

In one or more embodiments, a sealant 44 may be applied over the top edge of overlapping portion 24 of flashing 18 against parapet wall 16. In one or more embodiments, sealant 44 may also be provided over mechanical fasteners 38. Sealant 44 acts to prevent water from infiltrating through the holes in flashing 18 created by mechanical fasteners 38. In one or more embodiments, sealant 44 may include known adhesives. The use of adhesive layer 40 on termination bar 26 alleviates the need to provide a sealant on a top edge of termination bar 26 when it is installed against flashing 18 on parapet wall 16, thereby further reducing the labor involved in installation.

In one or more embodiments, the method of installing the flashing 18 and termination bars 26 may include the step of providing and installing roofing membranes 12 on a roof substrate. Roofing membranes 12 may be secured to the roofing substrate by any method known to those skilled in the art, such as, for example, an adhesive applied to the underside of membranes 12, or the use of batten bars and mechanical fasteners passing through membrane 12. In one or more embodiments, the step of providing and installing roofing membranes 12 includes forming lap seams 14 between adjacent membranes, as discussed above. In one or more embodiments, roofing membranes 12 may be positioned on the roof substrate so as to reduce the gap between an outer edge of membranes 12 and parapet wall 16.

In one or more embodiments, the method of installing flashing 18 and termination bar 26 next includes the step of providing a strip of roof flashing 18, and securing the flashing along first longitudinal edge 20 to an edge of roofing membrane 12 adjacent parapet wall 16. Flashing 18 may be adhered to roofing membrane 12 by any known method of forming a lap seam 14. In one or more embodiments, flashing 18 is then secured to the vertical surface of parapet wall 16. In these or other embodiments, flashing 18 may be secured to parapet wall 16 using a bonding adhesive. In one or more embodiments, the steps of securing flashing 18 to parapet wall 16 using a bonding adhesive further includes the step of assuring that the flashing and vertical surface of parapet wall 16 are clean and dry, applying the bonding adhesive to flashing 18 and the vertical surface of parapet 16, allowing the bonding adhesive to flash off until a desired tackiness is achieved, bonding the flashing 18 to the vertical surface of parapet wall 16, and compressing flashing 18 against parapet wall 16 to ensure proper bonding. In one or more embodiments, the method of installing flashing 18 and termination bar 26 further includes the step of providing a continuous bead of a sealant between flashing 18 and parapet wall 16 at the elevation at which termination bar 26 will be secured.

In one or more embodiments, the method of installation includes providing a self-adhered termination bar 26 having an adhesive layer 40 and a release liner 42. Installation of self-adhered termination bar 26 includes first removing release liner 42 from adhesive layer 40, and then positioning self-adhered termination bar 26 against flashing 18 in a desired location so that adhesive layer 40 contacts and adheres to flashing 18. In one or more embodiments, mechanical fasteners 38 are then driven into parapet wall 16 through apertures 36 in self-adhered termination bar 26. Self-adhered termination bar 26 remains in the desired position against flashing 18 as a result of the adhesive properties of adhesive layer 40, thereby requiring only a single installer to perform the installation of self-adhered termination bar 26. In one or more embodiments, a lap sealant 44 may be provided along a top edge of overlapping portion 24 to prevent water infiltration behind flashing 18. In these or other embodiments, the sealant may also be provided over mechanical fasteners 38.

Various modifications and alterations that do not depart from the scope and spirit of this invention will become apparent to those skilled in the art. This invention is not to be unduly limited to the illustrative embodiments set forth herein.

Claims

1. A termination bar for use in a single-ply membrane roofing system, the termination bar comprising:

an elongate body having a planar surface and a lip extending from an edge of said body away from said planar surface;

a plurality of apertures through said elongate body; and

an adhesive layer on said planar surface of said body, said adhesive layer adapted to temporarily secure said body to a vertical surface.

2. The termination bar of claim 1, wherein said apertures are spaced along a longitudinal length of said elongate body.

3. The termination bar of claim 1, further comprising a release paper positioned over said adhesive layer opposite said body.

4. The termination bar of claim 1, wherein said adhesive layer is a double-sided adhesive tape.

5. The termination bar of claim 1, wherein said elongate body includes a second lip extending from an opposite edge and away from said planar surface.

6. A method of installing a termination bar over a roofing system membrane positioned against a vertical surface of a structure protruding from the roof surface, the method comprising:

positioning a termination bar having an adhesive layer on a vertical surface having a single-ply membrane secured thereto, the termination bar being secured to the membrane solely by adhesive properties of the adhesive layer; and

driving mechanical fasteners through apertures in the termination bar and into the structure to permanently secure the termination bar in place.

7. The method of claim 6, further comprising the step of applying a sealant over a top edge of the single-ply membrane after driving the mechanical fasteners into the structure.

8. The method of claim 6, further comprising the step of applying a sealant over the mechanical fasteners on an outer surface of the termination bar after driving the mechanical fasteners into the structure.

9. The method of claim 6, wherein the adhesive layer of the termination bar includes a release paper positioned thereon.

10. The method of claim 9, further comprising the step of removing the release paper from the adhesive layer prior to the step of positioning the termination bar on a vertical surface.

11. The method of claim 6, further comprising the step of cutting the termination bar to a desired length.

12. A method of installing roof flashing on a vertical surface of a structure protruding from a roof surface, the method comprising:

adhering one longitudinally extending edge of the flashing to a roofing membrane;

adhering the other longitudinally extending edge of the flashing to a vertical surface of the structure protruding from the roof surface;

positioning a termination bar having an adhesive layer on the vertical surface of the structure over the flashing, wherein the termination bar is held in place on the flashing solely as a result of the adhesive properties of the adhesive layer; and

driving mechanical fasteners through apertures in the termination bar and into the structure to permanently secure the termination bar in place.

13. The method of claim 12, wherein the step of adhering the flashing to the vertical surface includes:

ensuring the flashing and the vertical surface are dry and free of contaminants;

applying a bonding adhesive to the flashing and the vertical surface;

allowing the bonding adhesive to flash-off; and

compressing the adhesive coating flashing onto the adhesive coated vertical surface to ensure proper bonding.

14. The method of claim 12, further comprising the step of placing a continuous bead of sealant between the flashing and the vertical surface at the height at which the termination bar is to be placed.

15. The method of claim 6, further comprising the step of applying a sealant over a top edge of the flashing and against the vertical surface after driving the mechanical fasteners into the structure.

16. The method of claim 12, further comprising the step of applying a sealant over the mechanical fasteners on an outer surface of the termination bar after driving the mechanical fasteners into the structure.

17. The method of claim 12, wherein the adhesive layer of the termination bar includes a release paper positioned thereon.

18. The method of claim 17, further comprising the step of removing the release paper from the adhesive layer prior to the step of positioning the termination bar on a vertical surface.

19. The method of claim 12, further comprising the step of cutting the termination bar to a desired length.