Coping Cleat and System for Roof Blocking Unit

Abstract

A cleat for use with a roof blocking unit has an integral leaf spring formed as a bend in a web intermediate its front and rear ends with a front side extending downward from the front end and a rear side extending downward from the rear end. In a coping unit, a diverter component defines a channel and is mounted over the cleat. The channel is disposed at an acute angle relative to the cleat web. In a coping assembly installation, a fluid impermeable membrane is disposed over the top of a roof blocking unit with the cleat mounted over the membrane and the diverter component mounted over the cleat. A pair of coping caps is disposed over the cleat and diverter in an offset arrangement with the channel beneath adjacent coping cap edges. The spring leaf biases the caps with a hook-like flange in engagement with a cleat flange.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. Provisional Application No. 62/003,250, filed May 27, 2014, for Cleat For Parapet Coping Assembly, the entire disclosure of which is hereby incorporated by reference in its entirety.

BACKGROUND

This disclosure relates generally to coping assemblies for implementing waterproofing for a roof blocking unit, such as a parapet wall. More particularly, the present disclosure relates to coping system hardware which is employed for sealing the top of a parapet wall of a building.

For coping systems to which the present disclosure relates, cleats are spaced and secured across the top of the wall. A second component, which may have several forms and is occasionally referred to as a shoe, is placed over the cleat. The component has a drain joint splice recess to divert water onto the roof. Coping caps, which are typically in the form of pre-determined lengths such as, for example, ten-foot lengths, and have an inverted channel-shape structure, are mounted over the cleats. The cleats with the drain recesses are disposed below the ends of the coping caps. Water, which may pass between the ends of the coping caps, flows onto the roof. The coping caps are typically resiliently secured by lower hook-like flanges which engage lower flanges of the cleats for securing the caps to the top of the wall.

The top of the parapet wall is typically initially covered by a waterproof membrane. The coping system components are dimensioned to accommodate the thickness dimensions of the parapet wall. The cleats are typically formed from galvanized metal and stainless steel and are secured to the top of the parapet wall over the membrane by numerous methods including the use of fasteners and/or adhesives. In many conventional systems, the cleat also has a spring element that is mounted at the top of the cleat to provide an upward spring bias. The biasing force is exerted against the underside of the top panel of the cap to securely maintain the coping cap to the cleat via the lower hook/flange engagement and hence to the top of the wall.

SUMMARY

An embodiment of a cleat for a coping assembly has a web with opposed front and rear ends. A front side integrally extends from the front end to an outwardly extending distal flange. A rear side integrally extends from the rear end to an outwardly extending distal flange. A first integral spring leaf is formed from a bend in and extends from the web intermediate the front and rear ends in a direction opposite from the front and rear sides.

In another embodiment, a coping unit for a roof blocking unit includes a cleat and a diverter component. The cleat has a web with opposed first and second ends. A front side integrally extends from the first end to an outwardly extending distal flange. A rear side integrally extends from the second end. An integral spring leaf extends from said web in a direction opposite from the front and rear sides. The diverter component includes a central panel that forms a diverter channel and has front and rear ends. A front panel integrally extends from the front end, and a rear panel integrally extends from the rear end. The diverter component is mounted over the cleat with the front panel engaging the front side in a substantially surface-to-surface relationship. The rear panel engages the rear side in a substantially surface-to surface relationship. The spring leaf biases the central panel in the direction opposite from the front and rear sides. The channel is disposed at an acute angle relative to the web.

In yet another embodiment, a coping assembly installation comprises a roof blocking unit, a fluid impermeable membrane, a cleat, a diverter component and a pair of coping caps. The roof blocking unit wall has a top surface extending between front and rear faces. The membrane is disposed over the top surface of the wall. The cleat is mounted over the membrane and secured to the wall. The cleat has an integral spring leaf that extending away from the top surface and a lower flange. The diverter component is mounted over the cleat and forms a drain recess disposed at an acute angle relative to the top surface. The coping caps each have a lower hook-like flange and extend transversely between opposite edges. The caps are disposed over the cleat and diverter component in an offset arrangement with the drain recess disposed substantially beneath adjacent edges of the coping caps. The spring leaf biases the caps away from the top surface to urge the lower hook-like flange in each cap into engagement with the cleat flange.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the preferred embodiment will be described in reference to the drawings, where like numerals reflect like elements:

FIG. 1 is an exploded view, portions shown in broken lines, of a representative portion of a roof blocking unit and a coping system incorporating a cleat in accordance with the disclosure;

FIG. 2 is an annotated, side sectional view, partly in diagram form, of the roof blocking unit and the installed coping system of FIG. 1;

FIG. 3 is a front elevation view, partly in phantom and partly in diagram form, of a portion of the installed coping system of FIG. 2;

FIG. 4 is an exploded view, partly in schematic, illustrating an assembly stage for the coping system of FIG. 1;

FIG. 5 is an exploded view, partly in schematic, illustrating a second assembly stage of the coping system of FIG. 1;

FIG. 6 is a top plan view, partly in diagram form, of a preferred embodiment of a cleat employable in the coping system;

FIG. 7 is a simplified elevation profile view, partly in diagram form, of the cleat of FIG. 6;

FIG. 8 is a top plan view, partly in diagram form, of another embodiment of a cleat employable in the coping system;

FIG. 9 is an elevation profile view, partly in diagram form, of the cleat of FIG. 8;

FIG. 10 is a top plan view, partly in diagram form, of yet another embodiment of a cleat employable in the coping system;

FIG. 11 is a simplified elevation profile view, partly in diagram form, of the cleat of FIG. 10;

FIG. 12 is an elevation face view, partly in diagram form, of the cleat of FIG. 10;

FIG. 13 is a perspective view of a drain joint splice component for the coping system;

FIG. 14 is an annotated elevation profile view of the drain joint splice component of FIG. 13;

FIG. 15 is an annotated, side sectional view, partly in diagram form, of another embodiment of the coping assembly installed on a roof blocking unit;

FIG. 16A is an exploded view of a pre-attached cleat-splice unit according to the disclosure;

FIG. 16B depicts the pre-attached cleat-splice unit in commercial distribution form;

FIG. 16C is an exploded view of a coping assembly, including a transverse support member;

FIG. 17A depicts embodiments of inner and outer corner coping caps for use in the disclosed assembly;

FIG. 17B depicts embodiments of end coping caps for use in the disclosed assembly;

FIG. 18 is an annotated, side sectional view, partly in diagram form, of an embodiment of the coping assembly installed on a masonry wall;

FIG. 19 shows an embodiment of a cleat member for use with deeper roof blocking units, including a top plan view and side elevation profile and preferred dimensions;

FIG. 20 shows an embodiment of a cleat member for use with a roof blocking unit with a short depth, including a front elevation, top plan and side elevation views and preferred dimensions;

FIG. 21 shows an embodiment of a cleat member for use on a tall roof blocking unit, including a front elevation, top plan and side elevation views and preferred dimensions;

FIG. 22 shows an alternate embodiment of the disclosed coping assembly for use in providing a flat upper surface or installation on a curved roof blocking unit; and

FIG. 23 shows a top plan view and a side elevation view of the cleat of FIG. 22, including preferred dimensions.

DETAILED DESCRIPTION

With reference to the drawings wherein like numerals represent like parts throughout the several figures, a cleat which is employed in a coping system or assembly 100 is generally designated by the numeral 10. The preferred application of the cleat 10 is in connection with a coping system which is used to provide a water seal and improved aesthetics for the top of a roof blocking unit (oftentimes a parapet wall).

With reference to FIGS. 1-3, a representative roof blocking unit, here a parapet wall P, is typically arranged at the edge of a roofing structure, and has a top which is crowned by a blocking B. Additional roof edge blocking systems, such as that disclosed in commonly owned U.S. Pat. No. 8,381,451 (disclosure incorporated herein by reference), are also suitable for use with the disclosed cleat 10 and coping system. A water-impervious membrane M lays over the roofing structure and covers the top surface of the blocking B. As will be further described below, the wall P has a front face side and a back side (adjacent the roof). A multiplicity of cleats 10 receive a mounted joint splice or drain component 12 and a plurality of the cleat/drain component units are secured to the top of the wall P at pre-established spacings. The spacings correspond generally to the length of a standard coping cap 14 which has a typical transverse length of approximately 10 feet, though this preferred length and spacing is nonlimiting. The ends of the coping cap 14 are mounted over the cleat/drain component unit in edge-to-edge relationship which oftentimes necessarily defines a small gap G therebetween, as best illustrated in FIG. 3. The gap G can be up to approximately 0.25 inches. In some embodiments, adjacent coping caps 14 may meet in a flush edge-to-edge abutment or even overlap slightly. Regardless of the exact relative positioning of adjacent caps 14, the system is susceptible to fluid leakage between the caps.

The cleats 10 are unitary components designed to receive and securely mount elongated coping caps 14 to the top of the wall P. The cleats 10 may be secured to the blocking B by stainless steel or similar fasteners 16 or similar material such as zinc coated fasteners, such as screws, and optionally washers 18. The cleats 10 are principally dimensioned to accommodate the thickness of the parapet wall. Various representative sizes and configurations of the disclosed cleat are designated as cleat 10A, 10B and 10C in FIGS. 6-7, 8-9 and 10-12. The cleats 10 are preferably manufactured from 20 gauge to 16 gauge galvanized metal and, for some applications, 20 gauge to 16 gauge stainless steel.

The cleat has a central planar web 20 of uniform length (generally commensurate with or slightly longer than the parapet wall is deep) ranging from approximately 4 inches to 36 inches and a uniform lateral width typically of approximately 8 inches to 16 inches, and more preferably approximately 12 inches. A back side 22 integrally extends via a bend from one end of the web approximately perpendicular to the web and terminates in a lower laterally extending, outwardly facing flange 24. The front end of the web integrally connects via an upper compound bend forming an upper vertex 30 with a front side 32 which extends downwardly a distance greater than that of back side 22 at an orientation approximately perpendicular to the plane of the web. The front side 32 terminates in a lower laterally extending, frontally facing flange 34. The front side 32 may also include a pair of laterally spaced slots 36.

The cleat 10 has an integral spring leaf 50 which extends upwardly from a plane defined by the web 20 at a preferred angle of approximately 15-20°. In this embodiment, the distal end of the integral leaf has a bent end portion 52. End portion 52 functions to reinforce the leaf 50 when the system is assembled. The integral leaf 50 provides an upward supporting bias against an installed overlying coping cap 14, as will be further described.

With additional reference to FIGS. 13 and 14, an auxiliary diverter drain component (splice) 12 is dimensioned to mount over the cleat 10 in a substantially central nested relationship. Component 12 is typically manufactured from metal, such as aluminum, and is also available in 24 gauge galvanized metal. The drain component 12 includes a central web 60 with laterally spaced multi-folded sides 62, defining a channel. The sides cooperate to provide a drain recess or channel for diverting water which may flow through between adjacent coping caps 14, such as through the gap G, onto the roof (not illustrated). A back panel 64 integrally extends from the central web in essentially a downward direction. A front panel 66 integrally extends from the front of the central web and may include a forwardly facing terminal flange 68. Upon mounting the components over the cleat 10, the front panel 66 is dimensioned to mate with the front side 32 of the cleat in a substantially surface-to-surface relationship. A pair of rearward protrusions 67 may be punched in the front face 66 and are positioned so that when the component 12 is nested over the cleat, the protrusions 67 mate with the openings 36 of the cleat to form a closely received, nested unitized assembly wherein the drain channel is oriented at a downward angle toward the rear, and thus upon installation, toward the roof. The splice component 12 and the cleat 10 may be attached via other methods known in the field, such as for example, adhesive, rivet, screws and staples.

With additional reference to FIGS. 6 and 7, the cleat 10A is adapted for a wall thickness of approximately 12 inches and accordingly has a length between the front and rear faces of approximately 12 inches. The cleat is formed from 20 gauge to 16 gauge galvanized material or 20 gauge to 16 gauge stainless steel and is cut, drilled, stamped, shaped and/or bent to the configurations illustrated in the drawings. The cleat 10A includes a pair of 0.250 inch diameter holes 26 centered approximately 10 inches apart and 0.1875 inch slots 28 centered approximately 10 inches apart adjacent the back side 22. The holes 26 and slots 28 provide openings for fastening the cleat 10 to the blocking with fasteners 16. This cleat is also available for masonry conditions with the use of Tapcon® concrete fasteners or other masonry/concrete fasteners (see FIG. 18).

The intermediate portion of the web is scored with a three sided rectilinear U-shaped slot 21 so that a formed rectangular appendage may be bent upwardly along the open end of the U-shaped slot at an angle of approximately 15° to form the spring leaf 50. In this embodiment, the free distal end 52 of the leaf is bent downwardly at an approximately 75° angle and extends approximately 0.375 inches. In preferred form, the leaf 50 is centrally positioned relative to the opposite lateral edges of the cleat. It should be appreciated that the angles and bends which form the described front, side, back side and the respective flanges are subsequently formed and configured. For the illustrated cleat 10A, the face side 32 extends 5.22 inches (with ranges from 2.5 inches to 12 inches for some embodiments) from the vertex 30 of the bend, and the rear side 22 extends downwardly approximately 2.54 inches (with ranges from 2.5 inches to 10 inches for some embodiments) from the web at the rear.

Cleat 10B in FIGS. 8 and 9 is adapted for a wall thickness of approximately 24 inches and also has a lateral dimension of approximately 12 inches. For cleat 10B, two integral leafs 50 and 54 are formed in the web. Each leaf is centrally located between the lateral edges. The leafs are substantially identical and each extends approximately 5 inches in length at an angle of approximately 15° to the planar surface of the web 20.

Cleat 10C illustrated in FIGS. 10-12 is adapted for a wall having a thickness of approximately 4 inches. In this embodiment, the leaf 50 is significantly shorter in length and has an angle relative to the plane of the web of approximately 20°. In this embodiment, no fasteners are required on the face side 32 of cleat 10C. With reference to FIG. 12, the front face side includes slots 33 for splice attachment through the use of a custom button tool designed to hold the splice in place. The height of the front face side in the vertical direction may vary from approximately 2.5 to 12 inches.

Nonlimiting representative dimensions for preferred embodiments of cleats 10A, 10B and 10C, shown respectively in FIGS. 6-7, FIGS. 8-9, and FIGS. 10-12, are set forth in Table I below (units in inches):

	TABLE I
	DIMENSION	CLEAT 10A	CLEAT 10B	CLEAT 10C
	h1	5.835	5.835	3.835
	h2	5.221	5.221	3.221
	h3	3.256	3.256	2.256
	h4	2.539	2.539	1.539
	l1	12.375	24.375	4.375
	l2	11.221	23.221	3.221
	d1	5.000	5.000	1.664
	d2	5.000	5.000	4.500
	d3	5.000	5.000	—
	d4	0.904	0.904	0.500
	d5	5.625	5.625	2.188
	d6	0.375	0.375	0.375
	d7	—	13.091	—
	d8	5.375	5.375	1.938
	d9	5.376	5.376	5.000
	d10	10.000	10.000	10.000

It will be appreciated that the aluminum joint splice or diverter drain component 12 is initially nested over the galvanized cleat 10 having the integral bias member in the form of leaf 50, as best illustrated in FIG. 4. This cleat-splice unit comprising the drain component and the cleat is then fastened as a single piece to the top of the parapet wall P, as herein described. The coping cap 14 is then forced downwardly over the fastened cleat and drain component so that the edge of the coping cap 14 is slightly off center and an adjacent cap 14 may then be positioned oppositely in edge-to-edge relationship, as shown in FIG. 3, or in a slightly overlapping configuration (not depicted). The coping caps are retained by the transverse hook 15 in cooperative engagement with the cleat and drain component flanges, 34 and 68, without requiring fasteners through the outer surfaces of the coping cap, thereby enhancing the fluid sealing integrity of the installed coping system. Each integral leaf, 50 and 54, functions as a spring to bias the cap upwardly and maintain a tight hook/flange engagement, and thus securedly attach the caps to the top of the wall. Naturally, multiple cleats/diverter drain components are spaced along the top of the wall and multiple coping caps are secured in the aforementioned edge-to-edge relationship. The joint splice components 12 and cleats 10 also eliminate the danger of fastening in the front faces over the edge of the roof for the engagement of coping.

FIG. 15 depicts a preferred embodiment of the coping system 100′ installed on a parapet wall of standard blocking material. Preferably the FACE dimension ranges in height from approximately 3 inches to approximately 12 inches, while the BACK dimension ranges in height from approximately 3 inches to approximately 6 inches. The FRONT face typically extends approximately 1-2 inches above the upper surface of the blocking material. The leaf spring 50 extends relative to the web 20 at an angle A, which ranges from approximately 15° to approximately 60°, and most preferably is approximately 30° prior to being compressed toward the web 20 by the joint splice component 12. Notably, as shown in FIG. 15, the disclosed embodiments may also employ a support channel 70 for improving the strength and stability of the system once installed and preventing downward sagging of any of the web elements. As shown, the support channel 70 may comprise a simple elongate C-channel member bent from metal, such as steel. Embodiments of the C-channel may be rearwardly angled slightly downward at an angle A_c, ranging from approximately 89° to 80°, and most preferably 88°, relative to the vertical. The slight downward angle accommodates the trajectory of the joint splice 12 and upper surface of the coping cap 14. In practice, the depicted support channels are installed on walls having a relatively larger depth of preferably approximately 24 inches or greater to prevent or reduce sagging.

FIGS. 16A and 16B depict the cleat 10 and joint splice 12 attached prior to installation on a parapet wall. In practice, the pre-attached unit 13 depicted in FIG. 16B is provided commercially, and thereafter mounted over a membrane layer M on a parapet wall as a single integral unit prior to attachment of adjacent coping caps in a laterally offset position with the channel of the joint splice positioned underneath the adjacent edges of the respective caps, which may abut, overlap or define a small gap G of up to approximately 0.25 inches (see FIG. 16C).

FIG. 17A depicts coping caps for use on inside and outside wall corners (14a, 14b), while 17B depicts end coping caps (14c, 14d).

FIG. 18 depicts an alternate embodiment of the coping assembly 100″ configured for attachment primarily to masonry parapet walls W_m. The key distinguishing features of the cleat 10″ for masonry are pop rivets 72 for aiding in pre-attaching the splice member 12″, which is configured with complimentary slots in the front panel. The coping cap 14 may be mounted over the installed cleat-splice unit.

FIG. 19 depicts an embodiment of a cleat member 10′″ with a pair of spaced spring leafs (50A and 50B). Here, both the front leaf 50A and rear leaf 50B extend rearwardly from the web at approximately 30°, though the respective leafs may fall within the aforementioned approximate range of 15°-60°. Also, of note in FIG. 19 are several preferred dimensions for elements of the cleat member 10′″.

FIG. 20 depicts a cleat member with short front and rear faces for use with shorter parapet walls, and includes representative dimension measurements. Similarly, FIG. 21 depicts a cleat member with longer front and rear faces for installation on a taller parapet wall.

FIG. 22 shows another embodiment of the coping assembly for use primarily with a deeper wall wherein a substantially flat upper surface is preferred over a top surface that transitions downward toward the roof structure, like the previously depicted embodiments. In the FIG. 22 embodiment, the cleat member includes a front spring leaf 50A and a rear spring leaf 50B. In contrast to the embodiment of FIG. 19, the front spring leaf 50A extends forward from the web at an acute angle, while the rear spring leaf 50B extends rearwardly in this embodiment. This particular dual spring embodiment has been shown to be particularly useful on curved or arched walls because the coping caps may be mounted thereon by pushing straight downward into a mounted position engaged with the front and rear flanges of the cleat, rather than first engaging the front flange and rotating the cap rearward onto the wall for engagement with the rear flange. FIG. 23 shows preferred dimensions of the cleat member of the embodiment of the coping assembly shown in FIG. 22. As with all of the embodiments depicted and described herein, the particular dimensions noted are preferred and non-limiting.

Additional embodiments of the coping assembly exist featuring a cleat member that is not fastened to the front surface of the parapet wall with a fastener, such as a screw, nail or staple. This system is typically employed with walls having a shorter height, of up to approximately 6 inches.

The disclosed coping assembly that includes the cleat-splice unit with integral spring leaf provides a substantial advantage over known coping systems. The disclosed assembly allows a two-step installation, which dramatically simplifies installation while improving safety. Some disclosed embodiments eliminate the dangerous practice of an installer hanging over a parapet wall to manually secure a coping cleat with a fastener in the front face. The pre-attached cleat-splice units streamline the installation process, by eliminating the need to split apart attached series of splice members and identify the proper sized splice to attach to a certain cleat.

While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the claimed coverage.

Claims

1. A cleat for a coping assembly for use with a roof blocking unit, comprising:

a web having opposed front and rear ends;

a front side integrally extending from the front end to an outwardly extending distal flange;

a rear side integrally extending from the rear end to an outwardly extending distal flange; and

a first integral spring leaf formed from a bend in and extending from said web intermediate the front and rear ends in a direction opposite from the front and rear sides.

2. The cleat of claim 1, wherein said spring leaf defines a plane that lies at an acute angle relative to the web.

3. The cleat of claim 2, wherein the spring leaf includes a bend at the distal portion of the leaf.

4. The cleat of claim 2, wherein the plane defined by the spring leaf lies at an angle of between approximately 15° and approximately 60° relative to the web.

5. The cleat of claim 1, comprising a second integral spring leaf extending from said web at the same approximate angle relative to the web as the first spring leaf.

6. The cleat of claim 5, wherein the second integral spring leaf extends from the web in the same relative direction as the first integral spring leaf.

7. The cleat of claim 5, wherein the second integral spring leaf extends from the web in the opposite relative direction from the first integral spring leaf.

8. The cleat of claim 1, wherein said spring leaf is formed as a cut in a portion of said web and upward bending of said portion.

9. The cleat of claim 8, wherein said leaf is substantially rectilinear formed by a substantially U-shaped cut in the web defining an open end and bending along a substantially linear portion of the web at the open end.

10. The cleat of claim 1, wherein the front end of the web transitions to the front side in a compound bend defining a vertex opposite the front side distal flange.

11. The cleat of claim 1, wherein the web defines a plane that is substantially perpendicular to the front and rear sides.

12. The cleat of claim 1, wherein said spring leaf defines a plane that lies at an angle of approximately 30° relative to the web.

13. A coping unit for a roof blocking unit comprising:

a cleat comprising a web having opposed first and second ends, a front side integrally extending from the first end to an outwardly extending distal flange, a rear side integrally extending from the second end, and an integral spring leaf extending from said web in a direction opposite from the front and rear sides; and

a diverter component comprising a central panel forming a diverter channel with a front end and a rear end, a front panel integrally extending from said front end, a rear panel integrally extending from said rear end; wherein

said diverter component is mounted over said cleat and said front panel engages said front side in a substantially surface-to-surface relationship, said rear panel engages said rear side in a substantially surface-to-surface relationship with the spring leaf biasing the central panel in the direction opposite from the front and rear sides, and said channel is disposed at an acute angle relative to said web.

14. The coping unit of claim 13, wherein the channel is angled downward toward the rear side of the web.

15. The coping unit of claim 13, wherein the first end transitions to the front side via a compound bend defining a vertex opposite the distal flange.

16. The coping unit of claim 15, wherein the front panel extends from said front end via a bend that mates substantially with the vertex.

17. The coping unit of claim 13, wherein the diverter channel is defined by a central web extending between opposite lateral edges, each lateral edge being bent in the direction opposite from the rear and front panels.

18. The coping unit of claim 13, wherein the diverter component is substantially rigidly attached to the cleat in the mounted configuration without an external fastener.

19. The coping unit of claim 13, wherein the diverter component front panel includes a distal flange disposed and angled to substantially abut the cleat first end flange.

20. A coping assembly installation comprising:

a roof blocking unit having a top surface extending between front and rear faces;

a fluid impermeable membrane disposed over said top surface;

a cleat mounted over said membrane and secured to said wall, the cleat having an integral spring leaf extending away from said top surface and a lower flange;

a diverter component mounted over said cleat and forming a drain recess disposed at an acute angle relative to said top surface; and

a pair of coping caps each having a lower hook-like flange and extending transversely between opposite edges disposed over said cleat and said diverter component in an offset arrangement, such that said drain recess is disposed substantially beneath adjacent edges of the coping caps, said spring leaf biasing said caps away from said top surface to urge the lower hook-like flange in each cap into engagement with the cleat flange.