Note: Descriptions are shown in the official language in which they were submitted.
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ROOFING SYSTEM AND METHOD
TECHNICAL FIELD
Applicant's invention relates to roofing for buildings, and more specifically
to a slate
roofing system and method of installation.
BACKGROUND
Slate roofs are appreciated for their aesthetic and durable qualities. Slate
is one of the
finest roofing materials available and has several advantages over asphalt
shingle roofs. For
example, state roofing is fireproof, resists hail damage, and often has a
service life of 100
years or more. However, slate is a rigid natural stone product which
unfortunately can be
damaged by stress. Stress can be introduced into slate in several ways, but
the most common
cause of stress to slate is nails used to attach the slate to the roof deck.
With nail installation,
the nails need to be fastened so the slate hangs on the nail. If the nail is
inserted too tightly,
the nail will pinch the slate. On the other hand if the nail is not inserted
deep enough, the
overlapping piece of slate may crack from the hidden pressure point.
Environmental effects
on the wood decking and nails may also contribute to the stress. Environmental
changes such
as swings in temperature and humidity can cause the decking to expand and
contract. If the
nails are in a bind in this situation, the slate can crack or fall.
Furthermore, slate roofs are quite expensive (typically two to three times
more
expensive than composition asphalt roofing), and the weight of the slate is
quite high
compared to composition shingles (which may require additional support for the
roof, further
adding cost). Slate materials are expensive themselves, so any reduction in
the amount of
slate necessary for effective roofing would lead to both a decrease in cost
and weight of a
roof.
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CA 02625597 2008-03-14
A good background for slate roofing and the method for installing the same may
be
found in the NRCA Roofing and Waterproofing Manual--4th Edition, pp. 1179-
1227. Typical
slate roofs are constructed such that a wood roof is first covered with an
underlayment layer,
typically asphalt felt paper. Overlapping slate courses are then applied with
slate covering the
roof in two plies except where there is overlap, in which case there are three
plies of slate.
Through joints should not occur from the slate roof surface to the felt. So
using the
conventional slate roofing technique, slate tiles must be elongated
sufficiently to allow for
three-ply overlap (and two plies of slate on the exposed portions of the roof)
in order to ensure
that water cannot penetrate the roof between the seams between slate tiles.
Accordingly, the
conventional slate roofing technique requires the use of a great deal of slate
material, due to
the need for double ply coverage and three-ply overlap for water resistance,
greatly increasing
the cost and weight of a slate roof.
Slate roofs may be improved by reducing the amount of slate used to create a
waterproof roofing surface, and by eliminating the use of nails (or any other
penetration or
system requiring a hole in the slate) to secure the slate tiles in place on
the roof. This may
allow for a more durable, but less expensive and heavy, slate roof.
Furthermore, the slate roof
would be more durable if there was some means of resisting uplift forces
generated by winds
on the slate tiles. High winds may catch under the leading edge of the slate
tiles, applying a
lifting force to the slate. In this manner, wind may increase stresses on the
slate tiles. In
addition, the wind may actually lift the slate tiles, exposing the underlying
roof to the
elements. Thus, an improved slate roofing system would attach the slate tiles
to the rook deck
using some means that would resist wind uplift forces, providing a more
durable and weather
resistant roof.
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SUMMARY
The embodiments of the present disclosure include a roof having slate members
attached by battens and hangers. The slate tiles are typically attached to the
roof in
overlapping rows. Underlayment may be attached to the roof, positioned below
the battens.
In some embodiments, battens are attached to the roof, stretching across the
length of the roof
and spaced vertically at regular intervals upon the roof The hangers may then
attach to the
battens in order to support slate tiles, thereby affixing the slate tiles to
the roof. Generally, the
hangers could either be removably secured to the battens and/or secured to the
battens in such
a way as to be repositionable along the length of the battens. In some
embodiments, the
hangers are generally tension sprung to resist uplift. Accordingly, the
hangers help the slate
tile they support to resist uplift forces generated by wind. Additionally, the
hangers may help
the slate tiles of the lower row to resist uplift by pressing down across the
top portion of the
slate tiles (on the overlap section). In essence, the overlapping nature of
the slate rows allows
the hangers to maximize resistance to uplift.
The roof may further include interlayment material (often referred to as
"slate liner")
underlying the slate. Generally, slate liner associated with each row of slate
underlies the
slate tiles of a row. Typically, the slate liner for a row of tile would be
positioned atop the
hangers associated with that row, and the slate tiles would then be placed in
the hangers atop
the slate liner. In addition, the roof may include valley metal, gable/rake
edge metal and drip
edge metal positioned on the roof deck. Generally, the slate roof may be
installed by
positioning and attaching the battens to a roof deck. The hangers would then
be secured to the
battens, positioned on the battens in order to properly support slate tile
across the roof In one
embodiment, the battens would have regularly spaced hanger holders or slots
along their
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length, shaped and sized to accept the hangers. The hangers are operable to
fit securely
within the hanger holders, such that the hangers could be securely attached as
necessary along
the length of the battens to affix slate tiles to the roof. By providing
hangers that are
removably secured to the battens, the hangers may be appropriately positioned,
regardless of
an edge or a valley in the roof. An alternative embodiment might have hangers
that are
repositionable along the length of the battens, so that the hangers may be
properly positioned,
regardless of an edge or valley. Once the hangers have been appropriately
placed on the
battens, the state liner would be positioned atop the hangers before placing
down the slate. In
addition, underlayment may be placed below the battens, with a self-adhering
membrane
placed below the underlayment.
By underlaying each course of slate with an interlayment material layer, the
interlayment material acts as a base to the through joints, preventing water
penetration to the
underlying roof through seams in the slate tiles. This can reduce the amount
of slate used to
form a waterproof roof by approximately 40% to 50% (since the interlayment
material blocks
water seepage through seams between slate tiles, less slate overlap is
required to provide a
waterproof roof. Rather than two plies of exposed slate and three-plies of
slate at areas of
overlap, the present embodiments use only a single ply of exposed slate with
two-plies of
slate at areas of overlap). Generally, heavy-duty, weatherproof interlayment
material layer
would be used, typically plastic 20 to 60 mil in thickness. Moreover, where
slate meets side
to side (the through joint), the underlaying interlayment material provides
sufficient
waterproofing to protect the roof. The interlayment material is also less
expensive and lighter
weight than the slate it replaces. Thus, disclosed embodiments improve upon
prior art slate
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roofs by providing for a markedly improved weather barrier, lighter weight,
and more
economical slate roof.
Disclosed hanger embodiments do not require nails to mount the slate on the
roof,
improving the durability of the slate tiles by reducing stresses. The
disclosed embodiments
allow a plurality of hangers to be installed at one time. Since damage can
also be caused
during roof construction, the installation of a plurality of hangers at one
time allows the slate
to be installed from the top down. In addition, the nature of the hangers
allows the roof to be
easily repaired without tools. The metal used in some embodiments of the
hangers can also
be a more durable means of attachment of slate tiles to the roof, since the
hanger shape
provides for strong, durable attachment. The hangers are also generally spring
tempered,
which helps them spring against the roof deck. By being tension-sprung, the
hangers may
provide superior wind uplift protection.
While examples in this application make specific reference to slate and slate
installation, the invention and techniques provided herein apply to tile and
tile installation
regardless of material, and any sort of shingle, as well.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a roof deck.
FIG. 2 is a top view of the roof deck illustrating valley preparation and drip
edge installation.
FIG. 3 is a top view of the roof deck illustrating placement of underlayment.
FIG. 4 is a top view of the roof deck illustrating placement of valley metals
and rake edge
metals.
FIG. 5 is a top view of the roof deck illustrating preparation of all valleys,
hips, ridges, walls
and roof penetrations.
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FIG. 6 is a top view of the roof deck illustrating the installation of slate.
FIG. 7 is a perspective view of the roof deck illustrating installation of
slate.
FIG. 8 is a perspective view of the roof deck illustrating slate installation
at the valley.
FIG. 9A is a top view of a batten with exemplary hangers used according to the
present
disclosure.
FIG. 9B is a top view of a batten with exemplary hangers used according to the
present
disclosure.
FIG. 9C is a top view of a batten with exemplary hangers used according to the
present
disclosure.
FIG. 9D is a perspective view of a batten with exemplary hanger used according
to the present
disclosure.
FIG. 9E is a perspective view of a batten with exemplary hanger used according
to the present
disclosure.
FIG. 10 is a front view of the roof deck illustrating hip installation of
slate.
FIG. 11 is a top view of the roof deck illustrating the ridge.
FIG. 12 is a side view of the roof deck illustrating ridge installation of
slate.
FIG. 13 is a detailed view of slate installation step 1.
FIG. 14 is a detailed view of state installation step 2.
FIG. 15 is a detailed view of state installation step 3.
FIG. 16 is a perspective view of the roof deck illustrating flashing at
siding.
FIG. 17 is a perspective view of the roof deck illustrating flashing at
sidewall/chimney.
FIG. 18 is a perspective view of the roof deck illustrating plumbing vent
details with
installation.
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FIG. 19A is a side view of the hanger according to one aspect of the present
disclosure.
FIG. 19B is a plan view of the hanger of FIG. 19A.
DETAILED DESCRIPTION OF EMBODIMENTS
In FIG. 1 a top view of a roof deck 102 is shown. In the present methodology,
the
initial step is to inspect and prepare the roof deck 102. In one embodiment,
the roof deck 102
has a valley 104, eave 114, gable/rake 116 and ridge 118. In this exemplary
roof deck 102
inspection step, the existing roof sheathing is inspected for structural
integrity. The roof deck
102 should be preferably minimum 15/32 inch plywood or code approved oriented
strand
board (OSB). All roof deck 102 nails should be driven flush with the roof deck
102. The roof
deck 102 should be inspected for protrusions which may damage felt
underlayment 110 (See
FIG. 3).
FIG. 2 is a top view of the roof deck 102 illustrating valley 104 preparation
and drip
edge 108 installation. In this step of the present methodology, the user
installs peel and stick
membrane 106 in the valleys 104 while overlapping membrane 106 seams a
preferred
minimum of six inches. The membrane 106 used is preferably a self-adhering
poly(styrene-
butadiene-styrene) (SBS) type. For example, the membrane 106 used in the
preferred
embodiment is Tarco TM Leak Barrier Ice and Water Armor. However, it is to be
appreciated that any equivalent membrane can be utilized. The membrane 106 is
preferably
36 inches wide. All drip edge 108 metals are then installed. The drip edge 108
is preferably
D style No. 26 gauge galvanized or 16 ounce copper metal. On new construction,
if the
exterior fascia board has not been painted, the drip edge 108 may be delayed
and installed
after the underlayment 110 (See FIG. 3) is installed. The underlayment 110
(See FIG. 3)
should extend over the drip edge 108 metal.
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In FIG. 3 a top view of the roof deck 102 illustrating placement of
underlayment 110
is shown. In this step of the present methodology, the user installs
underlayment 110, which
is preferably a poly(styrene-butadiene-styrene) (SBS) multipurpose or Type 30
per ASTM
D226. During this step, the user will roll the underlayment 110 over the
gable/rake edge 112
a preferred minimum of one inch. There is a preferred minimum headlap of two
inches for
the underlayment 110. This may be increased to a minimum of four inches in wet
or snow
areas. Headlap for purposes of this application is defined as the portion of
slate 130 (See FIG.
6) overlapped by two layers of slate 130 (See FIG. 6) from the next two rows.
Headlap
facilitates making the roof watertight. Indeed, failure to adhere to the
recommended headlap
can lead to interior water damage. There is a preferred minimum six inch
sidelap for the
underlayment 110. For purposes of this application, sidelap is defined as side
edges of
adjoining pieces of underlayment. Nails (not shown) may be used to secure the
underlayment
110 and have a pattern of preferably 12 inches on center at the headlap and
preferably 36
inches on center at the center of the underlayment roll.
FIG. 4 is a top view of the roof deck 102 illustrating placement of valley
metals 120
and rake edge metals 154. In the present methodology, the user may install
valley metal 120
over membrane 106 (See FIG. 2). This valley metal 120 is preferably 26 gauge
galvanized,
24 inch "W", or 16 ounce copper metal. It is preferably installed with a one
inch splash
diverter (not shown) and preferably fastened with 1.25 inch roof nails or 1.25
inch copper
slating nails one inch from the edge. The user may also install gable/rake
edge metals 154 at
gable/rake edge 112. The gable/rake edge metal 154 is preferably 26 gauge
galvanized or 16
ounce copper metal. Next the user may install vertical wall flashings (See
FIGS. 16 and 17)
and plumbing stack and vent flashings (See FIG. 18). The vertical wall
flashings (See FIGS.
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16 and 17) are preferably 26 gauge galvanized or 16 ounce copper. At the next
step, the user
may install peel and stick membrane 106 over ridge 118. The membrane 106 used
is
preferably a self-adhering poly(styrene-butadiene-styrene) (SBS) type. The
membrane 106 is
preferably 12 inches wide having three inch endlaps.
In FIG. 5 a top view of the roof deck 102 illustrating preparation of all
valleys 104,
hips 156, ridges 118, walls and roof penetrations is shown. Peel and stick
membrane 106 is
applied over valley metal 120 (See FIG. 4) leaving preferably three inches
from the center
line of valley 104 uncovered. The membrane 106 should cover valley metal 120 a
preferred
minimum of 11 inches on each side of the center line and cover nails a
preferred minimum of
three inches. With a utility knife, the user may cut preferably ten inch wide
strips from the
roll of peel and stick membrane 106. The user may install peel and stick
membrane 106 over
the gable/rake edge metal 154 being sure to cover all fasteners. The membrane
106 should
extend a preferred minimum of six inches beyond the gable/rake edge metal 154
over the
underlayment 110. This gable/rake edge metal 154 membrane 106 may also extend
over the
valley 104 membrane 106. The membrane 106 on the valley metal 120 and the
gable/rake
edge metal 154 may be self-adhered, instead of nailed. The membrane 106 should
also be
installed over all other flashings and roof penetrations a preferred minimum
of six inches past
all flashings. Next the user may install the hip spacer 126 and the ridge
spacer 122 using
preferably 1.5 inch roofing nails or coated decking screws. These fasteners
are preferably
placed at 24 inches on center on each side of the nailer. Spacer flashing 124
is cut from slate
liner 140 (See FIG. 6) and placed over the ridge spacer 122 and should
preferably overlap 12
inches at sidelaps.
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FIG. 6 is a top view of the roof deck 102 illustrating the installation of
slate 130. In
the slate installation step, the roof deck 102 is outlined with slate 130. The
hips 156, ridges
118 and valleys 104 are outlined first. Next the user wilt locate and mark the
bottom batten
row 172 at the drip edge 108. The bottom row 174 (See FIG. 7) of hangers 134
(See FIG. 7)
should extend to the drip edge 108. The user may then use a chalk line and
measuring tape to
locate the remaining rows for battens 132. Battens 132 should be preferably
installed at 10
inch intervals. The battens 132 are preferably galvanized or stainless steel.
Stainless steel is
generally used where coastal salt water corrosion is a concern. It is to be
appreciated that
batten 132 spacing may be increased or decreased to accommodate fraction
spacing. The user
may begin at the hips 156 and valleys 104 and work up the roof deck 102
installing a full
batten 132, slate liner 140, and 2-3 slates 130 at each row, leaving the field
clear to walk.
Next, the user may locate and install top row battens 132, slate liner 140,
and top row of slates
130 (ridge row 178), then install ridge slates 150. The ridge slates 150
should overlap and
lock in the ridge row 178 of slates 130. The user may trim off any exposed
slate liner 140
with a utility knife.
In one embodiment, beginning four rows down from the ridge row 178 of slates
130,
the user may install batten 132. Hangers 134 may or may not be preinstalled on
battens 132.
The user may then lay slate liner 140 on hangers 134 (See FIG. 7) and drop
slate 130 onto
hangers 134 (See FIG. 7). The hangers 134 (See FIG. 7) are preferably spring
tempered
stainless steel. The user is cautioned to confirm that the keyways or joints
line up with the
ridge row 178 of slate 130. Next the user may install the next row of battens
132 locking in
the row of slate 130 below and repeating the process. In one embodiment, the
user offsets the
keyways 1/2 slate 130 every other row. The last row may be "shoehorned" in by
the user. The
CA 02625597 2008-03-14
user may then come down the roof four rows and repeat the process. A
perspective view of
this slate installation process is shown in FIG. 7 while FIG. 8 illustrates a
perspective view of
the slate installation at the valley 104. Greater detail on the slate 130
installation is show in
FIGS. 12-15.
In FIG. 9A a top view of batten 132 with hangers 134 used in the present
methodology
is shown. Hangers 134, which are preferably formed of spring tempered
stainless steel, can
be easily installed and removed to facilitate proper support for the slate
130. The hangers 134
provide a convenient way to quickly and easily install and remove individual
slate 130. In
one embodiment illustrated in FIG. 9A, the hangers 134 have a short member 158
and a long
member 160. The long member 160 has a curved distal end (upward facing hook
162 at one
end) and the remaining end is adjacent to a first outward extending arm 166.
In some
embodiments, the long member 160 may be modified to include a wider distal end
or two
distal ends. The first outward extending arm 166 is adjacent a central
connecting member
168. This central connecting member 168 is adjacent a second outward extending
arm 170.
This second outward extending arm 170 is adjacent the short member 158. While
the majority
of hanger 134 rests in one plane, long member 160 extends at an angle above
the plane of first
outward extending arm 166, curves downward at an angle and ends at a point
within the linear
plane of the first outward extending arm 166. This exemplary embodiment is
illustrated in
more detail in FIGS. 19A and 19B. When installing the hanger 134, the user
will insert the
second outward extending arm 170 of the hanger 134 into an opening formed by a
first hanger
holder 142. The hanger holder 142 is generally defined by the batten 132 to be
a pocket or
slot-like receiving portion for receiving a portion of the hanger 134. The
hanger holder 142
may be formed as an integral portion of the batten 132, or as a separable
element attached to
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the batten. The first outward extending arm 166 of hanger 134 will then be
inserted into an
opening formed by an adjacent hanger holder 142. When removing the hanger 134,
the user
squeezes together the short member 158 and long member 160 to remove the
hanger 134 from
the first hanger holder 142 and the adjacent hanger holder 142.
It is to be appreciated that the hanger 134 may take a variety of shapes and
configurations for interacting with the battens 132 and retaining the slate
members on the
roof Indeed, the hanger holders may be correspondingly altered to take a shape
and size
corresponding to, or otherwise accommodating, the various hanger shapes and
sizes. For
example, with reference to FIG. 9B, a head portion 200 of a hanger 234 may
take on a circular
or substantially circular configuration. A batten 232 may be provided such
that a pair of
hanger holders 242 are contoured to correspond to the shape of the head
portion 200 of the
hanger 234. The hanger 234 may further include a short member 258 and long
member 260
to facilitate insertion of the hanger 234 into the hanger holders 242 in a
manner similar to that
described with reference to FIG. 9A.
In another embodiment depicted in FIG. 9C, a head portion 300 of a hanger 334
may
be formed to have a hexagonal or substantially hexagonal shape. Corresponding
hanger
holders 342 may be provided to correspond to the shape of the head portion 300
of the hanger
334. Indeed, in some embodiments, the hanger holders 342 may include gaps at
the apices of
the hanger holders to permit extension of the hexagonal head 300 through the
hanger holder
when removably secured thereto. The hanger 334 may further include a short
member 358
and long member 360 to facilitate insertion of the hanger 334 into the hanger
holders 342 in a
manner similar to that described with reference to FIG. 9A.
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It is to be appreciated that additional embodiments are contemplated in which
the head
portion of the hanger is sized and shaped to fit into corresponding receiving
portions (such as
the exemplary hanger holders described above) of the batten, thereby
permitting the retention
of slate on a roof structure. In such embodiments, the hangers may be
removably secured to
the battens, thereby permitting hangers to be movable or repositionable along
the length of the
battens. This provides flexibility in deciding where to establish hangers
along the length of
the battens. Indeed, larger slate tiles may require a larger number of
hangers, whereas smaller
slate tiles may require a lesser number of hangers. Accordingly, efficiency of
resources can
be maximized according to the teachings of the present disclosure. The
removably securable
relationship between the hangers and the battens also permits quick
installation of the roofing
system of the present disclosure.
Additional exemplary embodiments are contemplated in which the head portion of
the
hanger is shaped and sized to fit into, snap into, or otherwise removably
attach to, the
corresponding receiving portions (e.g., hanger holders) defined in the batten.
For example,
with reference to FIG. 9D, a head portion 400 of a hanger 434 may include
projections 440
shaped and sized to snap-fit into a corresponding grid-like structure 450
(receiving portion) of
a batten 432. Of course, any number of projections 440 contemplated, so long
as they are
able to snap-fit, or otherwise attach to, the batten 132. Still further, in
FIG. 9E, a head portion
500 of a hanger 534 may include a pair of projections 540 designed to fit into
corresponding
receptacles 570 of a batten 532. In such an embodiment, the projections 540 of
the hanger
534 may be substantially L-shaped so as to minimize the distance the
projections extend from
the head portion 500. Indeed, the projections 540 may be fixed or actuateable
from a first
13
position to a second position, Of course, the projections $40 may take any
shape to permit operative
engagement of the hanger 534 with the batten 532.
FIG. 10 is a front view of the roof dock 102 illustrating hip 156 installation
of state 130. The hips
156 of the roof deck 102 are one of the first areas outlined with state 130
The user will install battens 132
on top of the underlayment 110. Hangers 134 are inserted into hanger holders
142 of battens 132. The
user will lay slate liner 140 on hangers 134 and drop slate 130 onto hangers
134, At the hips 156, hip
spacer 126 is applied followed by hip spacer cover 148. Slate trim pieces are
applied and attached to hip
156 by decking screws 144,
In FIG. 11 a top view of the roof deck 102 illustrating the ridge 118
installation is shown. With
the ridge 118 installation step, the user will install ridge spacers 122 by
making sure the ridge spacer 122
is preferably evenly spaced over the ridge 118 and fastened at preferably 24
inches on center along each
side of ridge 118 with preferably 1.5 inch roofing nails or screws. The user
will place preferably 13 inch
wide slate liner 140 over the ridge spacers 122 so that the center line of
slate liner 140 is centered along
the ridge 118. It is preferred to work with 10-12 foot lengths being sure to
preferably overlap end joints
12 inches minimum. Next, the user installs top batten 132 (See FIG. 12) along
a chalk line using a nail
gun and preferably 1,25 inch 0,120 galvanized standard coil fed roofing nails.
Hangers 134 (See FIG. 12)
are inserted into hanger holder 142 (See FIG. 12) of battens 132 (See FIG.
12). In some embodiments, the
batten 132 (See FIG. 12) is fastened at the center of the hanger 134 (See FIG.
12) except at the gable/rake
edges 112 (See FIG. 4). The user lays the slate liner 140 along row of hangers
134 (See FIG. 12) and
tucks under the plastic ridge spacer cover 152. The ridge spacer cover 152
should preferably overlap top
row of slate liner 140 by a minimum of three inches. The user will next lay
the first row of slate 130 by
placing
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bottom edge of each slate 130 into top row of hangers 134 (See FIG. 12). The
hangers 134
(See FIG. 12) are preferably preinstalled at six inches center. The slates 130
are preferably
twelve inches wide by twelve inches long standard quarried slate. Of course,
other spacing
dimensions for the hangers 134 and other sized slates 130 are contemplated to
fall within the
scope of the present disclosure. Also, it is to be appreciated that other
tiles other than slate
may be used in accordance with the principles of the present disclosure.
Indeed, it is
contemplated that any roofing or siding members may be used in accordance with
the
principles herein. The hangers 134 (See FIG. 12) are preferably evenly spaced
on the slate
130. Each hanger 134 (See FIG. 12) should be preferably three inches from the
edge of each
full piece of slate 130. On smaller pieces, it is preferable to have at least
two hangers 134
(See FIG. 12) are supporting each piece of slate 130. Hanger 134 (See FIG. 12)
can be easily
removed and replaced to facilitate spacing up to preferably 1.5 inches. In
some embodiments,
if a measurement calls for a piece of slate 130 less than four inches wide,
the adjacent piece
should be cut back so that the small piece is preferably a minimum of four
inches. The cut
edges can be placed side by side so that the cut edge disappears and is not
distinguishable.
The user preferably ensures that the ridge spacer cover 152 overlaps the top
row of slate 130 a
preferred minimum of two inches. The top edge of the top row of slate 130 is
preferably no
more than one inch from the bottom of the ridge spacer 122. The ridge trim
pieces 150 are
installed by nailing or screwing each piece of state 130 through two
predrilled holes 186
directly through the ridge spacer 122 into the roof deck 102. The trim pieces
150 are
preferably 16 inch×7 inch standard quarried slate predrilled. The edge
of each trim piece
150 must meet at the top of the ridge 118 and one piece should slightly
overlap the other so
that a clean, weather resistant joint is formed. If desired, the user may
apply a weatherproof
CA 02625597 2008-03-14
caulk of a matching color to the joint. The caulk is preferably a high quality
exterior grade
silicone. Next, the next ridge trim piece 150 is installed by overlapping the
previously
installed piece by preferably six inches. If desired, each nail hole can be
covered with a
weatherproof caulk. The ridge trim pieces 150 should overlap the top of the
first row of state
130 by a preferred minimum of two inches. Care should be taken not to
overdrive the
fasteners on ridge trim pieces 150. The slates 130 should be able to wiggle
slightly. Any
plastic ridge spacer cover 152 that is visible after the ridge trim pieces 150
are installed can be
carefully trimmed with a utility knife. FIG. 12 is a side view of the roof
deck 102 illustrating
ridge 118 installation of slate 130.
In FIG. 13 a detailed view of exemplary slate 130 installation step 1 is
shown. In
installation step 1, the user installs battens 132 end to end on a fourth
chalk line from the top
or ridge 118. The user fastens each batten 132 with roofing nails 138 at the
center of each
hanger 134 approximately every six inches. The slate liner 140 is next
installed by placing it
along the row of battens 132 using the hangers 134 to support the slate liner
140. It is
recommended that each piece of slate liner 140 be preferably a maximum of 25
feet long. The
pieces of slate liner 140 should preferably overlap a minimum of twelve inches
at side laps.
Slate liner 140 should be installed with the dull finish side up or shiny side
down. In some
embodiments, no nails are driven through the slate liner 140. Next the user
installs slates 130
by placing slates 130 on the hangers 134 being careful to keep hangers 134
centered on the
slates 130. In some embodiments, each slate 130 should have two hangers 134
supporting it
preferably evenly spaced from each side edge of the slate 130. Full slates 130
should have a
hanger 134 preferably three inches from each side edge. At the beginning or
end of each row
a one-half slate offset is recommended and can be achieved by placing
additional hangers 134
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CA 02625597 2008-03-14
at the hanger holders 142 provided in the battens 132. The battens 132 can be
cut with tin
snips. The user should align the battens 132 end to end preferably maintaining
a six inch
space between the hangers 134 for slates 130 (or three empty hanger holders
142 in the
battens 132). Battens 132 should be held back 1/2 inch from ridge spacers 122
or gable/rake
edge metals 154 (See FIG. 5).
FIG. 14 is a detailed view of exemplary slate 130 installation step 2. In this
step of
installation, the user will install the next row 180 of battens 132. The
battens 132 should lock
into the slates 130 below. The user should ensure the hangers 134 are
preferably evenly
spaced on the states 130 below. The hangers 134 should be preferably three
inches from each
edge of each slate 130. Tin snips are used to trim the battens 132 at the ends
to facilitate
hanger 134 spacing.
In FIG. 15 a detailed view of exemplary slate 130 installation step 3 is
shown. In this
step of installation, at the top row of each working section an open row 182
is created. To
complete the installation of the open row 182, the user should install slate
liner 140 by
slipping it under the top row 184 of slate 130. The bottom edge of the slate
liner 140 is held
in place by hangers 134. Next the user installs the slates 130 by slipping the
top edge of the
slate 130 under the top row 184 until the bottom edge of the slate 130 clears
the hangers 134
below. The user pulls or pushes the slate 130 downward slightly until the
hangers 134
support the bottom edge of the slate 130. Preferably an 18 inch wide piece of
slate liner 140
can be used as a shoehorn by inserting it first, then the slate 130 slides
easier into place. The
shoehorn is removed and the process is repeated.
While various embodiments in accordance with the principles disclosed herein
have
been described above, it should be understood that they have been presented by
way of
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CA 02625597 2008-03-14
example only, and not limitation. Thus, the breadth and scope of the
invention(s) should not
be limited by any of the above-described exemplary embodiments, but should be
defined only
in accordance with any claims and their equivalents issuing from this
disclosure.
Furthermore, the above advantages and features are provided in described
embodiments, but
shall not limit the application of such issued claims to processes and
structures accomplishing
any or all of the above advantages.
Additionally, the section headings herein are simply used to provide
organizational
cues. These headings shall not limit or characterize the invention(s) set out
in any claims that
may issue from this disclosure. Specifically and by way of example, although
the headings
refer to a "Technical Field," the claims should not be limited by the language
chosen under
this heading to describe the so-called field. Further, a description of a
technology in the
"Background" is not to be construed as an admission that certain technology is
prior art to any
invention(s) in this disclosure. Neither is the "Brief Summary" to be
considered as a
characterization of the invention(s) set forth in issued claims. Furthermore,
any reference in
this disclosure to "invention" in the singular should not be used to argue
that there is only a
single point of novelty in this disclosure. Multiple inventions may be set
forth according to
the limitations of the multiple claims issuing from this disclosure, and such
claims
accordingly define the invention(s), and their equivalents, that are protected
thereby. In all
instances, the scope of such claims shall be considered on their own merits in
light of this
disclosure, but should not be constrained by the headings set forth herein.
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