STRUCTURE AND METHOD OF REDUCING UPLIFT OF AND SCOURING ON MEMBRANE ROOFS

Abstract: A roof structure (10) and method for reducing uplift on a roof resulting from a wind blowing over the roof at a rooftop wind speed. The roof has a membrane (16) overlying a deck (12). An air permeable and resilient mat (24) is installed over the membrane (16). The mat (24) has openings of a size to reduce the wind velocity passing through it to the membrane (16) while the openings being of a size that the mat (24) is not lifted by a pressure differential therein reducing uplift on the membrane (16).

Description: STRUCTURE AND METHOD OF REDUCING UPLDJT OF AND SCOURING ON MEMBRANE ROOFS Field of the Invention This invention is related to the general field of membrane roofs, commonly referred to as flat or low-sloped roofs, and more particularly is related to a structure and method of distributing and reducing the uplift forces across the roof which are caused by wind velocity, and the reducing of scouring of any aggregate layer on the membrane caused by wind forces. Background of the Invention A common roof style for commercial and industrial buildings, apartment complexes and row homes is the flat or low-sloped roof. Although nominally flat, this roof style usually has a slight slope or pitch to cause and direct drainage. For purposes of brevity, the term "flat roof" will be used hereafter to describe roofs of this style. A flat roof comprises at a minimum a deck and a waterproof membrane. An insulation layer can be, and frequently is, installed between the deck and the membrane. There are two basic categories of flat roof construction. In the built-up roof system (BUR), felt and bitumen are layered to form the waterproof membrane, and a layer of gravel or a coating is placed on top to protect the membrane from ultraviolet radiation. In the single-ply roofing system (SPM), a single elastomeric sheet overlies the deck. The primary purpose of any roof is to separate the exterior atmosphere from the interior of the building, and maintain the integrity of that separation during all weather including expected extremes of ambient weather conditions throughout a reasonable lifetime. This requirement involves several design factors, which include the consideration of: (1) external and internal temperatures; (2) external moisture, air moisture, rain, snow, sleet and hail; (3) wind uplift of the membrane; (4) impact resistance to weather and other effects such as dropped tools and walking; (5) the esthetics of the roof; and (6) influence of solar radiation and ultraviolet rays. For flat roofs, the ability to withstand uplift forces caused by wind across the roof surface is one of the more critical design factors. The roof is a major portion of the surface area in building structures, accounting for as much as 40% of the surface area. Wind across the roof produces uplift forces at the roof surface, which may cause detachment and billowing of the membrane, scattering of ballast, and even catastrophic roof failure in extreme situations. Consequently, the flat roof design normally incorporates one or more features to counter the wind uplift forces, as described below. In a single-ply roof, one of the most common methods of countering uplift forces is the use of stone ballast. The waterproofing mem¬ brane is completely covered with a uniform layer of stone aggregate (usually #4 river rock or equivalent, # " to 2 l Λ" diameter), at layer depth sufficient to produce a down-load pressure of approximately 10 pounds per square foot. The substantial weight of this aggregate is an added load to the roof and support structure which must be factored into the design of the building. However, a major problem with stone ballast is that strong winds often cause the ballast stones to shift position, clustering in some areas and uncovering the membrane in other areas. This phenomena is referred to as scouring. Where the migration of the aggregate results in areas that are clear of ballast, die exposed membrane can billow upward from the aerodynamic lift of the wind, resulting in the membrane becoming damaged or disengaged. The membrane uplift and billowing accelerates the migration of ballast. Therefore, the exposed membrane has increased exposure to UV rays. Another counter to uplift forces in single-ply roofing systems involves mechanically affixing the waterproofing membrane and any underlying insulation to the deck with fasteners, which anchor the membrane and transfer the uplift load to the deck. In a majority of commercial and industrial buildings, the deck is formed of corrugated steel of 18 to 22 gauge thickness. Decks may also be formed from wood, concrete, gypsum and other suitable materials. The fasteners experience lateral and vertical loads, including uplift on the membrane, the oscillating loads of membrane billowing, and deck flutter, which may over time cause the fasteners to become disengaged, ultimately back- ing out and leaving the membrane unsecured. A backed-out fastener may punc¬ ture the waterproofing membrane, and membrane billowing can increase the forces acting on the membrane seams, therein resulting in seam failure. Another alternative is to fully adhere the waterproofing membrane to the top surface of a subcomponent sheet, which has in turn been mechanically affixed to the roof deck. The adhesive bond between waterproofing membrane and subcomponent's top surface is subjected to uplift forces from the passage of wind over the membrane. The adhesive bond between waterproofing membrane and subcomponent top surface is subjected to shear forces as a result of expansion and contraction of die membrane. Both d e subcomponent material and the adhesives are usually sensitive to moisture and condensation, which over time cause adhesive bond failure. Subsequent membrane failure occurs as oscillating and billowing causes the membrane to peel from die substrate. The built-up roof must also counter die effect of uplift forces, in that the built-up layers of felt and bitumen can delaminate, and chunks of asphalt/felt can be blown off die roof. The built-up roof system also experiences scouring problems when loose gravel is used as the top layer to protect d e membrane from ultraviolet radiation. In fact, the smaller sized gravel migrates even more easily than the larger ballast stone used with single- ply roofs. Consequently, their has been a continuing need for better methods and structures to counter die effects of uplift forces, or to counter the uplift forces direcdy. One mediod of countering uplift, in die type of roof where insulation panels are installed on top of the membrane, is disclosed in U.S. Patent 4,583,337, which teaches installing corrugated cover members overlying insulation panels along die periphery of the roof. The wind flowing around die corrugated cover members is purported to create a vacuum under die cover members, so diat die differential pressure pulls die cover members downward against die insulation to counter the uplift on die insulation, and thus retain die insulation. U.S. Patent No. 4,926,596 discloses an apertured overlay that is stretched over die membrane. The apertured overlay is secured at the periphery of the roof, and allows wind to pass dirough to die membrane. The overlay physically restrains die waterproof membrane from billowing. Bodi of diese mediods counter the uplift by creating an opposing force on die membrane, and in that sense are related in concept and approach to the older mediods of ballast, mechanical fasteners, and adhesives. It is an object of die present invention to counter d e uplift in different manner, in which the uplift force itself is reduced, and die uplift force is more uniform across die roof surface. In addition to its efficacy in reducing and evenly distributing uplift forces, another major advantage of die present invention is that it can be used alone or in conjunction with other uplift countering methods, such as ballast, affixed or adhered membrane, and built-up roofs, and in fact makes diese other mediods even more effective dian they would be if used alone. For example, the elimination of scouring permits die use of a smaller-size aggregate for ballast, and the reduction of uplift force permits die use of less total weight of ballast. The reduction and more even distribution of uplift forces reduces die frequency and likelihood of fastener or adhesive bond failure, or delamination of built-up roofs. Further, the invention itself provides a resilient cover to the roof therein protecting from physical damage and reduces the ultraviolet rays reaching the membrane. Summary of the Invention This invention relates to a roof structure for and method of reduc¬ ing and distributing uplift forces resulting from wind blowing across a flat roof and retaining ballast in position where present. The roof structure includes a waterproof membrane overlying a deck, and is characterized by an air permeable and resilient mat which is installed over die membrane. The mat has a random convoluted mesh of a size which breaks up die laminar flow of wind passing over d e membrane, slows and defuses die wind velocity directly above die membrane, and permits pressure equalization wid in die mat, so that die mat is not lifted away from die membrane. One object, feature and advantage resides in the air permeable and resilient mat overlying the ballast, if provided, to prevent scouring of the ballast. Another object, feature and advantage resides in die air permeable and resilient mat being adhered in a grid pattern to retain ballast, if provided, in die ballast respective grid. In a preferred embodiment, die waterproof membrane overlays a decking and is secured at die periphery of the roof. A layer of ballast overlies die membrane and is cleared in section to secure die air permeable and resilient mat by an adhesive. The mat reduces uplift on die membrane. In die preferred embodiment, die mat is constructed of syndietic fibers randomly aligned into a web and bonded togedier at dieir intersections, forming a relatively rigid mat having significant porous area between the random fibers to disrupt and diffuse the wind over die membrane. Further objects, features and advantages of the present invention will become more apparent to those skilled in d e art as die nature of die inven- tion is better understood from the accompanying drawings and detailed descrip¬ tion. Brief Description of the Drawings For die purpose of illustrating the invention, the drawings show a form which is presently preferred. However, diis invention is not intended to be limited, nor is it limited, to die precise arrangement and instrumentalities shown. The scope of die invention is determined by die claims found at die end of diis description. Figure 1 is a cross-sectional view of a single-ply stone-ballasted roof according to die invention; Figure 2 is a top view of the roof of Figure 1 with portions of the mat broken away; Figure 3 is a graphical presentation of die external pressure distribution above a corner of a flat roof which does not incorporate the invention; Figure 4 is a schematic representation of small-scale roof model for wind tunnel testing, widi the locations of pressure sensors identified. Figure 5A and 5B are graphical representation of die mean coefficient of pressure across die roof model of Figure 4 widiout (Figure 5A) and with (Figure 5B) the invention, generated by data smoothing of die readings of the pressure sensors in wind tunnel testing. Figures 6A and 6B are graphical representation of the minimum coefficient of pressure across the roof model of Figure 4 without (Figure 6A) and widi (Figure 6B) die invention, generated by data smoothing of die readings of die pressure sensors in wind tunnel testing. Figure 7A and 7B are graphical representation of die root mean square values of coefficient of pressure across die roof model of Figure 4 widiout (Figure 7A) and wid (Figure 7B) die invention, generated by data smoothing of die readings of die pressure sensors in wind tunnel testing. Figure 8 is a cross-sectional view of a roof of an alternative embodiment of a mechanical affixed single-ply roof; Figure 9 is a cross-sectional view of a roof of an alternative embodiment of a built-up roof system; and Figure 10 is a cross-sectional view of a roof of an alternative embodiment of a roof system called an "upside-down" roof. When referring to die drawings in die description which follows, like numerals indicate like elements, and primes (' and ") indicate counterparts of such elements. Detailed Description of the Invention Figure 1 illustrates an embodiment of a roof structure 10 according to ie invention. The structure includes a roof decking 12 and an insulation layer 14 laid on and overlying die decking. In a preferred embodiment, die roof has a single-ply waterproof membrane 16 secured at die periphery 18 of the roof deck in proximity to die roof parapet 20 by conventional mediods. The single-ply membrane is not secured except at die roof periphery and simply overlies die insulation. The single-ply membrane 16 is formed in sheets which are bonded together by heat welding, solvent welding or adhesives, to form a larger sheet as required to cover die entire roof. Overlying die single-ply membrane 16 is a layer of gravel aggre¬ gate 22 used as ballast. The size of die aggregate 22 is 3 /β of an inch nominal diameter gravel. This is considerably finer ian die stone aggregate of prior ballasted single-ply roofs which require #4 river rock (2" to 2 l A" diameter). The rate application per square is less tiian a typical rate of 10 pounds per square for conventional construction. (A square is 100 square feet, a common term in roofing.) An air permeable and resilient mat 24 overlies die aggregate 22. The mat preferred is a nonwoven air permeable and resilient mat made of syndietic fibers (usually nylon, PVC or polyester) which are opened and blended, men randomly aligned into a web by air flow. The web is treated wid binding agents of water based phenolics and latexes. The treated web is dien oven cured to bind die fabrics into relatively rigid mat having significant porous area between the random fibers. (The machinery used to produce diis material is sometimes called a "Rando- Webber"). U.S. Patent No. 5,167,579 describes an air permeable and resilient mat being used in conjunction with a ridge vent of a sloped roof. The further description of die mat material found therein is incorporated by reference, should any further description be sought. In a preferred embodiment, die mat material has a thickness of 3 / 8 of an inch and comes in rolls 78 inches wide and 60 yards long. The material weighs 11.11 pounds per square (1.8 oz./ft 2 ) and has a percent open area of 65 % . The aggregate can be laid in an even coverage layer over die roof, and men after shoveling out a row or grid pattern and sweeping die open grid lines clean, die air permeable and resilient mat 24 is laid over d e aggregate and secured to d e membrane at the bare grid lines by adhesive, as shown in Figure 2, where a 3-inch strip adhesive region 28 is shown in hidden line. The mat 24 is secured to die membrane 16 to prevent die mat 24 from being pushed across the roof 10. An adhesive 26 such as COBRA * Venom sold by GAF Building Materials Corp, or a neoprene cement, or a tape may be used to secure die mat 24 to die membrane 16. Small gaps are positioned in die adhesive to allow water to drain properly. The mat 24 retains die aggregate ballast 22 in die grid pattern, dius preventing die phenomena of scouring, which would oΛerwise occur widi such small aggregate. In addition, as discussed below, the mat reduces die wind speed across die ballast 22. Theory behind wind uplifts In die designing of a roof, die pressure differential on die mem¬ brane has to be determined. However, in the design of die roofs, not only average day basic wind speed has to be considered, but winds associated widi hurricanes and diunderstorms and Foehnlike winds need also to be considered. Therefore, tables, charts and equations are required to determine the maximum uplift force on die membrane. One of die items mat has to be determined is me basic wind speed (V 0 ). The speed of the wind is constantly changing. There¬ fore, me basic wind speed (V 0 ) is the average wind speed over time. The speed of die wind at die roof top (V R ) is calculated as a function of the basic wind speed (V 0 ), die height above die ground die roof is located (basic wind speed (V 0 ) is typically measured at 32.8 feet (10m)), and die type of terrain in the area. There are numerous dieories on how to deter¬ mine roof top wind speed (V R ) including methods from die Uniform Building Code, ANSI Standards, and Factory Mutual Standards, Standard Building Code. These dieories each achieve different results but the underlying equation is die same and is V R =AV 0 m H n . The constant "A" and exponent "n" are functions of ground roughness. The exponent "m" is a power constant and typically about 1.0. H represents the building height. Typically, die wind speed on die roof surface (V s ) is greater ian the roof top wind speed (V R ). The roof top wind speed is determined by the local wind speed as described above. Roof top wind speed (V R ) is die speed of the wind at that height of the roof and does not include die change of wind speed because of die interaction widi die roof. Using Bernoulli's equation P R /γ + W2g = P s /γ + VV2g where P R is die air pressure roof top level and P s is die air pressure on die roofs surface, the equation is rearranged to achieve a dimensionless coefficient of pressure C p =Ap(2g)ftV Therefore, substituting C p into the equation results in V s = V R (1-C P ) 05 . It is diis pressure differential tiiat exerts a force on the membrane causing the membrane to lift. Since the volume of wind having to pass over the roof includes a portion of die wind tiiat would have typically passed dirough die space occupied by die building, the velocity over die roof (V s ) must be greater than die roof top wind speed (V R ). Therefore, C p must be negative. It has been recognized diat the maximum coefficient of C p occurs when the wind impinges at 45° relative to die roof as shown in Figure 3. The maximum coefficient of pressure is about -3 to -3.3 for a roof without parapets. Parapets lower die maximum coefficient of pressure (e.g., maxi¬ mum -2.5). However, while die coefficient of pressure is lowered, die area influenced by me new maximum pressure is increased. The force on die mem¬ brane could be actually higher for a roof widi parapets. Factors included in determining die force are d e height of die parapets and die surface area of the roof. Critical pressure points on a membrane roof Typical pressures in four areas have to be determined before determining the pressure differential acting on die membrane 16. The pressures that need to be identified are die external pressure (P R ) associated widi roof top wind speed (V R ), die pressure in die interior of the building structure 10 (Pi) underlying die membrane 16, the roof surface pressure (P s ) associated widi die roof surface wind speed (V s ), and die pressure on top of die membrane (P M ). The pressure on top of die membrane (P M ) would equal die roof top surface pressure (P s ) if die membrane did not have an intervening layer such as ballast 22 or me air permeable and resilient mat 24. The pressure on me interior of die structure 10 (P,) would be equal to die roof top level pressure (P^ if the structure was completely open. If this was the case, die differential pressure would be equal to zero. However, structures 10 are not completely open and more closely resemble an unvented case. In diis situation, die internal pressures (Pi) equals the roof top flowable air pressure (P R ) when there is no wind or before die wind begins to blow. The internal pressure can, in addition, be influenced by die air handling and conditioning system in me building. Air handling system usually places a positive pressure in die structure resulting in a greater pressure differential. If die roof decking 12 were sealed such diat no air could penetrate, a vacuum could be created under die membrane 16. This vacuum would contract the uplift. However, due to normal cracks and openings in die deck, die pressure below the membrane 16 is assumed to be equal to die pressure inside die building (P,). In comparing the pressure at die roof surface (P s ) to diat at die top of die membrane (P M ), Bernoulli's equation can be used. As indicated previously, die wind speed of die roof surface (V s ) is larger tiian die wind speed at the membrane. Therefore, the relationship may be written as V s = kV M where K is a constant diat is less tiian 1. Therefore, die pressure of die membrane equals die P M = s + V 2 R (l-C P )(l-K 2 )γ/2g In field test, die constant for die air permeable and resilient mat 24 has been determined to be approximately 0.1. The air permeable and resilient mat reduces die wind velocity passing over me membrane 16 to one-tenm die speed of roof top wind speed (V s ). Theory on Why Air Permeable and Resilient Mat Succeed While not wishing to be bound by tiieory, it is thought diat the air permeable and resilient mat is successful in reducing uplift of die membrane because: 1) die mat reduces die wind velocity over die membrane, 2) die mat is porous so diat any lateral forces generated by die wind are compensated by die static coefficient of friction of die mat widi die roof, 3) the surface of die mat creates turbulence over the roof tiierein disrupting uplift and 4) if tiiere is ballast, the mat limits scouring of the ballast. Reduce wind velocity over die membrane In order for me wind to pass over die membrane, die wind must pass dirough the mat. The mat is comprised of syndietic fibers randomly aligned into a web having significant porous area to allow die wind to pass dirough the mat. However, die wind as it flows past die fibers are subject to boundary-layer effects resulting in the flow engaging die fibers being zero. The fibers are sufficiently close (35 % of die mat is fiber) that while the wind flows through die mat, the speed of die wind passing dirough the mat is greatly reduced. By reducing die wind uplift forces acting on die roof surface, the mat reduces die load required for die uplift forces on the building structural components, reducing construction costs. No uplift on mat As indicated above, die uplift of die membrane is created by die change of pressure (Δp) across die membrane resulting because die velocity under the membrane is substantially zero. The mat having significant porous area between me fibers has essentially the same pressure above and below die mat. Wind gusts are not constant, and therefore, die mat can dissipate die pressure differential over time, when me velocity of the wind approaches zero. Turbulence The mat having a porous surface and wind blowing dirough and across die mat create turbulence. The laminar flow of the wind is converted to turbulent flow. Whereas die laminar flow has a primary vectorial direction which transfers the energy of die wind into reducing die pressure and creating uplift, die turbulent flow has wind vectors in 4π steradians. The resulting average of all die vectors is a net velocity in any given direction that is less tiian that found in die laminar flow. Limit scouring In conventional ballasted single-ply roofs, me roof surface wind speed (V s ) engages die ballast on primarily one surface. The wind exerts a force on die ballast pushing it in a windward direction. The mat overlying die ballast reduces the wind speed on die ballast which is equal to the roof surface wind speed (V s ). In addition, the mat exerts a downward force on die ballast therein creating a larger force (weight) that the wind must move. Moreover, the contact of die mat widi the ballast increases the static coefficient of surface friction and increases the critical velocity. In addition, die mat adhered to the membrane defines grids which contain die ballast. Therefore, die size of die ballast can be reduced without concern of scouring of the ballast. Wind Tunnel Test A wind tunnel test was conducted to measure die coefficient of pressure (C p ) on die membrane, and is related to die pressure on top of die membrane (P . The model of die building had a roof area of 30 cm. x 30 cm. Twenty three pressure taps were located on die model roof to determine die pressure at various locations across the membrane. Figure 4 is a schematic representation of the small scale roof model that was wind tunnel tested with the pressure taps, pressure sensors, identified. Tests were conducted widi die wind flow both normal to one of die walls of die roof and diagonal such tiiat the wind impinged at 45° relative to die roof as shown in Figure 4. In addition, the roof was tested with the initially flow both being a smooth flow and a turbulent flow wind. While die tests were done in non-boundary layer wind and therefore absolute values of the pressure coefficients could not be extrapolated to full scale, die wind tunnel test clearly showed the benefit of the air permeable and resilient mat 34. The data for the worse cause situation for both uplift and scouring (i.e, smooth flow impinging at a diagonal) is listed in following table. In analyzing the data, two zones of effect were found. The approximate demarcation of the two zones is shown in Figure 4. ZONE I Tap No. Cp(mean) Cp(min) Cp(rms) with w/o with w/o with w/o mat mat mat mat mat mat 11 -1.03 -1.06 -1.12 -1.23 0.026 0.099 15 -1.05 -1.47 -1.13 -1.60 0.025 0.070 18 -1.09 -2.11 -1.17 -2.23 0.025 0.086 19 -1.07 -2.04 -1.18 -2.53 0.025 0.127 20 -1.12 -3.13 -1.20 -3.82 0.023 0.348 21 -1.11 -3.93 -1.19 -4.20 0.028 0.110 22 -1.14 -2.94 -1.25 -3.43 0.028 0.185 23 -1.10 -2.19 -1.18 -2.66 0.026 0.179 ZONE Π 5 -1.02 -0.67 -1.11 -0.72 0.023 0.015 6 -1.02 -0.63 -1.13 -0.69 0.026 0.019 7 -1.01 -0.78 -1.12 -0.91 0.027 0.045 8 -1.09 -0.75 -1.18 -0.80 0.020 0.011 9 -1.07 -0.69 -1.16 -0.73 0.027 0.014 10 -1.05 -0.68 -1.13 -0.86 0.026 0.051 12 -1.09 -0.79 -1.18 -0.85 0.029 0.012 13 -1.09 -0.73 -1.16 -0.80 0.023 0.015 14 -1.07 -0.92 -1.19 -1.23 0.028 0.126 16 -1.12 -0.99 -1.20 -1.05 0.021 0.013 17 -1.11 -0.86 -1.23 -1.16 0.025 0.041 Figure 5 A, 5B, 6A, 6B, 7 A and 7B are graphical representations of the data both interpolated and extrapolated. Figure 5 A shows the mean value of the coefficient of pressure of die membrane without die air permeable and resilient mat. Figure 5B shows die mean value of die coefficent pressure (Cp) of the top of the membrane with the air permeable and resilient mat located on top of the membrane. The data is both interpolated and extrapolated from the data in the above table. The mean value of the coefficent pressure (Cp) is associated widi the average load. The coefficient of pressure (Cp) decreased from above -3.50 to generally around -1.10 in zone I. It increased from about -.70 to generally around -1.05 in zone II. It is applicant's belief tiiat the increase in zone II was the result of the test parameters and would not exist in actually field use. Figure 6A shows the minimum coefficent of pressure without the air permeable and resilient mat. Figure 6B shows die minimum coefficent of pressure with the air permeable and resilient mat. The minimum value of the coefficient of pressure is associated widi maximum uplift. Wherein without the air permeable and resilient mat, portions of die roof membrane experienced uplift forces associated widi a Cp of -4.20 (See tap 21). While the membrane without the mat had a minimum maximum uplift associated with a C p of -.70 (see taps 5, 6, 9), with the air permeable and resilient mat overlaying die membrane, die minimum maximum uplift was related to a coefficient of pressure of approximately -1.10. (See taps 5, 6, 7, 11, 15). Therefore, the mat made certain areas have a larger maximum uplift. However, the maximum uplift experienced by any portion of the membrane with the mat was that associated widi a coefficient of pressures (C p ) of -1.25. Therefore, while the maximum load in certain areas increased, die maximum load for any portion of die roof decreased drastically. Figures 7A and 7B show the root mean square (RMS) of the coefficient of pressure which could be considered to be associated widi the energy transferred to die roof membrane by the wind. Figure 6 A shows the RMS of the coefficient of pressure of the membrane without the mat and varies from 0.1 to 0.348. However, die entire membrane which is covered by die mat, has a coefficient of pressure RMS of approximately 0.025. Therefore, the wind tunnel verifies that the air permeable and resilient mat reduces die maximum uplift experienced by die membrane and in addition creates a more uniform distribution of uplift on die roof. The more uniform uplift on the roof results in less stress to the membrane in that various portions of the membrane are not pulled by contrasting different levels of suction by the wind. Other benefits of invention In addition to protecting from wind uplift and preventing die aggregate ballast from scouring, the air permeable mat has additional benefits. As indicated previously, two other design factors tiiat are considered are 1) impact resistance, and 2) die influence of solar radiation and ultraviolet rays. Moreover, die air permeable and resilient mat can reduce the overall load on die roof and is easy to install. The mat is resilient and relatively rigid. These attributes of die mat result in the mat being able to be walked on and returning to its shape widiout damage to die underlying membrane. In addition, if a person working on the roof drops a tool such as a wrench, hammer, die impact of die tool will not damage me underlying membrane. Likewise, a sharp object such as a knife or a screw driver will not make contact with the membrane and possible puncture d e membrane. Weather-related damage that have been a concern for flat roofs include items such as wind blow debris including sheet metal, such as from ventilators and air conditioner units, and tree branches blowing across die roof and puncturing the membrane. Another weather-related concern for a membrane roof is hail hitting die membrane puncturing the membrane weakening the adhesive bonds between die membrane and the substrate. In addition in die case of certain rigid insulation, the hail damages the insulation underlying die membrane by permanently compressing the insulating cells. The mat protects the membrane from both kinds of weatiier related damage discussed, along with other weather-related damage. The membrane when exposed to ultra-violet rays of the sun deteriorates molecularly. One of the primary purposes of the gravel on the built-up roof is to prevent the ultra-violet rays from hitting the felt and bitumens of die built-up roof. The mat achieves a similar benefit, however not to die same extent. The mat also can be colored to provide radiation benefits by reducing heat load. In addition, if die roof is visible, die mat can be colored for aestiietic purposes. The mat does add weight (load) to the roof that must be accounted for in the design of die roof. However, as indicated previously, in a single-ply ballasted roof, the size of aggregate can be reduced. Therefore, die total load added to the roof with the mat is less than that with conventional ballasted single-ply roof. In mat the wind generate forces are compensated by die static coefficent of friction, tiierefore the air permeable and resilient mat will not blow on the roof while the adhesive is setting. Therefore, an installer will have an easy time installing the mat. Other preferred embodiments An alternative embodiment of a single-ply roof mechanically affixed is shown in Figure 8. The roof structure 10' has a roof deck 12', an insulation layer 14' overlying the roof deck 12'. The roof structure 10' has a single-ply membrane 16' overlying the insulation 14'. The membrane 16' is secured at die periphery 18' in proximity to a parapet 20'. In addition, the membrane 16' is secured to the decking 12' by a plurality of fasteners 30 at designated points to secure the insulation 14' and membrane 16' to die decking 12 ' . The fastener 30 is secured to the underside of die membrane 16' . Typical- ly die fastener 30 is located at a joint location 30 where the single-ply mem- brane 16' is formed by joining two sheets togetiier. The sheets are bonded together by heat welding, solvent welding or adhesives to form a larger sheet if required to cover the entire roof. The fastener 30 penetrates through an underlying sheet 32 and adheres to an overlying sheet 34. The sheets 32 and 34 are welded or adhered togetiier at joint 36 such that die fastener 30 is underlying die continuous single-ply membrane 16'. The above construction is conventional and well known. The roof 10' of the preferred embodiment has an air permeable and resilient member 24' overlying the membrane 16'. The air permeable and resilient member 24', similar to the first embodiment, is a non- woven air permeable and resilient mat made of syntiietic fibers (usually nylon, PVC, or polyester) which are open and blended, then randomly aligned into a web by air flow. The web is treated widi binding agents of water based phenolics and latexes. The treated web is tiien oven cured to bind die fabric into relative rigid mats having sufficient porous areas between die random fibers. In the preferred embodiment, the mat 24' has a thickness of % of an inch. The mat 24' comes in rolls 78 inches wide and 20 yards long. The mat 24' weighs 11.11 - 13.89 pounds per square and has a fiber percentage of between 35 and 45 percent. The air permeable and resilient mat 24' is secured to die roof 10' by placing an adhesive or neoprene cement or other comparable adhesive 26' in a 3 inch strip around die periphery of the mat and a 3 inch strip down die center line of die length of the mat 24'. The mat 24 is secured to the membrane 16' to prevent the mat 24' from being pushed across die roof 10. Another preferred embodiment having a built-up roof 10" widiout a parapet is shown in Figure 9. The roof structure 10" has a roof decking 12". The roof structure 10" has an insulation layer 14" or plurality of insulation layers. The insulation layer 14" overlies the roofing deck 12" and is laid on die decking 12" and is secured by mechanical fasteners. The roof structure 10" has a built-up membrane 46" comprising layers of roofing felt interposed with bituminous (roofing asphalt). The top layer of bitumen may or may not receive a layer of gravel aggregate 22" at a ratio of 200 pounds to 60 pounds square asphalt. The roof structure 10", in addition, may have 200 pounds per square of gravel of to % of an inch diameter on top. The above construction is conventional and well known. The roof 10" has an air permeable and resilient mat 24" over¬ lying die aggregate 22" or roof membrane 46". The air permeable and resilient mat 24" in the preferred embodiment is a non- woven air permeable and resilient mat made of synthetic fibers (usually nylon, PVC or polyester) which are open and blended, then randomly aligned into a web by air flow. The web is treated with binding agents or water based phenolics and latexes. The treated web is then oven cured to bind the fabric into relatively rigid mats having a significant porous area between the random fibers. The mat 24" has a thickness of % of an inch and comes in rolls 78 inches wide and 34 yards long. The mat 24" weighs 31.25 pounds per square and has a percent open area of 71.43. The air permeable and resilient mat 24" is secured to die roof 10" using a suitable adhesive in die same method described in the first embodiment or being hot mopped into place. An alternative method is to place a plurality of pavers 48 on the roof 10" underlying the mat 24" and secure the mat 24" to the pavers 48. Figure 10 shows an alternative embodiment of an "upside-down" roof 10'", a roof where the insulation layer is on top of the membrane 16'". The roof structure 10'" has a roof decking 12'". Figure 6 shows the roof decking 12'" formed of concrete; the roof decking 12'" can also be formed of wood, corrugated steel, gypsum and other suitable materials. The roof structure 10'" has a single-ply membrane 16'" overlies the roof decking 12'". The single-ply membrane 16'" is secured at die periphery of die roof deck 12'", not shown. The single-ply membrane 16'" is not secured except at the periphery 18 and simply overlies the roof deck 12'". The single-ply membrane 16'" is formed in sheets. The sheets are bonded togetiier by heat welding, solvent welding or adhesives, to form a larger sheet if required to cover the entire roof. Overlying die membrane 16'" is an insulation layer 14'", or plurality of insulation layers. The insulation layer 14'" is secured by an adhesive fastener to the underlying membrane 16'" . The above construction is conventional and well known. The roof 10'" has an air permeable and resilient mat 24 " ' over¬ lying the insulation layer 24'". The air permeable and resilient mat 24'" is similar to those described in the other embodiments. The air permeable and resilient mat 24" is secured to the roof 10" using neoprene or another suitable adhesive to the insulation layer 24'". An alternative metiiod is to place a plurality of pavers on die roof 10" underlying the mat 24" and secure the mat 24" to the pavers. The present invention may be embodied in other specific forms without departing from the spirit or central attributes thereof and, accordingly, reference should be made to die dependent claims, rather than to the foregoing specification, as indicating die scope of the invention

Claims: Claims I claim: 1. A method of reducing uplift on a roof resulting from a wind blowing over the roof at a rooftop wind speed, creating a pressure differential comprising the steps of: providing a roof having a membrane; and installing an air permeable and resilient mat constructed of randomly aligned synthetic fibers which are joined by a binding agent, over the membrane, the mat having openings of a size to reduce the wind velocity over the membrane from that of rooftop wind speed while die openings being of a size that the mat not being lifted by die pressure differential therein reducing uplift on the membrane. 2. A method of reducing uplift on a roof as in claim 1 wherein the mat has an upper surface to create turbulence. 3. A method of reducing uplift on a roof as in claim 1 wherein the mat decreases the coefficient of pressure. 4. A method of reducing uplift on a roof as in claim 1 wherein the mat redistributes die uplift forces on the membrane. 5. A method of reducing uplift on a roof as in claim 1 wherein the mat acts as ballast. 6. A method of reducing uplift on a roof as in claim 1 wherein die roof has a ballast layer comprising loose aggregate and die air permeable and resilient mat overlies the aggregate reducing the scouring of the aggregate across the roof. 7. A method of reducing uplift on a roof as in claim 6 wherein the step of installing an air permeable and resilient mat comprises the steps of: clearing away the aggregate from the membrane in specific segments; securing the air permeable membrane to the specific segments using an adhesive means. 8. A method of reducing uplift on a roof as in claims 1, 3, 4, 6 or 7 wherein the air permeable and resilient mat is constructed of randomly aligned syntiietic fibers which are open and blended, randomly aligned into a web by an airflow, joined by phenolic and latex binding agents and heat cured to produce a varying mesh. 9. A roof structure comprising: a roof decking; a membrane; means for securing die membrane to the roof decking; and air permeable and resilient mat constructed of randomly aligned syntiietic fibers overlying the membrane, the mat having openings of a size to reduce the wind velocity over the membrane while the openings being of such a size that the mat is not lifted, the fiber content by area of the mat is less than 45 percent of the mat. 10. A roof structure as in claim 9 wherein the membrane is a single-ply membrane. 11. A roof structure as in claim 9 wherein the membrane is a multi-ply built-up roof. 12. A roof structure as in claim 10 wherein the means for securing the single-ply membrane comprises aggregate overlying the membrane and underlying die air permeable and resilient mat, and at least a portion of the aggregate is loosely retained between die membrane and die mat. 13. A roof structure as in claims 9, 10, 11, or 12 further comprising an insulation between die roof decking and die membrane. 14. A method of reducing scouring of an aggregate on a roof comprising die following steps: providing a membrane roof over a deck, die roof having a layer of aggregate loosely placed on the membrane; installing an air permeable and resilient mat over the aggregate for reducing die wind velocity over the aggregate and applying a force to the aggregate. 15. A method of reducing scouring of aggregate on a roof as in claim 14 wherein the membrane is a single-ply and die aggregate is a ballast. 16. A method of reducing scouring of aggregate on a roof as in claim 15 wherein die membrane is a multi-ply built-up layer and die aggre¬ gate is a gravel. 17. A method of reducing scouring of aggregate on a roof comprising the following steps: providing a membrane roof over a deck, die roof having a layer of aggregate; clearing the aggregate from the membrane in a specific pattern; installing an air permeable and resilient mat over the aggregate by an adhesive to the cleared specific pattern on the membrane for reducing die wind velocity over die aggregate and retaining the aggregate with the specific pattern. 18. A method of reducing scouring of aggregate on a roof as in claim 17 wherein the specific pattern is a grid the size of the air permeable and resilient mat with a center line running the long direction of die mat. 19. A method of reducing scouring of aggregate on a roof as in claims 17 or 18 wherein die adhesive is a neoprene cement. 20. A method of reducing scouring as in claim 14 wherein die air permeable and resilient mat has a fiber content of approximately 35 percent by area.

Inventors: GODSCHALX RAYMOND D, GODSCHALX, RAYMOND, D.
Applicants: BUILDING MATERIAL CORP OF AMER, BUILDING MATERIAL CORPORATION OF AMERICA
Application year: 1995
Main classification: E04B5
IPC codes: E04D5, E04D11