Reusable isolation roof system and method

Abstract

A roofing system includes a waterproof layer and a foam glass isolation layer. A protective coating is applied on the uppermost surface of the foam glass barrier layer, i.e., the surface farthest from the roof deck. The waterproof layer is loosely laid on the uppermost surface of the foam glass isolation layer such that the protective coating is placed between the foam glass isolation layer and the waterproof layer. This arrangement facilitates subsequent separation (e.g., manual separation) of the water repellent layer from the foam glass barrier layer. A roof assembly is also provided that includes a roof system and a roof deck. A method of mounting and dismounting a roof assembly is also provided.

Description

Technical Field

[0001] The present disclosure relates to a roof system that can be easily dismantled and reused. The present disclosure also relates to a method for installing and dismantling such a roof system. Background Art

[0002] The roof is an important part of the building envelope. The roof primarily protects the building from the effects of inclement weather, such as precipitation. The roof should also provide insulation to keep conditioned air inside the building. In addition, the roof can perform other functions. For example, a flat roof can be used as a parking lot, a walkway, a playground, a terrace, and a platform for mechanical and electrical equipment.

[0003] A roof should provide reliable insulation and protection against the elements throughout the building's entire service life. Insulation is therefore also a key factor in the construction or renovation of a building, as it can account for up to 75% of a building's total energy saving potential. In this regard, the use of foam glass insulation materials in roof systems has increased in recent years. One reason for this is that these materials retain their strength and other properties, such as thermal performance and fire resistance, over time.

[0004] While foam glass insulation has proven to be a sustainable solution for roofing elements, there is a growing demand for products and solutions that reduce the carbon footprint and contribute to the circular economy.

[0005] The present invention was designed with these factors in mind. Summary of the invention

[0006] In one aspect, the present disclosure relates to a roof system for a (warm) roof assembly, comprising a foam glass insulation layer and a waterproof layer, wherein: the waterproof layer is loosely laid above the foam glass insulation layer; wherein the waterproof layer remains unattached to the foam glass insulation layer; wherein the foam glass insulation layer comprises one or more layers of foam glass insulation material; and wherein the uppermost layer of foam glass insulation material has a protective coating on its uppermost surface, such that the protective coating forms the upper surface of the foam glass insulation layer and is located between the foam glass insulation layer and the waterproof layer.

[0007] In one aspect, the present disclosure is directed to a roof assembly comprising a roof deck and the roof system described above.

[0008] In one aspect, the present disclosure relates to a method of installing a roof assembly, the method comprising: (i) installing a foam glass insulation layer to a roof deck, wherein the foam glass insulation layer comprises one or more layers of foam glass insulation material; (ii) coating an uppermost surface of an uppermost layer of foam glass insulation material with a protective coating; (iii) loosely laying a waterproof layer over the protective coating, wherein the waterproof layer remains unattached to the foam glass insulation layer; and (iv) placing (e.g., loosely laying) a roof ballast directly or indirectly against an upper surface of the waterproof layer.

[0009] In one aspect, the present disclosure is directed to a method of disassembling a roof provided with the above-described roof system. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 A schematic diagram of an exemplary roof assembly is shown.

[0011] Figure 2 A schematic diagram of an exemplary roof assembly is shown.

[0012] Figure 3 An exemplary roof system installation / removal is shown. DETAILED DESCRIPTION

[0013] Throughout the disclosure, including the appended claims, unless the context requires otherwise, the words "comprise" and "comprising" and variations such as "comprises" and "comprising", will be understood to imply the inclusion of stated components, integers or steps, or groups of components, integers or steps, but not the exclusion of any other components, integers or steps, or groups of components, integers or steps.

[0014] It must be noted that as used in this disclosure and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0015] The expression “element A is laid loosely on / over element B” or “element A is laid directly on / over element B” is intended to mean that no adhesive or any other fastening means is used between the two elements, i.e. element A is placed on element B as it is, so that element A and element B are not fixed to each other. This definition also applies to the expressions “element A is laid loosely on / over element B” and “element A is laid directly on / over element B”.

[0016] The present disclosure relates to a roof system comprising a foam glass insulation layer and a waterproof layer.

[0017] In one aspect, the present disclosure relates to a roof system for a roof assembly, the roof system comprising a foam glass insulation layer (4, 11) and a waterproof layer (5, 6; 13, 14), wherein the waterproof layer is loosely laid above the foam glass insulation layer; the waterproof layer remains unattached to the foam glass insulation layer; the foam glass insulation layer comprises one or more layers of foam glass insulation material; and the uppermost layer of foam glass insulation material has a protective coating (12) on its uppermost surface, so that the protective coating forms the upper surface of the foam glass insulation layer and is located between the foam glass insulation layer and the waterproof layer.

[0018] In some embodiments, the roof system further comprises a leveling layer (3) which can ensure that the roof deck (1) has a correct slope gradient so that rainwater flows from the roof of the building to the rainwater outlet and downpipes, gutter systems, funnels, etc.

[0019] In some embodiments, the roof system further comprises a vapor barrier (2). The vapor barrier (2) is placed directly or indirectly between the foam glass insulation layer (4) and the roof deck (1).

[0020] In some embodiments, the roof system further comprises a roof ballast (7, 15) placed directly or indirectly against the upper surface of the waterproof layer. Foam glass insulation layer

[0021] The foam glass insulation layer includes one or more layers of foam glass insulation material. The foam glass insulation material is generally provided in the form of a panel, in particular a cubic panel. The foam glass insulation material layer generally includes a single layer of orthogonal and / or cubic foam glass insulation panels arranged side by side. Two or more layers of cubic foam glass insulation panels arranged side by side can be stacked to form a foam glass insulation layer with more than one layer of foam glass insulation material. The insulation material generally has a closed pore structure, that is, the insulation material has a plurality of pores including a pore wall of the insulation material and a pore interior of a different material. Generally, the interior of the pore is composed of a gas (e.g., air, nitrogen and / or carbon dioxide). On the surface of the closed pore structure insulation material, the substrate may include open pores. The open pores may be formed by a portion of the closed pores. For example, an open pore may be created where a closed pore is formed, and then the substrate is cut through the closed pore to form the surface. Foam glass insulation material suitable for the roof system of the present disclosure can be obtained from Pittsburgh Corning Europe Ltd. Such insulation materials generally comply with EN 13167, EN 14305, and ASTM C552 standards.

[0022] In some embodiments, the total thickness of the foam glass insulation layer can be in the range of 100 to 500 millimeters. As used herein, the thickness of the foam glass insulation layer is the minimum distance from the uppermost portion to the lowermost portion of the layer. In some embodiments, the total thickness of the foam glass insulation layer can be in the range of 250 to 400 millimeters. Typical thicknesses of foam glass insulation material panels are in the range of 50 to 200 millimeters.

[0023] In some embodiments, the foam glass insulation layer includes 1 to 5 foam glass insulation material layers. In other words, the foam glass insulation layer can be formed by a single insulation material layer. Alternatively, the foam glass insulation layer can be formed by 2 to 5 insulation material layers stacked on top of each other. In a specific embodiment, the foam glass insulation layer includes 2 or 3 foam glass insulation material layers. In a more specific embodiment, the foam glass insulation layer includes 2 foam glass insulation material layers. When multiple foam glass insulation material layers are used, any seams between adjacent foam glass panels in one layer are substantially covered by foam glass panels in another layer (from above or below).

[0024] In some embodiments, the foam glass insulation layer has a fire reaction class of Class A according to standard EN 13501-1. In other words, according to standard EN 13501-1, the fire reaction class of the foam glass insulation layer is A1 or A2. In a more specific embodiment, according to standard EN 13501-1, the fire reaction class of the foam glass insulation layer is A1. Protective coating

[0025] The protective coating is applied to the upper surface of the foam glass insulation layer. When the foam glass insulation layer includes two or more layers of foam glass insulation material, the protective coating is applied to the upper surface of the uppermost layer of foam glass insulation material.

[0026] In some embodiments, the protective coating is selected from a mineral protective coating, a silicon-based protective coating, and an alkali metal silicate-based protective coating. Specific examples of protective coatings suitable for application to foam glass insulation materials include, but are not limited to: calcium hydroxide-based coatings; HTAA (available from Corning Europe Ltd., Pittsburgh); calcium sulfate-based coatings; for example, by mixing water with a product called 85 (available from Corning Europe Ltd., Pittsburgh); modified silicon-based coatings, such as a two-component system comprising an inorganic slurry (component 1) formed of glass powder and filler and a modified silicon dioxide dispersion (component 2); for example, a coating prepared by mixing with a product named 80M (available from Pittsburgh Corning Europe Ltd.); lime-based coatings and renders, such as mixtures of sand, cement and lime; for example, those made from products named Coatings prepared from products such as 74A1 or A2 (available from Corning Europe Ltd., Pittsburgh); alkali metal silicate-based coatings, also known as alkali silicate-based coatings.

[0027] For example, the protective coating may be a coating comprising sodium silicate, potassium silicate or a mixture thereof. In a particular embodiment, the alkali metal silicate protective coating may include potassium silicate. A specific example of a suitable alkali metal silicate protective coating is a potassium silicate coating described in EP-A-3 626 692, the entire contents of which are hereby incorporated by reference.

[0028] In some embodiments, the protective coating is applied in-situ to the upper surface of the foam glass insulation layer. In other embodiments, the protective coating is pre-applied to the upper surface of the foam glass insulation layer (ex-situ).

[0029] Application of the protective coating may be carried out by any suitable method, including known methods such as spray drying or application by means of a rubber scraper or spatula, as long as the surface pores (of the upper surface of the cellular glass insulation layer) are filled.

[0030] The protective coatings described herein are generally curable at ambient temperature. It should be understood that, depending on the time of year (and therefore the relative humidity), the curing of the protective coating (once applied to the upper surface of the foam glass insulation) may take from a few minutes (e.g., 10 to 30 minutes) to several hours (e.g., 2 to 5 hours), depending on the chemical composition of the coating and the reaction time of its components. Waterproof layer

[0031] The roof system includes a waterproof layer loosely laid over a foam glass insulation layer, which itself is coated with a protective coating. In this way, the waterproof layer remains unattached to the foam glass insulation layer. As described above, the protective coating forms an upper surface of the foam glass insulation layer and is located between the foam glass insulation layer and the waterproof layer.

[0032] In some embodiments, the waterproof layer includes at least two layers of waterproof material, and one of the at least two layers of waterproof material is loosely laid on the foam glass insulation layer. In such an embodiment, one layer (the first layer) of waterproof material is loosely laid on the uppermost layer of foam glass insulation material, and the other layer (the second layer) is either sintered or partially or completely adhered to the first layer.

[0033] Waterproofing layers suitable for the roof system of the present disclosure are known. Commonly used waterproofing layers include ethylene propylene diene monomer (EPDM), reinforced bituminous membranes (RBMs) and single-layer membranes. Reinforced bituminous membranes (RBMs) may require two layers of application. The thickness of the RBM may be in the range of 3 to 8 mm. The thickness of the single-layer membrane may be in the range of 1.2 to 2 mm. The single-layer membrane may require a screed to falls. A roof screed laid to a slope, also known as a screed, is a mortar layer of variable thickness that is laid on top of a roof deck or panel to provide the correct slope gradient for rainwater to be transported from the roof, thereby ensuring proper drainage of rainwater and preventing the accumulation of stagnant water and its infiltration into the building, which enhances the durability of the roof waterproofing and insulation layer. Roof ballast

[0034] If there is roof ballast, it is placed directly or indirectly against the upper surface of the waterproof layer. In other words, the roof ballast can be placed on top of the waterproof layer. In this way, the waterproof layer can be held down and / or substantially fixed by the roof ballast.

[0035] Roof ballast suitable for use with the roof system of the present disclosure is known. Examples of suitable roof ballast include concrete, stone or other paving slabs, gravel ballast, and large area green roofs. Alternatively, the roof ballast may be an elevated floor walkway or a base with a floor veneer or equivalent. Such roof ballast may be used for balconies, traversable areas, walkways, and the like.

[0036] In one aspect, the present disclosure is directed to a roof assembly (20) comprising a roof system as described herein and a roof deck (21), wherein the roof system is loosely laid on top of the roof deck.

[0037] In one aspect, the present disclosure relates to a roof assembly comprising a roof system as described herein, a roof deck (21), and a vapor barrier (22), wherein the vapor barrier is placed between a lowermost layer of foam glass insulation and the roof deck, and wherein the foam glass insulation layer is loosely laid over the vapor barrier.

[0038] In some embodiments, the vapor barrier is loosely laid onto the roof deck. In some embodiments, the vapor barrier is adhered to the roof deck. The vapor barrier functions to prevent the migration of water vapor. Vapor barriers suitable for use with the roof system of the present disclosure are known. Examples of suitable vapor barriers include polyethylene, aluminum laminate, asphalt glass felt, asphalt polyester felt, reinforced asphalt, and reinforced asphalt with metal foil.

[0039] In another aspect, the present disclosure provides a method for installing a roof assembly, the method comprising: (i) installing a foam glass insulation layer to a roof deck, wherein the foam glass insulation layer comprises one or more layers of foam glass insulation material; (ii) coating an uppermost surface of an uppermost layer of foam glass insulation material with a protective coating; (iii) loosely laying a waterproof layer on the protective coating, wherein the waterproof layer comprises one or more layers of waterproof material; and (iv) placing a roof ballast directly or indirectly against an upper surface of the waterproof layer.

[0040] Step (i) includes installing the foam glass insulation layer (usually formed of foam glass insulation panels) to the roof deck. This is accomplished by laying the foam glass insulation layer directly to the roof deck (sometimes called the structural deck). The roof deck generally provides a platform for installing the various layers of the roof system. Typically the roof deck is a concrete slab. However, wooden and metal roof decks may also be used.

[0041] Figure 3 The method of installing and removing the roof assembly disclosed herein is schematically shown. Symbol ① shows the step of installing, in particular loosely laying, the foam glass insulation layer on the top of the roof deck. The step of coating the uppermost surface of the uppermost foam glass insulation material with a protective coating is not shown. Figure 3 shown in Figure 2 Representative results can be seen in . Symbol ② shows the step of loosely laying the waterproof layer on the protective coating, thereby forming the structure represented by symbol ③.

[0042] In some embodiments ( Figure 3 ), the installation method also includes placing a vapor barrier between the roof deck and the foam glass insulation layer so that the vapor barrier is loosely laid on or adhered to the roof deck and the foam glass insulation layer is loosely laid on the vapor barrier.

[0043] It should be understood that the additional and alternative features described herein with respect to the roof system are also additional and alternative features of the method of installing the roof.

[0044] The roof system according to the present disclosure is designed so that the foam glass insulation material and other elements of the system can be reused. The individual elements of the system are loosely stacked and can be easily removed and separated by product, thereby making it possible to obtain, in particular, the foam glass insulation material (usually in the form of foam glass insulation panels), which, even if coated, can be directly used in other insulation applications, especially in the construction of buildings. For example, such recycled foam glass insulation panels can be reused in flat roof construction. In addition to being a sustainable product (it is an insulation product based on recycled glass and sand), the foam glass insulation material can be easily recycled when used according to the systems and methods disclosed herein. In some embodiments, depending on the new application, recycling may not require further processing of the foam glass insulation material before reuse.

[0045] On the other hand, the present disclosure accordingly provides a method for disassembling a roof assembly having the above-mentioned roof system, the method comprising: (i) removing the roof ballast if present; (ii) removing the waterproof layer; (iii) removing the foam glass insulation material coated with the protective coating; and (iv) recovering any remaining uncoated foam glass insulation panels forming the foam glass insulation layer.

[0046] refer to Figure 3 , symbol ④ represents the step of removing the waterproof layer, and symbol ⑤ represents the step of removing the foam glass isolation layer.

[0047] In some embodiments ( Figure 3 (not shown), the disassembly method also includes removing the vapor barrier if present and if it is loosely laid on the roof deck. This may be the case, for example, where the barrier is no longer needed.

[0048] As mentioned above, the coated foam glass insulation material can be recycled and reused in other insulation applications. Figure 3 (symbols ⑥ and ⑦). Therefore, in another aspect, the present disclosure provides a use of the coated foam glass insulation board recovered by the above method as an insulation material in a roof system for a flat roof assembly. The present disclosure also provides a method for recycling the coated foam glass insulation board recovered by the above method, i.e., building a flat roof assembly by using the recovered board.

[0049] It should be understood that the additional and alternative features described herein with respect to the roof system are also additional and alternative features of the method of disassembling a roof.

[0050] Although the present disclosure mentions the above exemplary embodiments, many equivalent modifications and variations will be apparent to those skilled in the art after obtaining the present disclosure. Therefore, the above exemplary embodiments are considered to be illustrative rather than restrictive. Various changes may be made to the described embodiments without departing from the spirit and scope of the present disclosure. Example

[0051] The present disclosure is illustrated with reference to the following non-limiting examples. Example 1

[0052] Various coatings were prepared by uniformly mixing the starting powder with water or silica dispersion in the proportions shown in Table 1. The coatings were applied to foamed glass panels to form a uniform coating thereon and then cured. The coverage, density, pot life and cure time of the coatings were measured and recorded in Table 1. Table 1

[0053] It can be seen that by 74A1 and The coating made with 80M showed slightly greater coverage but took longer to cure. Example 2

[0054] To evaluate the coating's performance under condensing conditions, 200 x 200 mm foam glass samples with different coatings and a bitumen film on top of each sample were tested in a climatic chamber. The samples were placed at a temperature of +40°C and a relative humidity of 95% for one week and at a temperature of +40°C and a relative humidity of 98% for another week. After these two weeks, no visible moisture was observed under the bitumen film, nor was there any degradation or chalking of the coating. Example 3

[0055] Foam glass panels with or without coating were mounted horizontally on a support in a climate chamber. The panels were completely wetted, covered with a loosely laid bitumen membrane and subjected to freeze-thaw cycle tests simulating a rapid aging test. That is, the samples were subjected to 12 cycles -10°C / +30°C (3 cycles per day with a temperature change of 1°C per minute and keeping the cycle limits constant for at least 2 hours). At the end of the freeze-thaw cycles, when the surface was wiped, a certain degree of degradation and chalking of the different coatings was observed for all samples.

[0056] The point load or crush penetration on different coatings was measured according to EN12430. A preload of 100 N was applied to a cylindrical steel indenter (80 mm in diameter) in contact with the sample, and the deformation was adjusted to zero at this time. To measure the point load / crush penetration, the increase in deformation was measured after increasing the force to 1000 N using a displacement speed of 2 mm / min. The results are shown in Table 2. Table 2 *Average of 4 samples

[0057] All coatings tested showed low crush penetration values. For those samples that had undergone freeze-thaw cycles, values ​​were found to be 30% to 60% higher than the reference samples, but still well below the quality control limit of 1.5 mm for uncoated foam glass. Example 4

[0058] The bonding strength of different coatings is evaluated by adhering a steel T-shaped iron of 150x150 millimeters to the top of the coated foam glass plate. Afterwards, (around the T-shaped iron) cut through the coating so that the combination between the coating and the foam glass substrate can be evaluated. The initial sample (i.e., after curing for 1 week at ambient temperature) and the sample (after 1 week curing period) soaked in tap water for 24 hours before the bonding strength test and then cured for 3 days at ambient temperature are tested for bonding strength. All samples are tested on Toniversal 20kN equipment at 23 ℃, and the test speed is set to 10 mm / min. The results are shown in Table 3. Table 3 *Average of 4 samples

[0059] Since all failures were found cohesively in the foamed glass, no significant differences in bond strength were observed. Example 5

[0060] Samples measuring 200 x 200 mm were cut from the coated panels prepared in Example 1 and tested for short-term water absorption by partial immersion at +23°C according to ISO 29767 (EN 1609) method B. The initial mass m0 was determined and the test sample was then placed in a water bath in such a position that the bottom surface of the test sample was partially immersed at 10 ± 2 mm below the water level. After 10 seconds, the test sample was removed while being kept horizontal and placed in a plastic dish of known mass for 5 seconds. This gave the initial water absorption m1. The test sample was placed in the water bath again and partially immersed (10 ± 2 mm), provided that the water level remained constant during the test. After 24 hours, the test sample was removed and the mass m24 was determined, from which the short-term water absorption value could be calculated. The results are shown in Table 4. Table 4

[0061] All coatings showed low water absorption values ​​(<0.5 kg / m 2 ). After three weeks of partial water absorption, some degree of degradation and chalking of the different coatings was observed for all samples when the surfaces were wiped.

Claims

1. A roof system for a roof assembly, the roof system comprising: Cellular glass insulation; and Waterproof layer, wherein the waterproof layer is loosely laid on top of the foam glass isolation layer; Wherein the foam glass insulation layer comprises one or more layers of foam glass insulation material; The uppermost layer of the foam glass insulation material has a protective coating on its uppermost surface, so that the protective coating forms the upper surface of the foam glass insulation layer and is located between the foam glass insulation layer and the waterproof layer.

2. The roof system according to claim 1, wherein the waterproof layer comprises at least two layers of waterproof material, and One of the at least two layers of waterproof material is loosely laid on top of the foam glass insulation layer.

3. The roof system according to claim 1 or 2, wherein the protective coating is selected from the group consisting of a mineral protective coating, a silicon-based protective coating and an alkali metal silicate-based protective coating.

4. The roof system according to claim 1 or 2, wherein the protective coating is selected from the group consisting of calcium hydroxide based coatings, calcium sulfate based coatings, modified silicon based coatings, lime based coatings and renders, and alkali metal silicate based coatings.

5. A roof system according to any one of the preceding claims, wherein: The foam glass insulation layer is formed by a plurality of foam glass insulation panels.

6. A roof system according to any one of the preceding claims, further comprising roof ballast placed directly or indirectly against an upper surface of the waterproof layer.

7. A roof assembly comprising a roof deck and a roof system according to any one of claims 1 to 6, wherein the roof system is loosely laid on top of the roof deck.

8. A roof assembly comprising: The roof system according to any one of claims 1 to 6; roof deck; and Vapor Barriers, wherein the vapor barrier is positioned between the lowermost layer of foam glass insulation and the roof deck, and The foam glass insulation layer is loosely laid on the vapor barrier.

9. The roof assembly of claim 8, wherein the vapor barrier is loosely laid on the roof deck.

10. A method of installing a roof assembly, the method comprising: (i) installing a cellular glass insulation layer to a roof deck, wherein the cellular glass insulation layer comprises one or more layers of cellular glass insulation material; (ii) coating the uppermost surface of the uppermost layer of cellular glass insulation material with a protective coating; (iii) loosely laying a waterproof layer on the protective coating, wherein the waterproof layer comprises one or more layers of waterproof material; (iv) placing roof ballast directly or indirectly against the upper surface of the waterproof layer.

11. The method of claim 10, wherein the foam glass insulation layer is formed from a foam glass insulation sheet.

12. The method of claim 10 or 11 further comprising placing a vapor barrier between the roof deck and the foam glass insulation layer such that the vapor barrier is loosely laid on or adhered to the roof deck and the foam glass insulation layer is loosely laid on the vapor barrier.

13. The method according to any one of claims 10 to 12, wherein the protective coating is selected from the group consisting of a mineral protective coating, a silicon-based protective coating and an alkali metal silicate-based protective coating.

14. The method according to any one of claims 10 to 12, wherein the protective coating is selected from calcium hydroxide based coatings, calcium sulphate based coatings, modified silicon based coatings, lime based coatings and renders, and alkali metal silicate based coatings.

15. A method for disassembling a roof assembly according to any one of claims 7 to 9, the method comprising: (i) removing roof ballast, if any; (ii) removing the waterproof layer; (iii) removing the foam glass insulation material coated with the protective coating; and (iv) if there is any foam glass insulation material not coated with the protective coating, the foam glass insulation material not coated with the protective coating is recycled.

16. The method of claim 15, further comprising removing the vapor barrier if present and if the vapor barrier is loosely laid on the roof deck.

17. Use of the coated foam glass insulation panels recycled by the method of claim 15 as insulation material in a roofing system for a flat roof assembly.

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