WO2016086262A1

WO2016086262A1 - Roof safety product

Info

Publication number: WO2016086262A1
Application number: PCT/AU2015/000731
Authority: WO
Inventors: Raymond Keith Stead
Original assignee: PTT Management Pty Ltd
Current assignee: PTT Management Pty Ltd
Priority date: 2014-12-03
Filing date: 2015-12-03
Publication date: 2016-06-09
Anticipated expiration: 2017-06-03

Abstract

The present invention is directed to a roof safety product having a reflective foil layer, a strengthening layer, a mesh layer and a finishing or further foil layer. The roof safety product of the preferred embodiment serves as a sarking type product with the added benefit of protecting a worker from injury. There is also the option of having one or more insulation layers to provide thermal insulation to the building.

Description

ROOF SAFETY PRODUCT

FIELD OF INVENTION

The present invention relates to building safety products. The present invention has particular but not exclusive application for roofs of residential, commercial and industrial buildings.

BACKGROUND OF THE INVENTION

There are a range of safety products that can be used to protect the workers from injury during building construction. The products can be generally classified as either fall arrest products or fall restraint products. The fall arrest products include a safety mesh which is positioned across openings in the roof space. The safety mesh is designed to stop a person's fall. Safety mesh should comply with AS/NZS 4389 safety mesh standards, which specifies the minimum requirements for the design, construction, testing and installation of safety mesh for use in domestic, commercial and industrial building applications. The mesh is formed from 2 mm diameter wire of not less than 450 MPa tensile strength, welded into a mesh with the longitudinal wires not more than 150 mm apart and the cross wires not more than 300 mm apart. Generally the safety mesh is covered by the roof cladding during the installation of the roof.

A safety net is installed below a high-level work area to reduce the distance that a worker can fall. They absorb the impact of the fall and provide a comparatively softer landing to reduce the likelihood of a person being injured. Safety nets provide passive protection from falls while allowing people to work at heights without restricting their movement. There are government guidelines that cover the safety requirements and safe use of safety nets to protect workers from being injured by a fall from a height.

While the use of safety mesh and safety nets has improved the safety conditions of roof installers and builders during the installation of roofs, this improvement has come at an additional expense to builders and subsequently to the owners of the building. This additional expense is incurred for a product that is not necessary for the integrity of the building but only used as an accessory during part of the building process. OBJECT OF THE INVENTION

It is an object of the present invention to provide for a safety product that at least in part addresses one or more of the aforementioned problems.

SUMMARY OF THE INVENTION

The current invention was developed by the inventors taking a different approach to the building process and combining two stages into one stage. The approach has been to design and manufacture products that address safety concerns and provide a protective sarking-type layer.

In one aspect, the invention broadly resides in a roof safety product having a plurality of layers including

at least one reflective foil layer with a strengthening layer;

a restraining layer; and

a finishing layer or another reflective foil layer.

Said restraining layer is a layer designed and made of materials that would stop a person's fall. Said restraining layer is preferably made of plastic, fabric or metal. Said restraining layer is preferably a mesh layer. Alternatively the restraining layer can be a complete sheet of material.

In another aspect, the invention broadly resides in a roof safety product having a plurality of layers including

at least one reflective foil layer with a strengthening layer;

a mesh layer; and

a finishing layer or another reflective foil layer.

Different embodiments can have different arrangements of the layers except the foil layer with the strengthening layer are bonded together.

The reflective foil layer is preferably an aluminum foil layer. The reflective foil layer preferably includes an antiglare layer which can be an overlying outer polymer layer or a painted or inked foil surface to reduce the glare reflecting from the foil surface.

The strengthening layer provides the foil layer with structural integrity and is preferably craft paper layer, a plastic or fiberglass layer, or a woven cloth layer that provides the reflective foil with strength and integrity. Other types of suitable materials can be used providing their use provides the associated foil layer with strength and integrity. The bonding of the strengthening layer to the foil layer is preferably achieved with flame retardant adhesive to reduce the risk of fire.

The mesh layer is made of any suitable material including metal, plastic, fabric and fiberglass. In one embodiment the mesh layer can be woven cloth. The mesh layer can comprise of any suitable lattice structure and lattice dimensions. In a preferred embodiment the mesh layer includes a wire lattice with 150mm by 150mm dimension or a 150mm by 300mm dimension.

The preferred mesh has an 1800mm width with a 2mm diameter wire. The wire preferably has 38g/m² zinc coating. Other mesh widths preferably include 1500mm and 2400mm.

Alternatively the mesh can be thicker in diameter to provide additional strength and support. Thicker mesh is important where the safety product needs to be placed at higher heights and or there is a greater spacing between the workers and the position of the installed safety product.

The mesh layer can be positioned before the reflective foil/strengthening layers.

The mesh layer can alternatively be positioned intermediate the reflective foil/strengthening layers and foil or finishing layer.

The mesh layer can alternatively be positioned after the further foil or finishing layer.

With the option of another reflective foil layer, the foil layer can be bonded with the mesh layer to provide the foil layer with the strength and integrity.

Alternatively the foil layer can be bonded with a strengthening layer similarly as described above.

With the option of a finishing layer, the layer can be decorative or be of a particular colour such as white or green.

The bonding of the strengthening layer to the foil layer is preferably achieved with flame retardant adhesive to reduce the risk of fire. Alternatively one or more of the layers can be bonded together through a lamination process.

A fire retardant adhesive is preferably used to bond one or more layers. There may also be at least one insulation layer which can include natural fiber insulation, plastic or polymer insulation, mineral fiber insulation, combinations thereof, or other suitable insulation materials.

Natural fibre insulation material can be selected from one or more of cotton, sheep's wool, straw, hemp, waste materials such as nut shells, the cob of corns, most straws including lavender straw, recycled granulated wine bottle corks . Plastic or polymer insulation materials can be selected from one or more of bubble layers, open and closed cell layers, foam, polystyrene, polyester. The polymer layer is a preferably a cross-polyethylene layer. The cross-polyethylene layer can include a colouring agent to provide the layer with a particular colour. In one preferred embodiment the polyethylene layer is white.

Mineral fibre insulation material can be selected from one or more of fibreglass and rockwool. Rockwool is formed from steel slag and basalt. Rockwool has the advantages that it is naturally flame retardant and resistant to mould.

Insulation material can be selected from one or more of recycled products such as cork, cotton, recycled tissue/clothes, hemp, flax, coco, wool, lightweight wood fibre, cellulose, seaweed, or other suitable plant waste.

The insulation layer can be of any suitable thickness but preferably between 2mm and 75mm. The thickness of the insulation layer will depend on the type of insulation material. In preferred embodiments, the insulation layer of mineral fibre has a thickness of 10mm, the insulation layer of closed cell polymer has a thickness of 6.5mm, and the insulation layer of fibreglass has a thickness of 25mm.

Preferably the safety product is prepared in rolls of 1500mm, 1800mm and or 2400mm widths.

at least one reflective foil layer;

at least one scrim layer;

a mesh layer; and

at least one insulation layer.

The scrim layer is preferably a plastic layer, a fiberglass layer or a woven cloth layer that provides the reflective foil with strength and integrity. In one preferred form the at least one insulation layer is a polymer layer. The polymer layer is a preferably a cross-polyethylene layer. The cross-polyethylene layer can include a colouring agent to provide the layer with a particular colour. In a preferred embodiment the polyethylene layer is white.

The roof safety product can include one or more insulation layers. The one or more insulation layers are preferably selected from a closed cell layer, foam layer and a fiberglass insulation layer. Preferably the closed cell layer is a polyethylene closed cell layer. Preferably the foam layer is a cross-linked polyethylene foam layer.

The roof safety product can include additional strengthening aluminum foil layers with a scrim layer or other materials.

In another aspect, the invention broadly resides in a roof safety product having a plurality of layers arranged in the following order:

a first reflective foil layer;

a first scrim layer;

a mesh layer;

one or more insulation layers;

a second scrim layer and

a second reflective foil layer.

The features and options described with respect to the earlier aspects also apply to this aspect of the invention.

A further aspect of the invention broadly resides in a method of installing the roof safety product as described above across roof purlins including

extending the roof safety product across the purlins; and

fixing the roof safety product in position.

A further aspect of the invention broadly resides in a system for using the roof safety product as described above to provide safety for the builders, roofing installers and others and insulation for the building. The system preferably allows the installed product to remain within the roof space and be of ongoing benefit to the building and its occupants.

The features described with respect to one aspect also apply where applicable to all other aspects of the invention. Furthermore different combinations of described features are herein described and claimed even when not expressly stated.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the present invention can be more readily understood reference will now be made to the accompanying drawings which illustrate a preferred embodiment of the invention and wherein:

Figure 1 is a diagrammatic view of a second preferred embodiment of the roof safety product;

Figure 2 is a diagrammatic view of a third preferred embodiment of the roof safety product; and

Figure 3 is a diagrammatic view of the installed roof safety product in the roof space. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Sarking is installed under the roof during the building to provide a pliable second skin to protect the roof cavity from storm driven rain and dust. The preferred embodiment of the present invention is a sarking-type product that includes a number of layers to provide a roof safety product with a number of advantages.

The preferred embodiment of the present invention includes an upper reflective foil layer bonded by fire retardant adhesive to a strengthening layer of craft paper. A mesh layer is sandwiched between the reflective foil/ strengthening layer and a plastic finishing layer. The plastic finishing layer is coloured white. The mesh layer is a zinc-coated wire lattice with 150mm by 150mm dimension.

The use of the preferred roof safety product provides the advantages of improved safety of workers during construction, protection from the weather during construction and protection of the constructed building from storm-driven rain, dust, heat and cold, lowering of fire risk and reduction of the risk of condensation during cold weather.

The roof safety product is laid over rafters but below roof battens. The roof safety product is installed with the reflective foil and strengthening layers positioned uppermost. The roof is installed over the roof safety product and covers the roof safety product. The roof can be a tiled roof or a metal roof. The installed roof safety product serves to provide a safety sheet to catch a builder if they fall while working on the roof. The installed roof safety product also provides insulation by reflecting light and heat and creating air spaces between the roof and the roof safety product and the roof safety product and the ceiling.

In a similar fashion the roof safety product can be used a wall wrap installed between an inner and outer wall of a structure.

With reference to the Figures, there is shown a second preferred embodiment of the roof safety product in Figure 1 . The roof safety product 10 has a plurality of layers bonded together to form a sheet with safety and insulation properties. The roof safety product 10 has a top reflective aluminum foil layer 1 1 with a tinted polymer coating 12 on the upper surface to reduce the reflective glare. There is a scrim layer 13 including a woven cloth fabric. The scrim layer 13 provides integral strength to the bonded aluminum foil layer 1 1. Below the scrim layer 13, there is a metal mesh layer 15 with a 150mm by 150mm lattice. Following the mesh layer 15, there is a polyethylene polymer cell bubble layer 16. The cell bubble layer 16 can be filled with air or other gas, liquid or material and has a depth of approximately 5 mm. Adjacent the air cell bubble layer 16 is a cross-polyethylene foam layer 17. The cross-polyethylene foam layer 17 has a depth of 3.5 mm. Below the cross- polyethylene foam layer 17, there is a second scrim layer 18 and a second aluminum foil layer 19.

A third preferred embodiment of the roof safety product is shown in Figure 2. Similar reference numbers that were used for the second embodiment shown in Figure 1 are used for the third embodiment that is shown in Figure 2. Where the parts are the same. The roof safety product 21 has the same layers as the second embodiment except that there is a cross-polyethylene foam layer 22 with a depth of 6.5mm instead of an air cell bubble layer 16 and a thinner cross-polyethylene foam layer 17.

In a fourth preferred embodiment of the roof safety product, there is a reflective foil layer strengthened by a scrim layer, a wire mesh layer having a150mm by 300mm lattice and sandwiched by a 10 mm thick mineral wool insulation layer and or 12 mm thick foam layer. In a fifth preferred embodiment, the parts are the same as described with the fourth embodiment except the last layer is coloured white to provide an aesthetically pleasing appearance in situations where a building has an exposed roof.

Irrespective of which embodiment is used, the roof safety product is installed similarly. The roof safety product 30 is rolled out across the roof space and across the purlins 31 . A nominal sag of 40mm is formed. An overlap of roof safety products of approximately 150mm to 300mm is formed. The ends of the longitudinally extending wires of the mesh are separated from the insulation layers so that there is approximately 300mm of free wire extending from the roof safety product 30. The ends of the longitudinal wires are twisted and tied off after passing through or around purlins 31 or a truss 32.

The installed roof safety product 30 serves to provide a safety sheet to catch a builder if they fall while working on the roof 35. The installed roof safety product 30 also provides insulation by reflecting light and heat and creating air spaces between the roof 35 and the roof safety product 30 and the roof safety product 30 and the ceiling 36.

ADVANTAGES

The advantages of the preferred embodiment of the present invention is that it provides a new type of product that provides a solution to several different problems. The roof safety product of the preferred embodiment serves as a safety product to prevent a person from injuring themselves and provides the advantages of sarking.

The system using the preferred roof safety product offers the unique benefit of a roof safety and safety system and thermal insulation in one product and in some instances an internal lining or finishing product. The nature of the installation of the system is such that it offers significant savings in time and money in the installation of a single product to perform multiple functions.

The roof safety product of the second and third preferred embodiment serves as a safety product to prevent a person from injuring themselves and provide insulation properties to control the rate of change of temperature within the building.

Conventional safety mesh and insulation requires the use of roof spacers to achieve minimum requirements of the building code and the required thermal performance for buildings. These spacers are often expensive to purchase and difficult to install and pose design problems such as increased wind load requirements and aesthetic issues for building designers and installers.

This system using the preferred roof safety products allows consistent thermal performance, without the use of roof spacers, thus reducing the cost of construction and meeting statutory requirements for roof safety and the thermal/ energy efficiency requirements of the industry.

VARIATIONS

It will of course be realised that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth.

Throughout the description and claims of this specification the word

"comprise" and variations of that word such as "comprises" and "comprising", are not intended to exclude other additives, components, integers or steps.

Claims

1 . A roof safety product having a plurality of layers including

at least one reflective foil layer with a strengthening layer;

a mesh layer; and

a finishing layer or another reflective foil layer.

2. A roof safety product as claimed in claim 1 wherein the mesh layer is above the foil layer with the strengthening layer, intermediate the layers, or below the finishing layer or further reflective foil layer.

3. A roof safety product as claimed in claim 1 or 2 wherein the strengthening layer is a scrim layer, craft paper layer, a plastic or fiberglass layer, or a woven cloth layer that provides the reflective foil with strength and integrity.

4. A roof safety product as claimed in any one of the preceding claims wherein there is an insulation layer.

5. A roof safety product as claimed in any one of the preceding claims wherein there is an insulation layer that is selected from natural fiber insulation including cotton, sheep's wool, straw, hemp, waste materials such as nut shells, the cob of corns, most straws including lavender straw, recycled granulated wine bottle corks; plastic or polymer insulation including one or more of bubble layers, open and closed cell layers, foam, polystyrene, polyester; mineral fiber insulation including fibreglass and rockwool; and or combinations thereof.

6. A roof safety product having a plurality of layers including

at least one reflective foil layer;

at least one scrim layer;

a mesh layer; and

at least one insulation layer.

7. A roof safety product as claimed in claim 6, wherein the at least one insulation layer is selected from natural fiber insulation including cotton, sheep's wool, straw, hemp, waste materials such as nut shells, the cob of corns, most straws including lavender straw, recycled granulated wine bottle corks; plastic or polymer insulation including one or more of bubble layers, open and closed cell layers, foam, polystyrene, polyester; mineral fiber insulation including fibreglass and rockwool; and or combinations thereof.

8. A roof safety product as claimed in claim 6 or 7 wherein the reflective foil layer is an aluminum foil layer that includes an overlying outer polymer layer or a painted or inked foil surface to reduce the glare reflecting from the foil surface.

9. A roof safety product as claimed in any one of the claims 6 to 8, wherein the scrim layer is a plastic layer, a fiberglass layer or a woven cloth layer that provides the reflective foil with strength and integrity; the mesh layer is made of any suitable material including metal, plastic, and fiberglass and have any suitable lattice structure and lattice dimensions.

10. A roof safety product as claimed in claim 6 or 7, wherein the at least one insulation layer is a cross-polyethylene layer that includes a colouring agent to provide the layer with a particular colour.

1 1 . A roof safety product as claimed in claim 6 or 7, wherein the at least one insulation layer is a cross-polyethylene layer and or a cross-linked polyethylene foam layer.