(19)
(11)EP 1 543 203 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
27.05.2015 Bulletin 2015/22

(21)Application number: 03770260.2

(22)Date of filing:  29.08.2003
(51)International Patent Classification (IPC): 
E04D 1/00(2006.01)
(86)International application number:
PCT/US2003/027067
(87)International publication number:
WO 2004/020762 (11.03.2004 Gazette  2004/11)

(54)

MODULAR BALLAST SYSTEM FOR MEMBRANE ROOFS

MODULARES BALLASTSYSTEM FÜR MEMBRANDÄCHER

SYSTEME DE LEST MODULAIRE POUR TOITURES A MEMBRANE


(84)Designated Contracting States:
AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LI LU MC NL PT RO SE SI SK TR

(30)Priority: 29.08.2002 US 406746 P
12.11.2002 US 426079 P

(43)Date of publication of application:
22.06.2005 Bulletin 2005/25

(73)Proprietor: American Builders & Contractors Supply Company, Inc.
Beloit, WI 53511-4441 (US)

(72)Inventor:
  • MISCHO, Donald, J.
    Janesville, WI 53546 (US)

(74)Representative: Quintelier, Claude et al
Gevers Patents Intellectual Property House Holidaystraat 5
1831 Diegem
1831 Diegem (BE)


(56)References cited: : 
EP-A- 0 857 926
JP-A- 2002 176 850
US-A1- 2002 007 592
US-B1- 6 606 823
FR-A- 2 703 213
US-A- 5 595 021
US-B1- 6 606 823
  
      
    Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


    Description

    Technical Field



    [0001] The present invention relates to a modular system adapted to provide ballast to hold a roofing membrane in position, and to retain a relatively large volume of water on the roof to assist in control of water runoff from the building.

    Background of the Invention



    [0002] Roof membranes of the type commonly specified on commercial or industrial buildings are held in place with weight resting on the membrane. The membrane is held in place with ballast materials such as round river rocks or weighted pavers made from concrete or other dense materials. Minimum ballast is commonly designated at approximately 11 lbs/sq-ft to hold the membrane in place. Additional ballast is specified as required such as to meet wind uplift resistance requirements.

    [0003] It is often desirable and advantageous to retain water on the roof of such industrial and commercial buildings during rainfall. Retaining water on the roof reduces peak load in storm sewers, and smoothes out the peak sewer drainage load over a period of time. In certain locations such as densely developed cities controlling water runoff from a building may affect the footprint size of the building which may be built on a particular lot. Retaining water on the roof of a building also permits the retained water to evaporate from the roof over a long period of time, contributing to cooling of the roof surface and the air above roof. This cooling reduces the urban heat-island problem that is often associated with large buildings in densely developed areas.

    [0004] Prior roof membrane ballast arrangements suffer from several drawbacks and disadvantages. Disadvantage of round river rocks is that they are relatively expensive, and it is difficult to maintain and repair the roof membrane because removal of the loose ballast material is a labor intensive, difficult and expensive process. It is also difficult to safely walk on a roof that is covered with loose round river rocks due to movement of rocks. And neither pavers nor round river rocks have any significant water retention capability.

    [0005] Another type of system that is capable of providing ballast for a roof membrane is a green roof. Green roofs are provided as either modular or non-modular systems. The modular green roofs include modules that are positioned across the membrane in side-by-side relation and filled with growing medium and vegetation. Non-modular green roofs are established with fibrous mats laid over the membrane, such as with a base support mat and a top mat in which the vegetation grows.

    [0006] One advantage of green roof systems is their ability to retain water during rainfall. However, green roofs are relatively expensive, and they do not provide easily predictable rainfall retention characteristics. Variations in growing medium, plant type, root structure, and other covering result in variation of water retention capability. Thus, the water retention capability of a green roof can not be predetermine with repeatable specificity. And to prevent root rot, green roofs are intentially designed to retain only limited volumes of water for any extended period of time. In modular systems, this is accomplished with drainage holes near the base of the modules below the growing medium, and in non-modular systems, this is accomplished through designation of the fiber structure and material of the base and top mats.

    [0007] Consequently, there is a need for an improved ballast system for roofing membranes that addresses the above-identified drawbacks and disadvantages of prior ballast systems. In addition, there is a need for a ballast system that is adapted to retain predictable volumes of water on a roof during and after a rainfall.

    [0008] US-A-2002/007592 describes a modular ballast system for roofs that comprises a plurality of rectangular modules connected in contiguous relation on the roof, each module having an open top and a closed bottom established with a floor configured for resting on the roof and for allowing multi-directional water flow thereunder and therebetween, and sidewalls extending upwardly from the bottom, the sidewalls having over-flow holes formed therethrough at a predetermined height above the bottom for retaining a predetermined volume of water therein. Each module also comprises substantially non-absorbent loose-fill ballast materials.

    Summary of the Invention



    [0009] The general aim of the present invention is to provide a new and improved ballast system that is also adapted for use as a mounting platform for alternate energy generating apparatus to promote efficient use of the roof. Such a system is defined by the characterizing portion of claim 1.

    [0010] These and other objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

    [0011] Briefly, a preferred ballast system of the present invention includes providing a plurality of modules that are capable of receiving and holding both a predetermined volume of water and a predetermined weight of loose ballast-fill material, filling the modules with the ballast material, and installing the modules in side-by-side relation on the roof membrane. The volume of water retained in the modules is established by the space-density of the ballast-fill material and the height of over-flow holes formed in the sides of the modules. Adjusting either the ballast-fill material or the height of the over-flow holes adjusts the water retention capability of the modules. The invention also provides for, among other things, connecting the modules together for enhanced resistance to wind uplift, including tying the modules over the entire roof or large sections together with wire cable, additional water retention capabilities in the modules, an edge finishing system, methods for pre-designating and predetermining ballast limits and water retention capabilities, and establishing a combined power generating ballast system for the roof.

    [0012] In certain preferred alternate embodiments, a ballast system in provided with modules to control the rate of water outflow therefrom according to a predetermined schedule, both during and after a rainfall, the schedule being established to control and achieve desired water retention characteristics during a heavy rainfall, and a desired rate of water runoff from a roof thereafter, and associated methods associate therewith.

    Brief Description of the Drawings



    [0013] 

    FIG. 1 is a fragmentary perspective view of a building and roof provided with a roofing membrane.

    FIG. 2 is a view similar to FIG. 1, with the roof provided with a modular ballast system in accordance with the invention.

    FIG. 3 is a perspective view of a module filled with ballast.

    FIG. 4 is a top perspective view of an empty module.

    FIG. 5 is a bottom perspective view of the module.

    FIG. 6 is an enlarged side view of the module taken along the line 6-6 of FIG. 4.

    FIG. 7 is an enlarged cross-sectional view taken along the line 7-7 of FIG. 4.

    FIG. 8 is an enlarged cross-sectional view taken along the line 8-8 of FIG. 4.

    FIG. 9A is an enlarged fragmentary cross-sectional view showing two filled ballast modules connected together.

    FIG. 9B is a view similar to FIG. 9A including a bug-screen covering the modules.

    FIG. 9C is a fragmentary side view of a module and screen held in place with a skirt connector.

    FIG. 10 is a perspective view of the connector shown in FIGS. 9A-B.

    FIG. 11 is a fragmentary cross-sectional view showing one embodiment edge finishing member connected to the ballast module.

    FIG. 12 is a fragmentary cross-sectional view showing a second embodiment edge finishing member connected to the ballast module.

    FIG. 13 is a fragmentary cross-sectional view showing a third embodiment edge finishing member connected to the ballast module.

    FIG. 14 is a fragmentary cross-sectional view showing fourth embodiment edge finishing member connected to the ballast module.

    FIG. 15 is an enlarged fragmentary cross-sectional view showing a ballast module provided with green roof materials.

    FIG. 16 is a perspective view of a ballast module equipped with a photo-voltaic panel.

    FIG. 17 is a side view of the ballast module equipped with the photo-voltaic panel.

    FIG. 18 is an enlarged fragmentary side view of the ballast module equipped and photo-voltaic panel.

    FIG. 19 is a perspective view of the ballast module adapted to support the photo-voltaic panel.

    FIG. 20A is a top plan view of a reflective sheet prior to forming into a cover onto a module.

    FIG. 20B is a top plan view of an alternate reflective sheet prior to forming into a cover onto a module.

    FIG. 21 is an enlarged fragmentary side view showing the reflective cover as formed and installed onto a module.

    FIG. 22 is an enlarged fragmentary view showing extensions of adjacent covers connected for use as a larger cover unit.

    FIG. 23 is a fragmentary side view of an installed ballast module system provided with photo-voltaic panels.

    FIG. 24 is a top view of the module showing the location of a cut line prior to cutting the module into two module-portions for production of a reduced-size module.

    FIG. 25 is a top view of the cut module-portions, with one of the portions shown in an intermediate position over the other portion.

    FIG. 26 is a top view of the cut module-portions, with the one module-portion in its final stacked position nested into the other module-portion to produce a reduced-size module.

    FIG. 27 is an enlarged fragmentary cross-sectional view showing two stacked module-portions with the flange of the upper module-portion expanded outwardly over the flange of the lower module-portion.

    FIG. 28 is an enlarged fragmentary cross-sectional view showing two stacked module-portions with the flange cut away from one of the module-portions.

    FIGS. 29 and 30 are perspective views of a ballast module provided with alternate wicking materials for controller outflow of water.

    FIG. 31 is an enlarged fragmentary view of the ballast module shown in FIG. 30, with the ballast materials therein.

    FIG. 32 is a perspective view of an alternate module adapted for controlled outflow of water.

    FIG. 33 is a graphical representation of rainfall v. time, and of water retention and outflow characteristics for three alternate ballast systems and/or three alternate rainfall magnitude scenarios.

    FIG. 34 is a fragmentary perspective view of an alternate connector, modules and a cable tie-down system.

    FIG. 35 is an exploded perspective view of the connector shown in FIG. 34.

    FIG. 36 is an exploded perspective view of another alternate connector.

    FIG. 37 a fragmentary perspective view of an alternate positioned photo-voltaic panel and anchoring system.

    FIG. 38 is a fragmentary side view of the installed ballast module system and photo-voltaic panels shown in FIG. 37.

    FIG. 39 is a fragmentary cross-section side view of an alternate arrangement to anchor a screen into a module.



    [0014] Reference numerals in the drawings correspond to the following items discussed in the detailed description below:
    10
    - ballast system
    12
    - roof membrane
    14
    - roof
    16
    - building
    18
    - module
    20
    - ballast materials
    22
    - over-flow holes
    24
    - sidewalls
    26
    - floor
    28
    - feet
    30
    - flange
    32
    - connector holes/slots in flange
    34
    - flange top
    36
    - flange skirt
    38
    - absorbent pad
    40
    - bentonite clay
    42
    - module connector
    44
    - top bar of connector
    46
    - legs of connector
    48
    - barbs of connector
    50
    - edge finishing system
    52
    - hollow extruded finishing-member
    54
    - clips
    56
    - first alternate edge finishing member
    58
    - elongated treated wood finishing-member
    60
    - retainer clips
    62
    - second alternate edge finishing member
    64
    - extruded composite finishing-member
    66
    - integrally extruded clip
    68
    - integral support extrusion
    70
    - third alternate edge finishing member
    72
    - concrete edge finishing-member
    74
    - masonry ties
    76
    - photo-voltaic panel
    78
    - corner gussets
    80
    - front p-v panel supports
    82
    - back p-v panel supports
    84
    - building drain facility
    86
    - fasteners
    88
    - holes in corner gussets
    90
    - inorganic root barrier
    92
    - growing medium
    94
    - plants
    96
    - rocks
    98
    - screen
    98A
    - screen
    100
    - screen clips
    102
    - reflective cover
    103
    - louvers
    104
    - flat panel
    105
    - perforations
    106
    - center of reflective cover
    108
    - extensions
    110
    - score lines
    112
    - first cut module-portion
    114
    - second cut module portion
    116
    - reduced-size module
    118
    - cut line
    120
    - absorbent wicking pad
    122
    - wicking rope
    124
    - seepage holes
    130
    - connector
    132
    - top connector member
    132A
    - horizontal top portion
    132B
    - downwardly extending legs
    132C
    - clearance holes
    134
    - bottom connector member
    134A
    - horizontal bottom portion
    134B
    - upwardly extending legs
    134C
    - threaded holes
    136
    - fasteners
    136A
    - eyelets
    138
    - wire cable
    140
    - connector
    142
    - top connector member
    142A
    - horizontal leg
    142B
    - vertical leg
    142C
    clearance holes
    144
    - threaded fasteners
    144B
    - clearance holes


    [0015] While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention.

    Best Mode for Carrying Out The Invention



    [0016] For purposes of illustration, one embodiment of the present invention is shown as ballast system 10 (FIG. 2) adapted to (i) provide the ballast requirement for a roof membrane 12 (FIG. 1) on the roof 14 of a building 16, and (ii) simultaneously retain a relatively large, predetermined volume of water on the roof during and after a rainfall.

    [0017] Briefly, these performance characteristics are accomplished by providing modules 18 that are capable of receiving and holding both a predetermined volume of rainfall and a predetermined weight of loose-fill ballast material 20, filling the modules with the ballast material, and installing the modules in side-by-side relation on the roof. The water retention capability of the modules is established by considering the volume of the ballast material in the modules and the over-flow capacity of the modules. The volume of water actually retained in the modules is established with over-flow holes 22 in the sides 24 of the modules at a designated height, and the rate of runoff thereafter is established by the size and number of holes at the over-flow height and thereabove. The preferred ballast roofing system also includes module connectors and an edge finishing system as required for the particular roof installation.

    [0018] Accordingly, the ballast module 18 (a) is suitable for both (i) holding required ballast material 20 and (ii) retaining a relatively large predetermined volume of water with the ballast, and (b) is intended for use on a roof that is capable of supporting the weight of both the ballast and the maximum retained water. Advantageously, the ballast module enables use of any suitable ballast material, including rocks or other decorative, preferably relatively dense, loose-fill materials.

    [0019] In general, the ballast module 18 is a rectangular module, with an open top, a closed bottom, and surrounding sidewalls 24. One preferred module presents an approximately 2 ft. x 2 ft. square footprint on the roof. This approximate size provides for ease of handling, particularly if the module is pre-filled with ballast 20 prior to installation onto the roof 14. A 2'x2' module pre-filled with ballast of approximately 11-12 lbs/sq ft. will weigh approximately 50 lbs, a weight that can be readily carried by installation workers. The sidewall structure of the modules provide lateral support for the ballast fill, to prevent shifting of the ballast in the modules, and thereby provide for ease of walking over the roof, on the loose ballast in the modules, as compared with walking on loose ballast laid directly on the roof membrane 12.

    [0020] Each module 18 shown include a floor 26, a plurality of feet 28 that support the floor in a raised position above the roof membrane 12, the sidewalls 24 that surround the floor and taper outwardly upon progressing upwardly, and an edge terminating flange 30 that surrounds the upper portion of the sidewalls. The flange (i) extends outwardly from the sidewalls and then turns downwardly in spaced relation to the upper portion of the sidewalls to establish a surrounding skirt 36, and (ii) is provided with vertically extending apertures 32 spaced along the sides of the module. The apertures 32 are sized and shaped for receiving connectors inserted therein in a downwardly direction after two modules are positioned adjacent one another, the connectors being adapted to span across and connect adjacent installed modules together. As discussed further below, the flanges also enable connection of an edge finishing system between the skirt 36 and outer sidewalls 24 of outer modules of an installed ballast system. The feet are formed as downwardly opening voids from the floor, i.e., upwardly opening cups that extend downwardly from the floor, and are approximately uniformly spaced to establish a set of interconnected water pathways below the floor and between the feet in a criss-cross or waffle-type pattern to allow multi-directional water flow on the membrane below the floor. In this way, the modules permit normal water drainage on the roof membrane to the building drainage facility 84. The downwardly extending, granular-receiving cups of the waffle-pattern floor, as well as the ribs in the sidewall, further stabilize the granular ballast in the modules for enhanced ease of walking on the ballast and across the roof. The feet are further provided with relatively flat co-planar bottoms sized to permit sufficient water flow under the module, while simultaneously providing sufficient contact surface area on the roof membrane to support the ballast without damage to the membrane from the weight of the ballast. Outer feet spaced along the edges of the module provide stable edge support of the filled module. The floor and feet cooperate to define a closed bottom through which no water is allowed to flow, and thus to retain water in the modules.

    [0021] The over-flow holes 22 are formed through the sidewalls 24 of the modules 18 at a predetermined position above the bottom of the feet to effect retention of a predetermined volume of rainfall in the modules. The position, size, and frequency of the over-flow holes establish the desired runoff control characteristics, and thus the characteristic of the smoothing of the peak load in the storm sewers. The vertical position of the over-flow holes provides the capability to retain a predetermined volume of water, up to the height of the holes. The volume of space available for water is equal to the volume of space in the module below the over-flow holes minus the volume of that space that is used by the ballast; and the volume of retained water is adjusted by adjusting either the volume of the ballast in the filled modules or the vertical position of the over-flow holes. The size and frequency of the over-flow holes, establishing the cumulative flow area of the holes, controls the rate of runoff from the modules after the water level reaches the height of the holes, up to the maximum capacity of the modules established at the top of the flanges.

    [0022] For optional extended water retention in a module 18, and to further slow evaporation of water from the module, an inorganic fibrous mat or pad 38 of highly absorbent material is provided across the floor 26, the pad being adapted to hold moisture for a longer period of time due to enhanced resistance to evaporation as compared with standing water in the module. A semi-porous ballast such as lava-rock may also be used as ballast fill for enhanced moisture retention capability in the modules. And for yet additional extended water retention capability, a layer of absorbent bentonite clay 40 may be provided below the mat 38, the bentonite clay being adapted to resist evaporation and hold water for an even longer period of time. The bentonite clay may be contained in close-woven fabric to establish a pad or pillow of clay laid in the bottom of the modules.

    [0023] One preferred module 18 is approximately 2½" deep. This preferred depth enables provision of sufficient ballast of at least 11 lbs/sq-ft to obtain the minimum required ballast for most roof membranes if the modules are filled with conventional rocks 96 of average density. Alternate depth modules will range from 2½ to 10 inches, with the deeper modules typically being used with less dense ballast and/or with additional green roof materials as discussed further below.

    [0024] To provide enhanced resistance to wind uplift, the sides of adjacent modules are connected together. Connectors are provided in the form of a quick-connect fastener such as a clip-in or push-in type fastener adapted for locking, vertical insertion into aligned apertures 32 formed in the sides of adjacent modules 18 after the modules are positioned on the roof. One preferred connector 42 shown as installed in FIG. 9A and in detail in FIG. 10 is provided with a top bar 44 that spans the horizontal space between the aligned apertures 32 in the adjacent modules and a pair of spaced legs 46 to define a generally U-shaped connector. The legs 46 are sized to extend through the apertures 32 to below the bottom of the horizontal portion 34 of the flange 30, and are provided with free ends having longitudinally spaced radially extending barbs 48 that are resiliently compressible for ease of insertion into appropriately sized apertures 32, but are resistively expandable to resist removal therefrom via contact with the bottom of the horizontal portion 34 of the flange.

    [0025] An alternate module connector 130 is shown installed in FIG. 34 and in detail in FIG. 35. Connector 130 includes a top member 132, a bottom member 134 and a set of fasteners 136. The top and bottom members are thin wall aluminum extrusions, or thick wall molded plastic members of a convenient length to span across the sides of adjacent module 18, such as 3" to ¼ the length of the module side. The top member is formed with a horizontal top portion 132A that spans across the joint between the adjacent modules, and legs 132B that extend downwardly from the sides of the top portion, and when the legs extend continuously from one end to the other, to establish a downwardly facing channel configuration. The width of the top portion 132A and the angle of the legs 132B are sized to fit snugly over the top of the adjacent module sides, and downwardly along the inside walls of the adjacent module sides. The bottom member is formed with a horizontal bottom portion 134A that spans across the bottom joint between the adjacent modules, and legs 134B that extend upwardly from the sides of the bottom portion, and when the legs extend continuously from one end to the other, to establish an upwardly facing channel configuration. The width of the bottom portion 134A and the angle of the legs 134B are sized to fit snugly around the open, lower, free-end portions of the flanges of the adjacent modules, and upwardly along the inside of the flanges to capture the free ends of the flanges together. The top member 132 is formed with vertical clearance fastener holes 132C, and the bottom member is formed with aligned threaded holes 134C. To install the connector, the top and bottom members are threaded together with the fasteners, but with the bottom member towards the lower end of the fasteners. The connector is then inserted between the adjacent modules, with the top portion aligned over the top of the flanges and the bottom portion aligned around the bottom of the flanges. The fasteners are then tightened to draw the sides of the modules snugly together. When the connector 130 is installed, as shown in FIG. 34, the threaded fasteners draw the top and bottom members snugly in position over the top and bottom of the sides and flanges of the adjacent modules, and draw the flanges of the adjacent modules together in a manner that precludes separation of the flanges such as under high wind conditions. Generally, the sides of the modules will flex sufficiently for the threaded fasteners to extend therebetween, without undue separation at a distance away from the fastener. In the event the sides of the modules are relatively stiff, the clearance holes in the top member may be used as a drill guide, to pre-drill clearance holes through the sides of the adjacent module flanges prior to installation of the connector.

    [0026] The fasteners 136 of the connector 130 shown are provided with an eyelet 136A at the upper free end. For further enhanced resistance to wind uplift, wire cables 138 are threaded between, and optionally wrapped around or otherwise connected to, the eyelets of connectors such as positioned between adjacent modules along rows or columns of modules on the roof. The cables may be anchored to the building structure such as to the roof deck or to anchors connected thereto.

    [0027] A second alternate connector 140 is shown in FIG. 36. The connector 140 includes a top member 142, the bottom member 134 described above, and threaded fasteners 144. The threaded fasteners shown are provided with conventional heads, but may be alternately provided with eyelets to enable a cable tie-down. In this instance, the top member is configured with an angle section having a horizontal leg 142A provided with fastener clearance holes 142C, and a vertical leg 142B extending upwardly from one side of the horizontal leg. The vertical leg is provided with means for attaching other structure thereto, such as the clearance holes 144B shown. This connector enables securing of structure to and above the ballast system, such as the photo-voltaic panels shown in FIGS. 37-38 and discussed below. Those skilled in the art will readily devise alternate connectors adapted for spanning across the flanges of adjacent modules, and adapted to provide locking engagement between adjacent modules as the modules are installed onto a roof. Such connectors will include additional connectors configured for vertical locking insertion into connector openings in the flanges of adjacent modules, and locking installation both above and below the flanges of adjacent panels, to draw the flanges into firm locking engagement.

    [0028] For use in geographic areas where standing water is of concern such as providing a breeding location for misquotes, the modules 18 are provided with a metal or fabric mesh screen 98 that covers the entire open top of the modules. The screens are secured in position with, for example, the connectors between adjacent modules (FIG. 9B), or with a lip extending down the skirt and/or folding around the bottom of the skirt for securing thereto, either by virtue of the self-retaining folded structure of metal screens or with clips 100 or elongated clip extrusions that slip snugly upwardly onto and secure the edges of the screens to the skirt (FIG. 9C). The screen may also be secured in position as sandwiched between two layers of ballast. As shown in FIG. 39, the screen 98A may be laid on top of ballast at a position above the vertical-position overflow holes 22 in the sidewalls, and then additional ballast laid on top of the screen. Positioning the screen above the overflow holed assures that the screen is positioned above the level of standing water, while the top layer of ballast secures the screen in position in the module without the need for bending the sides of the screen, or clips or provision of other mechanical fastening arrangement.

    [0029] An edge finishing system includes decorative, elongated terminating strips adapted to clip into position along the exposed sides of the installed modular ballast system 10. The edge finishing system enhances resistance against wind uplift by establishing a wind break between the potentially windy environment on the roof and otherwise exposed sides of outer modules of the installed ballast system. The edge finishing system also provide a completed, aesthetically appealing ballast system, concealing the outer sides of modules in those instances where such sides would otherwise be exposed to view. The edge finishing system is characterized with elongated beams (i) sized to extend along the length of the exposed side of the ballast system, spanning across adjacent modules, and extending from the flanges downwardly to the roof membrane 12 to establish the wind barrier, and (ii) provided with a connector mechanism for connecting to the flanges 30 of the outer modules after the modules have been installed into position on the roof 14.

    [0030] Four alternate edge finishing systems illustrating two installation techniques are shown in FIGS. 11-14. The edge finishing system 50 of FIG. 11 includes a hollow extruded finishing-member 52 provided with either an elongated retainer extrusion clip having the profile shown or a plurality of individual clips 54 that are spaced longitudinally along the length of the finishing-member. The finishing-member and clips are sized and configured for installation against the outer edges of the modules by (i) positioning the finishing-member proximate the outer module flanges at an angle from vertical, and (ii) pivoting the finishing-member, counter-clockwise in the view shown, to pivot the bottom of the finishing-member toward the floor of the modules while pivoting the clips upwardly from below the bottom of the skirt 36 and into position on the inside of and into resilient engagement with the inside surface of the skirt. The edge finishing system 56 of FIG. 12 includes an elongated treated wood finishing-member 58 provided with longitudinally spaced retainer clips 60 adapted for installation as described above. The edge finishing system 62 of FIG. 13 includes an extruded composite finishing-member 64 provided with (i) an integrally extruded clip 66 sized for insertion into the space between the skirt and the sidewalls of the module and (ii) an integral horizontal support extrusion 68 sized to proximately engage the sidewalls of the modules to prevent the finishing-member from being inadvertently rotated or kicked past vertical upon or after installation. The edge finishing system 70 of FIG. 14 includes a lightweight concrete edge finishing-member 72 provided with longitudinally spaced masonry ties 74 adapted to slip downwardly into position through the connector apertures 32 formed through the sides of the module. Other configured edge finishing systems with the above-disclosed characteristics will be devised by those skilled in the art in view of the disclosure hereof.

    [0031] Prior to installation of the ballast system 10, the modules 18 and ballast-fill materials 20 are selected and pre-designated to meet system weight distribution and predictable water retention characteristics. This includes determination and designation of module sizes, height(s) of over-flow holes 22, height(s) of sidewalls 24, and ballast-fill characteristics, details of which are discussed further below.

    [0032] During installation of the ballast system 10, the modules 18 are placed onto the roof membrane 12 in side-by-side, contiguous relation; they are provided with ballast material 20; and adjacent modules are connected together. The modules are either installed empty and then filled with the ballast material, or they are installed pre-filled with ballast material, either carried or dragged into position on the roof with the flange, in which case rounded outer feet assist in preventing damage to the membrane. An edge finishing system such as described above is then installed along the sides of any exposed modules.

    [0033] As previously noted, the water retention capability of the ballast system 10 is established by considering the volume of the ballast material 20 and the over-flow capacity of the modules. This enables predetermination of a predictable, constant volume water retention for an installed ballast roofing system. As also noted, the water retention capability of an installed ballast system is equal to the volume of space in the modules below the over-flow holes 22 minus the volume of that space taken by the ballast-fill material 20.

    [0034] Designation and determination of the water retention capability of a ballast system is accomplished with the following mathematical relationships:


    where:
    • subscript "i" designates individual modules 18;
    • VRW = volume of water retained in the ballast system;
    • VRWi = cumulative volume of water retained in the individual modules of the ballast system;
    • VMi = inside volume of the individual modules below the over-flow holes;
    • SDi = space-density of the ballast-fill material in the individual modules; the space-density is a unitless characteristic of the volume of air in a pile of ballast-fill material, as when piled into a module, that is available for occupancy by water;
      and


      where:
    • HRWi = height of retained water in the individual modules, as established by the height of the over-flow holes in the sidewalls of the modules;
    • Ai = the footprint area of the individual modules on the roof;
    • CFi1 = a correction factor, of value less than one, for the individual modules, to account for the fact that the "cross-sectional" area of retained water in the individual modules below the over-flow holes is not constant and not equal to the footprint area of the module, because of the tapered sidewalls and the reservoir units in the cupped feet;
      thus



    [0035] For modules having different ballast-fill materials, the same water retention volume is achieved with:


    where:
    • subscripts "1" and "2" designate first and second modules.


    [0036] And for modules having the same height over-flow holes, and the same ballast-fill material, the volume of retained water in a ballast system is determined by:


    where:
    • HRW = height of over-flow holes in modules;
    • SAR = surface area of roof membrane 12 covered by the ballast system = ∑Ai;
    • CF2 = correction factor, of value less than one, to account for the cumulative, weighted average CFi1 in the ballast system (∼∑CFi1/i) ;
    • SD = space-density of the ballast-fill material in the ballast system.


    [0037] Designation and determination of the weight of the retained water and the ballast-fill material is accomplished with the following relationships:


    where:
    • WRW = weight of water retained in ballast system;
    • WRWi = cumulative weight of water retained in the individual modules of the ballast roofing system;
    • ρw = weight density of water (conventional definition, e.g., kg/m3);


      where:
    • WB = weight of ballast-fill material in ballast roofing system;
    • WBD = weight distribution requirement of ballast on roof membrane (unit weight per unit surface area of roof membrane, e.g., 11 kg/ft2);
    • SAR = surface area of roof membrane covered by ballast system;


      where:
    • WBi = cumulative weight of ballast-fill material in the individual modules of the ballast roofing system;
    • VBi = volume of the ballast-fill material in the individual modules;
    • ρBi = weight density of ballast-fill material in the individual modules (conventional definition, e.g., kg/m3)
    • HBi = height of ballast-fill material in the individual modules
    • CFi3 = a correction factor, of value less than one, for the individual modules, to account for the fact that the "cross-sectional" area of the individual modules below the height of the top of the ballast-fill is not constant and not equal to the footprint area of the module, because of the tapered sidewalls and cupped feet
    • FDi = fill-density of ballast-fill material in the individual modules; the fill-density is a unitless characteristic of the cumulative volume of space that is occupied by individual pieces of ballast-fill material, as when piled into a module, per unit volume of the piled material; FDi = sum of the volume of individual pieces in a pile of ballast-fill material / the overall volume of the pile of ballast-fill material; FDi = 1 - SDi.


    [0038] And for a ballast system utilizing the same ballast-fill material at a constant weight distribution over the entire roof, the weight of the ballast is determined by:


    where:
    • HB = height of ballast in modules;
    • SAR = surface area of roof membrane covered by ballast system = ∑Ai;
    • CF4 = correction factor, of value less than one, to account for the cumulative, weighted average CFi3 in the ballast system (∼∑CFi3/I);
    • FD = fill-density of the ballast-fill material in the ballast system;
    • ρBi = weight density of ballast-fill material in the ballast system.


    [0039] Using conventional mathematical techniques, with the foregoing relationships, and additional relationships that result therefrom, the specific water retention capability of a ballast system 10 may be predictably pre-designated at a desired volume by providing modules 18 with over-flow holes 22 positioned to retain water to pre-determined desired height(s), or alternately, forming the over-flow holes in the modules at the height(s) required to obtain the desired water retention capability.

    [0040] One suitable method for providing a pre-designated water retention capability in accordance herewith includes:
    1. 1) selecting the ballast-fill material(s),
    2. 2) determining the space-density of the ballast-fill material(s),
    3. 3) determining the module-specific correction factor(s) (CFi1 and/or CFi2) for the module type(s) and size(s) to be used, and the surface area of the roof to be covered,
    4. 4) determining the height(s) of water retention to obtain the desired water retention capability, and
    5. 5) providing modules with over-flow holes positioned to retain water to the pre-determined height(s), or alternately, forming the over-flow holes in the modules at the height(s) required to obtain the desired water retention capability.


    [0041] The water retention capability of an installed ballast system may be predictably calculated by determining and multiplying:
    1. 1) the space-density of the ballast-fill material(s) in the ballast system,
    2. 2) the height(s) of the over-flow holes in the modules,
    3. 3) the footprint area of the modules, and
    4. 4) the associated module-specific correction factor(s).


    [0042] The maximum water retention capability of a specific roof may be determined by subtracting the weight of the required (or designated) ballast from the weight-carrying capability of the roof.

    [0043] The module height(s) required to obtain the desired ballast distribution on the roof is predetermined by:
    1. 1) selecting the ballast-fill material(s),
    2. 2) determining the fill-density of the ballast-fill material(s),
    3. 3) determining the module-specific correction factor(s) (CFi3 and/or CFi4) for the module type(s) and size(s) to be used, and the surface area of the roof to be covered,
    4. 4) determining the minimum height(s) of ballast-fill to obtain the desired ballast distribution on the roof, and
    5. 5) providing modules with sidewalls having height(s) sufficient to retain the pre-determined ballast height(s).


    [0044] The ballast on an installed roof may be calculated with:
    1. 1) the fill-density of the ballast-fill material(s) in the ballast system,
    2. 2) the weight-density of the ballast-fill material(s) in the ballast system,
    3. 3) the height(s) of the ballast in the modules,
    4. 4) the footprint area of the modules, and
    5. 5) the associated module-specific correction factor(s).


    [0045] The above-described techniques are intended as illustrative, but not exhaustive, of the techniques available for use in connection with predictably designating, determining, predetermining and/or pre-designating ballast-distribution and water retention characteristics of a modular ballast system 10 in accordance with the invention. The particular order of executing the above-described steps may be altered to obtain desired ballast system characteristics, and will be, in certain instances, be an iterative process for the system designer. The above relationships may also be used in alternate forms, and with alternate techniques to obtain desired ballast system weight distribution and water retention characteristics.

    [0046] As also previously noted, the flow area of the over-flow holes 22 establishes the rate at which water exits the modules 18 after the water reaches the height of these holes. With conventional mass-flow continuity relationships, the dynamic performance of the ballast system 10 may be predictably designated prior to installation to meet additional desired water run-off characteristics in the event that rainfall exceeds the steady state water retention capability of the ballast system. Accordingly, designation of the dynamic water run-off characteristics of the ballast roofing system is accomplished with the following mathematical relationships:


    where
    • dMRF/dt = mass flow rate of rainfall into a module
    • dMWR/dt = mass flow rate out of module
    • dMRW/dt = rate of change in mass of water retained in module


      where:
    • dVWR/dt = volumetric flow rate of water runoff out of module, through over-flow holes
    • AF = flow area of over-flow holes
    • f(AF) = function including AF
    • K = a proportionality constant


    [0047] In other words, the volumetric flow rate of water runoff through over-flow holes 22 is a function of the flow area of the over-flow holes, and in a linear model, the derivative is generally proportional to the flow area of the over-flow holes. Consequently, pre-designation or pre-determination of the dynamic over-flow characteristics of the ballast system 10 includes the additional step of calculating and/or pre-designating the cumulative over-flow hole area to meet the desired dynamic characteristics such as rate of runoff and maximum transient additional weight of retained water in modules. With the above and other characteristics of the ballast system, the skilled artisan will be able to further determine the smoothing of peak load of storm sewers during rainfall.

    [0048] Reduced-size modules 116 (FIG. 26) may be produced during installation of a ballast roofing system by cutting a module 18 through the strip of the floor such as at 118 between adjacent rows of feet to obtain first and second module-portions 112 and 114, respectively, and positioning the open end of the first module-portion into the open end of the second module-portion to produce a smaller module with a reduced space surrounded by the uncut end walls and the nested sidewalls. The reduced-size module is then used as other modules, installed into the ballast roofing system, connected to adjacent modules, filled with ballast materials, and provided with an edge finishing system as desired. The weight of the ballast materials in the reduced-size module and connection to adjacent modules maintains the two cut module-portions together. In the production of reduced-size modules, the overlapping flanges of one of the cut module-portions may be optionally cut away such as shown in FIG. 27 and/or the flange of the upper module-portion may be expanded outwardly over the flange of the lower modular portion as shown in FIG. 28.

    [0049] A ballast system in accordance with the invention is further uniquely adapted to serve as a roof-top mounting platform and anchoring system for a roof-top energy production system. In particular, the modular construction of the ballast system provides a mounting-adaptive structure, and the ballast provides anchoring of the structure and an energy production system connected thereto on the roof.

    [0050] In the embodiment shown in FIGS. 16-23, ballast modules 18 are adapted for use with photo-voltaic panels 76 that are electrically connected to a power utilization device, a power conversion device, or a power storage device such as a battery to produce a combination ballast and electrical generating system on the roof of a building. The modules are provided with base support such as shown in the drawings as corner braces 78, a pair of front supports 80 carried in the front corner braces, and a pair of back supports 82, carried in the back corner braces. The front supports pivotally carry the base of the photo-voltaic panel, while the back supports engage and support the top of the photo-voltaic panel. The back supports are adjustable in length to support the panel at a desired angle, to achieve a desired exposure to the sun, during installation of the ballast system. The corner braces are connected to the flanges 30 of the module 18 such as with fasteners 86 (FIG. 18), and are provided with mounting structure such as holes 88 for receiving and supporting base posts of the front and back supports. These or alternate support brackets may be integrally adhered to or molded in the module, and the ballast modules may carry alternate energy production such as small windmills connected to electrical generating devices, or solar energy absorption panels connected to energy storage or conversion devices. Additional grid-structure support braces may also be located between the roof membrane and the underside of the flange to provide additional support to the flange and equipment mounted thereon.

    [0051] The cost of photo-voltaic panels is relatively high. Therefore, in certain instances, it may be desirable that photo-voltaic panels are installed on less than all of the modules of the ballast system. In such installations, the remainder of the ballast modules are provided with light-colored reflective covers adapted to reflect sunlight impinging thereon onto a photo-voltaic panel proximate thereto (FIG. 23).

    [0052] The reflective covers are generally planar, sheet metal covers that slip over the entire open tops of the modules, are louvered or perforated to reflect and redirect the sunlight as desired while enabling rain-fall to enter the modules and permitting evaporation therethrough. The covers are secured in position on the modules such as with connectors 42 connecting the adjacent modules, or with a clip adapted to slip smugly around the bottom of the skirt.

    [0053] The covers 102 shown are made from thin reflective aluminum, and are provided to the roof site in the form of flat panels 104 (FIG. 20). The panels 104 are provided openings for further control of the evaporation rate from the modules, such as with fixed, slatted louvers 103 (FIG. 20A) or perforations 105 (FIG. 20B). The panels 104 are formed with a square center 106 sized to cover the open top of the modules 18, and with four rectangular panels 108 extending outwardly from each side of the center portion. Each extension 108 is provided with at least two and preferably three reduced-thickness score-lines (shown in dashed lines) that extend along the length thereof. For installation onto the module 18 as shown in FIG. 21, the cover is positioned onto the top of the module, each extension is first folded along score-line 110a around the top outer edge of the flange, and is then folded along the score-line(s) 110b and/or 110c (depending on the wall thickness of the skirt) around the bottom of the skirt with the free end of the extension into position between the skirt and the sidewall of the module.

    [0054] Provision of flat reflective panels 104 as described enables their use on modules of more than one size. For example, if the reflective panels are provided with 2'x2' square centers, they may be used to cover both 2'x2' modules and 2'x4' modules by folding extensions of adjacent reflective covers as shown in FIG. 22, and thereby establishing a 2'x4' ) center portion in the combined panel. The covers may be provided on the modules either with or without the covering screens 98 discussed above.

    [0055] The light reflective nature of the covers 102 is further advantageous because this characteristic assists in reducing the temperature of the roof surface, during summer months, as compared with the roof temperature associated with exposed dark materials such as from colored rocks in the modules. In particular, providing a light-colored reflective covering can reduce the temperature at the roof surface by up to 10 to 13 degrees Fahrenheit. Thus the light reflective covers 102 further reduce the air conditioning requirements of the top floor of the building.

    [0056] Accordingly, in still another alternate embodiment, all of the ballast modules on the roof are provided with the light reflective covers 102 to further reduce the temperature at the roof surface.

    [0057] In an alternate embodiment shown in FIGS. 37-38, photo-voltaic panels 76 are pivotally anchored to connectors 140 that are installed securing adjacent modules 18 together. The panels are positioned in the center portion of the modules to extend to a position above that module and the adjacent module. As shown in FIG. 38, this arrangement permits the panels to "catch" rainfall that might otherwise fall and drain between the modules, and direct such additional rainfall into the modules. As a result, positioning of the photo-voltaic panels further assists in diverting rainfall into the modules and thereby controlling runoff from the building.

    [0058] As noted above, green roof systems provide limited and unpredictable water retention capability. The ballast modules of the present invention may be used in a green roof system to enhance its water retention capability. The ballast modules may be used in a modular green roof system either in place of a number of green roof modules, or with both loose fill ballast up to approximately the overflow holes, and green roof materials including a root-barrier mat 90, growing medium 92 and live green roof plants 94 on top of the ballast and generally above the over-flow holes 22 as shown in FIG. 15. The modules may also be used in a non-modular green roof system with the modules surrounded by an appropriate edge finishing system as described above.

    [0059] In additional alternate embodiments in which long-term standing water is of concern, and in which maximum of predictable runoff characteristics are desired, there is provided a ballast system comprising ballast modules that utilize water out-flow control characteristics established as discussed above during times of heavy rainfall, and that further provides for continued predictable, controlled seepage from the modules after the rainfall has ceased, to achieve a desired rate of water runoff from the roof thereafter.

    [0060] In one alternate embodiment adapted for continued seepage, the ballast system is provided with wicking materials for predictable discharge of initially retained water from the modules over a shorter period of time as compared to the time required for unassisted evaporation.

    [0061] Referring to FIGS. 30-31, there is shown components of an alternate ballast system comprising modules provided with water discharge wicking materials in the form of an absorbent wicking pad 120 laid in the bottom of a module, and wicking rope 122 extending from the wicking pad through the water over-flow holes 22 and onto the roofing membrane. An alternate wicking arrangement shown in FIG. 30 comprises lengths of wicking rope laid in the bottom of the module and extending through the water over-flow holes 22 and onto the roofing membrane. In both instances, the wicking materials are designated to establish a controlled continued discharge of water from the modules after the rainfall has stopped, by wicking water from the pad and/or rope in the modules through the overflow holes and onto the roofing membrane, according to schedule that establishes a desired rate of water runoff from the roof.

    [0062] Determination of water retention capabilities and characteristics of a ballast system with outflow wicking materials (e.g., pad 120 and rope 122) proceeds as generally as discussed above with regard to water retention characteristics, but further considers the physical and operational characteristics of the wicking materials extending through the outflow holes. In particular, sizing of the modules, overflow holes, and other module outflow characteristics will consider the presence of the wicking materials in the modules and extending through the overflow holes, including the continuous wicking effect and the effect on the flow area of the overflow holes. Determination of dynamic water run-off characteristics for the roof with ballast system outflow wicking materials will consider the dynamic water flow wicking characteristics of such materials. In particular, the module characteristics and wicking materials are designated to simultaneously meet the desired water retention characteristics, and to smooth the rate of water runoff both during and after a rainfall, thus reducing peak water runoff rates, and extending the runoff at a reduced rate for a longer period of time.

    [0063] Referring to FIG. 32, there is shown a module 18A of another alternate ballast system configured for continued water seepage after the rainfall has stopped. In this instance, ) relatively small drainage or seepage holes 124 are provided in the raised floor 26 of the modules for controlled continued discharge of water after the rainfall has stopped. As with the wicking materials discussed above, the seepage holes are sized to achieve a desired continued outflow rate from the modules, so as to establish the desired water runoff schedule from the roof after the rainfall has stopped. In particular, the ballast module characteristics are established generally as discussed above to achieve a short-term water retention characteristic, but with the seepage holes being sized for dynamic flow characteristics both during and after a heavy rainfall to slowly discharge the initially retained water from the modules.

    [0064] By way of example, a ballast system provided with continued outflow wicking materials or seepage holes can be designed to retain a minimum of one inch of water during a heavy one hour rainfall, to smooth the peak rate of water runoff from the roof, and to then slowly discharge the initially retained over a designated longer period of time. Accordingly, the invention includes methods of providing and designating such ballast systems.

    [0065] Referring to FIG. 33, there is shown in curve "A" a graphical representation of a rainfall verses time. In curve "B" there is shown representation of a module outflow/roof runoff curve (verses time) for a ballast module provided with outflow holes 22. In this instance, runoff does not begin until the modules are filled to capacity (i.e., to the overflow holes), the peak runoff is reduced substantially as compared to the peak rainfall, and it occurs at approximately the point the rainfall ceases. Thereafter, the runoff ceases when the retained water in the modules lowers to its capacity at the height of the overflow holes. Curve "C" represents the roof runoff from a module provided with wicking or other residual controlled outflow characteristics (see FIGS. 29-32). In this instance, the runoff begins shortly after the rainfall begins, and continues at a relatively small rate until the retained water capacity of the module is reached, whereupon water flows directly out the overflow holes. As shown, the peak outflow drops after the rainfall stops to the seepage rate from the module, which continues for an extended period of time until the modules are substantially drained. The curve "D" represents zero outflow when the retained water capacity of a module, without residual runoff, is not reached. These curves represent a sampling of the possible controlled water runoff characteristics from a roof that is possible with a modular ballast system hereof; other characteristic runoff curves will be represented in embodiments designated in accordance herewith, and under different rainfall conditions.

    [0066] From the foregoing, it will be apparent that the present invention brings to the art a unique ballast system for roofing membranes of the type used on industrial and commercial buildings.

    [0067] By virtue of its modular construction the modular ballast system provides for ease of maintenance and repair of the roof membrane. The contained loose ballast material does not subject the roof membrane to wear such as from walking on or shifting of the ballast from windy conditions on the roof. The sidewall structure waffle-floor configuration of the modules provides ease of walking directly on ballast. Only the necessary modules need to be removed for repair to the roofing membrane in specific locations. And removal and reinstallation of the entire ballast system, by simply disconnecting and removing the filled modules, is much easier as compared with prior loose-fill ballast systems.

    [0068] The modular ballast system in accordance with the invention also predictably reduces water runoff from a building, by retaining a predetermined volume of water on the roof, and thus controls the rate of runoff thereafter up to a maximum volume capacity and rate of rainfall. This predictable water retention capability predictably eases peak load of storm sewers around building. The drain holes in the sides of the modules are positioned to meet minimum water retention requirements, and are sized to meet rate of runoff requirements thereafter. Consequently, the runoff from a particular roof is adjusted by adjusting the size, frequency and position of the drain holes in the sides of the modules. The modular ballast system also provides enhanced water runoff control from a building as compared with prior ballast systems and green roof systems, both during and optionally after a rainfall.

    [0069] Additional advantages and unique characteristics of the modular ballast system of the invention include: Evaporation of retained water from the modular ballast system cools the air above building, reducing urban heat island problem in large, crowded cities. The modular ballast system enables ease of predictable, predetermination of maximum ballast and water weight conditions on the roof. For a particular module size, with holes at an established height, the modular ballast system enables regulation of the ballast weight by the type of ballast selected. The modular ballast system permits use of many desired fill materials, including decorative rocks and other objects that may have relatively sharp corners so as to be unsuitable for use in a conventional loose-laid ballast system, but that are less expensive than round river rocks. The modular ballast system enables use of alternate textures, colors and loose-fill ballast materials for decorative effect; this is not conveniently possible on roofs with conventional loose-fill ballast material over entire membrane. The modular ballast system provides even distribution of weight over membrane, and prevents shifting of loose-fill ballast from changing wind conditions, good unidirectional water flow across membrane. The modular system provides enhanced resistance to wind uplift via connection of modules together and connection of an edge finishing system. The resistant to wind uplift is further enhanced with provision cable tie-down between the modules. The ballast modules may be alternately used in a modular green roof system, preferably provided with compatible modules, such as disclosed in U.S. Patent Application No.s 09/908,864, 09/908,880 and 09/908,881, for enhanced water retention capability. And the modular ballast system provides a mounting platform and anchoring system to establish a roof-top energy production system.


    Claims

    1. A modular ballast system (10) for roofs (14) comprising:

    a plurality of rectangular modules (18) connected in contiguous relation on the roof (14), the modules (18)_having an open top and a closed bottom, each module being established with a floor (26) configured for resting on the roof (14) and for allowing multi-directional water flow thereunder and therebetween, and sidewalls (24) extending upwardly from the bottom, the sidewalls (24) having over-flow holes (22) formed therethrough at a predetermined height above the bottom for retaining a predetermined volume of water therein and including flanges (30) each with a horizontal portion and a downwardly depending skirt (36); and

    substantially non-absorbent loose-fill ballast materials (20) in the modules (18);

    characterized in that the system further comprises connectors (132, 134, 136) having a top member (132) spanning across the sides of adjacent modules (18), a lower upwardly facing channel member (134) sized to the surround the skirt (36) of adjacent modules (18), and threaded fasteners (136), the top member (132) being configured as a downwardly facing channel sized to snugly engage the inside walls of the adjacent modules (18), the fasteners (136) drawing the top member (132) and the lower channel (134) into snug engagement against the skirts (36) of adjacent modules (18), the fasteners (136) including eyelets (136A) at the upper ends thereof;

    and in that the system further comprises cables (138) threaded through the eyelets (136A) and anchored to eyelets (136A) of adjacent modules (18) or an anchor connected to the roof (14).


     
    2. The modular ballast system as defined in claim 1 in which the connectors (132, 134, 136) secured to the ballast-weighted modules (18) establish a roof top mounting platform for mounting alternate energy collection apparatus (76) above the roof (14), wherein the alternate energy collection apparatus (76) includes photo-voltaic panels secured to the ballast-weighted modules (18).
     
    3. The modular ballast system as defined in claim 2 in which the photo-voltaic panels (76) are configured for positioning above the junction between adjacent modules (18).
     
    4. The modular ballast system as defined in claims 1 or 2 further comprising sunlight reflective covers (102) secured over open top of modules (18) to assist in cooling the roof (14).
     
    5. The modular ballast system as defined in any one of claim 1 to 4 in which the connectors (132, 134, 136) establish an anchoring platform for connection of articles above the ballast-weighted modules (18), the articles being secured to the connectors (132, 134, 136).
     
    6. The modular ballast system as defined in any one of claims 1 to 5 further comprising edge finishing having elongated edge termination members (50) extending from the sidewalls (24) of the modules (18) to the roof (14), and clip means (54, 60, 66) connecting the edge termination members(50) to the outer sidewalls (24) of the modules (18), said clip means (54, 60, 66) including an upwardly extending clip to engage between the skirt (36) and the sidewall (24) of the module (18).
     
    7. The modular ballast system as defined in any one of claims 1 to 5 further comprising an absorbent layer in bottom of the module (18), the absorbent layer comprising one of a fibrous mat or absorbent clay wherein the absorbent clay is enclosed in cloth to establish an absorbent pad (38).
     
    8. The modular ballast system as defined in any one of claims 1 to 7 in which the modules (18) are configured for a continuous controlled outflow of water so long as water is present in the module, each module (18) further comprising wicking (122) extending from the bottom out the over-flow holes (22) to achieve the continuous controlled outflow of water.
     
    9. The modular ballast system as defined in any one of claims 1 to7 in which the modules (18) are configured for a continuous controlled outflow of water so long as water is present in the module (18), wherein the floor (26) of the module (18) is formed with small holes sized to achieve a predetermined dynamic continuous outflow characteristic.
     
    10. The modular ballast system as defined in any one of claims 1 to 9 further comprising a bug screen (98) secured over the open top of the modules (18), at a height above the over-flow holes (22), and wherein the bug screen is connected to the sidewalls of the modules.
     
    11. The modular ballast system as defined in any one of claims 1 to 9 further comprising a bug screen (98) secured over the open top of the modules (18), at a height above the over-flow holes (22), and wherein the bug screen (98) is sandwiched in loose ballast (20) in the modules (18).
     
    12. The modular ballast system as defined in any one of claims 1 to 11 in which the floor (26) is configured in waffle pattern with upwardly opening cups to receive and assist in stabilizing the loose ballast (20) in the modules (18).
     
    13. A weighted modular system for positioning on roofs (14) comprising a modular ballast system as defined in any one of claim 1 to 12.
     
    14. A method for establishing a modular ballast system for roofs (14) comprising the steps of:

    a) providing a plurality of rectangular modules (18) each having an open top and a closed bottom, each module (18) being established with a floor (26) configured for resting on the roof (14) and for allowing multi-directional water flow thereunder and therebetween, and sidewalls (24) extending upwardly from the bottom, the sidewalls (24) including flanges (30) each with a horizontal portion and a downwardly depending skirt (36),

    b) installing the modules (18) in contiguous relation on the roof (14);

    c) one of

    i) filling the modules (14) to a predetermined level with substantially non-absorbent loose ballast fill (20), and cooperatively determining (a) the volume of the ballast fill materials (20) in the modules (18), and (b) the height of over-flow holes (22) in the sidewalls (24) to achieve predetermined water retention and out-flow characteristics for the modules (18); and

    ii) determining the water retention and out-flow characteristics of the modules (18) by determining the space density of the ballast (20), the flow characteristics of over-flow holes (22) in the sidewalls (24) of the modules (18), and the footprint area of the modules (18); wherein determining the water retention and out-flow characteristics of the modules (18) includes determining both steady state and dynamic characteristics thereof; and then filling the modules (18) with substantially non-absorbent loose ballast (20) to establish the determined water retention characteristics;

    d) connecting adjacent modules (18) using connectors (132, 134, 136) having a top member (132), a lower upwardly facing channel member (134) and a threaded fasterner (136) for drawing the top member (132) and lower member (134) into snug engagement against the skirts (36) of adjacent flanges (30); and

    e) threading cables (138) through eyelets (136A) formed in the connectors (132, 134, 136) to anchor each module (18) to one of an adjacent module (18) and an anchor connected to the roof (14).


     


    Ansprüche

    1. Modulares Ballastsystem (10) für Dächer (14), umfassend :

    mehrere rechteckige Module (18), die in einem angrenzenden Verhältnis auf dem Dach (14) verbunden sind, wobei die Module (18) eine offene Oberseite und eine geschlossene Unterseite haben, wobei jedes Modul mit einem Boden (26) errichtet ist, der so gestaltet ist, dass er auf dem Dach (14) liegt und einen Wasserstrom darunter und dazwischen in mehrere Richtungen ermöglicht, sowie mit Seitenwänden (24), die sich von der Unterseite aus nach oben erstrecken, wobei die Seitenwände (24) Überlauflöcher (22) aufweisen, die durch sie hindurch in einer vorbestimmten Höhe über der Unterseite gebildet sind, um ein vorbestimmtes Wasservolumen darin aufzunehmen, und Flansche (30) jeweils mit einem horizontalen Abschnitt und einer nach unten hängenden Schürze (36) enthalten; und

    im Wesentlichen nicht absorbierende, lose gefüllte Ballastmaterialien (20) in den Modulen (18);

    dadurch gekennzeichnet, dass das System des Weiteren Verbindungselemente (132, 134, 136) umfasst, die ein oberes Element (132), das die Seiten von benachbarten Modulen (18) überspannt, ein unteres, nach oben weisendes Kanalelement (134), das so bemessen ist, dass es die Schürze (36) benachbarter Module (18) umgibt, und gewindeförmige Befestigungsmittel (136) aufweisen, wobei das obere Element (132) als ein nach unten weisender Kanal gestaltet ist, der so dimensioniert ist, dass er die Innenwände der benachbarten Module (18) miteinander in Eingriff bringt, wobei die Befestigungselemente (136) das obere Element (132) und den unteren Kanal (134) in einen festen Eingriff gegen die Schürzen (36) der benachbarten Module (18) ziehen, wobei die Befestigungselemente (136) Ösen (136A) an ihren oberen Enden enthalten;

    und dass das System des Weiteren Kabel (138) umfasst, die durch die Ösen (136A) gefädelt sind und an Ösen (136A) benachbarter Module (18) oder einem mit dem Dach (14) verbundenen Anker verankert sind.


     
    2. Modulares Ballastsystem nach Anspruch 1, wobei die Verbindungselemente (132, 134, 136), die an den ballastbeschwerten Modulen (18) angebracht sind, eine Dachmontageplattform zur Montage einer Alternativenergiesammelvorrichtung (76) über dem Dach (14) errichten, wobei die Alternativenergiesammelvorrichtung (76) Photovoltaikpaneele enthält, die an den ballastbeschwerten Modulen (18) angebracht sind.
     
    3. Modulares Ballastsystem nach Anspruch 2, wobei die Photovoltaikpaneele (76) zur Positionierung über der Verbindung zwischen benachbarten Modulen (18) gestaltet sind.
     
    4. Modulares Ballastsystem nach Anspruch 1 oder 2, des Weiteren umfassend Sonnenlicht reflektierende Abdeckungen (102), die über der offenen Oberseite von Modulen (18) befestigt sind, um eine Kühlung des Dachs (14) zu unterstützen.
     
    5. Modulares Ballastsystem nach einem der Ansprüche 1 bis 4, wobei die Verbindungselemente (132, 134, 136) eine Verankerungsplattform zur Verbindung von Artikeln über den ballastbeschwerten Modulen (18) errichten, wobei die Artikel an den Verbindungselementen (132, 134, 136) befestigt sind.
     
    6. Modulares Ballastsystem nach einem der Ansprüche 1 bis 5, des Weiteren umfassend eine Kantenendbearbeitung mit länglichen Randabschlusselementen (50), die sich von den Seitenwänden (24) der Module (18) zum Dach (14) erstrecken, und Klemmelementen (54, 60, 66), die die Randabschlusselemente (50) mit den äußeren Seitenwänden (24) der Module (18) verbinden, wobei die Klemmelemente (54, 60, 66) eine sich nach oben erstreckende Klemme für einen Eingriff zwischen der Schürze (36) und der Seitenwand (24) des Moduls (18) enthalten.
     
    7. Modulares Ballastsystem nach einem der Ansprüche 1 bis 5, des Weiteren umfassend eine absorbierende Schicht in der Unterseite des Moduls (18), wobei die absorbierende Schicht eines von einer Fasermatte oder einem absorbierenden Ton umfasst, wobei der absorbierende Ton in Tuch eingeschlagen ist, um ein absorbierendes Kissen (38) zu erhalten.
     
    8. Modulares Ballastsystem nach einem der Ansprüche 1 bis 7, wobei die Module (18) für einen kontinuierlichen, kontrollierten Abfluss von Wasser gestaltet sind, solange Wasser im Modul vorhanden ist, wobei jedes Modul (18) des Weiteren ein Dochtmaterial (122) umfasst, das sich von der Unterseite aus den Überlauflöchern (22) erstreckt, um den kontinuierlichen, kontrollierten Abfluss von Wasser zu erreichen.
     
    9. Modulares Ballastsystem nach einem der Ansprüche 1 bis 7, wobei die Module (18) für einen kontinuierlichen, kontrollierten Abfluss von Wasser gestaltet sind, solange Wasser im Modul vorhanden ist, wobei der Boden (26) des Moduls (18) mit kleinen Löchern gebildet ist, die so dimensioniert sind, dass eine vorbestimmte dynamische, kontinuierliche Abflusseigenschaft erreicht wird.
     
    10. Modulares Ballastsystem nach einem der Ansprüche 1 bis 9, des Weiteren umfassend ein Insektenschutzgitter (98), das über der offenen Oberseite der Module (18) in einer Höhe über den Überlauflöchern (22) befestigt ist, und wobei das Insektenschutzgitter mit den Seitenwänden der Module verbunden ist.
     
    11. Modulares Ballastsystem nach einem der Ansprüche 1 bis 9, des Weiteren umfassend ein Insektenschutzgitter (98), das über der offenen Oberseite der Module (18) in einer Höhe über den Überlauflöchern (22) befestigt ist, und wobei das Insektenschutzgitter in losen Ballast (20) in den Modulen (18) eingelegt ist.
     
    12. Modulares Ballastsystem nach einem der Ansprüche 1 bis 11, wobei der Boden (26) in einem Waffelmuster mit nach oben offenen Bechern zur Aufnahme und Unterstützung in der Stabilisierung des losen Ballasts (20) in den Modulen (18) gestaltet ist.
     
    13. Beschwertes modulares System zum Positionieren auf Dächern (14), umfassend ein modulares Ballastsystem wie in einem der Ansprüche 1 bis 12 definiert.
     
    14. Verfahren zum Errichten eines modularen Ballastsystems für Dächer (14), umfassend die folgenden Schritte :

    a) Bereitstellen mehrerer rechteckiger Module (18) mit einer offenen Oberseite und einem geschlossenen Boden, wobei jedes Modul (18) mit einem Boden (26) errichtet ist, der so gestaltet ist, dass er auf dem Dach (14) liegt und einen Wasserstrom darunter und dazwischen in mehrere Richtungen ermöglicht, sowie mit Seitenwänden (24), die sich von der Unterseite aus nach oben erstrecken, wobei die Seitenwände (24) Flansche (30) jeweils mit einem horizontalen Abschnitt und einer nach unten hängenden Schürze (36) enthalten;

    b) Installieren der Module (18) in einem angrenzenden Verhältnis auf dem Dach (14);

    c) eines von

    i) Füllen der Module (18) auf ein vorbestimmtes Niveau mit im Wesentlichen nicht absorbierender, loser Ballastfüllung (20) und gemeinsam Bestimmen (a) des Volumens des Ballastfüllmaterials (20) in den Modulen (18) und (b) der Höhe von Überlauflöchern (22) in den Seitenwänden (24), um vorbestimmte Wasserrückhalte- und Abflusseigenschaften für die Module (18) zu erreichen; und

    ii) Bestimmen der Wasserrückhalte- und Abflusseigenschaften der Module (18) durch Bestimmen der Raumdichte des Ballastes (20), der Strömungseigenschaften der Überlauflöcher (22) in den Seitenwänden (24) der Module (18) und der Fußabdruckfläche der Module (18); wobei das Bestimmen der Wasserrückhalte- und Abflusseigenschaften der Module (18) das Bestimmen sowohl ihrer Beharrungszustands- wie auch dynamischen Eigenschaften enthält; und dann Füllen der Module (18) mit im Wesentlichen nicht absorbierendem losen Ballast (20), um die bestimmten Wasserrückhalteeigenschaften zu erreichen;

    d) Verbinden benachbarter Module (18) mit Verbindungselementen (132, 134, 136), die ein oberes Element (132), ein unteres, nach oben weisendes Kanalelement (134) und ein gewindeförmiges Befestigungselement (136), das das obere Element (134) und untere Element (134) in festen Eingriff gegen die Schürzen (36) benachbarter Flansche (30) zieht, aufweisen; und

    e) Einfädeln von Kabeln (138) durch Ösen (136A), die in den Verbindungselementen (132, 134, 136) gebildet sind, um jedes Modul (18) mit einem benachbarten Modul (18) und einem Anker, der mit dem Dach (14) verbunden ist, zu verankern.


     


    Revendications

    1. Système modulaire de lest (10) pour toitures (14) comprenant :

    une pluralité de modules rectangulaires (18) connectés en relation contiguë sur la toiture (14), les modules (18) ayant un dessus ouvert et un dessous fermé, chaque module étant établi avec un plancher (26) configuré pour reposer sur la toiture (14) et pour permettre un flux d'eau multi-directionnel en dessous de celui-ci et entre eux, et des parois latérales (24) s'étendant vers le haut à partir du dessous, les parois latérales (24) ayant des trous de débordement (22) formés à travers celles-ci à une hauteur prédéterminée au-dessus du dessous pour retenir un volume prédéterminé d'eau à l'intérieur et comprenant des brides (30) ayant chacune une partie horizontale et une jupe (36) pendant vers le bas ; et

    des matériaux de lestage (20) en vrac pratiquement non absorbants dans les modules (18) ;

    caractérisé en ce que le système comprend en outre des connecteurs (132, 134, 136) ayant un élément supérieur (132) enjambant les côtés de modules (18) adjacents, un élément de canal inférieur (134) orienté vers le haut, dimensionné pour entourer la jupe (36) de modules (18) adjacents, et des éléments de fixation filetés (136), l'élément supérieur (132) étant configuré comme un canal orienté vers le bas dimensionné pour s'accoupler intimement avec les parois intérieures de modules (18) adjacents, les éléments de fixation (136) tirant l'élément supérieur (132) et le canal inférieur (134) en accouplement intime contre les jupes (36) de modules (18) adjacents, les éléments de fixation (136) comprenant des oeillets (136A) à leur extrémité supérieure ;

    et en ce que le système comprend en outre des câbles (138) enfilés dans les oeillets (136A) et ancrés aux oeillets (136A) de modules (18) adjacents ou à une ancre connectée à la toiture (14).


     
    2. Système modulaire de lest tel que défini dans la revendication 1 dans lequel les connecteurs (132, 134, 136) fixés aux modules (18) chargés de lest établissent une plate-forme de montage de dessus de toiture pour monter un appareil de captage d'énergie alternative (76) au-dessus de la toiture (14), dans lequel l'appareil de collecte d'énergie alternative (76) comprend des panneaux photovoltaïques fixés aux modules (18) chargés de lest.
     
    3. Système modulaire de lest tel que défini dans la revendication 2 dans lequel les panneaux photovoltaïques (76) sont configurés pour être positionnés au-dessus de la jonction entre modules (18) adjacents.
     
    4. Système modulaire de lest tel que défini dans les revendications 1 ou 2 comprenant en outre des couvertures (102) réfléchissant la lumière solaire, fixées sur les dessus ouverts de modules (18) pour aider à refroidir la toiture (14).
     
    5. Système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 4 dans lequel les connecteurs (132, 134, 136) établissent une plate-forme d'ancrage pour la connexion d'articles au-dessus des modules (18) chargés de lest, les articles étant fixés aux connecteurs (132, 134, 136).
     
    6. Système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 5 comprenant en outre une finition de bord ayant des éléments de terminaison de bord (50) allongés s'étendant des parois latérales (24) des modules (18) jusqu'à la toiture (14), et des moyens d'attache (54, 60, 66) connectant les éléments de terminaison de bord (50) aux parois latérales extérieures (24) des modules (18), lesdits moyens d'attache (54, 60, 66) comprenant une attache s'étendant vers le haut pour s'engager entre la jupe (36) et la paroi latérale (24) du module (18).
     
    7. Système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 5 comprenant en outre une couche absorbante au fond du module (18), la couche absorbante comprenant un d'un tapis fibreux ou d'une argile absorbante, l'argile absorbante étant enfermée dans du tissu pour établir un matelas absorbant (38).
     
    8. Système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 7 dans lequel les modules (18) sont configurés pour un écoulement continu contrôlé d'eau tant que de l'eau est présente dans le module, chaque module (18) comprenant en outre un matériau à effet de mèche (122) s'étendant à partir du dessous et sortant par les trous de débordement (22) pour obtenir l'écoulement continu contrôlé d'eau.
     
    9. Système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 7 dans lequel les modules (18) sont configurés pour un écoulement continu contrôlé d'eau tant que de l'eau est présente dans le module, dans lequel le plancher (26) du module (18) est formé avec de petits trous dimensionnés pour obtenir une caractéristique prédéterminée d'écoulement dynamique continu.
     
    10. Système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 9 comprenant en outre un pare-insectes (98) fixé sur le dessus ouvert des modules (18), à une hauteur au-dessus des trous de débordement (22), et dans lequel le pare-insectes est connecté aux parois latérales des modules.
     
    11. Système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 9 comprenant en outre un pare-insectes (98) fixé sur le dessus ouvert des modules (18), à une hauteur au-dessus des trous de débordement (22), et dans lequel le pare-insectes (98) est pris en sandwich dans le lest (20) en vrac dans les modules (18).
     
    12. Système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 11 dans lequel le plancher (26) est configuré selon un motif gaufré avec des cuvettes s'ouvrant vers le haut pour recevoir et aider à stabiliser le lest (20) en vrac dans les modules (18).
     
    13. Système modulaire chargé à positionner sur des toitures (14) comprenant un système modulaire de lest tel que défini dans l'une quelconque des revendications 1 à 12.
     
    14. Procédé pour établir un système modulaire de lest pour toitures (14) comprenant les étapes consistant à :

    a) prévoir une pluralité de modules (18) rectangulaires, chacun ayant un dessus ouvert et un dessous fermé, chaque module (18) étant établi avec un plancher (26) configuré pour reposer sur la toiture (14) et pour permettre un flux d'eau multi-directionnel en dessous de celui-ci et entre eux, et des parois latérales (24) s'étendant vers le haut à partir du dessous, les parois latérales (24) comprenant des brides (30) ayant chacune une partie horizontale et une jupe (36) pendant vers le bas,

    b) installer les modules (18) en relation contiguë sur la toiture (14) ;

    c) un de

    i) remplir les modules (18) jusqu'à un niveau prédéterminé avec une charge de lest (20) en vrac pratiquement non absorbant, et déterminer coopérativement (a) le volume des matériaux de charge de lest (20) dans les modules (18), et (b) la hauteur des trous de débordement (22) dans les parois latérales (24) pour obtenir des caractéristiques prédéterminées de rétention d'eau et d'écoulement pour les modules (18) ; et

    ii) déterminer les caractéristiques de rétention d'eau et d'écoulement des modules (18) en déterminant la densité spatiale du lest (20), les caractéristiques d'écoulement des trous de débordement (22) dans les parois latérales (24) des modules (18), et la superficie occupée par les modules (18); la détermination des caractéristiques de rétention d'eau et d'écoulement des modules (18) comprenant la détermination de ces caractéristiques tant statiques que dynamiques, et puis remplir les modules (18) avec du lest (20) en vrac pratiquement non absorbant pour établir les caractéristiques déterminées de rétention d'eau ;

    d) connecter des modules (18) adjacents en utilisant des connecteurs (132, 134, 136) ayant un élément supérieur (132), un élément de canal inférieur (134) orienté vers le haut et un élément de fixation fileté (136) pour tirer l'élément supérieur (132) et l'élément inférieur (134) en accouplement intime contre les jupes (36) de brides (30) adjacentes ; et

    e) enfiler des câbles (138) dans les oeillets (136A) formés dans les connecteurs (132, 134, 136) pour ancrer chaque module (18) à un d'un module (18) adjacent et d'une ancre connectée à la toiture (14).


     




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    Cited references

    REFERENCES CITED IN THE DESCRIPTION



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    Patent documents cited in the description