Zinc flashing for roof penetrations

Abstract

An improved zinc flashing system for use with metal and non-metal roof systems. The improved zinc flashing system includes a base plate that includes an aperture and vertical tube that is attached to the base plate. The vertical tube form extends upwardly from the upper surface of the base plate or downwardly from the bottom surface of the base plate. The zinc flashing system is designed to form a water-tight seal about a roof penetration and/or a roof drain. A protective layer can be used to inhibit or prevent contact of the zinc material of the zinc flashing with a roofing structure. The protective layer can be connected and/or coated to the zinc flashing.

1 . A flashing for use on a roofing system, said flashing including a base plate having an aperture at least partially spaced from a peripheral edge of said base plate, said base plate having an average thickness of less than 0.25 inch, said base plate formed of pure zinc or a zinc alloy. 
     
     
         2 . The flashing material as defined in  claim 1 , wherein said base plate is formed of a zinc alloy, said zinc alloy including over 99 weight percent zinc and 0.005-0.9 weight percent alloying metal, said alloying metal including one or more metals selected from the group consisting of aluminum, cadmium, chromium, copper, iron, lead, magnesium, nickel, tin, and titanium, said zinc alloy including less than 0.75 weight percent copper and less than 0.13 weight percent titanium. 
     
     
         3 . The flashing material as defined in  claim 1 , including a vertical tube connected to said base plate, said vertical tube at least partially encircling said aperture. 
     
     
         4 . The flashing material as defined in  claim 2 , including a vertical tube connected to said base plate, said vertical tube at least partially encircling said aperture. 
     
     
         5 . The flashing material as defined in  claim 3 , wherein said vertical tube is formed of the same material as said base plate. 
     
     
         6 . The flashing material as defined in  claim 3 , wherein said vertical tube is formed of the same material as said base plate. 
     
     
         7 . The flashing material as defined in  claim 1 , wherein said base plate includes a coating material that inhibits or prevents corrosion of said pure zinc or a zinc alloy when exposed to an oxygen containing environment. 
     
     
         8 . The flashing material as defined in  claim 6 , wherein said base plate includes a coating material that inhibits or prevents corrosion of said pure zinc or a zinc alloy when exposed to an oxygen containing environment. 
     
     
         9 . The flashing material as defined in  claim 1 , wherein said base plate includes an adhesive on an upper surface, a bottom surface, and combinations thereof, said adhesive designed to at least partially secure said baseplate to the roofing system. 
     
     
         10 . The flashing material as defined in  claim 6 , wherein said base plate includes an adhesive on an upper surface, a bottom surface, and combinations thereof, said adhesive designed to at least partially secure said baseplate to the roofing system. 
     
     
         11 . The flashing material as defined in  claim 8 , wherein said base plate includes an adhesive on an upper surface, a bottom surface, and combinations thereof, said adhesive designed to at least partially secure said baseplate to the roofing system. 
     
     
         12 . The flashing material as defined in  claim 1 , wherein said base plate includes a protective barrier, said protective barrier preventing direct contact of said pure zinc or a zinc alloy with a metal structure roofing system. 
     
     
         13 . The flashing material as defined in  claim 3 , wherein said base plate, said vertical tube, and combinations thereof include a protective barrier, said protective barrier preventing direct contact of said pure zinc or a zinc alloy with a metal structure roofing system. 
     
     
         14 . The flashing material as defined in  claim 6 , wherein said base plate, said vertical tube, and combinations thereof includes a protective barrier, said protective barrier preventing direct contact of said pure zinc or a zinc alloy with a metal structure roofing system. 
     
     
         15 . The flashing material as defined in  claim 10 , wherein said base plate, said vertical tube, and combinations thereof include a protective barrier, said protective barrier preventing direct contact of said pure zinc or a zinc alloy with a metal structure roofing system. 
     
     
         16 . The flashing material as defined in  claim 11 , wherein said base plate, said vertical tube, and combinations thereof include a protective barrier, said protective barrier preventing direct contact of said pure zinc or a zinc alloy with a metal structure roofing system. 
     
     
         17 . The flashing material as defined in  claim 3 , wherein said base plate, said vertical tube, and combinations thereof include a split. 
     
     
         18 . The flashing material as defined in  claim 16 , wherein said base plate, said vertical tube, and combinations thereof include a split. 
     
     
         19 . The flashing material as defined in  claim 3 , wherein said vertical tube includes a fluted portion that enables adjustment of a longitudinal length of said vertical tube. 
     
     
         20 . The flashing material as defined in  claim 16 , wherein said vertical tube includes a fluted portion that enables adjustment of a longitudinal length of said vertical tube. 
     
     
         21 . The flashing material as defined in  claim 3 , including a sealing gasket connected to said vertical tube, said sealing gasket including an aperture designed to at least partially encircle a roof penetration. 
     
     
         22 . The flashing material as defined in  claim 20 , including a sealing gasket connected to said vertical tube, said sealing gasket including an aperture designed to at least partially encircle a roof penetration. 
     
     
         23 . A method for forming a water-tight seal about a roof penetration that extends above a surface of a roof deck, said method comprising the steps of:
 providing flashing, said flashing including a base plate and a vertical tube connected to the baseplate, said base plate having an aperture at least partially spaced from a peripheral edge of said base plate, said vertical tube at least partially encircling said aperture, said vertical tube having a cavity extending through said vertical tube and which one end of said cavity is at least partially aligned with said aperture of said base plate, said base plate and said vertical tube having an average thickness of less than 0.25 inch, said base plate and said vertical tube formed of pure zinc or a zinc alloy;   inserting said flashing on said roof penetration so that said aperture and said cavity telescopically receive at least a top portion of said roof penetration;   positioning said base plate at least partially on said roof deck;   forming a seal between a top portion of said vertical tube and an exterior surface of said roof penetration; and,   forming a seal between said base plate and said roof deck.   
     
     
         24 . The method as defined in  claim 23 , wherein said base plate and said vertical tube is formed of a zinc alloy, said zinc alloy including over 99 weight percent zinc and 0.005-0.9 weight percent alloying metal, said alloying metal including one or more metals selected from the group consisting of aluminum, cadmium, chromium, copper, iron, lead, magnesium, nickel, tin, and titanium, said zinc alloy including less than 0.75 weight percent copper and less than 0.13 weight percent titanium. 
     
     
         25 . The method as defined in  claim 23 , wherein said step of forming said seal between said top portion of said vertical tube and said exterior surface of said roof penetration includes the steps of a) bending at least part of said top portion of said vertical tube into at least a portion of a top opening of said roof penetration, b) applying a sealant between said top portion of said vertical tube and said exterior surface of said roof penetration, c) inserting a sealing gasket between said top portion of said vertical tube and said exterior surface of said roof penetration, and combinations thereof. 
     
     
         26 . The method as defined in  claim 24 , wherein said step of forming a seal between said top portion of said vertical tube and said exterior surface of said roof penetration includes the steps of a) bending at least part of said top portion of said vertical tube into at least a portion of a top opening of said roof penetration, b) applying a sealant between said top portion of said vertical tube and said exterior surface of said roof penetration, c) inserting a sealing gasket between said top portion of said vertical tube and said exterior surface of said roof penetration, and combinations thereof. 
     
     
         27 . The method as defined in  claim 23 , including the step of applying a protective barrier between an interior surface of said cavity of said vertical tube and an exterior surface of said roof penetration, said protective barrier designed to inhibit or prevent corrosive contact between said flashing and said roof penetration by limiting direct contact of said pure zinc or zinc alloy of said flashing with said roof penetration, said protective barrier including a) a non-zinc coating material on said flashing, b) a non-zinc coating material on said roof penetration, c) a non-zinc material connected to said flashing, d) a non-zinc material connected to said roof penetration, e) a non-zinc material unconnected to said flashing and said roof penetration, and combinations thereof. 
     
     
         28 . The method as defined in  claim 26 , including the step of applying a protective barrier between an interior surface of said cavity of said vertical tube and an exterior surface of said roof penetration, said protective barrier designed to inhibit or prevent corrosive contact between said flashing and said roof penetration by limiting direct contact of said pure zinc or zinc alloy of said flashing with said roof penetration, said protective barrier including a) a non-zinc coating material on said flashing, b) a non-zinc coating material on said roof penetration, c) a non-zinc material connected to said flashing, d) a non-zinc material connected to said roof penetration, e) a non-zinc material unconnected to said flashing and said roof penetration, and combinations thereof. 
     
     
         29 . A method for forming a water-tight seal about a roof drain that extends into a surface of a roof deck, said method comprising the steps of:
 providing flashing, said flashing including a base plate and a vertical tube connected to the baseplate, said base plate having an aperture at least partially spaced from a peripheral edge of said base plate, said vertical tube at least partially encircling said aperture, said vertical tube having a cavity extending through said vertical tube and which one end of said cavity is at least partially aligned with said aperture of said base plate, said base plate and said vertical tube having an average thickness of less than 0.25 inch, said base plate and said vertical tube formed of pure zinc or a zinc alloy;   at least partially inserting said vertical tube into an opening in said roof drain;   positioning said base plate at least partially on said roof deck; and,   forming a seal between said base plate and said roof deck.   
     
     
         30 . The method as defined in  claim 29 , wherein said base plate and said vertical tube is formed of a zinc alloy, said zinc alloy including over 99 weight percent zinc and 0.005-0.9 weight percent alloying metal, said alloying metal including one or more metals selected from the group consisting of aluminum, cadmium, chromium, copper, iron, lead, magnesium, nickel, tin, and titanium, said zinc alloy including less than 0.75 weight percent copper and less than 0.13 weight percent titanium. 
     
     
         31 . The method as defined in  claim 29 , including the step of applying a protective barrier between an exterior surface of said vertical tube and an interior surface of said opening of said roof drain, said protective barrier designed to inhibit or prevent corrosive contact between said flashing and said roof drain by limiting direct contact of said pure zinc or zinc alloy of said flashing with said roof drain, said protective barrier including a) a non-zinc coating material on said flashing, b) a non-zinc coating material on said roof drain, c) a non-zinc material connected to said flashing, d) a non-zinc material connected to said roof drain, e) a non-zinc material unconnected to said flashing and said roof drain, and combinations thereof. 
     
     
         32 . The method as defined in  claim 30 , including the step of applying a protective barrier between an exterior surface of said vertical tube and an interior surface of said opening of said roof drain, said protective barrier designed to inhibit or prevent corrosive contact between said flashing and said roof drain by limiting direct contact of said pure zinc or zinc alloy of said flashing with said roof drain, said protective barrier including a) a non-zinc coating material on said flashing, b) a non-zinc coating material on said roof drain, c) a non-zinc material connected to said flashing, d) a non-zinc material connected to said roof drain, e) a non-zinc material unconnected to said flashing and said roof drain, and combinations thereof.