Fastener systems for roof structures

Abstract

Fastener systems and methods of attaching one or more layers of materials to a roof deck of a roof structure for forming a roof are disclosed. In embodiments, the fastener systems can include a plate having first and second surfaces with an aperture extending between the first surface of the plate and the second surface of the plate and configured to receive a fastener therein. A cover portion is provided to substantially enclose the first end of the aperture so as to cover a head of the fastener received within the aperture and protect the fastener from impacts due to objects striking the roof structure.

1 . A fastener system, comprising:
 a plate including:
 a first surface and a second surface opposite the first surface, 
 an aperture extending through the plate from the first surface to the second surface, and 
 a cover portion configured to substantially cover the aperture; and 
   wherein the plate is configured to be installed on a roof structure with the second surface of the plate engaging an upper surface of the roof structure;   a fastener having a head and shank portion;   wherein the head of the fastener is installed within the aperture of the plate with the head of the fastener positioned below the upper surface of the plate;   wherein the cover portion of the plate is configured to cover head of the fastener;   wherein the roof structure with the fastener system installed therealong meets requirements for Very Severe Hail resistance according to FM Approvals FM 4470 VSH impact resistance testing standard for Single-Ply Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies.   
     
     
         2 . The fastener system of  claim 1 , wherein the cover portion comprises at least one flap, wherein the at least one flap is moveable between a first position, in which the at least one flap is substantially planar with the first surface of the plate, and a second position, in which the at least one flap extends obliquely relative to the first surface of plate. 
     
     
         3 . The fastener system of  claim 2 , wherein the at least one flap is resiliently biased, such that the at least one flap of the cover is moveable from its second position to its first position after the installation of the fastener within the aperture of the plate so as to cover the head of the fastener. 
     
     
         4 . The fastener system of  claim 1 , wherein the cover portion comprises a plug configured to be removably installed within the aperture of the plate. 
     
     
         5 . The fastener system of  claim 1 , wherein the first surface of the plate is convex, and wherein the second surface of the plate is substantially flat. 
     
     
         6 . The fastener system of  claim 1 , wherein the plate comprises a plurality of protrusions position along and extending outwardly from the second surface of the plate; wherein the plurality of protrusions is configured to grip the surface of the roof structure; and wherein the plurality of protrusions is configured to inhibit lateral movement of the plate relative to the first surface of the roof. 
     
     
         7 . The fastener system of  claim 1 , wherein the plate further comprises a recessed portion arranged along between the first surface of the plate and the second surface of the plate; wherein the aperture is configured to receive the head of the fastener when the fastener is installed in the aperture. 
     
     
         8 . The fastener system of  claim 1 , wherein the plate comprises a thermoplastic polymer, propylene, polypropylene, polyethylene, nylon, polyvinyl chloride, rubber, polyurethane, acrylonitrile butadiene styrene, acrylo nitrile styrene acrylate, carbon fiber, metal, or combinations thereof. 
     
     
         9 . The fastener system of  claim 1 , wherein the fastener comprises a nail, a screw, a rivet, a bolt, a rod, or a threaded rod. 
     
     
         10 . A roof structure, comprising:
 a roof deck;   at least one layer positioned over the roof deck;   a plurality of fastener systems, each comprising:
 a plate having a first surface, a second surface and an aperture extending between the first and second surfaces; and 
 a cover portion configured to substantially cover the aperture; and 
   a fastener having a head and shank portion configured to penetrate the roof deck;   wherein the plate is positioned over the at least one layer;   wherein the fastener is installed within the aperture of the plate with the shank portion penetrating the roof deck and with the head of the fastener positioned below the first surface of the plate;   wherein the roof structure meets requirements for Very Severe Hail Resistance (VSH) according to FM Approvals FM 4470 USH impact resistance testing standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies.   
     
     
         11 . The roof structure of  claim 10 , wherein the at least one layer comprises a polymer membrane overlying the roof deck. 
     
     
         12 . The roof structure of  claim 10 , wherein the at least one layer comprises at least one insulation layer positioned over an upper surface of the roof deck and a polymer membrane overlying the at least one insulation layer. 
     
     
         13 . The roof structure of  claim 10 , wherein the first surface of the plate comprises a convex surface extending above the second surface; and wherein the second surface comprises a substantially flat surface configured to be substantially flat against the at least one layer. 
     
     
         14 . The roof structure of  claim 10 , wherein the cover portion comprises at least one flap, wherein the at least one flap is moveable between a first position, in which the at least one flap is substantially planar with the first surface of the plate, and a second position, in which the at least one flap extends obliquely relative to the first surface of plate. 
     
     
         15 . The roof structure of  claim 14 , wherein the at least one flap is resiliently biased, such that the at least one flap of the cover is moveable from its second position to its first position after the installation of the fastener within the aperture of the plate so as to cover the head of the fastener. 
     
     
         16 . The roof structure of  claim 10 , wherein the plate comprises a plurality of protrusions position along and extending outwardly from the second surface of the plate; wherein the plurality of protrusions is configured to grip a surface of the at least one layer positioned over the roof deck; wherein the plurality of protrusions is configured to inhibit lateral movement of the plate relative to the first surface of the roof. 
     
     
         17 . A method, comprising:
 positioning a plurality of fastener systems along a roof structure;   wherein each of the fastener systems includes:
 a plate having a first surface, a second surface opposite the first surface, and an aperture extending from the first surface to the second surface; and 
 a cover portion configured to substantially enclose the aperture, 
   wherein the second surface of the plate is placed in engagement with an upper surface of the roof structure; and   installing a fastener through the aperture of the plate and into the roof structure;   wherein when the fastener is installed, a head of the fastener is positioned below the first surface of the plate with the cover portion covering the head of the fastener.   
     
     
         18 . The method of  claim 17 , wherein the roof structure comprises a roof deck having a first surface and a second surface; and further comprising positioning at least one layer over the first surface of the roof deck, the at least one layer having an upper surface defining an exposed surface of the roof structure; and wherein the plurality of fastener systems are positioned along the upper surface of the at least one layer. 
     
     
         19 . The method of  claim 18 , wherein positioning the at least one layer over the first surface of the roof deck comprises a first layer positioned over the first surface of the roof deck, and positioning at least one additional layer over the first layer, wherein the at least one additional layer comprising a protective layer configured to resist migration of water therethrough. 
     
     
         20 . The method of  claim 17 , wherein the roof structure comprises a roof deck having a first surface and a second surface; and further comprising positioning at least a first layer over the first surface of the roof deck, wherein the plurality of fastener systems are positioned along the first layer to attach the first layer to the roof deck; and applying a protective layer over the first layer and the plurality of fastener systems.