Under ballasted roof substrate assembly

Abstract

A roof substrate assembly includes a structured roof deck, at least one layer of insulation disposed in overlaid arrangement with the roof deck, and at least one layer of weighted coverboard positioned in direct contact with an upper surface of the at least one layer of insulation. The at least one layer of weighted coverboard includes a plurality of panels of coverboard separated by a plurality of abutting joints and a sealant positioned within the plurality of joints to couple the plurality of panels of coverboard.

What is claimed is: 
     
         1 . A roof substrate assembly comprising:
 a structure roof deck;   at least one layer of insulation disposed in overlaid arrangement with the roof deck; and   at least one layer of weighted coverboard positioned in direct contact with an upper surface of the at least one layer of insulation, the at least one layer of weighted coverboard further comprises:   a plurality of panels of coverboard separated by a plurality of abutting joints; and   a sealant positioned within the plurality of joints to couple the plurality of panels of coverboard.   
     
     
         2 . The roof system of  claim 1 , wherein the at least one layer of weighted coverboard is an air barrier. 
     
     
         3 . The roof system of  claim 1 , wherein the at least one layer of weighted coverboard is loosely laid in overlapping arrangement with the at least one layer of insulation. 
     
     
         4 . The roof system of  claim 1 , wherein the at least one layer of weighted coverboard further comprises a plurality of stacked layers of weighted coverboard. 
     
     
         5 . The roof system of  claim 4 , wherein the plurality of layers of weighted coverboard are adhered to one another. 
     
     
         6 . The roof system of  claim 1 , further comprising a waterproofing membrane arranged upwardly adjacent to an upper surface of the at least one layer of weighted coverboard. 
     
     
         7 . The roof system of  claim 6 , wherein the waterproofing membrane has a plurality of edges and the waterproofing membrane is affixed to the at least one layer of weighted coverboard at only the plurality of abutting edges. 
     
     
         8 . The roof system of  claim 6 , wherein the waterproofing membrane is affixed to the at least one layer of weighted coverboard at the plurality of joints. 
     
     
         9 . The roof system of  claim 8 , wherein the waterproofing membrane located between the plurality of joints is not attached to the at least one layer of weighted coverboard. 
     
     
         10 . The roof system of  claim 6 , further comprising:
 at least one opening extending upwardly from above the at least one layer of insulation; and   at least one equalizer valve mounted within the at least one opening, the at least one equalizer valve being sealed to the waterproofing membrane.   
     
     
         11 . The roof system of  claim 6 , further comprising a nailer mounted at a perimeter of the roof system, in overlapping arrangement with the waterproofing membrane. 
     
     
         12 . The roof system of  claim 11 , wherein the nailer is encapsulated by the waterproofing membrane. 
     
     
         13 . The roof system of  claim 12 , further comprising a flashing membrane separate from the waterproofing membrane, the nailer being encapsulated by the flashing membrane. 
     
     
         14 . A roof system comprising:
 a structural roof deck;   at least one layer of insulation disposed in an overlaying arrangement with the roof deck;   a plurality of layers of weighted coverboard positioned upwardly adjacent to an upper surface of the at least one layer of insulation, wherein adjacent layers of the plurality of layers of weighted coverboard are adhered to one another.   
     
     
         15 . The roof system of  claim 14 , wherein the plurality of layers of weighted coverboard is positioned in direct contact with an upper surface of the at least one layer of insulation. 
     
     
         16 . The roof system of  claim 14 , further comprising a waterproofing membrane arranged upwardly adjacent to an upper surface of the plurality of layers of weighted coverboard. 
     
     
         17 . A method of reroofing an existing roof system comprising:
 removing an existing ballast layer and waterproofing membrane to expose a partial roof system;   installing at least one layer of weighted coverboard in direct contact with an upper surface of the partial roof system; and   sealing a plurality of joints of the at least one layer of weighted coverboard with a sealant to form an air barrier at the at least one layer of weighted coverboard.   
     
     
         18 . The method of  claim 17 , further comprising installing another waterproofing membrane upwardly adjacent to the at least one layer of weighted coverboard. 
     
     
         19 . The method of  claim 18 , wherein only a portion of the another waterproofing membrane is adhered to a surface of the at least one layer of weighted coverboard. 
     
     
         20 . The method of  claim 18 , further comprising:
 mounting a nailer at a perimeter of the existing roof system, in overlapping arrangement with the waterproofing membrane; and   encapsulating the nailer within the waterproofing membrane.