Roofing system and self-bridging tape for modular building construction roof joints

Abstract

A membrane roofing system for buildings of modular construction includes a reinforced laminate tape that seals the roof joints between adjacent modular building units. The tape includes a tacky elastomeric adhesive layer with a release strip releasably adhered to the underside thereof to expose a tacky underside surface to be adhered to adjacent edges of the membrane sheets of adjacent building modules, a reinforcing scrim embedded in the tacky elastomer layer and bridging across the gap between the adjacent building modules, and a protective layer covering the outer surface of the tacky elastomer.

1 . A method for bridging gaps between modules of modular buildings using a reinforced tape,
 a. the tape including:
 i. a width extending from a first side to a second side; 
 ii. a tacky adhesive layer having an upper surface and an opposing lower surface; 
 iii. a protective membrane layer secured to the upper surface of the adhesive layer; and 
 iv. a porous reinforcing layer positioned between the upper and lower surfaces of the adhesive layer; 
   b. the method including the steps of:
 i. positioning the tape at a gap between a first module and an adjacent second module of a modular building such that:
 1) at least a portion of the first side of the tape overlaps at least a portion of the first module; and 
 2) at least a portion of the second side of the tape overlaps at least a portion of the second module; and 
 
 ii. securing the tape to the first and second modules by:
 1) applying pressure to the membrane layer at the first side of the tape such that the lower surface of the tape is pressed against the first module; and 
 2) applying pressure to the membrane layer at the second side of the tape such that the lower surface of the tape is pressed against the second module. 
 
   
     
     
         2 . The method of  claim 1  wherein:
 a. the first module includes a first roof, and the second module includes a second roof; and 
 b. the tape is secured to the first and second modules to bridge the gap between the first and second roofs. 
 
     
     
         3 . The method of  claim 2  wherein the tape is configured to have sufficient rigidity such that the tape does not substantially sag between the first and second modules when bridging the gap between the first and second roofs. 
     
     
         4 . The method of  claim 3  wherein the tape does not substantially sag between the first and second modules when:
 a. the tape is bridging a gap of four inches between the first and second roofs; and 
 b. there is no stiff bridging member:
 i. bridging the gap; and 
 ii. positioned between the tape and the first and second roofs. 
 
 
     
     
         5 . The method of  claim 3  wherein the tape is configured to have sufficient flexibility to be rollable into a roll of tape. 
     
     
         6 . The method of  claim 5  further including the steps of:
 a. transporting the tape to the modular building as a roll of tape; and 
 b. unrolling the tape prior to the step of securing the tape to the first and second modules. 
 
     
     
         7 . The method of  claim 1  wherein:
 a. the tape further includes a release strip removably adhered to the lower surface of the adhesive layer; and 
 b. the method further includes the step of removing the release strip prior to the step of securing the tape to the first and second modules. 
 
     
     
         8 . The method of  claim 7  wherein the release paper has a release strip width greater than an adhesive layer width of the adhesive layer. 
     
     
         9 . The method of  claim 1  wherein:
 a. the adhesive layer is a butyl adhesive layer having an adhesive layer thickness between at least substantially 0.04 inches and at least substantially 0.06 inches; and 
 b. the reinforcing layer has a reinforcing layer thickness between at least substantially 0.03 inches and at least substantially 0.05 inches. 
 
     
     
         10 . The method of  claim 9  wherein:
 a. the reinforcing layer is a porous plastic or metal strip having openings sized between at least substantially 1/16 inch and at least substantially ⅛ inch across corners; and 
 b. the adhesive layer at least substantially extends through the openings of the reinforcing layer. 
 
     
     
         11 . The method of  claim 1  wherein the protective membrane layer of the tape:
 a. is a fully-cured EPDM rubber layer; and 
 b. is between at least substantially 0.03 inches and at least substantially 0.06 inches thick. 
 
     
     
         12 . The method of  claim 1  wherein:
 a. the first and second modules include first and second roofing membranes, respectively; and 
 b. the method further includes the steps of:
 i. preparing edges of the first and second roofing membranes with a cleaner and a tape primer; 
 ii. positioning the tape to overlap the cleaned and primed first and second roofing membranes; and 
 iii. sealing the tape to the first and second modules with a caulk sealant after the step of securing the tape to the first and second modules. 
 
 
     
     
         13 . The method of  claim 12  further including the step of installing insulation in the gap prior to the step of securing the tape to the first and second modules. 
     
     
         14 . A method for bridging gaps between modules of modular buildings using a reinforced tape,
 a. the tape including:
 i. an adhesive layer having: 
 1) an upper surface and an opposing lower surface, the lower surface being tacky; and 
 2) a porous reinforcing layer embedded therein,
 a) the reinforcing layer being a perforated plastic or metal strip, 
 b) the adhesive layer at least substantially extending through perforations of the reinforcing layer; and 
 
 ii. a protective membrane layer secured to the upper surface of the adhesive layer; 
   b. the method including the steps of:
 i. positioning the tape at a gap between a first module and a second module such that the tape bridges the gap between a first roof of the first module and a second roof of the second module; and 
 ii. pressing the tape against the first and second modules such that the tacky lower surface of the tape is secured to the first and second roofs; 
   c. wherein the tape is configured to have sufficient rigidity such that the tape does not substantially sag between the first and second modules when bridging a gap of at least substantially four inches between the first and second roofs.   
     
     
         15 . The method of  claim 14  wherein the tape is directly secured to the first and second modules without a stiff bridging member between the tape and the first and second roofs. 
     
     
         16 . The method of  claim 14  wherein:
 a. the tape is further configured to have sufficient flexibility to be rollable into a roll of tape; and 
 b. the method further includes the step of unrolling the tape prior to the step of pressing the tape against the first and second modules. 
 
     
     
         17 . The method of  claim 16  wherein:
 a. the adhesive layer is between at least substantially 0.04 inches and at least substantially 0.06 inches thick; 
 b. the reinforcing layer is between at least substantially 0.03 inches and at least substantially 0.05 inches thick; and 
 c. the protective membrane layer of the tape is between at least substantially 0.03 inches and at least substantially 0.06 inches thick. 
 
     
     
         18 . A method for bridging gaps between modules of modular buildings using a reinforced tape,
 a. the tape including:
 i. an adhesive layer having:
 1) an upper surface and an opposing lower surface, the lower surface being tacky; 
 2) an adhesive layer thickness between at least substantially 0.04 inches and at least substantially 0.06 inches; 
 
 ii. a reinforcing layer embedded at least substantially entirely within the adhesive layer, the reinforcing layer having a reinforcing layer thickness between at least substantially 0.03 inches and at least substantially 0.05 inches; and 
 iii. a membrane layer secured to the upper surface of the adhesive layer, the membrane layer having a membrane layer thickness between at least substantially 0.03 inches and at least substantially 0.06 inches; 
   b. the method including the steps of:
 i. positioning the tape at a gap between a first module and an adjacent second module such that the tape bridges the gap between a first roof of the first module and a second roof of the second module, the first and second roofs having first and second roofing membranes, respectively; and 
 ii. applying pressure to the tape to press the tacky lower surface of the adhesive layer directly against the first and second roofing membranes to secure opposing sides of the tape to the first and second modules. 
   
     
     
         19 . The method of  claim 18  wherein the reinforcing layer and the membrane layer of the tape are configured to give the tape sufficient rigidity such that the tape does not substantially sag between the first and second modules when bridging a gap of at least substantially four inches between the first and second roofs. 
     
     
         20 . The method of  claim 19  wherein:
 a. the adhesive layer is a butyl adhesive layer; 
 b. the protective membrane layer is a fully-cured EPDM rubber layer; and 
 c. the method further includes the steps of:
 i. preparing edges of the first and second roofing membranes with a cleaner and a tape primer; 
 ii. positioning the tape to overlap the cleaned and primed first and second roofing membranes; 
 iii. installing insulation in the gap before the tape has been secured to the first and second modules; and 
 iv. sealing the tape to the first and second modules with a caulk sealant after the tape has been secured to the first and second modules.