Metal Roof Shingle System and Method of Installation

Abstract

A lightweight interlocking metal roof capping system for installation onto a steep or inclined structure roof either directly over the roof decking material or over an existing shingle roofing system, with the metal roofing system installed from the roof ridgeline down to the drip edge of the roof gutter. Cooperating outwardly extending flanges and receiving pockets for capturing and interlocking the metal panels of the roofing system create an interlock between and among panel members with overlying edge ends configured to be resistant to lift up due to winds either across the roof or along the roof edges.

1 . A lightweight interlocking roof capping system that inter-engages a plurality of preformed thermally insulative metal panels to create an integral roof surface over the roof decking or an existing roofing system of a structure having an inclined roof comprising:
 one or more triangularly shaped roof ridge cap panel members for positioning along a ridgeline of a structure roof each arrayed longitudinally along the roof ridge with the next, each said roof ridge cap panel member having a substantially planar outward facing central surface with a pair of flanges outwardly extending downwardly across the roof from each equal length sides of each of said panel members, each flange arranged at right angles to the other flange, with receiving pockets having a predetermined depth dimensionally sized and adapted for receiving within said pockets upwardly extending cooperating flanges from adjacently placed similarly dimensioned rectangularly shaped roof panel members and interlocking therewith;   said rectangular roof panel members having a substantially planar outward facing central surface with equal length sides arrayed on the roof between and a half panel member span below said roof ridge cap panel members or other adjacent roof panel members with a first set of opposite corners one above the other in a vertical line substantially in parallel relationship to the roof edges and a second set of opposite corners in a horizontal line substantially in parallel relationship to the ridgeline or eave edge of the roof, said rectangular roof panel members having flanges outwardly extending downwardly across the roof, along adjacent downward facing sides thereof, with receiving pockets having a predetermined depth dimensionally sized and adapted for receiving within said pockets upwardly extending cooperating flanges from other adjacently placed similarly dimensioned roof panel members and interlocking therewith;   said rectangular roof panel members having upper side indents along the entire length of each upper side extending into the planar central surface and an upwardly extending flange having a predetermined length dimensionally sized and adapted for fitting within and frictionally engaging with the cooperating pockets of the adjacent roof panel members;   said outwardly extending flanges of the roof ridge cap panel members and the roof panel members extending downwardly along the roof each having a lower extension beyond said pockets for receiving mechanical fasteners for securing said panel members to the roof and an upper extension beyond said pockets for overlying the joint between adjacent panel members a predetermined distance along the upper surface of adjacent roof panel members and overlying the opposing upper side indents in said adjacent panel members; and   said substantially planar central surfaces of each said roof ridge cap and rectangular panel members being preformed and dimensioned to provide a downward opening recess for housing a structural foam member for providing both thermal insulation and central support for said panel members creating a substantially uniform continuously integral surface for said roof capping system.   
     
     
         2 . The roof capping system of  claim 1 , wherein said rectangular roof panel members extending over the roof edges may be trimmed to dimensionally match the roof edge and have a roof edge member for extending over and beneath the roof edge to prevent wind uplift along said roof edge. 
     
     
         3 . The roof capping system of  claim 1 , further comprising roof edge panel members having a substantially planar outward facing central surface with equal length sides arrayed on the roof between and a half panel member span below said roof ridge cap panel members or the next higher course of rectangular roof panel members and the rectangular roof panel members and upper side indents along the entire length of the upper side extending into the planar central surface, an upwardly extending flange along the upward facing side thereof having a predetermined length dimensionally sized and adapted for fitting within and frictionally engaging with the cooperating pockets of the adjacent roof panel members, a downwardly extending flange along the downward facing side thereof with a receiving pocket having a predetermined depth dimensionally sized and adapted for receiving within said pockets upwardly extending cooperating flanges from other adjacently placed similarly dimensioned roof panel members and interlocking therewith, a lower extension beyond said pockets for receiving mechanical fasteners for securing said panel members to the roof and an upper extension beyond said pockets for overlying the joint between adjacent panel members a predetermined distance along the upper surface of adjacent roof panel members and overlying the opposing upper side indents in said adjacent panel members. 
     
     
         4 . A method for installing a lightweight interlocking roof capping system that inter-engages a plurality of preformed thermally insulated metal panels to create an integral roof surface over the roof decking or an existing roofing system of a structure having an inclined roof comprising the steps of:
 positioning and aligning a series of triangularly shaped roof ridge cap members along the ridgeline of the structure roof each arrayed longitudinally along the roof ridge with the next and having a substantially planar outward facing central surface with a pair of flanges outwardly extending downwardly across the roof from each equal length side of each said panel members, each flange arranged at right angles to the other flange, with receiving pockets having a predetermined depth dimensionally sized and adapted for receiving within said pockets cooperating flanges from one or more adjacently placed similarly dimensioned rectangularly shaped roof panel members and interlocking therewith;   securing each of said series of roof ridge cap panel members to the roof of the structure by mechanical fasteners placed through at least one pair of short flanges extending over the roof ridgeline and through a nailing hem at the distal end of the downwardly extending flanges creating a horizontally aligned first course of panel members;   positioning said rectangular roof panel members having a substantially planar outward facing central surface with equal length sides arrayed across the roof between and a half-panel member span below said roof ridge cap panel members, said rectangular roof panel members having flanges outwardly extending downwardly across the roof, along adjacent downward facing sides thereof, with receiving pockets having a predetermined depth dimensionally sized and adapted for receiving cooperating flanges within said pockets upwardly extending cooperating flanges from other adjacently positioned similarly dimensioned roof panel members and interlocking therewith;   positioning said one or more roof panel members, in a staggered array of additional courses of panel members extending from the ridgeline downward along the roof, into the pockets of the immediately adjacent roof ridge cap or roof panel member already secured to the roof, said roof panel members having upper side indents along the entire length of each upper side extending into the planar central surface and an upper extension beyond said receiving pockets for overlying the joint between adjacent roof panel members and covering over the flanges and fasteners used to secure the earlier secured courses of panel members to the roof;   preforming each said roof ridge cap and said roof panel members to provide a downward opening recess for housing a structural foam member for thermally insulating and supporting each said panel member for creating from the centrally disposed surfaces of each said roof ridge cap and roof panel member a substantially uniform continuously integral surface for said roof capping system.   
     
     
         5 . The roof capping installation method of  claim 4 , comprising the additional steps of trimming roof panel members extending over the roof edges to dimensionally match the roof edge and securing a roof edge member along the trimmed side of said roof edge panel member for extending over and beneath the roof edge to prevent wind uplift along said roof edge. 
     
     
         6 . The roof capping installation method of  claim 4 , forming a cascading downward half step as the staggered roof panel members are interconnected into courses from the ridgeline of the roof to the eave edge allowing water and other run off to move downward over the substantially uniform continuously integral roof surface formed by the inter-engaged plurality of roof ridge cap and roof panel members. 
     
     
         7 . The roof capping system of  claim 1 , further comprising a roof cap member bent to conform to the incline of the roof along a central line extending along its length dimension for fitting over said roof ridge cap panel members and attaching to them along the expanse of the roof ridge. 
     
     
         8 . The roof capping system of  claim 1 , further comprising a roof valley member bent to conform to the incline of the roof along a central line extending along its length dimension for fitting over abutting adjacent roof panel members along an angled joint and attaching to them along the length of said angled joint. 
     
     
         9 . The roof capping system of  claim 1 , further comprising a roof eave member having a substantially planar outward facing central surface with equal length upper sides arrayed on the roof between the next higher course of rectangular roof panel members and along the roof eave edge with upper side indents along the entire length of the upper side extending into the planar central surface, an upwardly extending flange along each upward facing side thereof having a predetermined length dimensionally sized and adapted for fitting within and frictionally engaging with the cooperating pockets of the adjacent roof panel members and interlocking therewith, and a roof edge member for extending over and beneath the roof edge to prevent wind uplift along said roof eave edge. 
     
     
         10 . The roof capping installation method of  claim 4 , further comprising the step of positioning and securing a roof cap member bent to conform to the incline of the roof along a central line extending along its length dimension for fitting over said roof ridge cap panel members and attaching to them along the expanse of the roof ridge. 
     
     
         11 . The roof capping installation method of  claim 4 , further comprising the step of providing a roof valley member bent to conform to the incline of the roof along a central line extending along its length dimension for fitting over abutting adjacent roof panel members along an angled joint and attaching to them along the length of said angled joint. 
     
     
         12 . The roof capping installation method of  claim 4 , further comprising the step of providing a roof eave member having a substantially planar outward facing central surface with equal length upper sides arrayed on the roof between the next higher course of rectangular roof panel members and along the roof eave edge with upper side indents along the entire length of the upper side extending into the planar central surface, an upwardly extending flange along each upward facing side thereof having a predetermined length dimensionally sized and adapted for fitting within and frictionally engaging with the cooperating pockets of the adjacent roof panel members and interlocking therewith, and a roof edge member for extending over and beneath the roof edge to prevent wind uplift along said roof eave edge.