Envelope Interface to Insulate a Post-Frame Building

Abstract

This invention is an envelope-structure interface, enabling the use of exterior insulation and pressure-equalized cladding with a post-frame structure. The present invention includes the following interface details: a continuous roof-to-wall water, vapor, and air impermeable weather barrier that is fully adhered to sheathing exterior of framing, girts, and purlins; continuous roof-to-wall insulation exterior of weather barrier that is mechanically fastened back to the post-frame structure; and removal of the requirement for an interior finish material in a conditioned post-frame building. The invention brings superior envelope performance to the structural and material efficiency, rapid rate of construction, and affordability of post-frame techniques.

What is claimed is: 
     
         1 . A wall assembly for a post-frame structure comprising the following components, in order from interior to exterior:
 a series of wood girts fastened to posts of said post-frame structure;   a layer of sheathing fastened to said girts;   a layer of water, vapor, and air impermeable weather barrier adhered to said sheathing;   a layer of vapor-permeable exterior insulation; and   a series of strapping members fastened by   a plurality of screws that penetrate said insulation, said weather barrier, said sheathing, and embed into said girts.   
     
     
         2 . The wall assembly of  claim 1 , wherein said girts are perpendicularly oriented in relation to said posts; said girts are spaced such that both the minimum fastening requirements of said insulation are satisfied and that the maximum tributary load for said screws is not exceeded; and said girts are of sufficient size and structural properties both to span between said posts while supporting live and dead loads of said wall assembly without deflecting beyond code-allowed limits, and to allow for required embedment of said screws. 
     
     
         3 . The wall assembly of  claim 2 , wherein said girts are regularly spaced. 
     
     
         4 . The wall assembly of  claim 3 , wherein said girts are comprised of dimensional lumber. 
     
     
         5 . The wall assembly of  claim 2 , wherein said sheathing is arranged to provide a continuous substrate; and said sheathing is of sufficient thickness and structural properties both to span between said girts while supporting live and dead loads of said wall assembly without deflecting beyond code-allowed limits, and to allow for required embedment of said screws. 
     
     
         6 . The wall assembly of  claim 5 , wherein said sheathing is selected from the group comprised of plywood, wood boards, reconstituted wood panel products, and composite reinforced fiber cement boards. 
     
     
         7 . The wall assembly of  claim 5 , wherein said weather barrier is a membrane applied continuously in a shingle-lapped configuration to said substrate; and said weather barrier is self-adhering. 
     
     
         8 . The wall assembly of  claim 7 , wherein said weather barrier is self-sealing. 
     
     
         9 . The wall assembly of  claim 8 , wherein said weather barrier is comprised of a polyethylene-faced, polymer-modified, bituminous sheet. 
     
     
         10 . The wall assembly of  claim 7 , wherein said insulation is installed with continuous coverage at all wall conditions including corners and edges; and said insulation is of sufficient compressive strength to resist dead and live loads of said wall assembly. 
     
     
         11 . The wall assembly of  claim 10 , wherein said insulation is comprised of mineral wool. 
     
     
         12 . The wall assembly of  claim 10 , wherein said insulation is a single layer of insulation panels. 
     
     
         13 . The wall assembly of  claim 10 , wherein said insulation is built-up from multiple layers of insulation panels with offset panel seams. 
     
     
         14 . The wall assembly of  claim 10 , wherein said strapping is vertically oriented along the face of said insulation; said strapping is spaced such that both the minimum fastening requirements of said insulation are satisfied and that the maximum tributary load for said screws is not exceeded; and said strapping is of thickness and structural properties sufficient both to provide an adequate ventilation cavity for a vented siding system and to secure said screws without failure. 
     
     
         15 . The wall assembly of  claim 14 , wherein said strapping is selected from the group comprised of plywood, wood board, reconstituted wood panel products, wood-thermoplastic composites, and metal. 
     
     
         16 . The wall assembly of  claim 14 , wherein said screws are embedded into said girt and said sheathing to a depth sufficient to support the live and dead loads of the wall assembly; and said screws are of sufficient diameter and structural properties to withstand the loads imposed by their tributary areas. 
     
     
         17 . The wall assembly of  claim 16 , wherein said screws are double-threaded. 
     
     
         18 . The wall assembly of  claim 16 , wherein said screws are comprised of steel. 
     
     
         19 . The wall assembly of  claim 16 , wherein said screws of two configurations are used in conjunction: one perpendicular to the wall and one oblique to the wall. 
     
     
         20 . The wall assembly of  claim 16 , wherein said screws are driven perpendicularly to the wall. 
     
     
         21 . The wall assembly of  claim 16 , wherein said screws are driven obliquely to the wall. 
     
     
         22 . The wall assembly of  claim 16 , wherein a pressure-equalized rainscreen cladding system is fastened to said strapping. 
     
     
         23 . A roof assembly for a post-frame structure comprising the following layers, in order from interior to exterior:
 a series of wood purlins fastened to roof trusses of said post-frame structure;   a layer of sheathing fastened to said purlins;   a layer of water, vapor, and air impermeable weather barrier adhered to said sheathing;   a layer of vapor-permeable exterior insulation; and   a series of strapping members fastened by   a plurality of screws that penetrate said insulation, said weather barrier, said sheathing, and embed into said purlins.   
     
     
         24 . The roof assembly of  claim 23 , wherein said purlins are perpendicularly oriented in relation to said trusses; said purlins are spaced such that both the minimum fastening requirements of said insulation are satisfied and that the maximum tributary load for said screws is not exceeded; and said purlins are of sufficient size and structural properties both to span between said trusses while supporting live and dead loads of said roof assembly without deflecting beyond code-allowed limits, and to allow for required embedment of said screws. 
     
     
         25 . The roof assembly of  claim 24 , wherein said purlins are regularly spaced. 
     
     
         26 . The roof assembly of  claim 24 , wherein said purlins are comprised of dimensional lumber. 
     
     
         27 . The roof assembly of  claim 24 , wherein said roof sheathing is arranged to provide a continuous substrate; said roof sheathing is cut flush with face of said wall sheathing, caps the uppermost condition of said wall sheathing without gaps, and is shingle-lapped over said wall sheathing; and said roof sheathing is of sufficient thickness and structural properties both to span between said purlins while supporting live and dead loads of said roof assembly without deflecting beyond code-allowed limits, and to allow for required embedment of said screws. 
     
     
         28 . The roof assembly of  claim 27 , wherein said sheathing is selected from the group comprised of plywood, wood boards, reconstituted wood panel products, and composite reinforced fiber cement boards. 
     
     
         29 . The roof assembly of  claim 27 , wherein said roof weather barrier is a membrane applied continuously in a shingle-lapped configuration to said substrate; said roof weather barrier shingle-laps over said wall weather barrier to form a continuous seal; and said roof weather barrier is self-adhering. 
     
     
         30 . The roof assembly of  claim 29 , wherein said weather barrier is self-sealing. 
     
     
         31 . The roof assembly of  claim 29 , wherein said weather barrier is comprised of a polyethylene-faced, polymer-modified, bituminous sheet. 
     
     
         32 . The roof assembly of  claim 29 , wherein said roof insulation is installed with continuous coverage at all roof conditions including corners and edges; said roof insulation is cut flush with face of said wall insulation, caps the uppermost condition of said wall insulation without gaps, and is shingle-lapped over said wall insulation; and said roof insulation is of sufficient compressive strength to resist dead and live loads of said roof assembly. 
     
     
         33 . The roof assembly of  claim 32 , wherein said insulation is comprised of mineral wool. 
     
     
         34 . The roof assembly of  claim 32 , wherein said insulation is a single layer of insulation panels. 
     
     
         35 . The roof assembly of  claim 32 , wherein said insulation is built-up from multiple layers of insulation panels with offset panel seams. 
     
     
         36 . The roof assembly of  claim 32 , wherein said strapping is vertically inclined following the slope of said roof; said strapping is spaced such that both the minimum fastening requirements of said insulation are satisfied and that the maximum tributary load for said screws is not exceeded; and said strapping is of thickness and structural properties sufficient both to provide an adequate ventilation cavity for a vented roofing system and to secure said screws without failure. 
     
     
         37 . The roof assembly of  claim 36 , wherein said strapping is selected from the group comprised of plywood, wood board, reconstituted wood panel products, wood-thermoplastic composites, and metal. 
     
     
         38 . The roof assembly of  claim 36 , wherein said roof strapping is aligned with said adjacent wall strapping. 
     
     
         39 . The roof assembly of  claim 36 , wherein said screws are embedded into said purlins and said sheathing to a depth sufficient to support the live and dead loads of the roof assembly; and said screws are of sufficient diameter and structural properties to withstand the loads imposed by their tributary areas. 
     
     
         40 . The roof assembly of  claim 39 , wherein said screws are double-threaded. 
     
     
         41 . The roof assembly of  claim 39 , wherein said screws are comprised of steel. 
     
     
         42 . The roof assembly of  claim 39 , wherein said screws are driven perpendicularly to said sheathing. 
     
     
         43 . The roof assembly of  claim 39 , wherein said screws are driven obliquely to said sheathing. 
     
     
         44 . The roof assembly of  claim 39 , wherein a pressure-equalized vented roofing system is fastened to said strapping.