Pipe Hanging and Rooftop Load Supporting System

This invention relates to the field of supports for hanging pipe and installing other loads on rooftops.

It is common in commercial and industrial surroundings for there to be various operating pipes and conduits exposed to the elements that extend along the ground and over the tops of roofs. For instance, these pipes and conduits may be connected to an air conditioning unit mounted on a building roof, or to various other service units. Frequently the pipes carry fluids where operating temperatures fluctuate over a wide range.

With temperature changes and/or with normal changes in the operating system parameters, the pipes expand and contract greatly, sometimes as much as 1 to 1.5 inches per linear foot. The support for these pipes as they run over the ground and/or over a roof must not only sustain the pipe load but also must be sufficiently flexible to withstand the expansion and contraction caused by fluctuation in operating parameters and the weather.

In the roof environment it is common practice for operating pipes to be supported by blocks of wood. The blocks are placed at intervals along the pipe track. They fit between the roof surface and the pipes. Partly because of the large contact surface area between a block and a pipe, the blocks frequently move. After a period of time, the movement of the block against a roof surface can cause damage. This usually results in a leak and requires expensive roof repair. Blocks have been nailed to the roof to prevent their movement, but the nails and the wood have proven to deteriorate in a relatively short time period. The blocks then break loose as before, and the system frequently results in the roof leaking about the nail holes in addition.

There is available a pipe holder for mounting on a roof that has a shaft mounted pulley or roller on which the pipe can rest and roll as it expands and contracts. This helps to prevent permanent problems due to the contraction and expansion of the pipes. It is still necessary with this system, however, to make holes in the roof for mounting purposes. Furthermore, the device is expensive. If many holders are required, they can cost more than a number of later roof repairs. As a result, this proposed solution to the problem of rooftop pipe support has not achieved a great deal of commercial success.

A non-fixed pipe-supporting device for roofs has been developed that comprises a substantially flat bottomed base having a support structure rising from the base. The design offers a channel or V-shaped support arrangement and purports to distribute the weight of the pipe over the bottom of the base. This system, however, teaches no underlying pad and more importantly, does not teach, suggest or propose to be capable of supporting pipe hung with a yoke. Especially in the environment of roofs, where pipe contraction and expansion is magnified, pipes not permitted to move sufficiently freely relative to their support can cause substantial damage to underlying surfaces.

The enhanced freedom of movement relative to the support obtained from hanging pipe from a suspended yoke is recognized. Hanging pipe via an adjustable yoke can accommodate greater pipe expansion and contraction in both axial and radial directions as well as torquing and skewing motions. However, the existing art teaches that such yokes are always secured to a firm overhead foundation, such as a ceiling, or suspended from a frame that is secured to a firm fixed foundation, such as a wall or a buried ground base.

In the roof environment, utilizing fixed bases would require holes to be placed in the roof surface. As discussed above, holes lead to leaks, a definite disadvantage of fixed bases. In general, fixed bases also lack a flexibility of adjustment during setup and use, and are expensive to reconfigure, a further disadvantage vis a vis portable bases.

A system for the use of a yoke for hanging pipe suspended from a frame attached to a portable base has not been taught or known in the art prior to this invention. There is no indication that anyone in the industry thought it feasible. It is herein disclosed, not only in a roof environment where its advantages are ample, but also in a ground based system. Even in the ground based system it offers advantages of ease of operation and flexibility. The absence of such teaching and practice in the prior art, where its efficiency and effectiveness would be clear, testifies to the current belief in the industry that pipe cannot be safely and securely hung from non-fixed bases.

The present invention discloses laying pipe with a yoke suspended from a frame attached to a portable base and further to utilize a set of such supports to hang pipe over a distance. On a roof surface the base is to be placed upon a pad, preferably adhered to the surface of the roof but alternately possibly adhered to the bottom of the base. The base is to distribute the weight of the pipe. The yoke should be adjustable.

It is the inventor's discovery that appropriate portable weight distributing bases do not impermissibly move out of position. The base system can be assembled quickly on location while being shipped in a broken down configuration. During set up and after use, the system can be adjusted as well as reconfigured, and the system can be utilized on the ground as well as on roof surfaces. Slanting surfaces can be compensated for by a wedge insert under the base. The combined adaptability, effectiveness, and efficiency of the system yields significant commercial advantages.

Not only will the instant system prove advantageous in supporting pipes over all sorts of surfaces, the base system involving a portable base resting on a pad adhered to the roof will also prove advantageous for supporting other rooftop loads, such as an air conditioning system.

The term "portable", as used herein with reference to a base, indicates that the base rests upon an underlying surface but is not permanently affixed to that surface. The base remains mobile, movable, and adjustable, in setup and afterwards. A portable base distinguishes itself from bases comprised of ceilings or walls or floors and from bases fixed into the ground.

The instant invention discloses apparatus and method for hanging pipe comprising a portable weight distributing base having a frame attachable to the base. The frame and base combination have a means for assembly and disassembly. An adjustable yoke attaches to the frame for suspending pipe.

The invention includes a pad for resting between the base and a roof surface, the pad either adhering to a portion of the roof surface or to the lower surface of the base by an adhesive.

The base may be comprised of concrete, steel, rubber, reclaimed rubber, plastic or fiberglass and resin.

A system for hanging pipe is disclosed that includes suspending a pipe in a plurality of yokes, adjustably attaching the yokes to frames, attaching the frames to portable weight distributing bases and distributing the bases along a path of the pipe. If the pipe is hung over a roof surface, the system includes adhering a plurality of foot pads to a roof, or possibly to the bases, and resting the bases upon the foot pads.

The invention also discloses a foundation apparatus for supporting rooftop loads comprising a pad adhered to a roof and a set of portable weight distributing bases resting upon the pad or pads.

FIG. 1 illustrates a partial roof segment with installation of piping using the inventive apparatus;

FIG. 2 is a side elevational view of one apparatus having an adjustable overhead yoke showing a section through the roof and a precast concrete base broken away;

FIG. 3 is an expanded view of the apparatus of FIG. 2 illustrating a segment of roof, adhesive, a concrete reinforced base and an overhead yoke;

FIG. 4 is the side elevational of the frame of FIGS. 2 and 3 illustrating a support collar;

FIG. 5 illustrates an embodiment of the apparatus wherein the frame rests on a pair of bases and supports three yokes;

FIG. 6 is similar to FIG. 3 but helps illustrate in FIGS. 6a through 6c different compositions of the base, such as concrete, rubber, and plastic;

FIG. 6d illustrates an insert that may be used on slanting roofs;

FIG. 7 is similar to FIG. 1 but illustrates a base comprised of channel steel;

FIG. 8 is similar to FIG. 2 but illustrates a base comprised of steel plate;

FIG. 9 illustrates the system of the present invention where a length of pipe is hung using a plurality of the pipe hanging apparatus;

FIGS. 10a, 10b and 10c provide three tables giving load information based upon different bases and different pipes; and

FIG. 11 illustrates use of the present invention to support other roof deck loads, such as the illustrated air conditioner.

With reference to FIG. 1, roof installation 10 includes an air conditioner 12 seated or mounted on a roof section 13. For providing service to the air conditioner 12 and other similar units on the roof (not shown), a pipe network 14 is provided and utilizes a yoke pipe support pedestal 20, as well as a yokeless pipe support pedestal 65.

Referring now to FIGS. 2 and 3, the details of the yoke pipe support pedestal 20 are described. Referring specifically to FIG. 3, yoke pedestal 20 is illustrated in an exploded view of its components and attachment to a roof section 23. The roof section 23 has an adhesive 24 applied to a clean place on the roof section 23, and a foot pad 25 is placed on the adhesive 24 to secure it to the roof section 23. A base 26 is then seated on the foot pad 25. Base 26 is of sufficient mass that it uniformly compresses the isolation or foot pad 25 and remains in place without further attachment to the roof. Pedestal 20 has a frame 33 which comprises a pair of side posts 34 and a cross bar 35. Referring to FIG. 2, the pedestal 20 is illustrated with a broken away section through one tubular steel insert 27 illustrating that side post 34 of yoke support bracket 33 seats in tubular insert 27. Collar 36 transfers the weight from frame 33 to base 26. The tables of FIG. 10 (FIGS. 10a-10c, discussed below) compare the load distributing characteristics of various bases.

A yoke 40 is suspended from a cross bar 35 of yoke support frame 33 by a threaded rod 41, extending through a hole 42 in cross bar 35 and through a hole 43 in yoke 40. One end of threaded rod 41 is secured to the yoke 40 by washers 44 and nuts 45 and the other end of threaded rod 41 is secured to the cross bar 35 with washers 44 and nuts 45. A conventional pipe support roller 48 is secured through holes 46 in yoke 40 by nuts 49 on threaded rod 47, which securing means retains pipe support roller 48 while permitting free rotation thereof corresponding to movement of pipe 50. It will be understood that nuts 45 on threaded rod 41 may be adjusted to raise or lower the roller 48 of yoke 40 and thus adjust for leveling pipe 14 to equalize and distribute the pipe load throughout a pipe support system.

Furthermore, hole 42 can be designed to be of a size to permit rod 41 room to move laterally side to side and front to back and to rotate, thereby permitting the yoke to accommodate expansion, contraction, rotational torquing and skewing of the pipe 14.

FIG. 4 illustrates one embodiment of frame 33. Frame 33 of FIG. 4 can be attached to base 26 by inserting end portions of side rods 34 into tubular inserts designed for such purpose in the base. Collar 36 affixed to side bars 34 is one means for frame 33 to transfer its weight to base 26. Frame 33 could come in one piece or more than one piece. For instance, frame 33 could telescope together at some place along its sides or top. Alternately, portions of frame 33 could be permanently fixed to the top of base 26, while other portions of frame 33 can be subsequently attached. It is preferable that frame 33 can be disassembled from base 26 as well as assembled in order to provide for efficient design and reconfiguration.

FIG. 5 illustrates an alternate embodiment according to the present invention. In the apparatus of FIG. 5, frame 33 is inserted into a pair of weight distributing bases 26. Collar 36, again, indicates how the load carried by frame 33 is transferred to bases 26. Three adjustable yokes 40 are shown suspended from frame 33.

It is important that the bases sufficiently distribute the weight. FIGS. 10a, 10b and 10c contain tables illustrating limited load calculations for three cases. The load is particularly pertinent for roof deck designs, but it is also important to understand for ground-based designs. The loads are calculated for both single and dual base assemblies. For comparison purposes, the identical loads are calculated for timber sleepers used in the current art in roof deck assemblies. In preparing the tables, the area of the assembly base was calculated by multiplying the assembly's width by its length. No reduction in area was included to account for rounded corners. The unit weight of the assembly frame and base was based on information of the inventor and the unit weight of standard steel pipe was obtained from published data in the Pipe Fitter's Handbook published by Grinell.

FIG. 6 repeats the illustration of FIG. 3. FIGS. 6a, 6b and 6c indicate that the base of FIG. 6 could be comprised of concrete, rubber or reconstituted rubber, and plastic or fiberglass and resin, respectively.

FIG. 6d illustrates an insert 26A. Insert 26A, indicated as comprised of rubber, illustrates the application of the present invention in the case in which the roof, as indicated by roof section 23, slants. In such a situation, wedge-shaped insert 26A can serve to level assembly 26.

FIG. 7 and FIG. 8 illustrate base 26 comprised of steel. In FIG. 7, base 26 is comprised of a piece of steel channel having flanged edges. In FIG. 8, base 26 as illustrated is comprised of sheet steel, or other metal.

FIG. 9 illustrates the apparatus and method of the present invention wherein a plurality of base, frame and yoke assemblies are utilized. The application of FIG. 9 could be installed upon a roof deck. In such case foot pads, as detailed above, would be utilized under bases 26. In a ground based system there is no need for such pads.

FIGS. 10a, 10b and 10c, discussed above, relates to FIG. 9 in that these figures indicate factors to be considered in determining pipe hanger spacing between assemblies 20. As a general rule of thumb in a roof deck situation, loads in excess of five pounds per square inch are avoided.

FIG. 11 indicates the application of the present invention in a roof deck situation for bearing a load other than pipe. FIG. 11 indicates a section of roof 23 having four areas of adhesive 24 applied, four pads 25 adhered to the adhesive and receiving four bases 26. Air conditioner load 12 is indicated as potentially resting upon four bases 26.

The invention disclosed herein is illustrated and described with specific reference to embodiments thereof presently contemplated as the best mode for carrying out the invention. However, it should be understood that various materials of construction other than those described herein which perform the same function may be utilized. It should be understood that various changes may be made in adapting the invention to different embodiments without departing from the broader inventive concepts disclosed herein and set forth in the claims that follow.