Roofing materials and roofing systems with improved fire resistance and methods of making thereof
This invention, in embodiments, relates to a roll comprising a roofing material. The roofing material includes a substrate having a first side and a second side, and a film layer attached to at least one of the first side or the second side of the substrate, the film layer comprising a polymer and having a thickness of 0.5 mils to 100 mils. A single layer of the roofing material achieves a Class A rating for steep slope roofing systems when tested according to UL 790 and/or ASTM E-108 Standard Test Methods for Fire Tests of Roof Coverings. This invention, in embodiments, further relates to a roofing material and a steep slope roofing system.
1 . A roll comprising:
a roofing material, wherein the roofing material comprises:
(a) an uncoated substrate having a first side and a second side, the uncoated substrate comprising a polyolefin base mat, wherein the uncoated substrate is a bottom layer of the roofing material, such that the second side of the uncoated substrate is configured to directly contact a roof deck;
(b) a reinforcement layer having a first side and a second side, the second side of the reinforcement layer being attached to the first side of the uncoated substrate, wherein the reinforcement layer comprises at least one of a scrim, a fiberglass mat, or a polyester mat; and
(c) a polymeric film layer directly attached to the first side of the reinforcement layer, wherein the polymeric film layer (i) consists essentially of at least one of polyvinyl chloride (PVC) or silicone, and (ii) has a thickness of 5 mils to 20 mils, and wherein the polymeric film layer is a top layer of the roofing material that is configured to directly contact a roofing shingle,
wherein the roofing material, when applied in a single layer and tested according to at least one of UL 790 or ASTM E-108 Standard Test Methods for Fire Tests of Roof Coverings, achieves a Class A rating for steep slope roofing systems.
2 . The roll according to claim 1 , wherein the film layer has a thickness of 10 mils to 20 mils.
3 . The roll according to claim 1 , wherein the polymeric film layer is metallized.
4 . A roofing material comprising:
(a) an uncoated substrate having a first side and a second side, the uncoated substrate comprising a polyolefin base mat, wherein the uncoated substrate is a bottom layer of the roofing material, such that the second side of the uncoated substrate is configured to directly contact a roof deck;
(b) a reinforcement layer having a first side and a second side, the second side of the reinforcement layer being attached to the first side of the uncoated substrate, wherein the reinforcement layer comprises at least one of a scrim, a fiberglass mat, or a polyester mat; and
(c) a polymeric film layer directly attached to the first side of the reinforcement layer, wherein the polymeric film layer (i) consists essentially of at least one of polyvinyl chloride (PVC) or silicone, and (ii) has a thickness of 5 mils to 20 mils, wherein the polymeric film layer is a top layer of the roofing material that is configured to directly contact a roofing shingle,
wherein the roofing material, when applied in a single layer and tested according to at least one of UL 790 or ASTM E-108 Standard Test Methods for Fire Tests of Roof Coverings, achieves a Class A rating for steep slope roofing systems.
5 . The roofing material according to claim 4 , wherein the polymeric film layer has a thickness of 10 mils to 20 mils.
6 . The roofing material according to claim 4 , wherein the roofing material comprises a roofing shingle.
7 . The roofing material according to claim 6 , wherein the roofing shingle is one of (i) a single layer shingle or (ii) a laminated shingle having two or more layers.
8 . A steep slope roofing system comprising:
(a) a roof deck; and
(b) a roofing material positioned above the roof deck, wherein the roofing material comprises:
(i) an uncoated substrate having a first side and a second side, the uncoated substrate comprising a polyolefin base mat, wherein the uncoated substrate is a bottom layer of the roofing material, such that the second side of the uncoated substrate directly contacts the roof deck;
(ii) a reinforcement layer having a first side and a second side, the second side of the reinforcement layer being attached to the first side of the uncoated substrate, wherein the reinforcement layer comprises at least one of a scrim, a fiberglass mat, or a polyester mat; and
(iii) a polymeric film layer directly attached to the first side of the reinforcement layer, wherein the polymeric film layer (i) consists essentially of at least one of polyvinyl chloride (PVC) or silicone, and (ii) has a thickness of 5 mils to 20 mils, wherein the polymeric film layer is a top layer of the roofing material that is configured to directly contact a roofing shingle,
wherein the roof deck is a steep slope roof deck having a pitch of Y/X, wherein Y and X are in a ratio of 2:12 to 12:12, with Y corresponding to the rise of the roof deck and X corresponding to the run of the roof deck, and
wherein the roofing system, when tested according to at least one of UL 790 or ASTM E-108 Standard Test Methods for Fire Tests of Roof Coverings, achieves a Class A rating for steep slope roofing systems.
9 . The steep slope roofing system according to claim 8 , wherein the roof deck is a steep slope roof deck having a pitch of Y/X, wherein Y and X are in a ratio of 4:12 to 12:12, with Y corresponding to the rise of the roof deck and X corresponding to the run of the roof deck.