Self-stress waterproof roof composite board, waterproof structure and construction method thereof

Abstract

The application provides a self-stress waterproof roof composite board, a waterproof structure and a construction method thereof, which comprises a leveling layer, a plurality of boards and a micro-expansion cement-based composite material layer, the boards are between the leveling layer and the micro-expansion cement-based composite material layer, gaps are between the boards, the gaps are filled with the micro-expansion cement-based composite material, the boards and the leveling layer are bonded by the viscosity of the leveling layer before solidification and hardening, and the boards and the micro-expansion cement-based composite material layer are bonded by the viscosity of the micro-expansion cement-based composite material layer before solidification and hardening; the micro-expansion cement-based composite material in the micro-expansion cement-based composite material layer comprises ECC concrete and one or both of an expanding agent and a shrinkage reducing agent. The application has the advantages of excellent anti-permeability, light weight, good rigidity, high strength, low cost, simple process and high construction efficiency.

Description

Technical Field

[0001] This invention relates to the field of building engineering, specifically to a self-stressing waterproof roofing composite panel, a waterproof structure, and a construction method thereof. Background Technology

[0002] Roofing is a crucial part of building construction, and the quality of roof waterproofing directly affects the lifespan of a building. During rainy days, typhoons, and other severe weather, rainwater can seep into ceilings, causing wall cracks, leaks, and mold growth. In severe cases, it can lead to large-scale wall peeling, affecting structural durability and even causing serious safety accidents. In recent years, roof leaks have been one of the most frequently reported problems in building construction. Waterproofing warranties are often long, and once a leak occurs, all structural layers of the roof must be excavated, resulting in a massive amount of rework. Sometimes, even after complete excavation, the leak cannot be found, leading to a significant waste of materials and manpower.

[0003] Roof waterproofing projects often use rolled waterproofing membranes and sealant-coated waterproofing films. However, after prolonged exposure to wind, sun, and rain, these materials are prone to deformation and aging, leading to leaks. Compared to flexible waterproofing layers, rigid waterproofing layers have a longer service life, are less affected by wind and rain, and can maintain a stable waterproofing effect over a long period. However, ordinary fine aggregate concrete rigid waterproofing layers are susceptible to structural deformation, temperature and humidity changes, and other factors, causing the waterproofing layer to crack and weakening the structure's waterproofing effect.

[0004] Fiber-reinforced cementitious composites (ECC) are strain-hardening and multi-crack-prone materials with outstanding ultimate tensile strain capacity, ranging from 1.7% to 7%. ECC's unique crack control allows crack widths to remain within 100 micrometers even with strains exceeding 3%, resulting in significantly superior impermeability and resistance to chloride ion attack compared to ordinary concrete. Furthermore, ECC exhibits strong resistance to various corrosive environments, making it an ideal material for durability and protecting internal steel reinforcement in structures. However, ECC typically experiences significant drying shrinkage, reaching −1500 με after 28 days. In roof waterproofing projects, this shrinkage can easily lead to cracking and leakage problems. Summary of the Invention

[0005] The purpose of this invention is to address the problems existing in existing ECC waterproof roof panels by providing a self-stressing waterproof roof panel composed of aluminum and high-ductility cement-based composite materials. This solution aims to address the cracking problem caused by drying shrinkage in cast-in-place ECC waterproof roof panels, reduce costs, and improve the impermeability and durability of the structure.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a self-stressing waterproof roofing composite panel, comprising a leveling layer, multiple panels, and a micro-expansion cement-based composite material layer. The panels are located between the leveling layer and the micro-expansion cement-based composite material layer, and there are gaps between the panels. The gaps are filled with the micro-expansion cement-based composite material. The panels are bonded to the leveling layer by adhesive bonding before the leveling layer solidifies and hardens, and the panels are bonded to the micro-expansion cement-based composite material layer by adhesive bonding before the micro-expansion cement-based composite material layer solidifies and hardens.

[0007] The micro-expansion cement-based composite material in the micro-expansion cement-based composite material layer includes ECC concrete and one or two of an expansion agent and a shrinkage reducer; wherein the expansion agent is 75-150 parts, the shrinkage reducer is 15-45 parts, the ECC concrete includes 480-520 parts, the expansion cement includes 950-1100 parts fly ash, 20-30 parts PVC fiber, 460-490 parts water, and 380-430 parts fine quartz sand.

[0008] Optionally, the coefficient of thermal expansion of the micro-expansion cement-based composite material is 0.01%–0.05%.

[0009] Optionally, the sheet material is a regular polygon.

[0010] Optionally, the sheet material is a metal sheet.

[0011] Optionally, the metal sheet is an aluminum sheet.

[0012] Optionally, the plate is a rectangular plate with a width of 1000-1300mm, a length of 1000-1300mm, and a thickness of 1.5-3mm, and the gap width is 10-30mm.

[0013] Optionally, the edge of the plate is provided with a rolled edge, which is rolled up toward the side of the micro-expansion cement-based composite material layer.

[0014] Optionally, a plurality of shear connectors are provided on the side of the plate that is bonded to the leveling layer, and the shear connectors are located at the four corners of the plate.

[0015] Optionally, the shear connector is a stud.

[0016] The waterproof structure using the above-mentioned self-stressing waterproof roofing composite panel includes the self-stressing waterproof roofing composite panel and a parapet wall, with a gap between the self-stressing waterproof roofing composite panel and the parapet wall, the gap being filled with a sealant.

[0017] Optionally, an additional layer may also be included, which spans across the self-stressing waterproof roofing assembly and the parapet wall, completely covering the transition area between the self-stressing waterproof roofing assembly and the parapet wall.

[0018] Optionally, the additional layer is a roll of material laid on the waterproof roofing assembly and the parapet wall, or a coating applied to the waterproof roofing assembly, the parapet wall, and the area where they meet.

[0019] Optionally, the parapet wall is a concrete structure, and the end of the roll material on the parapet wall is fixed to the wall with a pressure strip.

[0020] Optionally, a cover plate is provided at the pressure strip.

[0021] Optionally, the parapet wall is a brick wall structure with a groove, and the end of the roll material on the parapet wall is fixedly sealed in the groove.

[0022] The construction method of the above-mentioned waterproof structure is characterized by including the following steps.

[0023] Prefabricate multiple panels;

[0024] 1. Use cement mortar to lay a leveling layer on the roof, and lay the boards on the leveling layer before the leveling layer cures, leaving gaps between the boards. After the leveling layer cures, an effective bond is formed between the leveling layer and the boards.

[0025] 1. Pour a layer of micro-expansion cement-based composite material to fill the gaps between the boards, and then vibrate and compact it, smooth and polish it.

[0026] Water is sprayed to cure the micro-expansion cement-based composite material layer. The expansion of the micro-expansion cement-based composite material causes the boards to be squeezed against each other. After the micro-expansion cement-based composite material hardens and is formed, a self-stressed waterproof roofing composite board is formed.

[0027] The gaps between the self-stressing waterproof roofing panels are filled with sealant.

[0028] Optionally, a roll or coating film can be laid on one side of the self-stressing waterproof roofing panel and the parapet wall as an additional layer.

[0029] Optionally, when the parapet wall is a concrete structure, the end of the roll material on the parapet wall is fixed to the parapet wall by a strip; when the parapet wall is a brick wall structure, the end of the roll material on the parapet wall is sealed and fixed in a groove pre-set on the parapet wall.

[0030] Optionally, when the parapet wall is a concrete structure, a cover plate can be installed on the molding strip as a rain shield.

[0031] Optionally, the cover plate is made of metal or synthetic polymer material.

[0032] The advantages and positive effects of this invention are: due to the adoption of the above technical solution, it has excellent impermeability, light weight, good rigidity, high strength, low cost, simple process, and high construction efficiency. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the overall structure of a specific embodiment of the present invention;

[0034] Figure 2 yes Figure 1 Top view;

[0035] Figure 3 , Figure 4 yes Figure 1 Schematic diagram of the aluminum plate structure;

[0036] Figure 5 yes Figure 1 Schematic diagram of a partial cross-section structure;

[0037] Figure 6 , Figure 7 This is a schematic diagram of a waterproof structure;

[0038] In the diagram: 1. Aluminum plate; 2. Gap; 3. Micro-expansion cement-based composite material layer; 4. Rolled edge; 5. Stud; 6. Cement leveling layer; 7. Self-stressing waterproof roofing composite panel; 8. Parapet wall; 9. Void; 10. Additional layer; 11. Termination of the roll material; 12. Pressure strip; 13. Cover plate. Detailed Implementation

[0039] The present invention will be further described in detail below with reference to specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In the description of the present invention, it should be understood that the terms "center," "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. In the description of the present invention, it should be noted that unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention through specific circumstances.

[0040] like Figures 1 to 5 As shown, the present invention provides a self-stressing waterproof roofing composite panel, comprising a cement mortar leveling layer, multiple rectangular aluminum plates 1, and a micro-expansion cement-based composite material layer 3. The aluminum plates 1 are located between the leveling layer 6 and the micro-expansion cement-based composite material layer 3, and there are gaps 2 of 10-30mm between the aluminum plates 1. The gaps 2 are filled with micro-expansion cement-based composite material. The edges of the aluminum plates 1 are provided with rolled edges 4, and the four corners of the surfaces of the aluminum plates 1 in contact with the leveling layer 6 are provided with studs 5. The aluminum plates 1 are bonded to the leveling layer 6 by the adhesiveness of the leveling layer 6 before curing, and to the micro-expansion cement-based composite material layer 3 by the adhesiveness of the micro-expansion cement-based composite material before curing.

[0041] Micro-expansion cement-based composite materials include ECC concrete and one or two of the following: an expansion agent and a shrinkage-reducing agent. Commercially available engineering-grade expansion agents (such as CSA expansion agents, alum stone expansion agents, U-shaped expansion agents, and iron filings expansion agents) and shrinkage-reducing agents (such as alcohol-based shrinkage-reducing agents, polyoxyethylene shrinkage-reducing agents, and multi-component shrinkage-reducing agents) are suitable. The composite material contains 137 parts expansion agent and 31 parts shrinkage-reducing agent. The ECC concrete includes 490 parts silicate cement, 1077 parts fly ash, 26 parts PVA fiber, 470 parts water, and 400 parts fine quartz sand, with an expansion coefficient of 0.01%-0.05%.

[0042] The dimensions of aluminum plate 1 are determined according to the actual construction area, with a width of 1000-1300mm, a length of 1000-1300mm, and a thickness of 1.5-3mm.

[0043] In the aforementioned self-stressing waterproof roofing composite panel 7, the internal panels enhance the strength of the panel and reduce overall deformation. While metal panels offer better rigidity and strength, the aluminum panels chosen in this embodiment possess advantages such as light weight, high rigidity, high strength, good ductility, ease of processing, and excellent impermeability. The main body of the self-stressing waterproof roofing composite panel 7 is composed of aluminum panels 1, connected as a whole by high-ductility fiber-reinforced cement-based composite material, resulting in minimal deformation and effectively preventing cracking caused by drying shrinkage of the high-ductility fiber-reinforced cement-based composite ECC waterproof roofing panel. Simultaneously, the rolled edges 4 on the aluminum panels 1 increase the contact area between the edges of the aluminum panels 1 and the micro-expansion cement-based composite material, improving the bond between them. Furthermore, the aluminum panels 1 are low-cost and economically efficient, and the prefabricated construction method of the aluminum panels 1 improves construction efficiency and shortens the construction period. Finally, the shear connectors (studs 5) on the aluminum panels 1 effectively enhance the bond between the aluminum panels 1 and the leveling layer 6.

[0044] High-ductility fiber-reinforced cementitious composite material (ECC) has excellent basic mechanical properties such as deformation energy dissipation and crack control, as well as long-term durability properties such as waterproofing, seepage resistance, corrosion resistance, and frost resistance. Therefore, using ECC to make waterproof roof panels can not only meet the requirements of roof structure safety and waterproof performance and enhance the durability and safety of the structure, but also effectively avoid later repair and maintenance costs and material waste.

[0045] like Figure 6 , Figure 7 The present invention also provides a waterproof structure using the above-mentioned self-stressing waterproof roofing composite panel, including a self-stressing waterproof roofing composite panel 7 and a parapet wall 8. A gap 9 is reserved between the self-stressing waterproof roofing composite panel 7 and the parapet wall 8 and is filled with a sealant. The sealant can be a two-component polystyrene sealant, polyurethane building sealant, silicone sealant, water-swellable waterproof sealant, flexible filler, polyvinyl chloride putty, etc. An additional layer 10 is attached to the self-stressing waterproof roofing composite panel 7. The additional layer 10 covers the self-stressing waterproof roofing composite panel 7, the parapet wall 8 and the area where the two are connected. The additional layer 10 can be a roll material or a waterproof coating.

[0046] like Figure 6 As shown, if roll material is selected as the additional layer 10 and the parapet wall 8 is a concrete structure, the end 11 of the roll material can be directly fixed to the parapet wall 8 with the pressure strip 12, and a cover plate 13 as a rain shield is erected at the fixed position. The cover plate 13 is made of metal or synthetic polymer material.

[0047] like Figure 7 As shown, if roll material is selected as an additional layer and the parapet wall is a brick wall structure, a groove is reserved on the parapet wall, and the end of the roll material is fixed and sealed in the groove.

[0048] The present invention also provides a construction method for the above-mentioned waterproof structure, the steps of which are as follows:

[0049] 1. Prefabricate aluminum plates 1 of appropriate size and quantity according to the area of ​​the construction operation, wherein aluminum plates 1 are provided with rolled edges 4 and studs 5 are processed at the four corners;

[0050] 1. Use cement mortar to lay leveling layer 6 on the roof, and lay aluminum plate 1 on leveling layer 6 before leveling layer 6 cures. Leave gap 2 between aluminum plates 1. After leveling layer 6 cures, effective adhesion is formed between leveling layer 6 and aluminum plate 1.

[0051] 1. Pour a layer of micro-expansion cement-based composite material to fill the gaps 2 between the boards, and then vibrate and compact it, smooth and polish it.

[0052] Water is sprayed to cure the micro-expansion cement-based composite material layer 3. The expansion of the micro-expansion cement-based composite material causes the boards to be squeezed against each other. After the micro-expansion cement-based composite material hardens and is formed, a self-stressed waterproof roofing composite board 7 is formed.

[0053] The gaps 9 between the self-stressing waterproof roofing panels 7 are filled with sealant.

[0054] A layer of rolled material or a waterproof coating is installed on the self-stressing waterproof roofing composite panel 7 and the parapet wall 8 as an additional layer 10. If rolled material is selected as the additional layer 10, the end 11 of the rolled material is sealed and fixed at the connection with the parapet wall 8.

[0055] The embodiments of the present invention have been described in detail above, but the content described is only a preferred embodiment of the present invention and should not be considered as limiting the scope of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the patent coverage of the present invention.

Claims

1. A self-stressing waterproof roofing composite panel, characterized in that: The system includes a leveling layer, multiple boards, and a micro-expansion cement-based composite material layer. The boards are located between the leveling layer and the micro-expansion cement-based composite material layer, and there are gaps between the boards. The gaps are filled with the micro-expansion cement-based composite material. The boards are bonded to the leveling layer by adhesive bonding before the leveling layer solidifies and hardens, and the boards are bonded to the micro-expansion cement-based composite material layer by adhesive bonding before the micro-expansion cement-based composite material layer solidifies and hardens. The micro-expansion cement-based composite material in the micro-expansion cement-based composite material layer includes ECC concrete and one or two of an expansion agent and a shrinkage-reducing agent; wherein the expansion agent is 75-150 parts, the shrinkage-reducing agent is 15-45 parts, and the ECC concrete includes 480-520 parts of silicate cement, 950-1100 parts of fly ash, 20-30 parts of PVA fiber, 460-490 parts of water, and 380-430 parts of fine quartz sand. The coefficient of thermal expansion of the micro-expansion cement-based composite material is 0.01%–0.05%. The plate material is a regular polygon; The sheet material is a metal sheet; The metal sheet is an aluminum sheet; The board material is a rectangular board with a width of 1000-1300mm, a length of 1000-1300mm, and a thickness of 1.5-3mm; the gap width is 10-30mm. The edge of the plate is provided with a rolled edge, and the rolled edge is turned up toward the side of the micro-expansion cement-based composite material layer; Multiple shear connectors are provided on the side of the plate that is bonded to the leveling layer, and the shear connectors are located at the four corners of the plate. The shear connector is a stud.

2. A waterproof structure using the self-stressed waterproof roofing composite panel according to claim 1, characterized by: The system includes the self-stressing waterproof roofing panel and the parapet wall, with a gap between the self-stressing waterproof roofing panel and the parapet wall, the gap being filled with a sealant.

3. The waterproof structure according to claim 2, characterized by: It also includes an additional layer that spans across the self-stressing waterproof roofing assembly and the parapet wall, completely covering the transition area between the self-stressing waterproof roofing assembly and the parapet wall.

4. The waterproof structure according to claim 3, characterized by: The additional layer is either a roll of material laid on the waterproof roofing panel and the parapet wall, or a coating applied to the waterproof roofing panel, the parapet wall, and the area where they meet.

5. The waterproof structure according to claim 4, characterized by: The parapet wall is a concrete structure, and the end of the roll material on the parapet wall is fixed to the wall with a pressure strip.

6. The waterproof structure according to claim 5, characterized in that: A cover plate is installed at the pressure strip.

7. The waterproof structure according to claim 4, characterized by: The parapet wall is a brick wall structure with a groove, and the end of the roll material on the parapet wall is fixed and sealed in the groove.

8. The waterproof construction method according to claim 2, wherein: Includes the following steps , pre-fabricated multi-piece panels; 1. Use cement mortar to lay a leveling layer on the roof, and lay the boards on the leveling layer before the leveling layer cures, leaving gaps between the boards. After the leveling layer cures, an effective bond is formed between the leveling layer and the boards.

1. Pour a layer of micro-expansion cement-based composite material to fill the gaps between the boards, and then vibrate and compact it, smooth and polish it. Water is sprayed to cure the micro-expansion cement-based composite material layer. The expansion of the micro-expansion cement-based composite material causes the boards to be squeezed against each other. After the micro-expansion cement-based composite material hardens and is formed, a self-stressed waterproof roofing composite board is formed. The gaps between the self-stressing waterproof roofing panels are filled with sealant.

9. The construction method according to claim 8, characterized in that: A roll or coating is laid on one side of the self-stressing waterproof roofing panel and the parapet wall as an additional layer.

10. The construction method according to claim 9, characterized in that: When the parapet wall is a concrete structure, the end of the roofing membrane on the parapet wall is fixed to the parapet wall by a strip; when the parapet wall is a brick structure, the end of the roofing membrane on the parapet wall is sealed and fixed in a groove pre-set on the parapet wall.

11. The method of construction according to claim 9, wherein: When the parapet wall is a concrete structure, a cover plate is installed on the molding strip as a rain shield.

12. The method of construction according to claim 11, wherein: The cover plate is made of metal or synthetic polymer material.

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