Roof repairing method

Abstract

The present invention provides a roof repair method and a roof protection method by which a damaged portion of a roof of a structure can be easily repaired and water penetration can be sufficiently prevented. In a roof repair method, a repair sheet is adhered to a damaged portion of a roof of a structure, the repair sheet comprising a functional layer and an adhesive layer disposed on a roof side of the structure, the method includes a first step of laying the liner to cover the damaged portion of the roof and a second step of adhering a surface on the adhesive layer side of the repair sheet from above the liner.

Description

Technical Field

[0001] The present invention relates to a method for repairing a roof of a structure such as a house or a building. Background Art

[0002] Typically, when the roof of a structure such as a house or commercial building deteriorates due to long-term exposure to wind and rain or is damaged by natural disasters such as typhoons, the deterioration and damage may lead to water leakage. When the roof of a structure deteriorates or is damaged, emergency measures are required, such as Figure 7 The method shown is generally used as an emergency measure for the roof of a structure, for example, in which a blue sheet 31 is placed to cover the damaged position of a roof 30, and then a plurality of sandbags 32 are set as weights on the blue sheet 31. Further, in addition to the method of setting the blue sheet 31 using weights such as sandbags 32, for example, PTL 1, PTL 2, etc. propose a method for fixing the blue sheet using a bag filled with water.

[0003] Reference List Patent Literature [PTL 1] Japanese Utility Model Registration No. 3225057 [PTL 2] Japanese Utility Model Registration No. 3116572. Summary of the invention

[0004] Technical issues In recent years, roofs formed by arranging a plurality of roof members (e.g., slate roofs, steel roofs, and asphalt shingle roofs) have become increasingly common as roofs of buildings, but the surfaces of these roofs are generally non-planar surfaces having a plurality of steps, and problems arise when conventional roof repair using a blue sheet 31 is applied to such roofs: it is difficult to prevent the blue sheet 31 from being creased and there is a gap between the blue sheet 31 and the roof, making it impossible to prevent water from penetrating through the gap. In addition, the weather resistance of the blue sheet is generally not very strong, and therefore deteriorates after about one year, after which the blue sheet must be replaced.

[0005] In addition, a method of adhering a repair sheet instead of a blue sheet is also known as a method for repairing the roof of a structure, but when a conventional repair sheet is used to repair the surface of the roof, a gap is formed between the repair sheet and the roof surface due to the unevenness of the damaged portion, making it impossible to solve the problem of sufficiently preventing water penetration.

[0006] The present invention has been designed in consideration of these current circumstances, and an object of the present invention is to provide a roof repair method and a roof protection method by which a damaged portion of a roof of a structure can be easily repaired and water penetration can be sufficiently prevented.

[0007] Solution to the problem The roof repair method of the present disclosure is a roof repair method in which a repair sheet is adhered to a damaged portion of a roof of a structure, wherein the repair sheet includes a functional layer and an adhesive layer provided on the roof side of the structure, the method including a first step of laying a mat to cover the damaged portion of the roof and a second step of adhering a surface on the adhesive layer of the repair sheet from above the mat.

[0008] Advantageous Effects of the Invention According to the present disclosure, it is possible to provide a roof repair method and a roof protection method, by which a damaged portion of a roof of a structure can be easily repaired and water penetration can be sufficiently prevented. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] [ Figure 1 ] Figure 1 A and Figure 1 B is a cross-sectional view showing an example configuration of a repair sheet according to the present disclosure; [ Figure 2 ] Figure 2 A and Figure 2 B is a schematic diagram showing the manner in which a repair sheet according to the present disclosure is adhered to a roof member and / or underlayment; [ Figure 3 ] Figure 3 is a schematic diagram showing an example of a roof having a damaged portion; [ Figure 4 ] Figure 4 A is a schematic diagram showing an example of a pad, Figure 4 B and Figure 4 C is a cross-sectional view showing an example of a roof repair method of the present disclosure; [ Figure 5 ] Figure 5 A and Figure 5 B is a cross-sectional view showing another example configuration of a repair sheet according to the present disclosure; [ Figure 6 ] Figure 6 A is a schematic diagram showing an example of a mesh layer of a repair sheet according to the present disclosure, and Figure 6 B is Figure 6 A magnified view of the grid layer; [ Figure 7 ] Figure 7 It is a schematic diagram of conventional roof repair methods; [ Figure 8 ] Figure 8 is a schematic diagram showing another example of a pad; [ Fig. 9 ] Fig. 9is a cross-sectional view illustrating another example of a roof repair method of the present disclosure. DETAILED DESCRIPTION

[0010] An embodiment of the roof repair method of the present disclosure will be described below with reference to the accompanying drawings. It should be noted that the present disclosure is not limited to the aspects described below and shown in the accompanying drawings, and various modifications may be made to the present disclosure as long as its technical features are included.

[0011] As a result of the research devoted to the method for repairing the damaged portion of the roof of the structure, the inventors were able to eliminate the gap between the repair sheet and the roof by using a pad formed to cover the damaged portion. In addition, the inventors were able to provide the repair sheet with performance corresponding to the characteristics of the roof, or more specifically, a layer showing adaptability so as to be able to adapt to cracks and bulges on the roof, waterproof, salt-proof, and carbonization-proof to prevent the penetration of deteriorating factors (such as water and chloride ions), etc., and also ensure the strength of the repair sheet itself. Moreover, these technical concepts can be applied as a repair method using the repair sheet to members other than the roof of the structure, such as the wall, eaves, fence, gate post, gate, door top, etc. of the structure.

[0012] The present disclosure relates to a roof repair method (hereinafter also referred to as the repair method of the present disclosure) in which a repair sheet is adhered to a damaged portion of a roof of a structure.

[0013] The roof repair method of the present disclosure is a roof repair method in which a repair sheet is adhered to a damaged portion of a roof of a structure, wherein the repair sheet includes a functional layer and an adhesive layer provided on the roof side of the structure, and the method includes a first step of laying a mat to cover the damaged portion of the roof and a second step of adhering the surface on the adhesive layer side of the repair sheet from above the mat. It should be noted that the damaged portion is a portion where part of the original state is missing, such as a notch, a through hole, or a concave hole.

[0014] According to the roof repair method of the present disclosure, the repair sheet can be adhered via the pad covering the damaged portion formed in the roof, and thus the repair sheet can be adhered to the uneven damaged portion without forming a gap between the roof and the repair sheet. Therefore, water penetration can be fully prevented. In addition, the repair sheet is highly durable when it is set on the damaged portion of the roof surface, and thus the repaired state can be maintained for a long time. Therefore, the roof member having the damaged portion can be used without being discarded, thereby enabling contribution to the so-called circular economy.

[0015] According to the present disclosure, a roof repair method and a roof protection method using a repair sheet can be provided, by which a roof of a structure having a damaged portion can be easily repaired without forming a gap and the roof is in a repaired state for a long time. More specifically, a roof repair method and a roof protection method can be provided, by which a repair sheet can be adhered to a damaged portion of a roof without forming a gap, the repair sheet having properties corresponding to the characteristics of the roof of the structure and formed to adapt to cracks and bulges on the roof, preventing deterioration factors (such as water and chloride ions) from penetrating the roof of the structure, the repair sheet is permeable so that moisture and deterioration factors of the roof of the structure can be discharged, the strength of the repair sheet is improved, etc. Another advantage is that the quality stability and uniformity of the coating for repairing water leakage at the application site can be improved compared with the method of laminating a plurality of manual coating layers.

[0016] Figure 3 is a schematic diagram showing a portion of a roof formed by arranging a plurality of roof members, which can be repaired by the repair method of the present disclosure, wherein the roof 30 has a damaged portion 20. There is no particular limitation on the roof 30, and any conventional, well-known roof may be used, including a roof formed by arranging a plurality of roof members, a flat roof, etc.

[0017] The repair method of the present disclosure includes a first step of laying a pad to cover the damaged portion of the roof. As long as the pad is shaped to cover the damaged portion of the roof, there is no particular limitation on its shape, for example, the pad can be shaped to include a flat plate and a side plate connected to the flat plate.

[0018] The pad may also be formed to include a flat plate and side plates connected to the flat plate, wherein the flat plate and the side plates form a bent portion having an L-shaped cross-section. Figure 4 A is a schematic diagram showing an example of a pad. Figure 4 In the pad 22 shown in A, a bent portion 23 having an L-shaped cross section is formed by a flat plate 24 and a side plate 25 connected to the flat plate. Therefore, the side plate 25 of the bent portion 23 can be hooked on the end of the roof member, with the result that the pad can be stably laid on the damaged portion of the roof, thereby advantageously preventing the formation of creases on the repair sheet.

[0019] Regarding the shape of the pad, as a shape including a flat plate and a side plate connected to the flat plate, two flat plates may be provided, and the side plates may be connected to the two flat plates so that the two flat plates and the side plates form a bent portion having an angled U-shaped cross section. Figure 8 is a schematic diagram showing an example thereof. Figure 8On the illustrated pad 22, a bent portion 23 having an angled U-shaped cross section is formed by two flat plates 24 and side plates 25 connected to the two flat plates 24. Therefore, the side plates 25 of the bent portion 23 can be hooked on the ends of the roof member, with the result that the pad can be stably laid on the damaged portion of the roof, thereby advantageously preventing the formation of creases on the repair sheet.

[0020] In the present disclosure, a material having a certain degree of synthetic property and bendability is preferably used as the material of the gasket, and examples thereof include metal materials (such as metal sheets), resin materials (such as thermoplastic resins or thermosetting resins), etc. Among these materials, metal sheets are preferably used in consideration of cost and ease of machining.

[0021] In the present disclosure, there is no particular limitation on the size of the pad as long as the pad can be laid to cover the damaged portion of the roof. However, particularly in the case of a roof formed by arranging a plurality of roof members, the pad is preferably larger than one of the roof members forming the roof. As will be described below, the pad can be stably fixed to the damaged portion of the roof, and its purpose is to advantageously prevent creases from being formed when the repair sheet is adhered.

[0022] In the first step, the lining is laid to cover the damaged portion of the roof. When the roof is formed by at least one roof member, in the first step, the lining is laid to cover at least a portion of the upper surface of the roof member and also to cover the end surface. Further, in the first step, the lining is preferably laid to at least partially cover the upper surface and the rear surface of the roof member and also to cover the end surface. By laying the lining on the damaged portion in this way, the lining can be fixed in an advantageous manner, as a result of which the formation of creases when the repair sheet is adhered to the upper surface of the lining can be advantageously prevented.

[0023] More specifically, at this time, if Figure 4 As shown in FIG. 2B , the pad 22 is preferably laid on the damaged portion 20 so that the flat plate of the pad 22 is inserted into the gap between the roof member 21 having the damaged portion 20 and the roof member 21 above the roof member 21 having the damaged portion 20, and the side plate 25 of the pad contacts the end of the roof member 21 having the damaged portion 20. Therefore, the pad can be stably laid on the damaged portion, the formation of creases on the repair sheet can be advantageously prevented, and water penetration can be prevented for a long period of time.

[0024] Specific examples of the case where the underlay is laid in the first step so as to at least partially cover the upper and rear surfaces of the roof member and also cover the end surfaces include: (1) Fig. 9The case shown in FIG. 1 , in which the pad is laid so that a flat plate of the pad 22 is inserted into each of a gap between a roof member 21 having a damaged portion 20 and a roof member 21 above the roof member 21 having the damaged portion 20 and a gap between the roof member 21 having the damaged portion 20 and a roof member 21 below the roof member 21 having the damaged portion 20, and a side plate 25 of the pad contacts an end portion of the roof member 21 having the damaged portion 20; (2) a case in which the pad is laid so that a flat plate of the pad 22 is inserted into a gap between a roof member 21 having a damaged portion 20 and a roof member 21 below the roof member 21 having the damaged portion 20, but is not inserted into a gap between the roof member 21 having a damaged portion 20 and a roof member 21 above the roof member 21 having the damaged portion 20, and a side plate 25 of the pad contacts an end portion of the roof member 21 having the damaged portion 20, (3) a case in addition to the case (2), in which the top and bottom of the damaged portion 20 are covered by the pad 22, etc.

[0025] Further, by performing the second step of the roof repair method of the present disclosure, the repair sheet can be adhered to the damaged portion of the roof via the pad, thereby repairing the roof. It should be noted that the repair sheet is preferably shaped so as to cover the upper surface of the pad exposed to the outside. In addition, as an example of the second step, Figure 4 As shown in FIG. 2C, the surface on the adhesive layer side of the repair sheet 10 may be adhered from above the liner 22. Furthermore, the surface on the adhesive layer side of the repair sheet 10 may be adhered from above both the liner 22 and the roof member 21 so as to cover both.

[0026] The roof repair method according to the present disclosure is fundamentally different from the conventional method of setting a blue sheet, which is a method for temporary weatherproofing, and can achieve a more permanent and durable repair than the conventional repair by extremely simple operation. The reason for this is that the repair sheet according to the present disclosure exhibits excellent waterproof and salt blocking properties, and thus can protect the roof material from the material that penetrates into the roof material.

[0027] In the roof repair method of the present disclosure, before the first step of laying a mat to cover the damaged part of the roof, the damaged part can be roughly restored in advance by filling the damaged part with a resin material (such as a urethane resin, a urethane foam resin, or a polyurea resin), an inorganic material (such as mortar or cement, etc.). The advantage of urethane resins and polyurea resins is that the strength of the roof can be easily improved after repair, while the advantage of urethane foam resins is that the strength of the roof can be particularly improved after repair. Non-fluorocarbon urethane foam resins that do not cause global warming and are therefore environmentally friendly are preferred as urethane foam resins. Hard urethane foam resins prepared from polyols and isocyanates, etc. can be cited as examples of non-fluorocarbon urethane foam resins. More specifically, a combination of non-fluorocarbon polyol FF5020-UC manufactured by NIHON PUFTEM Co., Ltd. of Japan and isocyanate NP-90 manufactured by the same company can be cited as an example. Further, inorganic materials (such as mortar or cement) are particularly suitable for repairing flat roofs.

[0028] The roof repair method of the present disclosure may also be applied where a portion of the roof of a structure is already covered by another underlayment and damage occurs in the portion not covered by the other underlayment.

[0029] [Repair sheet] The repair sheet used in the repair method of the present disclosure includes a functional layer and an adhesive layer disposed on the roof side of the structure.

[0030] (Adhesive layer) By forming an adhesive layer on the roof side of the repair sheet, in the second step of adhering the repair sheet, it is not necessary to form an adhesive layer by applying an adhesive at the application position, and therefore excellent work efficiency can be achieved. Moreover, the repair sheet can be adhered to the surface of the roof, etc. via an adhesive layer with uniform thickness, without the need for skilled craftsmen. In addition, by providing an adhesive layer, the adhesive layer can be embedded in the depression on the uneven roof surface, and therefore the adhesion of the repair sheet can be improved. Moreover, the repair sheet can be mass-produced by performing a coating step and a drying step on a factory production line, and therefore according to the present disclosure, cost reduction, a significant reduction in on-site work time, and long-term protection of the roof of the structure can be achieved. In addition, the repair sheet is adhered to the roof via an adhesive layer and therefore exhibits excellent adhesion, etc., and the functional layer can have excellent performance in terms of waterproofing, salt resistance, carbonization resistance, etc.

[0031] The adhesive layer may be an adhesive layer formed using a pressure-sensitive adhesive or an adhesive layer formed using an adhesive, but in consideration of the pot life of the adhesive layer, a pressure-sensitive adhesive layer is preferred. Here, a pressure-sensitive adhesive is an adhesive having a predetermined elastic and sticky surface initially, and when the adhesive is pressed against an adherend, adhesion to the adherend is generated, while the adhesive is in a liquid state or a state having a predetermined fluidity before hardening, but becomes a solid state or a state maintaining a predetermined shape after hardening, thereby generating adhesion to the adherend.

[0032] There is no particular limitation on the pressure-sensitive adhesive, and well-known pressure-sensitive adhesives such as acrylic pressure-sensitive adhesives, silicone pressure-sensitive adhesives, urethane pressure-sensitive adhesives, or rubber pressure-sensitive adhesives can be cited as examples thereof. In the present disclosure, the adhesive layer is preferably formed of an acrylic pressure-sensitive adhesive. Using an acrylic pressure-sensitive adhesive, its adhesive strength to a roof having a ridge and a beam can be easily adjusted, so that a high degree of freedom is obtained in terms of material design. Moreover, the acrylic pressure-sensitive adhesive has excellent transparency, weather resistance, and heat resistance, and therefore can be advantageously used when the repair sheet is used to reinforce a roof having a ridge.

[0033] The acrylic pressure-sensitive adhesive is not particularly limited, and for example, commercially available products such as ORIBAIN (registered trademark) 6574 (manufactured by TOYOCHEM CO., LTD.) and the like can be used.

[0034] The lamination amount of the adhesive layer formed of the acrylic pressure-sensitive resin described above (hereinafter also referred to as a pressure-sensitive adhesive layer) is preferably not less than 20 g / m in order to obtain sufficient adhesive strength to the roof surface having a ridge. 2 And not more than 250 g / m 2 Furthermore, the adhesive strength obtained when the repair sheet is adhered to the surface of the liner via the pressure-sensitive adhesive layer described above is preferably not less than 0.5 N / mm 2 . Less than 0.5 N / mm 2 When the repair sheet is applied to the roof, the repair sheet may not exhibit sufficient adhesion to the surface of the roof, etc.

[0035] When the adhesive layer formed on the repair sheet is an adhesive layer composed of an adhesive, there is no particular limitation on the adhesive, and a well-known adhesive such as a UV curable adhesive or a heat curable adhesive can be used. Examples of such adhesives include urethane adhesives, epoxy resin adhesives, adhesives using acrylic resins having rubber properties (e.g., synthetic rubber having acrylate as a main component), etc. Among these adhesives, in the case where the repair sheet includes an adhesive layer, an intermediate layer, and a functional layer in this order and the intermediate layer is a layer formed of a composite material containing a filler and a resin, as will be described below, an adhesive having a resin component of the same type as that constituting the intermediate layer allows the adhesive strength relative to the intermediate layer to be increased, and is therefore preferred.

[0036] In the repair sheet described above, the adhesive layer preferably includes a hardener. By including the hardener, a greater adhesive strength can be obtained with respect to the surface of the roof having a ridge or the like, and a greater push-out strength can also be obtained in the repair sheet.

[0037] In the present disclosure, in the push-out test defined in JSCE-K-533, the push-out strength of the repair sheet is preferably not less than 1.5 kN. By setting the push-out strength at 1.5 kN or more, the collapse of the roof having the ridge reinforced by the repair sheet can be more advantageously prevented.

[0038] The hardener is not particularly limited, and a well-known hardener such as an isocyanate hardener, an amine hardener, an epoxy resin hardener, or a metal chelate hardener may be used.

[0039] In order for the repair sheet to exhibit excellent adhesive strength and push-out strength relative to the roof surface, cushion surface, etc., the gel fraction of the adhesive layer is preferably 30% to 70%, more preferably having a lower limit of 40% and an upper limit of 65%.

[0040] In the repair sheet described above, the thickness of the adhesive layer is preferably 50 μ m to 500 μ m. When the thickness is less than 50 μ m, the bonding strength of the repair sheet to the roof surface, underlayment surface, etc. may be insufficient, and when the thickness exceeds 500 μ When the thickness of the repair sheet is less than 100 μm, the thickness is more likely to vary, and when the repair sheet is smoothed by a roller or the like to obtain a smooth application surface when applied, excess adhesive may escape from the end of the repair sheet. A more preferred lower limit of the thickness of the adhesive layer is 90 μm. μ m, more preferably the upper limit is 200 μ m.

[0041] like Figure 1 A and Figure 1 The repair sheet 10 shown in B, the repair sheet described above preferably includes at least an intermediate layer 12 and a functional layer 13 disposed on the intermediate layer 12. The intermediate layer 12 and the functional layer 13 can both be formed by a single layer (such as Figure 1 A), or may be formed of laminated layers (such as Figure 1 B). Further, a separate layer may be provided between the intermediate layer 12 and the functional layer 13 according to the required performance.

[0042] With the repair sheet having such a configuration, water leakage and the like can be prevented for a long time, with the result that the roof can be protected for a long time. In addition, the functional layer can be endowed with excellent performance in terms of waterproofing, salt resistance, carbonization resistance, etc. Moreover, the repair sheet described above can be mass-produced by performing the coating step and the drying step on a factory production line, making it possible to achieve cost reduction, a significant reduction in on-site work time, and long-term protection of the structural roof.

[0043] In order to protect the surface of the adhesive layer of the repair sheet, a release film is preferably adhered to the surface of the adhesive layer. Figure 1 A and Figure 1 As shown in FIG. 1B , when the repair sheet 10 includes the intermediate layer 12, the adhesive layer 15 having the configuration described above is preferably formed on the surface of the intermediate layer 12 opposite to the functional layer 13 side, and preferably forms a release film 16. There is no particular limitation on the release film, and for example, a film having a base material layer and a release layer can be used.

[0044] Examples of materials forming the substrate layer include polyesters (such as polyethylene terephthalate or polyethylene naphthalate), polyolefins (such as polyethylene, polypropylene or polymethylpentene), polyamides (such as nylon 6), vinyl resins (such as polyvinyl chloride), acrylic resins (such as polymethyl methacrylate), cellulose resins (such as cellulose acetate), or synthetic resins (such as polycarbonate). Further, the substrate layer may be formed with paper as a main component. In addition, the substrate layer may be a laminate of two or more layers.

[0045] Examples of materials forming the release layer include silicone resins, melamine resins, fluorinated polymers, and the like. The release layer may be formed by a coating method in which a substrate layer is coated with a coating liquid containing a material for forming a release layer and an organic solvent using a well-known method such as a gravure coating method, a roll coating method, a doctor blade coating method, or a lip coating method, and then the resulting layer is dried and hardened. In addition, when forming the release layer, a corona treatment and an easy adhesion treatment may be applied to the laminated surface of the substrate layer.

[0046] When the release film is attached to the repair sheet of the present disclosure, as Figure 2 A and Figure 2As shown in FIG. 2B , by peeling the release film 16 from the repair sheet 10 , the surface on the adhesive layer side of the repair sheet 10 can be adhered to the roof member 21 and / or the gasket 22 .

[0047] The repair sheet can be used in a state where two or more repair sheets are stacked. The roof surface reinforced by the repair sheet can be further reinforced by stacking, and for this purpose, when two repair sheets are adhered side by side, for example, another repair sheet can be adhered to cover the boundary between the repair sheets.

[0048] When the repair sheet of the present disclosure includes an intermediate layer and the intermediate layer of the repair sheet contains cement and resin, the laminated repair sheet also exhibits favorable adhesion to the functional layer of the repair sheet already adhered to the roof surface, etc. Therefore, the repair sheet can be advantageously used in a laminated state.

[0049] (Middle layer) It is sufficient that the repair sheet of the present disclosure includes a functional layer and an adhesive layer disposed on the roof side of the structure, but the repair sheet preferably includes an adhesive layer, an intermediate layer, and a functional layer disposed on the roof side of the structure in sequence. In this case, the intermediate layer may be a layer disposed between the functional layer and the adhesive layer of the repair sheet. For example, the intermediate layer may be a single layer (such as a layer obtained by not laminating) Figure 1 A), or may be a laminate obtained by laminating (such as Figure 1 B). Whether to use a single layer or a laminate can be set as desired in consideration of the total thickness, the functions provided (adaptability, adhesion to the roof, etc.), the factory production line, the production cost, etc., and, for example, when the production line is short so that a predetermined thickness cannot be obtained by a single layer, the intermediate layer can be formed by stacking and applying two or more layers. It should be noted that when two layers are applied, for example, the second layer is formed after the first layer is dried.

[0050] In addition, when the intermediate layer 12 has a laminated structure of two or more layers, such as Figure 1As shown in FIG. 2B, these layers can be formed by laminating layers having different characteristics. Among the two or more layers constituting the intermediate layer, by increasing the ratio of the same type of material as the material forming the functional layer in the layer on the functional layer side and increasing the ratio of the same type of material as the roof in the layer on the adhesive layer side, the intermediate layer exhibits excellent adhesion to both the functional layer and the roof, and therefore this is preferred. For example, as will be described below, when the functional layer is a layer formed of a resin and the roof is formed of slate (or more specifically, artificial slate), by forming the layer on the functional layer side to have a higher ratio of the resin component, the layer with a high resin content is adhered to the functional layer, and among the layers on the adhesive layer side, the layer with a high cement content is adhered to the roof having a ridge or the like, and therefore, the intermediate layer can be easily provided with excellent adhesion to both the functional layer and the roof.

[0051] The intermediate layer may be a layer that contributes to the rigidity of the repair sheet, etc., and the intermediate layer may be a layer formed of a composite material containing a filler and a resin. When the intermediate layer is a layer formed of a composite material containing a filler and a resin, the intermediate layer is obtained by, for example, forming a resin containing a filler (resin component) into a coating form and applying the coating.

[0052] When the intermediate layer contains cement as a filler of a composite material, the composite material is referred to as polymer cement. When the intermediate layer is specifically a layer formed of polymer cement, the intermediate layer is also referred to as a "polymer cement hardened layer".

[0053] As cement components, different types of cement, limestone containing a component made of calcium oxide, clay containing silicon dioxide, etc. can be used. Any type of cement can be used advantageously, for example, Portland cement, high-alumina cement, early-strength cement, fly ash cement, etc. can be used. The cement to be selected is determined according to the characteristics to be given to the intermediate layer (for example, the degree of adaptability to the roof). Portland cement defined by JIS R5210 can be cited as a particularly advantageous example. Further, in order to adjust the workability of Portland cement or its characteristics after application, a well-known composition in which silicon dioxide, aluminum oxide, aluminum oxide, titanium oxide, etc. are added to Portland cement can also be used.

[0054] As the resin component of the composite material used in the intermediate layer, acrylic resin, acrylic urethane resin, acrylic silicone resin, fluororesin, soft epoxy resin, polybutadiene rubber, acrylic resin having rubber properties (e.g., synthetic rubber having acrylate as a main component), etc. can be used. The resin component may be the same as the resin component forming the functional layer which will be described below.

[0055] In addition, any one of a thermoplastic resin, a thermosetting resin, and a photocurable resin may be used as the resin component. When the intermediate layer is a "polymer cement hardened layer", the term "hardened" does not mean that the resin component is limited to a resin that polymerizes when hardened (such as a thermosetting resin or a photocurable resin), but is used to mean that any material that hardens (cures into a layer) when forming the final layer can be used.

[0056] When the intermediate layer is a layer formed of a composite material containing a filler and a resin, the resin content of the composite material is preferably greater than or equal to 10% by weight and less than or equal to 40% by weight. When the resin content is less than 10% by weight, the adhesion to the functional layer tends to decrease, and it is difficult to maintain the intermediate layer as a layer, and when the resin content exceeds 40% by weight, the adhesion to the roof surface and the like may be insufficient. From these viewpoints, a more preferred range of the resin content is not less than 15% by weight and not more than 35% by weight, and an even more preferred range is not less than 20% by weight and not more than 30% by weight.

[0057] Moreover, by controlling the ratio of the filler and the resin component, it is easier to form the intermediate layer and to form the intermediate layer as a compatible layer exhibiting excellent adaptability, with the result that the adhesion of the layer itself tends to be improved. For example, when the intermediate layer is a polymer cement hardened layer, the cement component included in the polymer cement hardened layer plays a role in improving the adhesion with respect to the concrete roof.

[0058] For example, a method of coating the functional layer with a solution obtained by dissolving a material for forming the intermediate layer in a solvent and then removing the solvent can be used as a method for forming the intermediate layer.

[0059] More specifically, when the intermediate layer is a layer formed of a composite material containing a filler and a resin, the solution (coating) used to form the layer is a coating liquid obtained by mixing the filler and the resin component in a solvent. The resin component is preferably an emulsion. For example, an acrylic emulsion is composed of polymer fine particles obtained by emulsion-polymerizing a monomer such as an acrylic ester using an emulsifier, and an acrylic polymer emulsion obtained by polymerizing a monomer or a monomer mixture containing one or more of an acrylic ester and a methacrylic ester in water containing a surfactant can be cited as a preferred example thereof.

[0060] The content of the acrylic acid ester and the like constituting the acrylic emulsion is not particularly limited, and the content is selected from the range of 20% to 100% by mass. In addition, a surfactant is added in a desired amount and the amount thereof is not particularly limited. Therefore, a surfactant is added in an amount required to form an emulsion.

[0061] The intermediate layer can be formed by coating the release sheet or the functional layer formed on the release sheet with a solution (coating liquid) to be described below, the solution being obtained by dissolving the composite material for forming the intermediate layer in a solvent, then drying and removing the solvent. When the intermediate layer is a polymer cement hardening layer, the intermediate layer is preferably formed using a mixture composition containing a cement component, an acrylic emulsion, and water used as a solvent as a coating liquid. It should be noted that the functional layer can be formed on the release sheet after the intermediate layer is formed, or the intermediate layer can be formed on the release sheet after the functional layer is formed. In the present disclosure, the following method can be used to manufacture a repair sheet, for example, embossing or matte processing (forming an uneven shape) is performed on the release sheet, and then a functional layer (a single layer or a laminate of two or more layers) and an intermediate layer (a single layer or a laminate of two or more layers) are formed in sequence, and then a design is added to the functional layer.

[0062] In order to be able to impart the performance of excellent strength to the repair sheet used in the roof repair method of the present disclosure, the repair sheet may include a mesh layer described below. The mesh layer may be disposed inside the functional layer, the intermediate layer, or the adhesive layer, or between these layers. When the intermediate layer includes a mesh layer, for example, the functional layer is coated on the release sheet and dried, and then a coating liquid for forming the intermediate layer is applied, and then the mesh layer is adhered to the coating liquid in a wet state before drying and dried. The surface to which the mesh layer has been adhered is then further coated with the coating liquid to form the intermediate layer, and the resulting layer is subsequently dried, and thus a repair sheet having a mesh layer in the intermediate layer can be obtained.

[0063] A repair sheet having a grid layer within an intermediate layer can also be obtained by coating a release sheet with a functional layer, drying the resulting layer, applying a coating liquid for forming an intermediate layer, adhering the grid layer in a wet state before drying, and then further coating the surface to which the grid layer has been adhered with the coating liquid for forming the intermediate layer without a drying step, and then drying the entire sheet.

[0064] There is no particular limitation on the thickness of the intermediate layer, and the thickness is set as desired according to the size, age, shape, etc. of the roof member. For example, a range of 0.5 mm to 1.5 mm may be set as the specific thickness of the intermediate layer. For example, when the thickness is set to 1 mm, the variation in thickness is preferably maintained within ± 100 mm. μ m. This level of thickness accuracy cannot be achieved through field application, but can only be achieved through stable application on a factory production line. It should be noted that even when the thickness is greater than 1 mm, the thickness variation can be kept within ± 100 μ In addition, when the intermediate layer is thinner than 1 mm, the thickness variation can be further reduced.

[0065] For example, the filler, or more specifically the cement component of the intermediate layer, exhibits favorable compatibility with the cement component of the concrete, and thus the intermediate layer can be formed to exhibit excellent adhesion to the concrete surface. In addition, the intermediate layer can have stretchable properties, and thus can adapt to changes in the roof surface when cracks or bulges appear on the surface of the roof.

[0066] (Grid layer) like Figure 5 As shown in Figure A, in order to provide excellent bonding strength to the repair sheet 10, the mesh layer 17 is preferably provided between the adhesive layer 15 and the functional layer 13, and when the intermediate layer 12 is provided, the mesh layer 17 is preferably provided on the boundary between the intermediate layer 12 and the functional layer 13. The bonding strength is obtained by adhering the intermediate layer side surface of the repair sheet to the concrete surface via the adhesive layer, fixing a tensile jig to the surface of the functional layer, pulling the tensile jig toward the side opposite to the concrete side at a speed of 1500 n / min, and measuring the strength when tensile delamination occurs.

[0067] Furthermore, when the intermediate layer 12 is provided, the mesh layer 17 may be present in the interior of the intermediate layer 12, such as Figure 5 B. The mesh layer may be provided on the surface of the intermediate layer on the side opposite to the surface contacting the functional layer, but is preferably embedded in the interior of the intermediate layer. By embedding the mesh layer in the interior of the intermediate layer, the contact area between the mesh layer and the intermediate layer is increased, making it easier to achieve excellent bonding strength therebetween, and the strength of the entire intermediate layer can be easily ensured. When the mesh layer is not embedded in the interior of the intermediate layer, peeling is more likely to occur at the boundary between the mesh layer and the intermediate layer.

[0068] In addition, when the mesh layer exists in the interior of the intermediate layer, the mesh layer may exist in a position corresponding to half the thickness of the intermediate layer, but preferably exists closer to the functional layer side. When the mesh layer exists on the functional layer side of the intermediate layer, the adhesion is increased by an average of 1.3 times.

[0069] When the repair sheet of the present disclosure includes an intermediate layer, the mesh layer is preferably impregnated with a material for forming the intermediate layer (e.g., a filler or a resin component). The state in which the mesh layer is impregnated with the material for forming the intermediate layer means a state in which the material for forming the intermediate layer is filled between the fibers forming the mesh layer, and by establishing this impregnation state, it is easy to achieve extremely favorable bonding strength between the mesh layer and the intermediate layer. Moreover, the interaction between the mesh layer and the material of the intermediate layer may be stronger, which makes it easier to further improve the strength of the repair sheet.

[0070] like Figure 6 A and Figure 6As shown in FIG. 1B , the mesh layer 17 may have a structure in which warp fibers and weft fibers are arranged in a lattice pattern. The fibers are preferably composed of at least one type of fiber selected from the following group, including: polypropylene fibers, vinylon fibers, carbon fibers, aramid fibers, glass fibers, polyester fibers, polyethylene fibers, nylon fibers, and acrylic fibers, among which polypropylene fibers and vinylon fibers may be advantageously used.

[0071] Moreover, there is no particular limitation on its shape except that Figure 6 A and Figure 6 In addition to the biaxial woven fabric shown in B, any other desired mesh layer 17, such as a triaxial woven fabric, may be used.

[0072] The mesh layer preferably has a line spacing of 50 mm to 1.2 mm (line density of 0.2 to 8.0 lines / cm). When the spacing is equal to or less than 1.2 mm and the repair sheet of the present disclosure includes an intermediate layer, the mesh may not be sufficiently bonded to the intermediate layers above and below it, with the result that the surface strength of the repair sheet may be insufficient. Further, when the line spacing exceeds 50 mm, although there is no adverse effect on the surface strength of the repair sheet, the tensile strength may be weakened.

[0073] In the present disclosure, the tensile strength and the surface strength of the repair sheet have a trade-off relationship, and the mesh layer that can be appropriately applied to the roof repair method of the present disclosure has a line spacing in the range of 50 mm to 1.2 mm.

[0074] When viewed from the upper surface side of the intermediate layer, the mesh layer may have a size covering the entire surface of the adhesive layer, functional layer or intermediate layer, or may be smaller than the adhesive layer, functional layer or intermediate layer. In other words, when viewed in a plan view, the surface area of ​​the mesh layer in a plan view may be the same as or smaller than the surface area of ​​the adhesive layer, functional layer or intermediate layer, and the plan view surface area of ​​the mesh layer is preferably not less than 60% and not more than 95% of the plan view surface area of ​​the adhesive layer, functional layer or intermediate layer. When the plan view surface area is less than 60%, the strength of the repair sheet may be insufficient and its strength may change. When the plan view surface area exceeds 95%, the repair sheet of the present disclosure includes an intermediate layer, and the intermediate layer is laminated via the mesh layer, and the bonding strength between the intermediate layers may decrease, which leads to an increased risk of partial peeling of the intermediate layer when the repair sheet according to the present disclosure is applied to the structure. It should be noted that the plan view surface area of ​​the mesh layer, etc. can be measured by a well-known method.

[0075] (Functional layer) The functional layer is a layer provided on the side opposite to the roof so as to appear on the upper surface. For example, the functional layer may be a single layer (such as Figure 1A), or a laminate formed of at least two layers (such as the functional layer 13 shown in FIG. Figure 1 B). Whether to use a single layer or a laminate can be set in consideration of the total thickness, the function to be imparted (waterproof, salt proof, carbonization proof, etc.), the length of the factory production line, production costs, etc., and, for example, when the production line is short so that a predetermined thickness cannot be obtained by a single layer, the functional layer can be formed by stacking two or more layers. It should be noted that in the case of stacking application, the second layer is applied after the first layer is dried. The second layer is then dried.

[0076] The functional layer is preferably flexible and can adapt to cracks and fissures formed on a roof with a ridge, and is preferably obtained by applying a coating with which a functional layer exhibiting excellent waterproof, salt-proof, and carbonization-proof properties can be formed. Acrylic resins having rubber properties (e.g., synthetic rubber having acrylate as a main component), acrylic urethane resins, acrylic silicone resins, fluororesins, soft epoxy resins, polybutadiene rubbers, etc. can be used as the resin forming the functional layer. When the repair sheet of the present disclosure includes an intermediate layer, the resin material is preferably the same as the resin component forming the intermediate layer described above. Resins containing an elastic film-forming component such as rubber are particularly preferred.

[0077] Among these resins, the acrylic resin with rubber properties is preferably composed of an aqueous emulsion of an acrylic rubber copolymer, because its stability and coating ability are excellent. It should be noted that the ratio of the acrylic rubber copolymer in the emulsion is, for example, 30% to 70% by mass. For example, the acrylic rubber copolymer emulsion is obtained by emulsion polymerization of monomers in the presence of a surfactant. Any of anionic surfactants, nonionic surfactants and cationic surfactants can be used as a surfactant.

[0078] Regarding the coating for forming the functional layer, the functional layer can be formed by preparing a mixed coating liquid containing a resin composition and a solvent, coating a release sheet with the coating liquid, and then drying and removing the solvent. The solvent can be water or a water-based solvent, or can be an organic solvent such as xylene or rosin water. It should be noted that the order of the layers formed on the release sheet is not limited to the above description, for example, the layers can be formed in the order of the functional layer and the intermediate layer as described above, or in the order of the intermediate layer and the functional layer.

[0079] The thickness of the functional layer is set as desired according to the age, shape, etc. of the roof. For example, the thickness is preferably set to 50 µ m to 150 µ m, and the thickness variation is preferably within ± 50 μm. This level of thickness accuracy is impossible to achieve through field application, but can be stably achieved on a factory production line.

[0080] Furthermore, from the viewpoint of providing the repair sheet 10 with various colors, the functional layer may contain a pigment.

[0081] The functional layer may also contain an inorganic material. By including an inorganic material, scratch resistance may be provided to the functional layer. There is no particular limitation on the inorganic material, and conventional, well-known materials may be used, such as metal oxide particles of silicon dioxide, aluminum oxide, or titanium dioxide.

[0082] In addition, when the intermediate layer side surface and the opposite side surface of the functional layer are contaminated by oil containing carbon particles, and then the repair sheet is vertically set, and the cleaning is carried out by using a hose to spray tap water onto the contaminated surface substantially horizontally and forcefully from a distance of about 2 meters, the contaminant removal rate of the repair sheet is preferably 95% or more. Therefore, the surface of the functional layer has excellent cleanability. When the contaminant removal rate is less than 95%, the stain resistance may be insufficient, making it easier to visually obtain the impression that the repair sheet is "dirty". However, although the contaminant removal rate is preferably as high as possible, it is usually set to 98% or less.

[0083] It should be noted that a repair sheet having such a contaminant removal rate can be obtained by, for example, selecting a material from which contaminants can be easily removed (such as an acrylic silicone resin) as the resin of the functional layer or including a material from which contaminants can be easily removed (an antifouling agent) (such as a silicone resin or silicone particles, etc.) in the functional layer.

[0084] In addition, the functional layer may contain additives, through which different functions can be provided. Examples of such additives include cellulose nanofibers and the like.

[0085] (Base coating) In the roof repair method of the present disclosure, a primer layer may be provided between the backing and the adhesive layer of the repair sheet. The primer layer provided between the backing and the adhesive layer is used to increase the adhesion therebetween, with the result that the roof can be stably protected by the repair sheet for a long time.

[0086] Furthermore, since the primer layer provided between the gasket and the adhesive layer serves to increase adhesion therebetween, the roof can be stably protected by the repair sheet for a long period of time.

[0087] As an example of a roof repair method employed when providing a primer coating, a method can be used in which a mat is set on the roof in a first step of laying a mat to cover the damaged portion of the roof, and then a second step is performed to form a primer coating on the upper surface of the mat and the adhesive layer side surface of the repair sheet is adhered from above the formed primer coating.

[0088] As a method for forming the primer layer, the primer layer can be formed by coating the gasket with a coating liquid obtained by mixing a resin such as an epoxy resin with a solvent, and then evaporating and drying the solvent in the coating liquid. At this time, water or the like can be used as the solvent.

[0089] The thickness of the primer layer is not particularly limited. For example, the thickness can be set at 100 µ m to 150 µ Since the primer layer provided between the pad and the adhesive layer of the repair sheet serves to increase the adhesion therebetween, the roof can be stably protected by the repair sheet for a long time.

[0090] (roof) There is no particular limitation on the roof to which the roof repair method of the present disclosure is applied, and a roof formed by arranging a plurality of roof members, such as a slate roof, a steel roof, an asphalt shingle roof, a flat roof, etc., can be used. Among these roofs, the roof repair method can be advantageously applied to a slate roof, and further, since the slate roof includes a natural slate roof and an artificial slate roof, the roof repair method can be particularly advantageously applied to an artificial slate roof. The roof repair method can also be applied to the repair of a roof member in contact with another member (such as a skylight) or the repair of a tip portion of a roof.

[0091] The present disclosure also relates to a method for protecting a roof of a structure by adhering a sheet to the roof (hereinafter also referred to as the roof protecting method of the present disclosure).

[0092] A first roof protection method of the present disclosure is a method for protecting a roof of a structure by adhering a sheet to the roof, wherein the sheet includes a functional layer and an adhesive layer provided on the roof side of the structure, the method including a first step of laying a mat on the roof, and a second step of adhering a surface on the adhesive layer side of the sheet from above the mat.

[0093] Further, the second roof protection method of the present disclosure is a method for protecting a roof of a structure by adhering a sheet to the roof, wherein the sheet includes a functional layer and an adhesive layer provided on the roof side of the structure, and a mat is laid on the roof, and the method includes the step of adhering the surface on the adhesive layer side of the sheet from above the mat. The second roof protection method of the present disclosure can also be applied to a case where a damaged portion exists in a portion where no mat is laid, and the surface on the adhesive layer side of the sheet can be applied from above both the mat and the damaged portion (in which no mat is laid) so as to cover both.

[0094] The first roof protection method and the second roof protection method are similar to the roof repair method of the present disclosure except that they are applied to the roof of the structure without the damaged part, and therefore a detailed description thereof is omitted. Regarding the sheet and the pad of the protection method of the present disclosure, for example, components having the same configuration as the repair sheet and the pad used in the roof repair method can be used, and the roof to which the method is applied is also the same.

[0095] According to the roof protection method of the present disclosure, the roof of the structure can be reinforced, thereby reducing the possibility of damage, with the result that damage to the roof can be prevented in advance, thereby making it possible to reduce the number of times the damage needs to be repaired.

[0096] The following items list preferred aspects of the present disclosure. However, the present invention is not limited to the following items: [Project 1] A roof repair method in which a repair sheet is adhered to a damaged portion of a structure's roof. wherein the repair sheet comprises a functional layer and an adhesive layer arranged on the roof side of the structure, The method comprises a first step of laying a mat to cover the damaged portion of the roof, and a second step of adhering the surface on the adhesive layer side of the repair sheet from above the liner; [Project 2] The roof repair method according to item 1, wherein the underlayment comprises a flat plate and a side plate connected to the flat plate; [Item 3] The roof repair method according to item 1 or 2, wherein the pad comprises a flat plate and a side plate connected to the flat plate, and a bent portion having an L-shaped cross section is formed by the flat plate and the side plate; [Item 4] The roof repair method according to any one of items 1 to 3, wherein the pad comprises two flat plates and side plates connected to the two flat plates, and a bent portion having an angled U-shaped cross section is formed by the two flat plates and the side plates; [Item 5] The roof repair method according to any one of items 1 to 4, wherein the roof is composed of at least one roof element, and In the first step, the underlay is laid to cover at least a portion of the upper surface of the roof element and to cover the end surface of the roof element; [Item 6] The roof repair method according to any one of items 1 to 5, wherein the roof is composed of at least one roof element, and In the first step, the underlay is laid to cover at least a portion of the upper and rear surfaces of the roof element and to cover the end surfaces of the roof element; [Item 7] The method for repairing a roof according to any one of items 1 to 6, wherein the roof is composed of at least one roof element, In the first step, the flat plate of the pad is inserted into a gap between the roof element having the damaged portion and a roof element above the roof element having the damaged portion, and The underlayment is laid so that a side plate of the underlayment contacts an end of the roof member having the damaged portion; [Item 8] The roof repair method according to any one of items 1 to 7, wherein the repair sheet comprises the adhesive layer, the intermediate layer and the functional layer in this order, and the intermediate layer is a layer formed of a composite material containing a filler and a resin; [Item 9] The roof repair method according to item 8, wherein the resin content of the composite material is not less than 10% by weight and not more than 40% by weight; [Item 10] The roof repair method according to any one of items 1 to 9, wherein a primer layer is provided between the underlay and the adhesive layer of the repair sheet; [Item 11] The method for repairing a roof according to any one of items 1 to 10, wherein the roof is a slate roof, a steel roof, an asphalt shingle roof, or a flat roof; [Item 12] A method for protecting a roof of a structure by adhering a sheet to the roof of the structure, wherein the sheet comprises a functional layer and an adhesive layer disposed on the roof side of the structure, The method comprises a first step of laying a mat on the roof, and a second step of adhering the surface on the adhesive layer side of the sheet from above the liner; [Item 13] A method for protecting a roof of a structure by adhering a sheet to the roof of the structure, wherein the sheet comprises a functional layer and an adhesive layer disposed on the roof side of the structure, and The roof is covered with a mat. The method includes the step of adhering the surface on the adhesive layer side of the sheet from above the liner.

[0097] List of Reference Numerals 10 Repair sheet 12 Middle Layer 13 Functional layer 15 Adhesive layer 16 Release film 17 Grid Layer 20 Damaged parts 21 Roof components 22 Pad 23 Bending part 24 Tablet 25 Side Panel 30 Roof 31 blue sheet 32 Sandbags.

Claims

1. A method of roof repair wherein a repair sheet is adhered to a damaged portion of a roof of a structure, in, The repair sheet comprises a functional layer and an adhesive layer disposed on the roof side of the structure, The method comprises: a first step of laying a mat to cover the damaged portion of the roof; and A second step of adhering the surface on the adhesive layer side of the repair sheet from above the liner.

2. The roof repair method according to claim 1, wherein: The cushion includes a flat plate and side plates connected to the flat plate.

3. The roof repair method according to claim 1, wherein: The pad includes a flat plate and a side plate connected to the flat plate, and a bent portion having an L-shaped cross section is formed by the flat plate and the side plate.

4. The roof repair method according to claim 1, wherein: The pad includes two flat plates and side plates connected to the two flat plates, and a bent portion having an angled U-shaped cross section is formed by the two flat plates and the side plates.

5. The roof repair method according to claim 1, wherein: The roof is formed from at least one roof element, and In the first step, the underlayment is laid to cover at least a portion of the upper surface of the roof element and to cover the end surface of the roof element.

6. The roof repair method according to claim 1, wherein: The roof is formed from at least one roof element, and In the first step, the underlay is laid to cover at least a portion of the upper and rear surfaces of the roof element and to cover the end surfaces of the roof element.

7. The roof repair method according to claim 1 or 2, wherein: The roof is composed of at least one roof element. In the first step, the flat plate of the pad is inserted into a gap between the roof element having the damaged portion and a roof element above the roof element having the damaged portion, and The underlayment is laid so that a side plate of the underlayment contacts the end of the roof member having the damaged portion.

8. The roof repair method according to claim 1 or 2, wherein: The repair sheet comprises the adhesive layer, the intermediate layer and the functional layer in this order, and The intermediate layer is a layer formed of a composite material containing a filler and a resin.

9. The roof repair method according to claim 8, wherein: The resin content of the composite material is not less than 10% by weight and not more than 40% by weight.

10. The roof repair method according to claim 1 or 2, wherein: A primer layer is provided between the liner and the adhesive layer of the repair sheet.

11. The roof repair method according to claim 1 or 2, wherein: The roof is a slate roof, a steel roof, an asphalt shingle roof, or a flat roof.

12. A method for protecting a roof of a structure by adhering a sheet to the roof of the structure, in, The sheet comprises a functional layer and an adhesive layer disposed on the roof side of the structure, The method comprises: a first step of laying a mat on the roof; and A second step is to adhere the surface on the adhesive layer side of the sheet from above the liner.

13. A method for protecting a roof of a structure by adhering a sheet to the roof of the structure, in, The sheet includes a functional layer and an adhesive layer disposed on the roof side of the structure, and The roof is covered with a mat. The method includes the step of adhering the surface on the adhesive layer side of the sheet from above the liner.

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