Polyurethane rock wool heat preservation waterproof roof construction system and construction method

Abstract

The invention discloses a polyurethane rock wool heat preservation waterproof roof construction system and a construction method, a profiled steel bottom plate is fixed on a structural purline, a non-woven fabric, sound absorption glass wool, a gas insulation film and a polyurethane rock wool heat preservation plate are sequentially laid on the profiled steel bottom plate, and a polyurethane foaming layer filling hole is formed in the upper surface of the polyurethane rock wool heat preservation plate; a galvanized aluminum magnesium steel flat plate and an SBS waterproof coiled material are arranged on the polyurethane foaming layer, and a polyurethane waterproof layer is sprayed on the SBS waterproof coiled material. The mode that polyurethane is foamed on the polyurethane rock wool board is adopted, so that the polyurethane rock wool board uniformly covers and permeates into pores of the rock wool heat preservation board, a continuous and closed waterproof and moisture-proof sealing layer is formed, the pore opening structure of rock wool is improved, and the problem that the rock wool is prone to absorbing water is solved. And meanwhile, a polyurethane waterproof layer is sprayed on the outermost layer of the surface structure by utilizing a spraying process, so that the waterproof layer forms a complete surface without lap joint, the waterproof layer is easy to form at complex nodes, and the heat preservation and waterproof functions of the roof are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of building roof engineering, and in particular to a polyurethane rock wool thermal insulation and waterproof roof construction system and a construction method. Background Art

[0002] The primary functions of building roofs are waterproofing and insulation. Therefore, the choice of waterproofing and insulation materials directly impacts the final roofing performance. Currently, large-scale building venues commonly use rock wool combined with membrane waterproofing materials, such as asphalt (SBS), ethylene propylene diene monomer (EPDM), polypropylene (PVC), and thermoplastic polyolefin (TPO). However, rock wool insulation is porous and highly absorbent. Once water enters its pores, its thermal insulation performance is significantly reduced. Furthermore, membrane waterproofing is often laid using overlapping joints, which is significantly affected by the quality of manual construction. Leakage or inadequate joints can lead to leakage. Summary of the Invention

[0003] The present invention provides a polyurethane rock wool thermal insulation and waterproof roof construction system and construction method. The "polyurethane rock wool board + polyurethane waterproof layer" construction form and construction method are adopted to effectively solve the above-mentioned problems and improve the thermal insulation and waterproof functions of the roof.

[0004] To achieve the above-mentioned objectives, the present invention adopts the following technical solution: a polyurethane rock wool thermal insulation and waterproof roof construction system, comprising structural purlins, a corrugated steel base plate fixed on the structural purlins, non-woven fabrics, sound-absorbing glass wool, air-isolating membrane, and polyurethane rock wool insulation board laid in sequence, a polyurethane foam layer is provided on the upper surface of the polyurethane rock wool insulation board to fill the pores to form a closed waterproof layer, a galvanized aluminum-magnesium steel flat plate and an SBS waterproof membrane are provided on the polyurethane foam layer, and a polyurethane waterproof layer is sprayed on the SBS waterproof membrane.

[0005] The polyurethane rock wool insulation board's surface structure is similar to that of a conventional rock wool board, with the upper surface filled with polyurethane foam to create a closed outer surface. The galvanized aluminum-magnesium steel plate not only compacts the foam layer but also serves as a leveling layer, ensuring a smooth and even foaming surface. The lower surface of the galvanized aluminum-magnesium steel plate is connected to the polyurethane rock wool insulation board via the polyurethane foam layer, providing a seal and connection. The SBS waterproofing membrane is applied to the upper surface of the finished galvanized aluminum-magnesium steel plate, bonding the membrane to the upper surface and providing a waterproof barrier.

[0006] Furthermore, the structural purlins are made of galvanized rectangular steel tubes or other steel sections, fixed to the main structure by welding or bolts, arranged in a matrix with adjustable spacing.

[0007] Furthermore, the corrugated steel base plate is a perforated corrugated steel plate coated with aluminum zinc magnesium. The webs on both sides are provided with a number of punched holes and are fixed to the structural purlins with self-tapping screws. The punched holes in the webs allow indoor noise to pass through the punched holes and be absorbed by the sound-absorbing glass wool, thereby reducing indoor noise.

[0008] Furthermore, the non-woven fabric is fully laid on the corrugated steel base plate, and sound-absorbing glass wool is also fully laid on it. Both the non-woven fabric and the sound-absorbing glass wool are flexible materials, which can follow the shape of the corrugated steel base plate and fit the surface of the corrugated steel base plate.

[0009] Furthermore, the air barrier membrane is made of a thin polymer material and is fully laid on the sound-absorbing glass wool. The polyurethane rock wool insulation board is laid on the air barrier membrane and fixed to the corrugated steel base plate with rock wool nails. The air barrier membrane is used to prevent water vapor from entering the insulation layer, preventing the insulation layer from absorbing water and reducing its thermal resistance, which would affect the insulation effect.

[0010] Furthermore, the polyurethane waterproof layer includes a three-layer structure of a two-component epoxy resin primer, a two-component polyurethane waterproof middle coating and an anti-ultraviolet polyurethane top coating.

[0011] A construction method of a polyurethane rock wool thermal insulation and waterproof roofing structure system comprises the following steps: 1) Install structural purlins: The structural purlins are arranged at intervals according to the specific requirements of the project and fixed to the main structure by welding or bolts; 2) Fixed corrugated steel bottom plate: The corrugated steel bottom plate is fixed on the structural purlin; 3) Laying the middle layer: Lay non-woven fabric, sound-absorbing glass wool, and air barrier film in sequence; 4) Install the insulation layer: Use urethane rock wool insulation board as the insulation layer, seal the surface with polyurethane foam layer, and fix it to the corrugated steel base plate; 5) Leveling and sealing: The galvanized aluminum-magnesium steel flat plate is covered with a polyurethane foam layer, compacted and leveled, and then bonded and sealed with the polyurethane foam layer; 6) Waterproof construction: hot-melt laying of SBS waterproof membrane, and finally spraying of polyurethane waterproof layer on the whole.

[0012] Furthermore, the SBS waterproof membrane is constructed by hot-melting with a high-pressure blowtorch, with the blowtorch angle at 45° and a distance of approximately 300mm from the adhesive surface.

[0013] Furthermore, the spray polyurethane waterproof layer adopts a combination of roller coating and spraying process, and constructs a two-component epoxy resin primer, a two-component polyurea waterproof middle coating and an anti-UV polyurethane top coating in sequence.

[0014] The present invention adopts a structural mode of arranging a polyurethane foam layer on the polyurethane rock wool board, so that it evenly covers and penetrates into the pores of the rock wool insulation board, forming a continuous closed waterproof and moisture-proof sealing layer, improving the open-pore structure of the rock wool, and overcoming the problem that the rock wool itself is easy to absorb water. At the same time, a spraying process is used to spray a polyurethane waterproof layer on the outermost layer of the surface structure. The polyurethane waterproof layer adopts a three-layer structure of a two-component epoxy resin primer, a two-component polyurethane waterproof middle coating, and an anti-ultraviolet polyurethane top coating, so that the waterproof layer forms a complete surface without overlap, and a waterproof layer is easily formed at complex nodes. The polyurethane waterproof material has the characteristics of aging resistance, corrosion resistance, heat and cold resistance, strong adhesion, and strong adhesiveness, and is more suitable for use as a roof waterproof material. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 A cross-sectional diagram of a construction system according to an embodiment of the present invention; Figure 2 This is a schematic diagram of perforation of a corrugated steel bottom plate according to an embodiment of the present invention; Figure 3 This is an enlarged view of the sprayed polyurethane waterproof layer according to an embodiment of the present invention.

[0016] Reference numerals: 1. Structural purlins; 2. Corrugated steel base plate; 21. Punched holes; 3. Non-woven fabric; 4. Sound-absorbing glass wool; 5. Air barrier membrane; 6. Polyurethane rock wool insulation board; 61. Rock wool nails; 62. Polyurethane foam layer; 7. Galvanized aluminum-magnesium steel flat plate; 8. SBS waterproof membrane; 9. Sprayed polyurethane waterproof layer; 91. Two-component epoxy resin primer; 92. Two-component polyurethane waterproof midcoat; 93. UV-resistant polyurethane topcoat. DETAILED DESCRIPTION

[0017] The following is a further detailed description of the specific implementation of the polyurethane rock wool thermal insulation and waterproof roofing structure system and construction method of the present invention.

[0018] like Figure 1 and Figure 2As shown, a polyurethane rock wool thermal insulation and waterproof roofing structural system of the present invention comprises: a structural purlin 1; a corrugated steel base plate 2 fixed on the structural purlin 1; non-woven fabrics 3 and sound-absorbing glass wool 4 are laid all over the corrugated steel base plate 2 from bottom to top; a gas barrier membrane 5 laid on the sound-absorbing glass wool 4, which is a thin polymer material and plays a role in preventing water vapor from entering the insulation layer; a polyurethane rock wool insulation board 6 laid on the gas barrier membrane 5 and fixed to the corrugated steel base plate 2 by rock wool nails 61; and a polyurethane rock wool insulation board 6 laid on the gas barrier membrane 5. The lower surface of the galvanized aluminum-magnesium steel flat plate 7 on the warm plate 6 is connected to the polyurethane rock wool insulation board 6 through a polyurethane foam layer, which plays a role of sealing and leveling; the SBS waterproof membrane 8 laid on the galvanized aluminum-magnesium steel flat plate 7 is bonded to the galvanized aluminum-magnesium steel flat plate 7 by a high-pressure blowtorch hot-melt construction process, which plays a waterproof role; the outermost waterproof layer is a sprayed polyurethane waterproof layer 9 composed of a three-layer structure of a two-component epoxy resin primer 91, a two-component polyurethane waterproof middle coating 92 and an anti-ultraviolet polyurethane top coating 93.

[0019] The implementation steps are as follows: First, install the structural purlins 1. In this embodiment, the purlins 1 are made of 150x100x4mm galvanized rectangular steel pipes, spaced 3.6 meters apart. Depending on the specific project requirements, galvanized rectangular steel pipes of other cross-sectional dimensions or other types of steel sections can also be used, and the spacing can also be adjusted accordingly. They are then secured to the main structure by welding or bolting.

[0020] A corrugated steel base plate 2 is installed on the structural purlin 1. In this embodiment, the corrugated steel base plate 2 is made of a 1.2 mm thick YX-76-200-600 type aluminum-zinc-magnesium perforated corrugated steel plate, with a wave peak height of 76 mm, a wave pitch of 200 mm, and an effective plate width of 600 mm; punching holes (21) are set on the web of the corrugated steel base plate 2, with a hole diameter of 4 mm and an average perforation rate of 20%; the corrugated steel base plate 2 is fixed to the structural purlin 1 using stainless steel composite screws with a diameter of 5.5 mm, and two stainless steel composite screws are set at each wave trough contacting the structural purlin 1.

[0021] Then, non-woven fabric 3, sound-absorbing glass wool 4, and air barrier film 5 are laid in sequence. In this embodiment, the sound-absorbing glass wool 4 has a bulk density of 24 kg / m3 and a thickness of 75 mm; the air barrier film 5 has a thickness of 0.3 mm.

[0022] A urethane rock wool insulation board 6 is laid on the top as an insulation layer. In this embodiment, the urethane rock wool insulation board 6 has a bulk density of 120 kg / m3 and a thickness of 50 mm and is fixed to the corrugated steel bottom plate 2 by rock wool nails 61.

[0023] The polyurethane foam layer 62 on the polyurethane rock wool insulation board 6 has a surface structure in which the upper surface of the ordinary rock wool board is filled with pores by a polyurethane foaming method so as to form a closed surface on the outer surface, thereby improving the waterproofness of the rock wool.

[0024] After the polyurethane foam layer 62 is sprayed, a galvanized aluminum-magnesium steel flat plate 7 is promptly laid flat on the surface of the polyurethane foam layer 62 to compact the foam. The galvanized aluminum-magnesium steel flat plate 7 also serves as a leveling layer to make the foam layer smooth. At the same time, the lower surface of the galvanized aluminum-magnesium steel flat plate 7 is connected to the polyurethane rock wool insulation board 6 through the polyurethane foam, which plays a role of sealing and connection. In this embodiment, the galvanized aluminum-magnesium steel flat plate 7 is a 0.6 mm thick galvanized aluminum-magnesium steel flat plate.

[0025] Using a high-pressure torch heat-melting process, SBS waterproofing membrane 8 is bonded to the upper surface of a galvanized aluminum-magnesium steel plate 7. A high-pressure torch is used to evenly heat the angle between the SBS waterproofing membrane 8 and the galvanized aluminum-magnesium steel plate 7. The torch is positioned at the center of the angle, preferably at a 45° angle, and approximately 300 mm from the bonding surface. Once the surface of the SBS waterproofing membrane 8 is melted, the rolled membrane is rolled forward to bond to the galvanized aluminum-magnesium steel plate 7. In this embodiment, the SBS waterproofing membrane 8 is 4 mm thick.

[0026] Finally, a polyurethane waterproof layer 9 is sprayed. The sprayed polyurethane waterproof layer 9 consists of three layers: a two-component epoxy resin primer 91, a two-component polyurethane waterproof midcoat 92, and an anti-UV polyurethane topcoat 93. All of the layers are in liquid form and are applied using a roller coating and spraying process. Due to the fluidity of the liquid, it can also better seal small gaps in the roof, playing the role of external waterproofing.

[0027] The specific construction process is as follows: 1. Grassroots processing: Clean the SBS waterproof membrane 8.

[0028] 2. Construction of two-component epoxy resin primer 91 (roller coating) Stir and mix the two-component epoxy primer, and apply it on the cleaned SBS waterproof membrane 8 with a wool roller.

[0029] Function: The purpose of applying the primer is to enhance the bonding between the two-component polyurea waterproof midcoat 92 and the SBS waterproof membrane 8.

[0030] 3. Spraying two-component polyurea waterproof midcoat 92 construction: Before application, stir the two-component polyurea with a pneumatic stirrer for at least 15 minutes before spraying. The two-component polyurea waterproofing midcoat 92 should be applied within 4-48 hours of the two-component epoxy resin primer 91. When spraying, ensure the next coat is applied perpendicular to the previous one to ensure an even coating.

[0031] In this embodiment, the thickness of the two-component polyurea waterproof mid-coat 92 is 2 mm.

[0032] Function: It forms a high-elasticity, high-strength continuous waterproof coating, which is the most important functional part of the waterproof system.

[0033] 4. Construction of UV-resistant polyurethane topcoat 93 The UV-resistant polyurethane topcoat 93 is a weather-resistant polyurethane coating. Use a wool roller to apply the topcoat within 6-48 hours after spraying the two-component polyurea waterproofing midcoat 92. Ensure the two-component polyurea waterproofing midcoat 92 is dry before rolling.

[0034] Function: The topcoat has good resistance to UV aging, which can ensure the long-term exposed use requirements of the spray waterproofing system. It also seals the small pinholes on the surface of the two-component polyurea waterproof midcoat 92.

[0035] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A polyurethane rock wool thermal insulation and waterproof roofing system, characterized by: It includes structural purlins, on which a corrugated steel base plate is fixed, on which non-woven fabric, sound-absorbing glass wool, air-isolating membrane and polyurethane rock wool insulation board are laid in sequence, and a polyurethane foam layer is provided on the upper surface of the polyurethane rock wool insulation board to fill the pores to form a closed waterproof layer, and a galvanized aluminum-magnesium steel flat plate and SBS waterproof membrane are provided on the polyurethane foam layer, and a polyurethane waterproof layer is sprayed on the SBS waterproof membrane.

2. The polyurethane rock wool thermal insulation and waterproof roofing structure system according to claim 1, characterized in that: The structural purlins are made of galvanized rectangular steel tubes or other steel sections, fixed to the main structure by welding or bolts, arranged in a matrix, and have adjustable spacing.

3. The polyurethane rock wool thermal insulation and waterproof roofing structure system according to claim 1, characterized in that: The corrugated steel bottom plate is an aluminum-zinc-magnesium perforated corrugated steel plate, and a plurality of punching holes are provided on the webs on both sides, and the bottom plate is fixed to the structural purlin by self-tapping screws.

4. The polyurethane rock wool thermal insulation and waterproof roofing structure system according to claim 1, characterized in that: The non-woven fabric is fully laid on the corrugated steel base plate, and sound-absorbing glass wool is also fully laid on it. Both the non-woven fabric and the sound-absorbing glass wool are flexible materials, which can follow the shape of the corrugated steel base plate and fit the surface of the corrugated steel base plate.

5. The polyurethane rock wool thermal insulation and waterproof roofing structure system according to claim 1, characterized in that: The air barrier membrane is a thin polymer material and is fully spread on the sound-absorbing glass wool. The polyurethane rock wool insulation board is laid on the air barrier membrane and fixed to the corrugated steel bottom plate by rock wool nails.

6. The polyurethane rock wool thermal insulation and waterproof roofing structure system according to claim 1, characterized in that: The polyurethane waterproof layer comprises a three-layer structure of a two-component epoxy resin primer, a two-component polyurethane waterproof middle coating and an anti-ultraviolet polyurethane top coating.

7. The construction method of the polyurethane rock wool thermal insulation and waterproof roofing structure system according to any one of claims 1 to 6, characterized in that: The steps include: 1) Install structural purlins: The structural purlins are arranged at intervals according to the specific requirements of the project and fixed to the main structure by welding or bolts; 2) Fixed corrugated steel bottom plate: The corrugated steel bottom plate is fixed on the structural purlin; 3) Laying the middle layer: Lay non-woven fabric, sound-absorbing glass wool, and air barrier film in sequence; 4) Install the insulation layer: Use urethane rock wool insulation board as the insulation layer, seal the surface with polyurethane foam layer, and fix it to the corrugated steel base plate; 5) Leveling and sealing: The galvanized aluminum-magnesium steel flat plate is covered with a polyurethane foam layer, compacted and leveled, and then bonded and sealed with the polyurethane foam layer; 6) Waterproof construction: hot-melt laying of SBS waterproof membrane, and finally spraying of polyurethane waterproof layer on the whole.

8. The construction method of the polyurethane rock wool thermal insulation and waterproof roofing structure system according to claim 7, characterized in that: SBS waterproof membrane is constructed by hot-melting with a high-pressure blowtorch, with the blowtorch angle at 45° and about 300mm away from the adhesive surface.

9. The construction method of the polyurethane rock wool thermal insulation and waterproof roofing structure system according to claim 7, characterized in that: The spray polyurethane waterproof layer adopts a combination of roller coating and spraying technology, and is constructed in sequence with a two-component epoxy resin primer, a two-component polyurea waterproof middle coat and an anti-UV polyurethane top coat.

Images