A roof leveling and anti-cracking integrated structure and a synchronous construction method thereof

Abstract

The application discloses a roof leveling and anti-cracking integrated structure and a synchronous construction method thereof, and relates to the technical field of building roof engineering, which comprises: an elastic stress buffer layer composed of a cement-based composite material, having a set breaking elongation and compressive strength; an active honeycomb water stop unit array regularly embedded in the elastic stress buffer layer at a preset interval during paving of the elastic stress buffer layer, wherein the active honeycomb water stop unit comprises a honeycomb hollow shell and a water-swelling water stop material filled in the shell, the top of the shell is flush with the upper surface of the elastic stress buffer layer, and the sidewall of the shell is provided with water-permeable holes; and a gradient protective surface layer which is combined on the elastic stress buffer layer and the water stop unit array, and has a gradient decreasing elastic modulus from bottom to top. Through the integrated structure design, the leveling layer has self-adapting anti-cracking and water stopping capabilities, the process is simplified by more than 30%, the anti-cracking performance is improved by 50%, and the reliability and durability of the roof engineering are significantly improved.

Description

Technical Field

[0001] This invention relates to the field of building roofing engineering technology, specifically to an integrated structure for roof leveling and crack prevention and its simultaneous construction method. Background Technology

[0002] The leveling layer of the roof is a key support layer of the waterproofing system, and its cracking is the primary cause of roof leakage. Traditional cement mortar leveling layers are brittle and are prone to cracking under temperature stress, drying shrinkage stress and base deformation. Currently, the common remedies are "adding crack-resistant mesh" and "setting expansion joints", which have the following inherent defects: (1) The mechanical bonding interface between the crack-resistant mesh and the mortar is weak, which is prone to hollowing and cannot suppress structural cracks caused by uneven settlement of the base layer; (2) Although the expansion joint can release stress, it itself becomes a weak link in waterproofing and requires additional sealing treatment, which increases the number of procedures and leakage points; (3) The leveling layer and the subsequent waterproofing layer are constructed in layers, which poses a risk of interlayer peeling.

[0003] The commonly used technical solution of "adding crack-resistant mesh" mainly improves crack resistance by incorporating short fibers and laying steel wire mesh, but it does not solve the problems of stress concentration and self-repair after water seepage. Another technical solution, "setting expansion joints," focuses on drainage, and the crack resistance mechanism still relies on traditional expansion joints. These technologies all belong to the "passive resistance" or "post-event drainage" approach, and fail to achieve "active adaptation" and "damage self-repair" of the leveling layer from the structural design. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated structure for roof leveling and crack prevention, along with its simultaneous construction method, to address the challenges posed by the commonly used "adding crack-resistant mesh" technique mentioned in the background section. This technique primarily enhances crack resistance by incorporating short fibers and laying wire mesh, but fails to resolve issues of stress concentration and self-repair after water seepage. Another technique, "setting expansion joints," focuses on drainage, but its crack-resistant mechanism still relies on traditional expansion joints. These techniques all fall under the category of "passive resistance" or "post-conference drainage," failing to achieve "active adaptation" and "self-repair" of the leveling layer through structural design.

[0005] To achieve the above objectives, the present invention provides the following technical solution: an integrated structure for roof leveling and crack prevention, installed on the roof base layer, characterized in that it comprises:

[0006] Elastic stress buffer layer: composed of cement-based composite materials, with a set elongation at break and compressive strength;

[0007] Active honeycomb water-stop unit array: The active honeycomb water-stop unit is pre-embedded at predetermined intervals before the elastic stress buffer layer is initially laid and set. Each active honeycomb water-stop unit includes a honeycomb-shaped hollow shell and a water-swellable water-stopping material filled within it. The top of the shell is flush with the upper surface of the elastic stress buffer layer, and the sidewalls of the shell are provided with permeable holes. The honeycomb pore diameter of the active honeycomb water-stop unit is 20-30mm, the shell is made of polypropylene, and the wall thickness is 1-1.5mm. The expansion ratio of the water-swellable water-stopping material is not less than 200%, and the pre-embedding depth is 1 / 2 to 2 / 3 of the thickness of the elastic stress buffer layer.

[0008] Gradient protective surface layer: Composite on the elastic stress buffer layer and the water-stop unit array, its elastic modulus decreases gradually from bottom to top.

[0009] Preferably, the elastic stress buffer layer is a modified cement mortar layer containing crack-resistant fibers and micro-expansion agents, with an elongation at break of not less than 8%, a compressive strength of not less than 25 MPa, and a thickness of 20-30 mm.

[0010] Preferably, the crack-resistant fiber is a polyacrylonitrile fiber with a length of 12-15 mm, and the dosage is 2-4% of the mass of the cement-based material; the micro-expansion agent is an ettringite-based expansion agent, and the dosage is 1-3% of the mass of the cement-based material.

[0011] Preferably, the pre-embedded spacing of the active honeycomb water-stop unit is 300-500mm.

[0012] Preferably, the gradient protective surface layer comprises:

[0013] The interfacial bonding layer is a polymer cement-based material with a thickness of 1-2 mm;

[0014] The flexible transition layer is a rubber-modified asphalt coating with a thickness of 2-3 mm;

[0015] The wear-resistant protective layer is a polymer coating containing aggregate, with a thickness of 0.5-1mm.

[0016] A method for simultaneous construction of an integrated roof leveling and crack prevention structure includes the following steps:

[0017] S1. Base layer processing and interface preparation;

[0018] S2. Spreading the prepared elastic stress buffer layer material;

[0019] S3. Before the elastic stress buffer layer material initially sets, press the active honeycomb water-stop unit into its interior according to the designed array;

[0020] S4. Perform stress pre-release treatment on the surface of the buffer layer after the water-stop unit is implanted;

[0021] S5. On top of the buffer layer and water-stopping unit after stress pre-release treatment, the gradient protective surface layer is continuously constructed;

[0022] S6. Apply a protective film to moisturize and nourish the skin.

[0023] Preferably, the stress pre-release treatment in step S4 includes surface rolling using a rolling device with a frequency of less than 5 Hz, supplemented by manual patting.

[0024] Preferably, in step S2, after paving, a vibration leveling device is used to compact the surface, with the vibration depth being 2 / 3 of the thickness of the buffer layer, and the vibration head is made of non-metallic elastic material to avoid damaging the pre-embedded water-stop unit shell.

[0025] Preferably, the construction interval between each layer of the gradient protective surface layer in step S5 is 4-6 hours, and the construction of the flexible transition layer must ensure the formation of a continuous, pinhole-free coating.

[0026] Compared with the prior art, the beneficial effects of the present invention are:

[0027] 1. A fundamental breakthrough in crack resistance mechanism: shifting from the traditional "strengthening resistance" approach to an integrated proactive defense approach of "dredging and absorption + intelligent repair". By using a pre-embedded array of honeycomb water-stopping units, a regularly distributed stress absorption and water-stopping network is constructed within the leveling layer, solving the two core problems of stress concentration and micro-crack seepage diffusion.

[0028] 2. Deep integration of structure and function: Leveling, stress buffering, waterproofing, and protection are integrated into a single continuous structural layer, eliminating the need for crack-resistant mesh, expansion joints, and their sealing processes. Engineering calculations show that this reduces construction steps by 30%-40% and overall costs by approximately 20%.

[0029] 3. Significantly improved interface reliability: The gradient protective surface layer and the underlying buffer layer are tightly connected through an interfacial adhesive layer, and the modulus transition is smooth, overcoming the "two-layer" phenomenon caused by the mismatch of material properties between the traditional waterproof layer and leveling layer. Tests show that the interlayer bond strength is more than 60% higher than that of traditional methods.

[0030] 4. Comprehensive enhancement of durability: After undergoing 50 cycles of (-20℃ to 60℃) and a 24-hour continuous rain erosion simulation test, no visible cracks or leaks were found in the integrated structure. The crack resistance and waterproof performance were improved by more than 50%, and the service life is expected to be doubled. Attached Figure Description

[0031] Figure 1 This is a cross-sectional schematic diagram of the integrated structure of the present invention;

[0032] Figure 2This is a three-dimensional structural diagram of the active honeycomb water-stopping unit of the present invention.

[0033] In the diagram: 1-Roof base layer, 2-Elastic stress buffer layer, 3-Active honeycomb water-stop unit, 4-Interface bonding layer, 5-Flexible transition layer, 6-Wear-resistant protective layer, 31-Shell, 32-Water-swellable water-stop material, 33-Water-permeable hole. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Example 1

[0036] Please see Figure 1-2 This invention provides an integrated structure for roof leveling and crack prevention, installed on the roof base layer, characterized by comprising:

[0037] Elastic stress buffer layer: Composed of cement-based composite materials, with a set elongation at break and compressive strength, the mortar matrix is ​​prepared using P•O 42.5 silicate cement, Grade II fly ash, and medium-fine sand (mass ratio 4:1:5). 9 kg of 12 mm long polyacrylonitrile fiber (approximately 3% of cement mass) and 6 kg of ettringite-based expansive agent (approximately 2% of cement mass) are added per cubic meter of mortar. After mixing and molding, the 28-day compressive strength was measured to be 28 MPa, and the elongation at break was 8.5%. The paving thickness is 25 mm.

[0038] Active honeycomb water-stop unit array: Pre-embedded at preset intervals during the paving of the elastic stress buffer layer. Each active honeycomb water-stop unit comprises a honeycomb-shaped hollow shell and a water-swellable water-stopping material filled within it. The top of the shell is flush with the upper surface of the elastic stress buffer layer. The sidewalls of the shell have permeable holes. The shell is injection-molded from polypropylene, with regular hexagonal honeycomb cells, an inscribed circle diameter of 25mm, and a wall thickness of 1.2mm. The unit dimensions are 150mm × 150mm × 12mm (height). Each honeycomb cell is filled with a water-swellable rubber strip with an expansion ratio of 220%. The pre-embedded spacing is 400mm, and the units are vertically pressed in with a special press before the buffer layer initially sets (approximately 40 minutes after paving), to a depth of 12mm.

[0039] Gradient protective surface layer: Composite on the elastic stress buffer layer and the water-stop unit array, its elastic modulus decreases gradually from bottom to top.

[0040] The elastic stress buffer layer is a modified cement mortar layer mixed with crack-resistant fibers and micro-expansion agents, with an elongation at break of not less than 8%, a compressive strength of not less than 25MPa, and a thickness of 20-30mm.

[0041] The crack-resistant fiber is a polyacrylonitrile fiber with a length of 12-15 mm, and the dosage is 2-4% of the mass of the cement-based material; the micro-expansion agent is an ettringite-based expansion agent, and the dosage is 1-3% of the mass of the cement-based material.

[0042] The active honeycomb water-stopping unit has a honeycomb pore size of 20-30mm, a shell made of polypropylene, and a wall thickness of 1-1.5mm; the water-swellable water-stopping material has an expansion ratio of not less than 200%.

[0043] The pre-embedded spacing of the active honeycomb water-stop unit is 300-500mm, and the pre-embedded depth is 1 / 2 to 2 / 3 of the thickness of the elastic stress buffer layer.

[0044] The gradient protection surface layer includes:

[0045] The interface bonding layer uses an acrylic copolymer cementitious coating, applied in one coat with a thickness of approximately 1.5 mm.

[0046] The flexible transition layer uses butyl rubber modified emulsified asphalt coating, applied in two coats, with a thickness of approximately 2.5 mm.

[0047] The wear-resistant protective layer is made of quartz sand-reinforced acrylic topcoat, applied in one coat with a thickness of approximately 0.8 mm.

[0048] A method for simultaneous construction of an integrated roof leveling and crack prevention structure includes the following steps:

[0049] S1. Substrate treatment and interface preparation: clean the substrate, repair defects, and apply cement-based penetrating crystalline interface agent;

[0050] S2. Spread the prepared elastic stress buffer layer material mechanically, and compact it using a rubber-headed vibrator (frequency 35Hz) to a depth of about 17mm.

[0051] S3. Before the elastic stress buffer layer material initially sets, press the active honeycomb water-stop unit into its interior according to the design array, immediately press the active honeycomb water-stop unit into the layout position, and gently tap the top of the active honeycomb water-stop unit with a scraper to make it flush with the mortar surface.

[0052] S4. Perform stress pre-release treatment on the surface of the buffer layer after the water-stop unit is implanted. After the water seepage on the surface of the buffer layer disappears, use a low-frequency (3Hz) rubber wheel roller with a self-weight of about 50kg to roll it once in both the longitudinal and transverse directions at a speed of 0.8m / min. At the same time, the worker pats the surface with a wooden trowel.

[0053] S5. After the buffer layer and water-stop unit have completed stress pre-release treatment, the gradient protective surface layer is continuously applied. After the surface of the buffer layer has hardened (about 6 hours), the interface bonding layer, the flexible transition layer (5 hours apart), and the wear-resistant protective layer are applied in sequence (5 hours apart).

[0054] S6. Cover with a plastic film for moisturizing and maintenance, and finally cover with a plastic film and spray water for maintenance for 10 days.

[0055] The stress pre-release treatment described in step S4 includes surface rolling using a rolling device with a frequency of less than 5 Hz, supplemented by manual patting.

[0056] In step S2, after paving, a vibratory leveling device is used to compact the surface. The compaction depth is 2 / 3 of the thickness of the buffer layer, and the vibrator head is made of non-metallic elastic material to avoid damaging the pre-embedded water-stop unit shell.

[0057] In step S5, the construction interval between each layer of the gradient protective surface layer is 4-6 hours, and the construction of the flexible transition layer must ensure the formation of a continuous, pinhole-free coating.

[0058] Example 2

[0059] The difference from Example 1 is that:

[0060] The thickness of the buffer layer was increased to 30mm, and the fiber length was 15mm to accommodate greater deformation of the steel structure.

[0061] The pre-embedded spacing of the active honeycomb water-stop unit is increased to 300mm to provide stronger stress dispersion capability.

[0062] During the curing period, cover the film with a shade cloth to control the surface temperature to not exceed 35℃.

[0063] Performance Verification: The finished surfaces of the two embodiments were monitored for one year and inspected using infrared thermal imaging and tapping methods. The results showed that the roof flatness met the standards, and no cracks, hollow areas, or leaks were found. Compared with the control area constructed using traditional methods (leveling with mesh fabric + waterproofing rolls), the area of ​​this invention performed significantly better after experiencing high summer temperatures and low winter temperatures, with no cracks appearing.

[0064] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An integrated structure for roof leveling and crack prevention, installed on the roof base layer, characterized in that: include: Elastic stress buffer layer: composed of cement-based composite materials, with a set elongation at break and compressive strength; Active honeycomb water-stop unit array: The active honeycomb water-stop unit is pre-embedded at predetermined intervals before the elastic stress buffer layer is initially laid and set. Each active honeycomb water-stop unit includes a honeycomb-shaped hollow shell and a water-swellable water-stopping material filled within it. The top of the shell is flush with the upper surface of the elastic stress buffer layer, and the sidewalls of the shell are provided with permeable holes. The honeycomb pore diameter of the active honeycomb water-stop unit is 20-30mm, the shell is made of polypropylene, and the wall thickness is 1-1.5mm. The expansion ratio of the water-swellable water-stopping material is not less than 200%, and the pre-embedding depth is 1 / 2 to 2 / 3 of the thickness of the elastic stress buffer layer. Gradient protective surface layer: Composite on the elastic stress buffer layer and the water-stop unit array, its elastic modulus decreases gradually from bottom to top.

2. The integrated roof leveling and crack prevention structure according to claim 1, characterized in that: The elastic stress buffer layer is a modified cement mortar layer mixed with crack-resistant fibers and micro-expansion agents, with an elongation at break of not less than 8%, a compressive strength of not less than 25MPa, and a thickness of 20-30mm.

3. The integrated structure for roof leveling and crack prevention according to claim 2, characterized in that: The crack-resistant fiber is a polyacrylonitrile fiber with a length of 12-15 mm, and the dosage is 2-4% of the mass of the cement-based material; the micro-expansion agent is an ettringite-based expansion agent, and the dosage is 1-3% of the mass of the cement-based material.

4. The integrated roof leveling and crack prevention structure according to claim 1, characterized in that: The pre-embedded spacing of the active honeycomb water-stop unit is 300-500mm.

5. The integrated structure for roof leveling and crack prevention according to claim 1, characterized in that: The gradient protection surface layer includes: The interfacial bonding layer is a polymer cement-based material with a thickness of 1-2 mm; The flexible transition layer is a rubber-modified asphalt coating with a thickness of 2-3 mm; The wear-resistant protective layer is a polymer coating containing aggregate, with a thickness of 0.5-1mm.

6. A synchronous construction method for constructing an integrated roof leveling and crack prevention structure as described in any one of claims 1-5, characterized in that: Includes the following steps: S1. Base layer processing and interface preparation; S2. Spreading the prepared elastic stress buffer layer material; S3. Before the elastic stress buffer layer material initially sets, press the active honeycomb water-stop unit into its interior according to the designed array; S4. Perform stress pre-release treatment on the surface of the buffer layer after the water-stop unit is implanted; S5. On top of the buffer layer and water-stopping unit after stress pre-release treatment, the gradient protective surface layer is continuously constructed; S6. Apply a protective film to moisturize and nourish the skin.

7. The synchronous construction method of the integrated roof leveling and crack prevention structure according to claim 6, characterized in that: The stress pre-release treatment described in step S4 includes surface rolling using a rolling device with a frequency of less than 5 Hz, supplemented by manual patting.

8. The synchronous construction method of the integrated roof leveling and crack prevention structure according to claim 6, characterized in that: In step S2, after paving, a vibratory leveling device is used to compact the surface. The compaction depth is 2 / 3 of the thickness of the buffer layer, and the vibrator head is made of non-metallic elastic material to avoid damaging the pre-embedded water-stop unit shell.

9. The synchronous construction method of the integrated roof leveling and crack prevention structure according to claim 6, characterized in that: In step S5, the construction interval between each layer of the gradient protective surface layer is 4-6 hours, and the construction of the flexible transition layer must ensure the formation of a continuous, pinhole-free coating.

Images