Roof integrated prefabricated slab structure and construction method

Abstract

The invention relates to a roof integrated prefabricated slab structure and a construction method, and the roof integrated prefabricated slab structure comprises prefabricated slabs which have various sizes and specifications and are continuously paved and fixed on a roof leveling layer to form a roof paving layer; the prefabricated slab comprises a waterproof layer, a heat preservation layer, an isolation layer and a facing layer which are sequentially laid in an overlapped mode from bottom to top. The thermal insulation layer is bonded and fixed on the waterproof layer, and the thickness of the thermal insulation layer is gradually reduced from right to left, so that the prefabricated slab forms a slope far away from the roof; the edges of the two adjacent sides of the waterproof layer extend out of the range of the heat preservation layer to form waterproof lap joint edges, and the prefabricated slabs are pressed and fixed to the waterproof lap joint edges of the adjacent prefabricated slabs. The isolating layer is evenly laid and fixed on the heat preservation layer. The thickness and gradient of each layer in the prefabricated slab can be controlled during prefabrication, so that the roof paving layer forms a continuous slope surface, the tedious procedures of gradual construction of each layer and on-site slope finding in traditional construction are reduced, the speed and precision of overall construction are improved, and the stability and waterproofness of a roof system are ensured.

Description

Technical Field

[0001] This invention relates to the field of roofing tiling technology, specifically to an integrated precast roofing panel structure and construction method. Background Technology

[0002] With the development of urban clusters, buildings are becoming increasingly dense. To meet the needs of roof insulation and waterproofing, traditional building roofs are generally equipped with multiple surface layers, such as slope-finishing layer, leveling layer, insulation layer, waterproofing layer, protective layer, and surface layer. These layers need to be constructed one by one, which results in problems such as complicated construction, high labor consumption, and long construction period.

[0003] Furthermore, since roofs require slope, the slope-forming layer is often distributed on the lower layer. When constructing layer by layer on the slope-forming layer, multiple slope-forming processes are required, mostly on-site. This not only makes the construction process cumbersome, but also the differences in the experience of construction workers and environmental factors can lead to uneven thickness and slope variations among the layers. This makes it difficult to maintain a uniform slope and thickness, which can easily cause localized reverse slopes and insufficient waterproofing. As a result, the drainage effect of the roof is affected, leading to problems such as water accumulation and leakage, which seriously affects the waterproofing and insulation performance of the roof system.

[0004] Therefore, it is necessary to study an integrated prefabricated roof panel structure and construction method. Summary of the Invention

[0005] Therefore, the purpose of this invention is to provide an integrated precast roof structure and construction method, which can effectively solve the problems of cumbersome construction and difficulty in ensuring consistent thickness and slope of each layer in the existing layer-by-layer roof construction.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: An integrated prefabricated roof structure includes prefabricated panels of various sizes and specifications that are continuously laid and fixed on the roof leveling layer to form a roof cladding layer; The precast slab includes a waterproof layer, a thermal insulation layer, an isolation layer, and a finishing layer, which are laid in sequence from bottom to top; The insulation layer is bonded and fixed to the waterproof layer. The thickness of the insulation layer gradually decreases from right to left, so that the precast slab forms a slope away from the roof. The insulation layer thicknesses of the opposite sides of the adjacent precast slabs are matched, so that the roof cladding layer forms a continuous and uniform slope away from the roof. The adjacent two sides of the waterproof layer extend out of the insulation layer to form a waterproof overlap edge, and the precast slab is pressed and fixed on the waterproof overlap edge of the adjacent precast slab. The isolation layer is evenly laid and fixed on the insulation layer; the finishing layer is laid and fixed on the isolation layer.

[0007] There is a joint between the two adjacent precast slabs, and a joint filling structure is provided in the joint. The joint filling structure includes a waterstop strip, waterproof sealant and grout. The waterstop strip is fixedly attached to the joint and extends along the length of the joint. The waterproof sealant is filled in the joint and located above the waterstop strip. The grout is filled above the waterproof sealant to fill the joint.

[0008] Furthermore, the insulation layer includes an upper insulation layer and a lower insulation layer, the thickness of the lower insulation layer gradually decreasing away from the roof; the upper insulation layer is uniformly and fixedly laid on the lower insulation layer.

[0009] Furthermore, a water-stop layer is fixedly laid between the upper and lower insulation layers; the water-stop strip is pasted and fixed to the side wall of the insulation layer and covers the side wall of the water-stop layer.

[0010] Furthermore, both the left and right sides of the precast slab are configured as inclined surfaces sloping downwards to the left, and the shapes and sizes of the adjacent inclined surfaces are adapted to each other.

[0011] Furthermore, the left and right sides of the precast slab are respectively fixed with a front buckle with an upper opening and a back buckle with a lower opening. When two adjacent precast slabs form a joint, the front buckle and the back buckle are matched and engaged.

[0012] Furthermore, the finishing layer is evenly laid on the isolation layer, and multiple small tiles are evenly spaced on the finishing layer. The small tiles on the same precast slab have grout joints of the same width as the joints, and the edges of the small tiles distributed around the perimeter of the precast slab are flush with the edges of the finishing layer.

[0013] Furthermore, the lower surface of the waterproof layer and the upper surface of the waterproof overlap edge are both provided with an adhesive surface, and a release film is attached to the adhesive surface.

[0014] A construction method for an integrated precast roof panel structure includes the following steps: S100: Layout design; According to the standard dimensions of the precast slabs, the roof is initially laid out from the inside out, starting from the junction of the expansion joints; Design precast slabs of non-standard sizes for uncovered areas; Precast slabs are manufactured and different precast slabs are numbered; S200: Positioning and layout, and pre-layout; Based on the roof layout design, positioning and layout lines are drawn at the joints and protruding roof structures; After positioning and laying out the lines, first lay out the precast slabs at the corners of the area enclosed by the lines, and then lay out the precast slabs on the far right and far back. S300: Continuous paving; Precast slabs are laid continuously from back to front and from right to left, with the later-laid precast slabs overlapping the waterproof joints of the already laid precast slabs. When laying and fixing, first apply waterproof adhesive to the bottom of the waterproof layer and the waterproof overlap edge to ensure that the precast panel is bonded to the adjacent waterproof overlap edge after laying. S400: Seam treatment; Before laying the precast slabs, according to the layout design, waterstop strips are pre-attached to the sides of the insulation layer and coated with cold primer. The thickness of the waterstop strips is consistent with the joint. After the precast slabs are laid, first fill the joints with waterproof sealant, then fill them with grout, and finally use a grouting tool to grout along the longitudinal and transverse joints.

[0015] The beneficial effects of the above technical solution are: (1) This invention uses precast slabs of various sizes and specifications to continuously lay the roof cladding layer, integrating waterproofing, insulation, isolation, decoration and leveling into the precast slabs. It adopts factory prefabrication and on-site installation, which effectively reduces on-site wet work compared to the existing layer-by-layer laying construction process. This significantly reduces the number of roof construction layers, effectively reduces on-site wet work, reduces the complexity of on-site construction procedures, and thus greatly improves the efficiency of roof construction and effectively reduces the total cost of roof construction. In addition, the thickness and slope of each layer in the precast slab can be controlled during prefabrication, so that the roof cladding layer forms a continuous slope. This reduces the cumbersome process of layer-by-layer construction and on-site slope finding in traditional construction. It can effectively solve the problems of cumbersome construction and difficulty in ensuring the consistency of thickness and slope of each layer in the existing layer-by-layer roof construction, improve the speed and accuracy of the overall construction, and ensure the stability and waterproofing of the roof system.

[0016] (2) The adjacent two sides of the waterproof layer of the present invention extend out of the insulation layer to form a waterproof overlap edge, and are fixed to the overlap edge of the adjacent precast slab by pressing, which enhances the waterproof sealing of the roof system; in addition, the joint between the precast slabs is filled with a waterstop strip, waterproof sealant and grout, which can effectively prevent water penetration, solve the problem of water seepage caused by poor waterproofing at the joint in traditional construction, and ensure the long-term stability of the waterproof function of the roof. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a precast slab according to the present invention; Figure 2 This is a side sectional view of another precast panel after being laid according to the present invention; Figure 3 for Figure 2 A schematic diagram of the splicing of precast slabs; Figure 4 for Figure 3 A magnified view of a section at point A in the middle; Figure 5 A schematic diagram for pre-laying out the four corners; Figure 6 A schematic diagram for laying out and pre-laying precast blocks on both sides; Figure 7 This is a schematic diagram of continuous tiling. Figure 8 Plan view for numbering prefabricated roof panels; Figure 9 A schematic diagram showing the filling of corner construction areas.

[0018] Attached diagram labels: 1. Waterproof layer; 2. Insulation layer; 3. Isolation layer; 4. Finishing layer; 5. Joint; 6. Waterstop strip; 7. Waterproof sealant; 8. Grout; 9. Positive snap fastener; 10. Negative snap fastener; 11. Structural layer; 12. Leveling layer; 101. Waterproof overlap edge; 201. Upper insulation layer; 202. Lower insulation layer; 203. Waterstop layer; 401. Small ceramic tile. Detailed Implementation

[0019] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: This embodiment aims to provide an integrated precast roof structure and construction method, which is mainly used for roof waterproofing and insulation installation. It addresses the problems of cumbersome construction and difficulty in ensuring consistent thickness and slope of each layer in existing roof layer-by-layer construction.

[0020] A type of integrated prefabricated roof structure, such as Figure 8 and Figure 9 The roof cladding layer consists of precast slabs of various sizes, continuously laid and fixed on the roof leveling layer 12. The leveling layer 12 is laid and fixed on the structural layer 11 of the roof.

[0021] Precast panels include standard and non-standard sizes. The standard size is 200×200mm, while non-standard sizes need to be customized according to the layout design, with the aim of completely covering the roof cladding area.

[0022] like Figure 1 and Figure 2 The precast slab comprises, from bottom to top, a waterproof layer 1, an insulation layer 2, an isolation layer 3, and a finishing layer 4, laid in sequence. The waterproof layer 1 is made of waterproof membrane. The insulation layer 2 is bonded and fixed to the waterproof layer 1 using an adhesive consisting of aggregate and an alkali activator. The aggregate and alkali activator undergo a polymerization reaction after combining, providing both adhesive strength and structural reinforcement. Since the insulation layer 2 is positioned above the waterproof layer 1, it should ideally be made of materials with moisture-proof and mildew-resistant properties, such as inorganic plasticized microporous insulation boards, polyurethane boards, or extruded polystyrene boards.

[0023] like Figure 2The thickness of insulation layer 2 gradually decreases from right to left, causing the precast slab to slope away from the roof, thus enabling insulation layer 2 to achieve slope-finding capability. (Left and right direction reference) Figure 2 The left and right directions are defined in the text, with the left direction being the direction away from the roof, i.e., the downward slope. For example... Figure 3 and Figure 4 The insulation layer 2 thicknesses on opposite sides of adjacent precast slabs are matched, i.e. Figure 3 The highest point of the insulation layer 2 of the precast slab on the right side is the same as the lowest point of the precast slab on the left side, and the slopes of the adjacent insulation slabs on the left and right sides are the same, so that the roof cladding layer forms a continuous and uniform slope away from the roof.

[0024] In practice, not all insulation layers 2 need to have a slope. For example, precast slabs used at the highest point of the roof or other areas where levelness is required may be used. Figure 1 In the precast slab shown, the insulation layer 2 has a uniform thickness.

[0025] Therefore, the differences between precast slabs are not limited to size specifications; because the roof cladding layer after construction has a slope away from the roof surface, such as... Figure 3 The thickness of the precast slabs arranged in the left and right directions also varies, such as Figure 8 and Figure 9 There are various types of precast slabs, and slabs of the same type are numbered the same.

[0026] The adjacent two sides of the waterproof layer 1 extend beyond the range of the insulation layer 2 to form a waterproof overlap edge 101. The precast slab is pressed and fixed on the waterproof overlap edge 101 of the adjacent precast slab to improve the continuity of waterproofing.

[0027] The isolation layer 3 is evenly laid and fixed on the insulation layer 2. The isolation layer 3 is used to prevent the insulation layer 2 and the finishing layer 4 from deforming and sticking together due to differences in material properties and thermal performance, which could damage each other. The isolation layer 3 can be made of dry-laid non-woven fabric, plastic film, etc.

[0028] The finishing layer 4 is laid and fixed on the insulating layer 3. The finishing layer 4 is mainly used to provide protection and aesthetics, and can be used as follows: Figure 1 The precast slabs include a mortar layer laid on the isolation layer 3 to form a protective layer after curing. Nine small ceramic tiles 401 are evenly spaced on the mortar layer. The small ceramic tiles 401 on the same precast slab maintain a gap of the same width as the joint 5, and are grouted. The edges of the small ceramic tiles 401 distributed around the perimeter of the precast slab are flush with the edges of the finishing layer 4, so that adjacent precast slabs can form joints 5, and after the joints 5 are treated, the same grooving is formed to improve the decorative effect.

[0029] A 5mm joint, 10mm wide, is maintained between adjacent precast slabs. Figure 4The joint 5 is equipped with a joint filling structure, which includes a waterstop strip 6, waterproof sealant 7, and grout 8. The waterstop strip 6 is 10mm wide, made of rubber, and is fixedly attached to the joint 5, extending along the length of the joint 5. This is beneficial for protecting the finished product and facilitates a one-time completion during construction.

[0030] Waterproof sealant 7 is filled into the joint 5 and positioned above the waterstop strip 6 to ensure the sealing and waterproofing performance of the joint. Grout 8 is filled on top of the waterproof sealant 7 to fill the joint 5, and then grouting is performed after filling.

[0031] In this embodiment, the insulation layer 2 includes an upper insulation layer 201 and a lower insulation layer 202. Only the thickness of the lower insulation layer 202 gradually decreases towards the direction away from the roof, thus creating a slope. The upper insulation layer 201 is uniformly and fixedly laid on the lower insulation layer 202, and the thickness of the upper insulation layer 201 is uniform. By dividing the insulation layer 2 into upper and lower layers, two different materials can be used to achieve the overall effect of the insulation layer 2. For example, the upper insulation layer 201 can use an inorganic plasticized microporous insulation board, primarily responsible for the roof's heat insulation function, ensuring stable roof temperature and effectively reducing building energy consumption; while the lower insulation layer 202 can use a more inexpensive extruded polystyrene foam board, mainly used for slope creation and secondary insulation, effectively reducing costs. In other embodiments, the insulation layer 2 can also use an integrated inorganic plasticized microporous insulation board, etc.

[0032] A water-stop layer 203 is fixedly laid between the upper insulation layer 201 and the lower insulation layer 202. A waterproof membrane can be used to prevent seepage downwards layer by layer. The water-stop strip 6 is pasted and fixed to the side wall of the insulation layer 2 and covers the side wall of the water-stop layer 203, making it difficult for water accumulated on the waterproof membrane to enter the joint 5 and continue to seep downwards. The edge of the water-stop layer 203 adjacent to the drainage ditch is not covered by the water-stop strip 6 to facilitate water drainage.

[0033] The left and right sides of the precast slab can be like Figure 2 and Figure 3 The inclined surface is set to tilt downward to the left, and the shape and size of the adjacent inclined surfaces are matched so that the seam 5 is arranged diagonally to improve splicing stability and waterproofing, and reduce water accumulation and reverse slope.

[0034] Alternatively, it can be used Figure 1 The vertical surfaces shown are designed for easy alignment and installation, reducing construction errors.

[0035] like Figure 4 The left and right sides of the precast slab are respectively fixed with a positive buckle 9 with an upper opening and a negative buckle 10 with a lower opening. When two adjacent precast slabs form a joint 5, the positive buckle 9 and the negative buckle 10 are matched and engaged to enable the precast slab to be pre-positioned quickly.

[0036] The lower surface of the waterproof layer 1 and the upper surface of the waterproof overlap edge 101 are both provided with adhesive surfaces, and a release film is pasted on the adhesive surfaces. In use, the release film can be peeled off and bonded to the leveling layer 12 or other precast panels through the adhesive surfaces.

[0037] A construction method for an integrated precast roof panel structure includes the following steps: S100: Layout design; like Figure 8 and Figure 9 Using Building Information Modeling (BIM) technology, the roof slope layer and insulation layer 2 were modularly designed, modeled, and laid out, and numbered. The layout incorporated waterproof overlapping and staggered joints, while minimizing the number of non-standard blocks. It also required the provision of space for joints 5, expansion joints, and drainage ditches.

[0038] When laying out the plan, first arrange the roof plan from the inside out, starting from the junction of the expansion joints, according to the standard size of 200×200mm precast panels. This will help to rationally arrange the expansion joints, drainage ditches, etc., and reduce the number of non-standard blocks.

[0039] At the corners of the parapet wall, non-standard sections are laid out. By adjusting the width of the internal drainage ditch, the non-standard blocks are made as rectangular and uniform in size as possible to reduce processing costs. Furthermore, all uncovered areas are designed with prefabricated slabs of non-standard dimensions.

[0040] After the layout is completed, prefabricated panels are made and numbered according to the layout design.

[0041] S200: Positioning and layout, and pre-layout; Before constructing precast blocks, layout lines should be laid out according to the roof layout design. Lines should be marked at the joints and locations protruding from the roof structure. After positioning and laying out the lines, as follows Figure 5-7 ( Figure 5-7 (This is only to illustrate the laying method and does not show staggered joints; it is not equivalent to the actual layout design.) First, pre-lay the precast slabs at the corners of the area enclosed by the lines, then pre-lay the rightmost and backmost precast slabs; the rightmost slab is for reference only. Figure 2 The right side of the text can also be referenced. Figure 5-7 Top side; Last side reference Figure 2 The rear side of the middle can also be referenced. Figure 5-7 The left side, the right side, and the last side refer to two mutually perpendicular directions at a high position in the roof layout design. The specific design needs to be combined with the actual roof structure, so as to facilitate the subsequent laying of precast panels on the waterproof overlap edge 101 of the precast panels that have already been laid.

[0042] S300: Continuous paving; From back to front, from right to left (or refer to...) Figure 5-7The precast slabs are laid continuously from top to bottom and from left to right, ensuring that the later-laid precast slabs are pressed onto the waterproof overlap edge 101 of the already laid precast slabs.

[0043] When laying and fixing, first apply waterproof adhesive to the bottom of the waterproof layer 1 and the waterproof overlap edge 101, then peel off the release film on the waterproof overlap edge 101 in advance so that the precast panel can be bonded to the adjacent waterproof overlap edge 101 after laying. At the same time, attention should be paid to staggering the joints between adjacent layers.

[0044] S400: Seam treatment; Before laying the precast slabs, according to the layout design, from bottom to top, rubber waterstop strips 6 are pre-attached to the sides of the insulation layer 2 according to the layout design. The thickness of the waterstop strip 6 is the same as that of the joint 5 or it can be slightly thicker than the joint 5. At the same time, cold primer is brushed on the sides of the insulation layer 2 in advance to improve the adhesion of the waterproof sealant 7.

[0045] After the precast slabs are laid, waterproof sealant 7 is first applied to the joints 5 to ensure the sealing and waterproofing performance of the joints. Then, grout 8 is used to fill the gaps, and finally, a grouting tool is used to grout along the longitudinal and transverse joints. The grouting is flat and 3mm deep, and the grouting should be consistent with the grouting between the small tiles 401 on the finishing layer 4 to improve aesthetics. The finished floor tile joints should have uniform width and be neat and uniform, and the floor tile surface should be dense, flat, and smooth.

Claims

1. A prefabricated roofing panel structure, characterized in that: Precast panels of various sizes are laid and fixed on the roof leveling layer (12) to form a roof cladding layer; The precast slab includes a waterproof layer (1), a thermal insulation layer (2), an isolation layer (3), and a finishing layer (4) that are laid in sequence from bottom to top. The insulation layer (2) is bonded and fixed to the waterproof layer (1). The thickness of the insulation layer (2) gradually decreases from right to left, so that the precast slab forms a slope away from the roof. The insulation layer (2) on the opposite sides of the adjacent precast panels is of suitable thickness, so that the roof cladding layer forms a continuous and uniform slope that is downward away from the roof. The adjacent two sides of the waterproof layer (1) extend out of the range of the insulation layer (2) to form a waterproof overlap edge (101), and the precast slab is pressed and fixed on the waterproof overlap edge (101) of the adjacent precast slab. The isolation layer (3) is evenly laid and fixed on the insulation layer (2); the finishing layer (4) is laid and fixed on the isolation layer (3); and there is a joint (5) between two adjacent precast panels. The joint (5) is provided with a filling structure, which includes a waterstop strip (6), waterproof sealant (7) and grout (8); The waterstop strip (6) is fixedly attached to the joint (5) and extends along the length of the joint (5). The waterproof sealant (7) is filled in the joint (5) and located above the waterstop strip (6). The grout (8) is filled above the waterproof sealant (7) to fill the joint (5).

2. The prefabricated roofing panel structure according to claim 1, characterized in that: The insulation layer (2) includes an upper insulation layer (201) and a lower insulation layer (202). The thickness of the lower insulation layer (202) gradually decreases in the direction away from the roof. The upper insulation layer (201) is uniformly and fixedly laid on the lower insulation layer (202).

3. The prefabricated roofing panel structure according to claim 2, characterized in that: A water-stop layer (203) is fixedly laid between the upper insulation layer (201) and the lower insulation layer (202); the water-stop strip (6) is pasted and fixed on the side wall of the insulation layer (2) and covers the side wall of the water-stop layer (203).

4. A prefabricated roofing panel structure according to any one of claims 1-3, characterized in that: The left and right sides of the precast slab are both set as inclined surfaces sloping downward to the left, and the shapes and sizes of the adjacent inclined surfaces are matched.

5. A prefabricated roofing panel structure according to any one of claims 1-3, characterized in that: The precast slab is fixed with a front buckle (9) with an upper opening and a back buckle (10) with a lower opening on its left and right sides respectively. When two adjacent precast slabs form a joint (5), the front buckle (9) and the back buckle (10) are fitted together.

6. A prefabricated roofing panel structure according to any one of claims 1-3, characterized in that: The finishing layer (4) is evenly laid on the isolation layer (3). Multiple small ceramic tiles (401) are evenly spaced on the finishing layer (4). The small ceramic tiles (401) located on the same precast slab have a grout joint of the same width as the joint (5). The edges of the small ceramic tiles (401) distributed around the periphery of the precast slab are flush with the edges of the finishing layer (4).

7. A prefabricated roofing panel structure according to any one of claims 1-3, characterized in that: The lower surface of the waterproof layer (1) and the upper surface of the waterproof overlap edge (101) are provided with an adhesive surface, and a release film is pasted on the adhesive surface.

8. A construction method for an integrated precast roof structure, characterized in that: Using the integrated prefabricated roof structure according to any one of claims 1-3 includes the following steps: S100: Layout design; According to the standard dimensions of the precast slabs, the roof is initially laid out from the inside out, starting from the junction of the expansion joints; Design precast slabs of non-standard sizes for uncovered areas; Precast slabs are manufactured and different precast slabs are numbered; S200: Positioning and layout, and pre-layout; According to the roof layout design, positioning lines are laid out at the joints (5) and the locations of the protruding roof structures; After positioning and laying out the lines, first lay out the precast slabs at the corners of the area enclosed by the lines, and then lay out the precast slabs on the far right and far back. S300: Continuous paving; Precast slabs are laid continuously from back to front and from right to left, with the later-laid precast slabs pressing on the waterproof overlap edge (101) of the already laid precast slabs. When laying and fixing, first apply waterproof adhesive coating to the bottom of the waterproof layer (1) and the waterproof overlap edge (101) so that the precast panel can be bonded to the adjacent waterproof overlap edge (101) after laying. S400: Seam treatment; Before the precast slabs are laid, according to the layout design, waterstop strips (6) are pre-attached on the side of the insulation layer (2) and cold primer is applied. The thickness of the waterstop strips (6) is consistent with the joint (5). After the precast slabs are laid, waterproof sealant (7) is first filled into the joints (5), then grout (8) is used to fill them, and finally grout along the longitudinal and transverse joints with a grouting tool.

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