Patent Application
20250179819
The present invention relates to a roof repair method for a structure such as a house or a building.
Typically, when a roof of a structure such as a house or a commercial building deteriorates due to longterm exposure to wind or rain, or is damaged by a natural disaster such as a typhoon, the deterioration and damage may cause leaks. When the roof of a structure deteriorates or is damaged, emergency measures are required, and at present, a method such as that shown in
[PTL 1] Japanese Utility Model Registration No. 3225057
[PTL 2] Japanese Utility Model Registration No. 3116572
In recent years, roofs formed by arranging a plurality of roofing members, such as slate roofs, steel roofs, and asphalt shingle roofs, are becoming more widespread as roofs for buildings, but the surfaces of these roofs are often non-planar surfaces having a plurality of steps, and when conventional roof repair using the blue sheet 31 is applied to such a roof, problems occur in that it is difficult to prevent the blue sheet 31 from becoming creased, and in that gaps exist between the blue sheet 31 and the roof, making it impossible to prevent water from infiltrating through the gaps. Furthermore, a blue sheet is not usually very weather-resistant and therefore deteriorates in around one year, after which the blue sheet must be replaced.
Moreover, a method of adhering a repair sheet instead of a blue sheet is also known as a method for repairing a roof of a structure, but when a conventional repair sheet is used to repair the surface of a roof, gaps are formed between the repair sheet and the surface of the roof due to unevenness in the damaged part, making it impossible to solve the problem of adequately preventing infiltration of water.
The present invention has been designed in consideration of these current circumstances, and an object thereof is to provide a roof repair method and a roof protection method with which a damaged part of a roof of a structure can easily be repaired, and infiltration of water can be adequately prevented.
A roof repair method of the present disclosure is a roof repair method in which a repair sheet is adhered to a damaged part 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 pad so as to cover the damaged part of the roof, and a second step of adhering the surface on the adhesive layer side of the repair sheet from above the pad.
According to the present disclosure, it is possible to provide a roof repair method and a roof protection method with which a damaged part of a roof of a structure can easily be repaired, and infiltration of water can be adequately prevented.
Embodiments of the roof repair method of the present disclosure will be described below with reference to the figures. Note that the present disclosure is not limited to the aspects described below and illustrated in the figures, and as long as the technical features thereof are included, the present disclosure may be subjected to various amendments.
As a result of committed research into methods for repairing a damaged part of a roof of a structure, the present inventors were able to eliminate gaps between a repair sheet and the roof by using a pad that is shaped so as to cover the damaged part. Furthermore, the present inventors were able to provide the repair sheet with a performance that corresponds to the characteristics of the roof, or more specifically to provide layers that exhibit adaptability so as to be able to adapt to cracks and swelling on the roof, waterproofing, salt-proofing, and carbonation-proofing for preventing causes of deterioration, such as water and chloride ions, from penetrating, and so on, and that also secure strength in the repair sheet itself. Moreover, these technical concepts can be applied as a repair method using a repair sheet to members other than a roof of a structure, for example walls, eaves, fences, gateposts, gate doors, gate roofs, and so on of structures.
The present disclosure relates to a roof repair method (also referred to hereinafter as the repair method of the present disclosure) in which a repair sheet is adhered to a damaged part of a roof of a structure.
The roof repair method of the present disclosure is a roof repair method in which a repair sheet is adhered to a damaged part 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 pad so as to cover the damaged part of the roof, and a second step of adhering the surface on the adhesive layer side of the repair sheet from above the pad. Note that the damaged part is a part where the original state is partially missing, such as a chip, a through hole, or a recessed hole.
According to the roof repair method of the present disclosure, the repair sheet can be adhered via the pad covering the damaged part formed in the roof, and therefore the repair sheet can be adhered onto an uneven damaged part without gaps being formed between the roof and the repair sheet. As a result, infiltration of water can be adequately prevented. Furthermore, the repair sheet is highly durable when disposed on the damaged part of the surface of the roof, and can therefore maintain the repaired state over a long period. Thus, a roofing member having a damaged part can be used without being discarded, thereby making it possible to contribute to the so-called circular economy.
According to the present disclosure, it is possible to provide a roof repair method and a roof protection method using a repair sheet with which a roof of a structure having a damaged part can be repaired easily, without gaps being formed, and over a long period. More specifically, it is possible to provide a roof repair method and a roof protection method with which a repair sheet can be adhered onto a damaged part of the roof without forming gaps, the repair sheet being provided with a performance that corresponds to the characteristics of the roof of the structure, and is formed so as to adapt to cracks and swelling on the roof, prevent causes of deterioration, such as water and chloride ions, from penetrating the roof of the structure, be permeable so that moisture and causes of deterioration in the roof of the structure can be discharged, have improved strength, and so on. Another advantage is that the quality stability and uniformity of a coating for repairing leaks can be improved at the site of application in comparison with a method of laminating a plurality of hand-coated layers.
The repair method of the present disclosure includes a first step of laying a pad so as to cover the damaged part of the roof. As long as the pad is shaped to be able to cover the damaged part of the roof, there are no particular limitations on the shape thereof, and for example, the pad may be shaped to include a flat plate and a side plate connected to the flat plate.
The pad may also be shaped to include a flat plate and a side plate connected to the flat plate, wherein the flat plate and the side plate form a bent part having an L-shaped cross-section.
As regards the shape of the pad, as a shape that includes a flat plate and a side plate connected to the flat plate, two flat plates may be provided and a side plate may be connected to the two flat plates so that the two flat plates and the side plate form a bent part having an angular U-shaped cross-section.
In the present disclosure, a material having a certain degree of synthesis and bendability is preferably used as the material of the pad, and for example, a metallic material such as sheet metal, a resin material such as thermoplastic resin or thermosetting resin, or the like may be cited as examples thereof. Of these materials, sheet metal is preferably used in consideration of cost and ease of machining.
In the present disclosure, there are no particular limitations on the size of the pad as long as the pad can be laid so as to cover the damaged part of the roof. However, particularly in the case of a roof formed by arranging a plurality of roofing members, the pad is preferably larger than one of the roofing members forming the roof. As will be described below, the pad can be fixed onto the damaged part of the roof with stability, and the purpose thereof is to favorably prevent creases from forming when the repair sheet is adhered.
In the first step, the pad is laid so as to cover the damaged part of the roof. When the roof is formed from at least one roofing member, in the first step, the pad is laid so as to cover at least a part of the upper surface of the roofing member, and also the end surface. Further, in the first step, the pad is preferably laid so as to at least partially cover the upper surface and rear surface of the roofing member, and also the end surface. By laying the pad over the damaged part in this manner, the pad can be fixed in a favorable manner, and as a result, the formation of creases when the repair sheet is adhered to the upper surface of the pad can be favorably prevented.
More specifically, at this time, as shown in
Specific examples of cases in which the pad is laid in the first step so as to at least partially cover the upper surface and rear surface of the roofing member and also cover the end surface include (1) a case such as that shown in
Further, by executing the second step of the roof repair method of the present disclosure, the repair sheet can be adhered to the damaged part of the roof via the pad, whereby the roof can be repaired. Note that the repair sheet is preferably shaped so as to be able to cover the upper surface of the pad that is exposed to the outside. Furthermore, as an example of the second step, as shown in
The roof repair method according to the present disclosure differs fundamentally from a conventional method of disposing a blue sheet, which is a method for temporarily protecting against wind and rain, in that repair that is longer-lasting and more durable than conventional repair can be achieved by means of an extremely simple operation. The reason for this is that the repair sheet according to the present disclosure exhibits superior water resistance and salt blocking properties and can therefore protect roofing materials from materials that penetrate the roofing materials.
In the roof repair method of the present disclosure, prior to the first step of laying the pad so as to cover the damaged part of the roof, the damaged part may be roughly restored in advance by filling the damaged part with a resin material such as urethane resin, urethane foam resin, or polyurea resin, an inorganic material such as mortar or cement, or the like. Urethane resin and polyurea resin are favorable in that the strength of the roof can easily be improved following repair, while urethane foam resin is favorable in that the strength of the roof can be particularly improved following repair. Non-fluorocarbon urethane foam resin, which does not cause global warming and is therefore kind to the environment, is preferable as the urethane foam resin. Hard urethane foam resin prepared from polyol and isocyanate or the like may be cited as an example of non- fluorocarbon urethane foam resin. More specifically, a combination of the non-fluorocarbon polyol FF5020-UC, manufactured by NIHON PUFTEM CO., LTD., and the isocyanate NP-90, manufactured by the same company, may be cited as an example. Further, an inorganic material such as mortar or cement is particularly suitable for use in a case where a flat roof is repaired.
The roof repair method of the present disclosure can also be applied to a case in which a part of the roof of the structure is already covered with another pad, and damage occurs in a part that is not covered with the other pad.
The repair sheet used in the repair method of the present disclosure includes a functional layer and an adhesive layer provided on the roof side of the structure.
By forming the adhesive layer on the roof side of the repair sheet, there is no need to form an adhesive layer by applying an adhesive at the site of application in the second step of adhering the repair sheet, and therefore excellent work efficiency can be achieved. Moreover, the repair sheet can be adhered to the surface of the roof or the like via the adhesive layer, which has a uniform thickness, without the need for a skilled craftsman. Furthermore, by providing the adhesive layer, the adhesive layer can be embedded in recesses on the surface of an uneven roof, and therefore the adhesiveness 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, it is possible to achieve a cost reduction, a large reduction in the on-site work time, and long-term protection of the roof of the structure. In addition, the repair sheet is adhered to the roof via the adhesive layer and therefore exhibits excellent adhesiveness and so on, while the functional layer can be provided with a superior performance in terms of waterproofing, salt-proofing, carbonation-proofing, and so on.
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 preferable. Here, a pressure-sensitive adhesive is an adhesive that initially has a predetermined elasticity and a tacky surface, and generates adhesiveness in relation to an adherend when pressed against the adherend, while an adhesive is in a liquid state or a state having a predetermined fluidity prior to hardening, but when hardened changes to a solid state or a state that maintains a predetermined shape, and thereby generate adhesiveness in relation to the adherend.
There are no particular limitations on the pressure-sensitive adhesive, and well-known pressure-sensitive adhesives such as an acrylic pressure-sensitive adhesive, a silicone pressure-sensitive adhesive, a urethane pressure-sensitive adhesive, or a rubber pressure-sensitive adhesive can be cited as examples thereof. In the present disclosure, the adhesive layer is preferably formed from an acrylic pressure-sensitive adhesive. With an acrylic pressure-sensitive adhesive, the adhesive strength thereof to a roof having a ridge and crosspieces can be adjusted easily so that a high degree of freedom is obtained in terms of material design. Moreover, an acrylic pressure-sensitive adhesive has excellent transparency, weather resistance, and heat resistance, and can therefore be used favorably when the repair sheet is used to reinforce a roof having a ridge.
There are no particular limitations on the acrylic pressure-sensitive adhesive, and a commercially available product such as ORIBAIN (registered trademark) 6574 (manufactured by TOYOCHEM CO., LTD.) or the like, for example, can be used.
As regards the lamination amount of the adhesive layer (also referred to hereinafter as the pressure-sensitive adhesive layer) formed from the acrylic pressure-sensitive resin described above, in order to obtain sufficient adhesive strength with regard to the surface of a roof having a ridge, not less than 20 g/m2 and not more than 250 g/m2 is preferable. Furthermore, the adhesive strength obtained when the repair sheet is adhered to the surface of the pad via the pressure-sensitive adhesive layer described above is preferably not less than 0.5 N/mm2. At less than 0.5 N/mm2, the repair sheet may not exhibit sufficient adhesiveness with respect to the surface of the roof or the like.
When the adhesive layer formed on the repair sheet is an adhesive layer constituted by an adhesive, there are no particular limitations on the adhesive, and a well-known adhesive such as a UV-curable adhesive or a heat-curable adhesive may be used. Examples of such adhesives include a urethane adhesive, an epoxy adhesive, an adhesive that uses an acrylic resin having rubber characteristics (for example, synthetic rubber having acrylic acid ester as the main component), and so on. Among these adhesives, in a case where the repair sheet includes the adhesive layer, an intermediate layer, and the functional layer in that order, and the intermediate layer is a layer formed from 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 the resin component constituting the intermediate layer allows for an increase in the adhesive strength with respect to the intermediate layer and is therefore preferable.
In the repair sheet described above, the adhesive layer preferably includes a hardening agent. By including the hardening agent, greater adhesive strength can be obtained with respect to the surface of a roof having a ridge or the like, and greater push-out strength can also be obtained in the repair sheet.
In the present disclosure, the push-out strength of the repair sheet in a push-out test defined by JSCE-K-533 is preferably not less than 1.5 kN. By setting the push-out strength at 1.5 kN or more, a roof having a ridge that has been reinforced by the repair sheet can be more favorably prevented from collapsing.
There are no particular limitations on the hardening agent, and a well-known hardening agent such as an isocyanate hardening agent, an amine hardening agent, an epoxy hardening agent, or a metal chelate hardening agent can be used.
In order for the repair sheet to exhibit superior adhesive strength and push-out strength in relation to the surface of the roof, the surface of the pad, or the like, the gel fraction of the adhesive layer is preferably 30 to 70%, and more preferably has a lower limit of 40% and an upper limit of 65%.
In the repair sheet described above, 50 to 500 μm is preferable as the thickness of the adhesive layer. When the thickness is less than 50 um, the adhesive strength of the repair sheet with respect to the surface of the roof, the surface of the pad, or the like may be insufficient, and when the thickness exceeds 500 um, variation is more likely to occur in the thickness, and moreover, when the repair sheet is smoothed by a roller or the like in order to obtain a smooth application surface at the time of application, excess adhesive may project from the ends of the repair sheet. A more preferable lower limit for the thickness of the adhesive layer is 90 μm, and a more preferable upper limit is 200 μm.
As in the repair sheet 10 shown in
With the repair sheet having this configuration, leaks and so on can be prevented over a long period, and as a result, the roof can be protected over a long period. Furthermore, a performance that is superior in terms of waterproofing, salt-proofing, carbonation-proofing, and so on can be imparted to the functional layer. Moreover, the repair sheet described above can be mass-produced by performing a coating step and a drying step on a factory production line, making it possible to achieve a cost reduction, a large reduction in the on-site work time, and long-term protection of the roof of the structure.
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. As shown in
Examples of the material forming the base material layer include a polyester such as polyethylene terephthalate or polyethylene naphthalate, a polyolefin such as polyethylene, polypropylene, or polymethyl pentene, a polyamide such as nylon 6, a vinyl resin such as polyvinyl chloride, an acrylic resin such as polymethyl methacrylate, a cellulose resin such as cellulose acetate, or a synthetic resin such as polycarbonate. Further, the base material layer may be formed to have paper as the main component. Furthermore, the base material layer may be a laminated body of two or more layers.
Examples of the material forming the release layer include silicone resin, melamine resin, a fluorinated polymer, and so on. The release layer can be formed by a coating method in which the base material layer is coated with a coating liquid containing the material for forming the release layer and an organic solvent using a well-known method such as a gravure coating method, a roll coating method, a comma coating method, or a lip coating method, whereupon the resulting layer is dried and hardened. Furthermore, when forming the release layer, corona treatment and easy adhesion treatment may be implemented on the laminated surface of the base material layer.
When a release film is adhered to the repair sheet of the present disclosure, as shown in
The repair sheet may be used in a state where two or more repair sheets are layered. The surface of the roof reinforced by the repair sheet can be further reinforced by layering, and for this purpose, when two repair sheets are adhered side by side, for example, another repair sheet can be adhered so as to cover the boundary between the repair sheets.
When the repair sheet of the present disclosure includes the intermediate layer and the intermediate layer of the repair sheet contains cement and a resin, the layered repair sheet also exhibits favorable adhesiveness to the functional layer of the repair sheet already adhered to the surface of the roof or the like. Thus, the repair sheet can be used favorably in a layered state.
It is sufficient for the repair sheet of the present disclosure to include the functional layer and the adhesive layer provided on the side of the roof of the structure, but the repair sheet preferably includes the adhesive layer provided on the side of the roof of the structure, the intermediate layer, and the functional layer in that order. 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 not obtained by layered application, as illustrated by the intermediate layer 12 in
Furthermore, when the intermediate layer 12 has a laminated structure of two or more layers, as shown in
The intermediate layer may be a layer that contributes to the rigidity and so on of the repair sheet, and the intermediate layer may be a layer formed from a composite material containing a filler and a resin. When the intermediate layer is a layer formed from a composite material containing a filler and a resin, the intermediate layer is obtained by, for example, forming a resin containing a filler (a resin component) into coating form and applying this coating.
When the intermediate layer contains cement as the filler of the composite material, the composite material is known as polymer cement. When the intermediate layer is specifically a layer formed from polymer cement, the intermediate layer is also known as a “polymer cement hardened layer”.
As the cement component, various types of cement, limestone containing a component made of calcium oxide, clay containing silicon dioxide, and so on may be used. Cement of any type can be used favorably, and for example, Portland cement, alumina cement, early strength cement, fly ash cement, and so on may be used. Which cement to choose is determined in accordance with the characteristics to be imparted to the intermediate layer, for example the degree of adaptability to the roof. The Portland cement defined by JIS R5210 can be cited as a particularly favorable example. Further, in order to adjust the workability of the Portland cement or the properties thereof following application, a well-known composition in which silicon dioxide, aluminum oxide, aluminum oxide, titanium oxide, or the like is also added to the Portland cement can also be used.
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 (for example, synthetic rubber having acrylic acid ester as the main component), and so on may be used. The resin component may be the same as the resin component forming the functional layer, to be described below.
Furthermore, any of thermoplastic resin, thermosetting resin, and 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 upon hardening, such as a thermosetting resin or a photocurable resin, and is used to mean that any material that hardens (sets as a layer) upon forming the final layer may be used.
When the intermediate later is a layer formed from a composite material containing a filler and a resin, the resin content of the composite material is preferably 10% or more by weight and 40% or less by weight. When the resin content is less than 10% by weight, the adhesiveness to the functional layer tends to decrease, and it becomes difficult to maintain the intermediate layer as a layer, whereas when the resin content exceeds 40% by weight, the adhesiveness to the surface of the roof and so on may be insufficient. From these viewpoints, a more preferable range for the resin content is not less than 15% by weight and not more than 35% by weight, and an even more preferable range is not less than 20% by weight and not more than 30% by weight.
Moreover, by controlling the ratio of the filler and the resin component, it becomes easier to form the intermediate layer and easier to form the intermediate layer into a compatible layer that exhibits superior adaptability, and as a result, the adhesiveness of the layer itself tends to improve. For example, when the intermediate layer is a polymer cement hardened layer, the cement component included in the polymer cement hardened layer acts to improve the adhesiveness with respect to a concrete roof.
A method of coating the functional layer with a solution obtained by dissolving the material for forming the intermediate layer in a solvent and then removing the solvent, for example, may be used as a method for forming the intermediate layer.
More specifically, when the intermediate layer is a layer formed from a composite material containing a filler and a resin, the solution (the coating) for forming 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 constituted by polymer fine particles obtained by emulsion-polymerizing a monomer such as an acrylic acid ester using an emulsifier, and an acrylic acid polymer emulsion obtained by polymerizing a monomer or a monomer mixture containing one or more of an acrylic acid ester and a methacrylic acid ester in water containing a surfactant can be cited as a preferred example thereof.
There are no particular limitations on the content of the acrylic acid ester or the like constituting the acrylic emulsion, and the content is selected from a range of 20 to 100% by mass. Furthermore, the surfactant is added in a required amount and there are no particular limitations on the amount thereof. Hence, the surfactant is added in an amount required to form an emulsion.
The intermediate layer may be formed by coating the release sheet or the functional layer formed on the release sheet, to be described below, with a solution (a coating liquid) obtained by dissolving the composite material for forming the intermediate layer in a solvent, and then drying and removing the solvent. When the intermediate layer is a polymer cement hardened layer, the intermediate layer is preferably formed using a mixture composition containing the cement component, the acrylic emulsion, and water serving as the solvent as the coating liquid. Note that the functional layer may be formed on the release sheet after forming the intermediate layer, or the intermediate layer may be formed after forming the functional layer on the release sheet. In the present disclosure, the repair sheet may be manufactured using a method of, for example, performing embossing or matte processing (forming an uneven shape) on the release sheet, then forming the functional layer (a single layer or a laminate of two or more layers) and the intermediate layer (a single layer or a laminate of two or more layers) in that order, and then adding a design to the functional layer.
In order to be able to impart to the repair sheet used in the roof repair method of the present disclosure a performance exhibiting superior strength, the repair sheet may include a mesh layer, described below. The mesh layer may be provided in the interior of the functional layer, the intermediate layer, or the adhesive layer, or between the layers. When the intermediate layer includes the mesh layer, for example, the release sheet is coated with the functional layer and dried, then the coating liquid for forming the intermediate layer is applied, and then, in a wet state prior to drying, the mesh layer is adhered thereto and dried. The surface to which the mesh layer has been adhered is then further coated with the coating liquid for forming the intermediate layer, whereupon the resulting layer is dried, and thus a repair sheet in which a mesh layer exists within the intermediate layer can be obtained.
A repair sheet in which a mesh layer exists within the intermediate layer can also be obtained by coating the release sheet with the functional layer, drying the resulting layer, applying the coating liquid for forming the intermediate layer, adhering the mesh layer in a wet state prior to drying, then further coating the surface to which the mesh layer has been adhered with the coating liquid for forming the intermediate layer without passing through a drying step, and then drying the entire sheet.
There are no particular limitations on the thickness of the intermediate layer, and the thickness is set as desired in accordance with the size, age, shape, and so on of the roofing member. A range of 0.5 to 1.5 mm, for example, can be set as the specific thickness of the intermediate layer. When the thickness is set at 1 mm, for example, variation in the thickness is preferably kept within ±100 μm. This level of thickness precision is impossible to achieve by on-site application, and can only be realized by stable application on a factory production line. Note that the thickness variation can be kept within ±100 μm even when the thickness is greater than 1 mm. Furthermore, when the intermediate layer is thinner than 1 mm, the thickness variation can be further reduced.
The filler, or more specifically the cement component, of the intermediate layer exhibits favorable compatibility with the cement component of concrete, for example, and therefore the intermediate layer can be formed to exhibit superior adhesiveness to a concrete surface. Furthermore, the intermediate layer can be provided with a stretchable property and can therefore adapt to changes on the surface of the roof when cracks or swelling occur on the surface of the roof.
As shown in
Moreover, when the intermediate layer 12 is provided, the mesh layer 17 may exist in the interior of the intermediate layer 12, as shown in
Furthermore, 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 adhesive force improves by an average of 1.3 times.
When the repair sheet of the present disclosure includes the intermediate layer, the mesh layer is preferably impregnated with the material (the filler or the resin component, for example) for forming the intermediate layer. A state in which the mesh layer is impregnated with the material for forming the intermediate layer denotes a state in which the material for forming the intermediate layer is filled between fibers forming the mesh layer, and by establishing this impregnated state, it is easy to realize extremely favorable adhesion strength between the mesh layer and the intermediate layer. Moreover, the interaction between the mesh layer and the material of the intermediate layer is likely to be stronger, which makes it easier to further improve the strength of the repair sheet.
As shown in
Moreover, there are no particular limitations on the shape thereof, and as well as a biaxial woven fabric such as that shown in
The mesh layer preferably has a line pitch of 50 mm to 1.2 mm (a line density of 0.2 to 8.0 lines/cm). When the pitch is equal to or less than 1.2 mm and the repair sheet of the present disclosure includes the intermediate layer, the mesh may not be bonded sufficiently to the intermediate layer thereabove and therebelow, and as a result, the surface strength of the repair sheet may be insufficient. Further, when the line pitch exceeds 50 mm, although there is no adverse effect on the surface strength of the repair sheet, the tensile strength may weaken.
In the present disclosure, the tensile strength and the surface strength of the repair sheet have a trade-off relationship, and a mesh layer that can be suitably applied to the roof repair method of the present disclosure has a line pitch within a range of 50 mm to 1.2 mm.
The mesh layer may have a size that covers the entire surface of the adhesive layer, the functional layer, or the intermediate layer when seen from the upper surface side of the intermediate layer, or may be smaller than the adhesive layer, the functional layer, or the intermediate layer. In other words, the surface area of the mesh layer in plan view may be the same as or smaller than the surface area of the adhesive layer, the functional layer, or the intermediate layer when seen in plan view, 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, the functional layer, or the intermediate layer. When the plan-view surface area is less than 60%, the strength of the repair sheet may be insufficient and variation in the strength thereof may occur. When the plan-view surface area exceeds 95%, the repair sheet of the present disclosure includes the intermediate layer, and the intermediate layer is laminated via the mesh layer, the adhesion strength between the intermediate layers may deteriorate, leading to an increase in the risk of peeling occurring in the intermediate layer part when the repair sheet according to the present disclosure is applied to a structure. Note that the plan-view surface area of the mesh layer and so on can be measured by a well-known method.
The functional layer is a layer disposed on the opposite side to the roof so as to appear on the upper surface. For example, the functional layer may be a single layer, as illustrated by the functional layer 13 shown in
The functional layer is preferably flexible and capable of adapting to cracks and fissures formed in a roof having a ridge, and is preferably obtained by applying a coating with which it is possible to form a functional layer that exhibits superior waterproofing, salt-proofing, and carbonation-proofing properties. An acrylic resin having rubber properties (for example, synthetic rubber having acrylic acid ester as the main component), acrylic urethane resin, acrylic silicone resin, fluororesin, soft epoxy resin, polybutadiene rubber, and so on may be used as the resin forming the functional layer. When the repair sheet of the present disclosure includes the intermediate layer, the resin material is preferably the same as the resin component forming the intermediate layer, described above. A resin containing an elastic film-forming component such as rubber is particularly preferable.
Of these resins, the acrylic resin having rubber properties is preferably constituted by an aqueous emulsion of an acrylic rubber copolymer due to the superior stability and coating ability thereof. Note that the proportion of the acrylic rubber copolymer in the emulsion is 30 to 70% by mass, for example. The acrylic rubber copolymer emulsion is obtained by emulsion-polymerizing a monomer in the presence of a surfactant, for example. Any one of an anionic surfactant, a nonionic surfactant, and a cationic surfactant can be used as the surfactant.
As regards 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 the release sheet with the coating liquid, and then drying and removing the solvent. The solvent may be water or a water-based solvent, or may be an organic solvent such as xylene or mineral spirits. Note that the order of the layers formed on the release sheet is not limited to that described above, and for example, the layers may be formed in order of the functional layer and the intermediate layer, as described above, or in order of the intermediate layer and the functional layer.
The thickness of the functional layer is set as desired in accordance with the age, shape, and so on of the roof. For example, the thickness is preferably set at a value within a range of 50 to 150 μm, and the variation in the thickness is preferably within ±50 μm. This level of thickness precision is impossible to achieve by on-site application, but can be realized with stability on a factory production line.
Furthermore, the functional layer may contain a pigment from the viewpoint of providing the repair sheet 10 in a wide variety of colors.
The functional layer may also contain an inorganic material. By including an inorganic material, the functional layer can be provided with scratch resistance. There are no particular limitations on the inorganic material, and a conventional, well-known material such as metal oxide particles of, for example, silica, alumina, or titania, may be used.
Furthermore, the contaminant removal rate of the repair sheet when the intermediate layer-side and opposite-side surfaces of the functional layer are contaminated with oil containing carbon particles and then the repair sheet is disposed vertically and cleaned by using a hose to spray tap water substantially horizontally and forcefully onto the contaminated surfaces from a distance of about 2 meters is preferably 95% or more. Thus, the surfaces of the functional layer have excellent cleanability. When the contaminant removal rate is less than 95%, the dirt resistance may be insufficient, making it more likely to visually obtain the impression that the repair sheet is “dirty”. However, although the contaminant removal rate is preferably as high as possible, the rate is normally set at 98% or lower.
Note that a repair sheet having this contaminant removal rate can be obtained by, for example, either selecting a material from which contaminants can easily be removed, such as acrylic silicone resin, as the resin of the functional layer, including a material (an anti-fouling agent) from which contaminants can easily be removed, such as silicone resin or silicone particles, in the functional layer, or the like.
Furthermore, the functional layer may contain additives with which various functions can be provided. Examples of these additives include cellulose nanofiber and so on.
(Undercoat layer)
In the roof repair method of the present disclosure, an undercoat layer may be provided between the pad and the adhesive layer of the repair sheet. The undercoat layer provided between the pad and the adhesive layer acts to increase the adhesion therebetween, and as a result, the roof can be protected by the repair sheet with stability over a long time period.
Furthermore, since the undercoat layer provided between the pad and the adhesive layer acts to increase the adhesion therebetween, the roof can be protected by the repair sheet with stability over a long period.
As an example of a roof repair method employed when the undercoat layer is provided, a method in which the pad is provided on the roof in the first step of laying the pad so as to cover the damaged part of the roof, whereupon a second step is executed to form the undercoat layer on the upper surface of the pad and adhere the surface on the adhesive layer side of the repair sheet from above the formed undercoat layer can be used.
As a method for forming the undercoat layer, the undercoat layer can be formed by coating the pad with a coating liquid obtained by mixing a resin such as epoxy resin with a solvent and then evaporating and drying the solvent in the coating liquid. Water or the like can be used as the solvent at this time.
There are no particular limitations on the thickness of the undercoat layer, and the thickness can be set within a range of 100 to 150 μm, for example. Since the undercoat layer provided between the pad and the adhesive layer of the repair sheet acts to increase the adhesion therebetween, the roof can be protected by the repair sheet with stability over a long period.
There are no particular limitations on the roof to which the roof repair method of the present disclosure is applied, but a roof formed by arranging a plurality of roofing members, such as a slate roof, a steel roof, an asphalt shingle roof, a flat roof, and so on may be used. Of these roofs, the roof repair method can be applied favorably to a slate roof, and furthermore, since slate roofs include natural slate roofs and artificial slate roofs, the roof repair method can be applied particularly favorably to an artificial slate roof. The roof repair method can also be applied to the repair of a roofing member that is in contact with another member, such as a skylight, or the repair of a tip end part of the roof.
The present disclosure also relates to a method for protecting a roof of a structure by adhering a sheet to the roof (also referred to hereinafter as the roof protection method of the present disclosure).
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 pad on the roof, and a second step of adhering the surface on the adhesive layer side of the sheet from above the pad.
Further, a 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 the roof has a pad laid thereon, the method including a step of adhering the surface on the adhesive layer side of the sheet from above the pad. The second roof protection method of the present disclosure can also be applied to a case in which the damaged part exists in a part on which the pad is not laid, and the surface on the adhesive layer side of the sheet may be applied from above both the pad and the damaged part in the part where the pad is not laid so as to cover both thereof.
Other than being applied to a roof of a structure not having a damaged part, the first and second roof protection methods are similar to the roof repair method of the present disclosure, and therefore detailed description thereof has been omitted. As regards the sheet and the pad of the protection methods of the present disclosure, components having identical configurations to the repair sheet and pad used in the roof repair method, for example, can be used, and the roof to which the methods are applied is also identical.
According to the roof protection method of the present disclosure, a roof of a structure can be reinforced, thereby reducing the likelihood of damage, and as a result, damage to the roof can be forestalled, enabling a reduction in the number of times damage needs to be repaired.
The following items list preferred aspects of the present disclosure. However, the present invention is not limited to the following items.
A roof repair method in which a repair sheet is adhered to a damaged part of a roof of a structure,
The roof repair method according to item 1, wherein the pad includes a flat plate and a side plate connected to the flat plate.
The roof repair method according to item 1 or 2, wherein the pad includes a flat plate and a side plate connected to the flat plate, and a bent part having an L-shaped cross-section is formed by the flat plate and the side plate.
The roof repair method according to any one of items 1 to 3, wherein the pad includes two flat plates and a side plate connected to the two flat plates, and a bent part having an angular U-shaped cross-section is formed by the two flat plates and the side plate.
The roof repair method according to any one of items 1 to 4, wherein the roof is constituted by at least one roofing member, and
The roof repair method according to any one of items 1 to 5, wherein the roof is constituted by at least one roofing member, and
The roof repair method according to any one of items 1 to 6, wherein the roof is constituted by at least one roofing member,
The roof repair method according to any one of items 1 to 7, wherein the repair sheet includes the adhesive layer, an intermediate layer, and the functional layer, in this order, and
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.
The roof repair method according to any one of items 1 to 9, wherein an undercoat layer is provided between the pad and the adhesive layer of the repair sheet.
The roof repair method 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.
A method for protecting a roof of a structure by adhering a sheet to the roof,
A method for protecting a roof of a structure by adhering a sheet to the roof,
| Number | Date | Country | Kind |
|---|---|---|---|
| 2022-127974 | Aug 2022 | JP | national |
| 2023-128626 | Aug 2023 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2023/028888 | 8/8/2023 | WO |
