DE10208602A1 - Roof construction in a flat and / or flat inclined configuration and insulation element therefor - Google Patents

Abstract

The invention relates to a flat and/or flatly inclined roof construction, consisting of a lower structure carrying a heat insulating element and/or sound insulating element, especially consisting of mineral fibre insulating boards, said insulating element being partly arranged on upper chords of the carrier elements forming the lower structure. Said roof construction also comprises an upper structure, the lower structure and/or the upper structure forming carrier elements consisting of individual profiled sheets. The aim of the invention is to create a roof construction without the cited disadvantages, providing insulation which is more easily and more reliably accessible, at least during the construction phase, and which has a low total weight and high insulating power. To this end, the insulation (2) consists of at least two layers, at least one (14) of said layers, i.e. at least the layer (14) on the lower structure (1), being embodied in a tension-resistant manner.

Description

The invention relates to a roof structure in a flat and / or flat inclined Design consisting of a substructure on which a heat and / or sound insulation, in particular from insulation boards Mineral fiber insulation materials, preferably made of glass and / or stone fibers, on part of the surface Upper chords of the supporting shells forming the substructure and one Superstructure, with the substructure and / or superstructure made as carrying sheep individual profiled sheets exist. The invention further relates to a Insulation element for a roof construction in a flat and / or flat inclined configuration, in the form of an insulation board made of mineral fiber insulation materials, preferably glass and / or stone fibers that are partially on top of a substructure rests.

Flat or gently sloping roof structures of hall-like buildings very often consist of a carrier shell made of profiled sheet steel, from which the Substructure, but often also the roof covering is formed. Around To achieve the largest possible spans with small sheet thicknesses, the as Profiled sheet steel with a relatively large height and medium width used. In doing so, certain, from the own burdens and when committing or Driving, i.e. deflections resulting from dynamic loads in Taken purchase. The clear distances between those through the profiling Upper chords formed vary between approximately 130 mm and approximately 175 mm. The latitudes of In contrast, upper belts are significantly smaller at approx. 108 mm to approx. 145 mm.

To keep the costs for the substructure low, the profiles are included large spans. Because the connection of the individual profiles is also done only point by point with each other, there is an oscillatory Membrane that can be excited even by low forces.

For thermal insulation and as a fire protection pad on this relatively unstable Substructures are characterized in particular by elastic, resilient insulation materials Mineral fibers, especially proven from rock wool. These insulation materials can on the one hand follow the movements of the substructure, and on the other hand also then have a dampening effect if they only lie loosely on the substructure. Further Advantages of these insulation materials are the non-combustibility in the sense of DIN 4102, the high sound absorption capacity and the economy of their manufacture and processing. To improve the load-bearing behavior of the insulation materials and At the same time increasing the laying speed, the insulation materials preferably as large-format insulation boards, for example with the Dimensions approx. 2 m × 1.2 m delivered and installed on site. But there are also areas of application for conventional, in contrast small-sized insulation board known. Because the dimensions of the insulation materials, especially the insulation boards regularly not on the dimensions of the support shells, namely the distance between the top chords are matched, this also reduces the specific number of free cantilevered and therefore particularly easy to damage insulation panels or Sections of insulation material that are formed and laid in a sheet shape.

A common roof construction in a flat and / or flat inclined configuration thus consists of a profiled sheet metal tray, a loosely laid one Polyethylene film as a vapor barrier air barrier, which is between about 50-160 mm thick thermal insulation layer and a cover made of plastic films, Synthetic rubber or bitumen sheets, which are screwed into the carrier shell Screws are fixed point by point. To ensure the tensile force of the screws is appropriate to the material distribute, sheet metal plates are used, which seal against the Press the insulation material.

Roof structures constructed in this way represent in accordance with the technical rules of the Roofing craft represents "unused roofs", whereas terraces or Parking areas are to be regarded as used roof structures. Is in use consequently unlimited walking and driving as well as the parking of Containers, goods etc. or the erection of scaffolding, ladders.

Even with roof structures not used in the sense of the preceding However, a definition already occurs when the roof structure is created punctual and / or large-scale loading of the roof structure by during the creation of people working on the roof and / or installed there Machines and equipment. Poor management of the sequence of the trades working in the roof area or on the roof surfaces and a negligent handling of the own work, the finished roof areas are considered flat, easy-to-walk and drive-over areas, traffic and Storage areas used, the insulation materials repeatedly in preferred places subjected to high mechanical loads that lead to damage the structure and consequently lead to a defective work.

To a higher pressure resistance and a higher resistance against walking and driving with transport carts or trolleys during the Construction phase of the building or roof structure together with any The structure of the insulation materials has become clear in recent years changed in such a way that the individual fibers in a relatively steep Storage to the large surfaces of the insulation materials, especially the insulation boards or insulation panels are arranged. In terms of process engineering, this happens in the manufacture of the insulation materials by a longitudinal and a Height compression of the fiber mass impregnated with binders and a subsequent one Fixation of the strongly deformed fiber mass through the hardening of the mostly used thermosetting resins or resin mixtures. The longitudinal / Height compression usually takes place in the direction of production, so that Fibers set up steeply in the direction of production and strongly deformed and transverse to Production direction are stored flat.

The bending tensile strength of one made from such an insulating material web Depending on the bulk density, the insulation board is therefore transverse during the test to the production direction about 3 to 6 times higher than in the production direction. to The structure must be prevented from collapsing too early Insulation boards are always designed so that the insulation board axis with the higher Bending tensile strength is arranged transversely to the top chords. This will, however the fundamental problems are not eliminated, but only reduced.

Compared to the bending tensile strength, the compressive stress increases very significantly, so that the average bulk density of the insulation materials, in particular the insulation boards, can be reduced on a regular basis. For insulation boards with this structure, this bulk density is in the range of approx. 130 to 180 kg / m ³ . The commercially available insulation boards are offered with medium compressive stresses of approx. 55 to 70 kPa, whereby a ten percent compression of the insulation board is permitted. This information only applies to unused samples. The values represent a one-time achievable maximum value because structural changes already occur below this limit. Therefore, even if the insulation layer is treated carefully during the construction phase, strength losses of around 20 to 35 kPa regularly occur. The resulting compressive strength then reflects the relatively stable initial level for the actual use phase of the building or the service life of the flat roof construction.

A disadvantage is that with such structured insulation panels around 2 to 3 mW / mK increased thermal conductivity, so that these insulation boards frequently in the Thermal conductivity group 045 according to DIN 4108 fall.

The surface of such insulation boards is very sensitive to shear loads caused by walking or driving on. This disadvantage is avoided by the insulation boards described in DE 37 01 592 C1 and EP 0 277 500 B1. These insulation boards have an integrated, highly compressed zone in which the individual fibers are pressed together to bulk densities of approx. 160 to 220 kg / m ³ and thereby brought into a horizontal position.

The roof insulation panels as well as the sloping roof elements are covered loose insulation boards with a thickness of approx. 20-50 mm protected.

The resilience of the surface of insulating boards designed in this way is by gluing fabrics made of glass, plastic or natural fibers or of glass fleeces with the help of relatively thick layers of viscous glue, such as bitumen or the like. However, such cover layers lead to classification the insulation board as a flammable building material, which has considerable economic disadvantages entails as far as the use of the insulation boards is sustainable being affected.

For example, the best protection of the insulation is provided by rigid concrete slabs of approx. 20 to 50 mm thick or large-format light grid grids, laid on Rubber shot mats, which are laid out on the roof sealing. This Procedures, however, lead to high roof weights and thus expensive Wall constructions, which reduces costs especially in the industrial building sector increase.

Based on this prior art, the object of the invention to create a roof structure and an insulation element with which or which the above disadvantages are avoided and with which Insulation that is better and safer to walk on, at least during construction with a low overall weight and high insulation performance.

The solution to this problem is a generic one Roof structure that the insulation consists of at least two layers, from which at least one layer, namely at least that on the substructure overlying layer is designed to be tensile.

To solve the problem is with an inventive Insulation element provided that the insulation board at least two layers exists, of which at least one layer, namely at least that on the Substructure or any other overlying layer is designed to be tensile is.

The roof structure according to the invention thus sees the installation of a Insulation material, which by the tensile layer facing the substructure does not tend to under load due to walking and / or storage Objects, with particular emphasis on selective loads, to bend between the top chords. With such loads, the roof construction according to the invention both bending cracks and Avoided shear stresses.

The static and dynamic occurring must be taken into account Loads on the roof structure, in which the insulation, especially the individual insulation boards are only partially supported on the upper chords of the support shells. Insulation boards with a small material thickness are mainly subjected to bending and tension loaded. In the case of larger material thicknesses, the shear stress is particularly important Foreground, d. H. the loaded volume element above the range between two adjacent top chords of the carrier shell are pushed through under load. With conventional insulation boards with a steep orientation to the surfaces Mineral fibers reduce the combination that occurs in the usual way Types of stress also the directional dependence of the bending tensile strength. Around but the basically low bending tensile strength in the production direction of the To make insulation material less effective, the material thickness of the Insulation material can be increased significantly. Such an approach is available against economic reasons. Furthermore, the desire often determines the Insulation made of multiple or at least two layers with staggered joints Form insulation boards, the material thickness of the individual insulation boards or Layers of insulation, such as sheet-like insulation material is relocated. But since when the individual are stacked, in the Surfaces also profiled insulation panels a non-positive bond between If the layers of insulation do not arise, the individual insulation board reacts individually with deformations to the loads that occur.

These disadvantages are in the roof structure according to the invention and the Insulation element according to the invention avoided in that the Load-bearing behavior of the insulation, especially the insulation elements, preferably the Insulation boards is significantly improved by at least one tensile layer in the Area of the large surface of the substructure facing the Insulation, especially the insulation element, preferably the insulation panels is provided. With multilayer insulation, the design of the Insulation with a tensile layer on the substructure overlying position of the insulation. However, this has proven to be advantageous also proved to form additional layers with an insulation element, the one have a tensile layer in the manner according to the invention.

The tensile layer can be made in one piece with the further layer or layers of the Insulation element be formed. Alternatively or additionally, a tensile layer can also be designed as a separately manageable element, which in a further process step on the further layers of the Insulating element is glued.

The tensile layer preferably consists of at least one tearproof Fabric, in particular a mesh fabric made of glass, plastic and / or Textile fibers. In the same way as an alternative or as additional reinforcement Glass fleece suitable, preferably glass fleece with a thread reinforcement.

In an improved and preferred embodiment, the individual Mineral fibers in a near-surface area from a few millimeters to 5 cm of the insulation elements forming the insulation with an additional Binder bound. So this is an increase in Binder content in the near-surface area, the additional binder in this area with the binder of the insulation, namely the Insulation element match or may differ. The binder can both with regard to the mineral fibers of the insulation element as well as in relation to the additionally applied tensile layer have an adhesive effect.

According to further features of the invention it is provided that the mesh fabric in front curing the binder into one with preferably additional Binder-impregnated endless mineral fiber web is pressed, from which the Insulation elements, in particular insulation panels, are formed.

Is it also provided that the mineral fiber web in longitudinal and / or Compression is subjected to a higher stiffness of the height direction to achieve insulation elements made therefrom. Will this compression after the application of the tensile layer, in particular the mesh fabric carried out, an almost complete embedding of this mesh is achieved. To for this purpose, part of the mineral fiber web can also be separated and that Mesh fabric before re-merging the parallel to the large ones Partial webs formed on the surface are inserted between these partial webs. To joining the partial webs together with the mineral fiber web the mesh fabric and the created structure of the mineral fiber web fixed by curing the binder.

According to a further feature of the invention it is provided that on the large Surfaces of the partial webs and / or the mesh fabric additional binder is arranged.

Organic and / or inorganic binders or mixtures are preferred both provided.

An improved and in particular more intensive embedding of the Insulation element provided as reinforcement fabric and a good bond with the endless mineral fiber web is made by introducing short to very short, e.g. B. mineral fibers prepared by chopping or grinding, in particular Glass fibers in the area of the separating surfaces between the partial webs or the large ones Surface and the mesh to be glued achieved.

A further development of the invention provides that the additionally introduced short mineral fibers are introduced as fiber mass with a bulk density of 200-800 kg / m ³ . To increase the bulk density, low compressive forces can act on the mineral fiber web, which do not lead to unwanted compression of the non-tensile areas of the mineral fiber web, but lead to a bulk density of the fiber mass of 400-800 kg / m ³ .

The short fibers are with about 6 to 14% by mass of binders, especially with conventional thermosetting resins and / or resin mixtures bound.

In order to create insulation elements that, despite the additional binding agent Having non-flammability requirements within the meaning of DIN 4102 is according to Another feature of the invention provided that as a binder inorganic binders, especially nanoscale silica sol (Ormocere®), silica sol, Water glasses alone, in combinations with each other or in combination with organic binders or binder mixtures or adhesive Binders are used.

It can also advantageously be provided that at least the tensile layers additionally have water-repellent substances.

The tensile layers described above are preferably and / or in particular the introduced reinforcement means open to diffusion formed so that a provided in the roof structure according to the invention vapor-blocking air barrier or existing on the substructure Moisture, does not lead to the inclusion of water in the insulation. The at the Roof waterproofing can trap moisture in this configuration quickly dissipated through the vapor-permeable insulation and over the Roof sealing to be released to the outside air.

According to a further advantage of the invention, it is provided that at least one Foil, preferably made of metal, a bitumen sheet and / or another, at Mineral fiber insulation materials, normal or full-surface lamination, in particular glued in strips to the insulation element and / or mechanically attached, for example sewn on.

Further features and advantages of the invention result from the following Description of the accompanying drawing, in which a preferred Embodiment is shown. The drawing shows:

Fig. 1 shows a detail of a roof structure with insulation in a perspective view and

Fig. 2 shows an insulation element of the insulation according to FIG. 1 in a perspective and partially sectioned view.

Fig. 1 shows a section of a roof structure in a flat design. The roof structure consists of a substructure 1 , on which an insulation 2 is placed. The substructure consists of support shells 3 , which are formed from profiled sheets which have meandering U-shaped profiles. Each carrier shell 3 thus consists of upper chords 4 and lower chords 5 , each upper chord 4 being connected to a lower chord 5 via a web 6 .

On the top chords 4 of the trays 3 , a vapor-retardant air barrier designed as a film 7 is placed. It can be seen in FIG. 1 that the film 7 sags slightly between adjacent webs 6 in the region of the lower chords 5 .

The insulation 2 , which consists of individual insulation panels 8, is arranged above the film 7 . The insulation 8 has two mutually parallel and mutually spaced large surfaces 9, two major surfaces 9 joining, aligned at right angles to the major surfaces 9 and mutually parallel longitudinal sides 10 as well as to the longitudinal sides 10 and the large surfaces arranged at right angles narrow sides 11 on.

Here, the narrow sides 11 are oriented transversely to the direction of production in a conventional, known continuous production of such insulation panels 8 . The insulation panels 8 are usually made of an endless mineral fiber web and consist of stone fibers, each of which has a length in the micrometer range and are bound with binders.

It can be seen that the individual mineral fibers in the region of the narrow sides 11 have a flat orientation relative to the large surfaces. In contrast, the mineral fibers 12 are oriented steeply towards the large surfaces 9 in the region of the long sides 10 of the insulation board 8 . This orientation of the mineral fibers 12 is achieved by compression of the aforementioned endless mineral fiber web in the longitudinal direction of the production line, ie in the direction of the surface normal of the narrow sides 11 and / or compression in the direction of the surface normal of the large surfaces 9 .

It can also be seen from FIG. 1 that the insulation board, which is shown in more detail in FIG. 2, has a layer 13 with a higher fiber density or binder density in the area of the large surface 9 , which is arranged facing away from the substructure 1 . In the area of the large surface 9 arranged opposite, the insulation board 8 has a tension-resistant layer 14 , which is described below with reference to FIG. 2.

The tensile layer 14 consists of a highly compressed top layer 15 , in which a mesh 16 is embedded. The cover layer 15 is glued to the large surface 9 of the insulation board 8 , which faces the substructure 1 . A glass fleece 17 is additionally glued onto the cover layer 15 as a final lamination.

The glass fleece 17 has a thread reinforcement in order to further increase its tensile strength. The cover layer 15 consists of short to very short mineral fibers, which in the form of a fiber mass with a bulk density of 300 kg / m ³ and a binder content of 14% by mass, an inorganic binder being selected as the binder. The cover layer 15 is designed to be open to diffusion, so that despite the high bulk density, diffusion of moisture contained in the roof structure is possible through the insulation 2 .

Claims (32)

1. Roof construction in a flat and / or flat inclined configuration, consisting of a substructure on which thermal and / or acoustic insulation, in particular of insulating boards made of mineral fiber insulation materials, preferably made of glass and / or stone fibers, partially on upper straps of the supporting shells forming the substructure rests and an upper structure, the lower and / or upper structure consisting of individual profiled sheets as support shells, characterized in that the insulation ( 2 ) consists of at least two layers, of which at least one layer ( 14 ), namely at least that on the substructure ( 1 ) overlying layer ( 14 ) is designed to be tensile. 2. Roof structure according to claim 1, characterized in that the tensile layer ( 14 ) is glued to the at least one further layer. 3. Roof structure according to claim 1, characterized in that the tensile layer ( 14 ) made of a glass fleece ( 17 ), in particular with thread reinforcement and / or a tear-resistant fabric ( 16 ), in particular a lattice fabric made of glass, plastic and / or textile fibers consists. 4. Roof structure according to claim 1, characterized in that the tensile layer ( 14 ) has an increased bulk density compared to the further layer. 5. Roof structure according to claim 1, characterized in that the further layer in the region near the surface, the tensile layer ( 14 ) facing area has an increased binder content, which both the improved connection of the mineral fibers arranged there, as well as the connection of the two layers ( 8 ; 14 ) serves. 6. Roof structure according to claim 3, characterized in that the glass fleece ( 17 ) and / or the tear-resistant fabric ( 16 ) is embedded in the tensile layer ( 14 ), in particular before vertical and longitudinal compression of a fibrous web forming the tensile layer ( 14 ) , 7. Roof structure according to claim 1, characterized in that the glass fleece ( 17 ) and / or the tear-resistant fabric ( 16 ) is arranged between the tensile layer ( 14 ) and the further layer. 8. Roof structure according to claim 1, characterized in that the tensile layer ( 14 ) is formed as a partial web of the further layer and, after compression of the further layer, in particular with the interposition of the tear-resistant fabric ( 16 ) and / or the glass fleece ( 17 ) being fed. 9. Roof structure according to claim 1, characterized in that the tensile layer ( 14 ) is glued to the further layer by organic and / inorganic binders. 10. Roof structure according to claim 1, characterized in that the tensile layer ( 14 ) has short to very short glass fibers, in particular in the region of the tear-resistant fabric ( 16 ) and / or the glass fleece ( 17 ). 11. Roof structure according to claim 10, characterized in that the glass fibers are contained in a fiber mass with a bulk density between 200 and 300 kg / m ³ , with additional compression between 400 and 800 kg / m ³ . 12. Roof structure according to claim 10, characterized, that the glass fibers with 5 to 20% by mass, in particular 6 to 14% by mass thermosetting resins and / or resin mixtures or inorganic Binders, such as, in particular, nanoscale silica sol, silica sol, water glass or Mixtures thereof with or without organic binders or Binder mixtures or adhesive binders are bound. 13. Roof structure according to claim 1, characterized in that the tensile layer ( 14 ) and / or the further layer has or have water-repellent substances. 14. Roof structure according to claim 1, characterized in that the tensile layer ( 14 ) and / or the further layer is or are permeable. 15. Roof structure according to claim 1, characterized in that on the tensile layer ( 14 ) and / or the further layer a tensile film, in particular made of metal, a bitumen sheet or the like is glued over the entire surface or in part, in particular in strips. 16. Roof structure according to claim 1, characterized in that between the insulation ( 2 ) and the substructure ( 1 ) a vapor retardant air barrier, in particular a polyethylene film is arranged. 17. Insulation element for a roof construction in a flat and / or flat inclined configuration, in the form of an insulation board made of mineral fiber insulation materials, preferably made of glass and / or stone fibers, which partially rests on the upper straps of a substructure, characterized in that the insulation board ( 8 ) at least consists of there are two layers ( 14 ), of which at least one layer ( 14 ), namely at least the layer ( 14 ) resting on the substructure ( 1 ) or another support, is designed to be tensile. 18. Insulating element according to claim 17, characterized in that the tensile layer ( 14 ) is glued to the at least one further layer. 19. Insulating element according to claim 17, characterized in that the tensile layer ( 14 ) made of a glass fleece ( 17 ), in particular with thread reinforcement and / or a tear-resistant fabric ( 16 ), in particular a lattice fabric made of glass, plastic and / or textile fibers consists. 20. Insulating element according to claim 17, characterized in that the tensile layer ( 14 ) has an increased bulk density compared to the further layer. 21. Insulating element according to claim 17, characterized in that the further layer in the region near the surface facing the tensile layer ( 14 ) has an increased binder content, which improves both the connection of the mineral fibers arranged there and the connection of the two layers ( 14 ). serves. 22. Insulating element according to claim 21, characterized in that the glass fleece ( 17 ) and / or the tear-resistant fabric ( 16 ) is embedded in the tensile layer ( 14 ), in particular before vertical and longitudinal compression of a fibrous web forming the tensile layer ( 14 ) , 23. Insulating element according to claim 17, characterized in that the glass fleece ( 17 ) and / or the tear-resistant fabric ( 16 ) is arranged between the tensile layer ( 14 ) and the further layer. 24. Insulating element according to claim 17, characterized in that the tensile layer ( 14 ) is formed as a partial web of the further layer and, after compression of the further layer, in particular with the interposition of the tear-resistant fabric ( 16 ) and / or the glass fleece ( 17 ). 25. Insulating element according to claim 17, characterized in that the tensile layer ( 14 ) is glued to the further layer by organic and / inorganic binders. 26. Insulating element according to claim 17, characterized in that the tensile layer ( 14 ) has short to very short glass fibers, in particular in the area of the tear-resistant fabric ( 16 ) and / or the glass fleece ( 17 ). 27. Insulating element according to claim 26, characterized in that the glass fibers are contained in a fiber mass with a bulk density between 200 and 300 kg / m ³ , with additional compression between 400 and 800 kg / m ³ . 28. Insulating element according to claim 26, characterized, that the glass fibers with 5 to 20% by mass, in particular 6 to 14% by mass thermosetting resins and / or resin mixtures or inorganic Binders, such as, in particular, nanoscale silica sol, silica sol, water glass or Mixtures thereof with or without organic binders or Binder mixtures or adhesive binders are bound. 29. Insulating element according to claim 17, characterized in that the tensile layer ( 14 ) and / or the further layer has or have water-repellent substances. 30. Insulating element according to claim 17, characterized in that the tensile layer ( 14 ) and / or the further layer is or are designed to be permeable to diffusion. 31. Insulating element according to claim 17, characterized in that a tensile film, in particular made of metal, a bitumen sheet or the like, is adhered to the tensile layer ( 14 ) and / or the further layer over the full or partial area, in particular in the form of a strip. 32. Insulating element according to claim 17, characterized in that between the insulation ( 2 ) and the substructure ( 1 ) a vapor retarding air barrier, in particular a polyethylene film, is arranged.