Pouring the roof with concrete

For many construction projects, pouring a concrete roof is a strong and long-lasting solution. This technique improves the structural integrity of your residential or commercial building and provides superior weather protection. If you’re thinking about going this route, it’s critical to comprehend the procedures and advantages.

Concrete roofs are renowned for being long-lasting and requiring little upkeep. Concrete, as opposed to conventional roofing materials, is resistant to severe weather, such as intense rain, powerful winds, and even fire. For regions that are prone to severe weather, this makes it a favorite option.

The energy efficiency of concrete roofing is an additional benefit. Because of its inherent insulating qualities, concrete can help keep your building warmer in the winter and colder in the summer. Over time, this may result in considerable energy bill savings.

Planning is essential when pouring concrete roofing. A strong and long-lasting roof is achieved by making sure the concrete is mixed correctly, installing the necessary reinforcement, and using exact pouring techniques. Whether you’re an experienced builder or a do-it-yourself enthusiast, knowing these fundamentals will get you started in the right direction.

How to decide on the type of roof?

Choose the shape of the roof before beginning any arrangement work, as this will dictate how easy it will be to install and how convenient it will be to operate afterwards. A garage’s concrete surface could be:

• horizontal;
• sloping.

Gable roofs are not often filled with concrete mortar, since this is quite difficult to do. Due to the device of a gable roof, which is two surfaces located at an angle to each other, the concrete will flow down during the laying process. It will not be possible to make a uniform layer with the same thickness along the entire perimeter of the surface. In this case, a frame structure is used to form a gable roof, which can be moved. But it is not so easy to make it either. It will take a significant amount of time to build a gable roof, which will increase labor costs many times over. It is much faster to arrange a gable roof from other roofing materials, then the installation process will consist of the following stages:

• installation of load-bearing beams;
• installation of battens;
• laying of roofing material.

Roofs are equipped with slabs of reinforced concrete. They need additional equipment because they are heavy. Additionally, the joints created by laying reinforced concrete slabs must be waterproofed. Horizontal roofs are more common because the difficulty of installing such coverings does not always justify its use. Their structure is comparable to that of a traditional concrete screed. However, it is important to keep in mind that when working with concrete, it is crucial to get the mixture to the construction site as soon as possible.

When concrete is poured, a strong, long-lasting surface with exceptional resistance to weathering is produced. Because this method requires less maintenance than traditional roofing materials and offers strong thermal insulation and fire resistance, it is becoming more and more popular. Concrete is a practical and appealing option for both residential and commercial buildings because it gives a smooth, contemporary appearance and has the strength and durability to last a long time.

Preparation of tools and materials

The following tools are ready before the pouring stage:

It is impossible to lay concrete without certain supplies, such as:

• reinforcement;
• metal beams, which are designed to strengthen the load-bearing elements of the building;
• boards;
• concrete mortar;
• roofing felt.

Stages of roofing

The following steps are involved in concrete roofing of roof surfaces:

• Lay boards on the lower tier of planks and spread a layer of roofing felt or a metal sheet.
• If necessary, install supports that will ensure the reliability of the structure and support the weight of the roof. Supports are attached in increments of 50 square centimeters.
• When erecting a structure, monitor the joints, they must fit tightly to each other. If you miss this moment, then when laying the mortar, concrete milk will appear through the cracks, which is responsible for the strength of the concrete coating.

Preparation of formwork

Formwork installation ensures the strength and evenness of the concrete surface and is the first step in the construction of a roof. Formwork may consist of:

• wooden;
• metal;
• reinforced concrete;
• reinforced cement.

• Place boards on the lower beams and lay roofing felt on them without allowing gaps . It is necessary to place the boards as tightly as possible against each other to avoid gaps between them. Possible gaps will lead to leakage of concrete milk, which affects the strength of the structure.
• Next, install reinforcement in the direction of the beams and across them. The laid reinforcement is fixed with wire, which will ensure strength when filled with concrete mortar.
• At the last stage, add a layer of crushed stone under the reinforcement, which will level the surface and reduce the consumption of concrete mortar.

Oils or lubricants are applied to the formwork prior to installation, reducing the adherence of the concrete to the formwork and making it easier to remove the structure once the concrete mortar has dried.

Reinforcement

Installing the reinforcing mesh along and across the beams requires constant observation of the cells’ consistency, which should measure twenty by twenty centimeters. In the event that welding the reinforcing mesh is required, the structure is raised to the roof while the welding is being done on the ground. They begin knitting the reinforcement right on the roof after fixing it together.

Crushed stone is placed beneath the reinforcing mesh in order to use less concrete mortar. For the surface to be even, the crushed stone layer needs to be the same thickness. Pay attention to the four-centimeter gap that should exist between the mesh and the frame when you install the reinforcement. If you ignore this, the uneven application of the concrete mortar and the consequent corrosion will cause the roof’s appearance to deteriorate.

Pouring concrete

Following specific guidelines is necessary when laying the concrete mortar.

• The mortar is poured in strips along the beams.
• The thickness of the laid mortar should exceed 15 centimeters, this will ensure the required strength of the structure.
• For uniform drying of the concrete mortar, the mixture is poured continuously.
• You need to periodically pay attention to the reinforcing layer and its location. It should be in the same place, achieve this, using a wire to fix metal rods even at the stage of installation of the reinforcing structure.
• Before laying concrete mortar in the formwork, it is pre-lubricated with oil. This will ensure its trouble-free removal in the future.

Laying concrete mortar in stages:

• A mixture of cement, sand, water and crushed stone is poured evenly.
• The surface is leveled using a rule.
• The concrete mortar is compacted from formed air bubbles using special equipment. These can be: surface or deep vibrators, vibrating screeds, vibrating plates and other mechanisms. The choice of concrete compactor depends on the purpose of the concrete product, its design and manufacturing technology. If there are large bubbles, use a probe with which you can pierce them.
• During the process of pouring the mortar, tap on the formwork, which allows the mixture to be evenly distributed in the structure.
• To achieve the required quality characteristics of the mortar, it is tamped until a shine appears on the surface.
• The evenly stacked mixture is equal to a shovel, and then – a construction cell.
• After the concrete mortar has been laid, it is necessary to ensure that it dries properly. Failure to comply with the temperature conditions and humidity levels in the room will result in cracks appearing on the surface of the mortar, which will require additional work to seal them.

Drying

Make sure the concrete mixture dries properly after it has been laid:

• Cover the mixture with any loose material.
• Periodically spray the concrete surface with water.
• After the concrete has set, lay a layer of film on the roof to prevent moisture and direct sunlight.

Ten days after the mortar has dried, the formwork can be taken down.

Finishing operations

Concrete roof waterproofing is used to stop materials from corroding when precipitation gets on the structural elements. For this:

• Make a concrete screed at an angle in the desired direction. Such a structure must be made of concrete that can retain moisture and not let it through.
• Apply the solution to a pre-prepared surface, which is cleaned of dirt and dust.
• After the mixture has dried, apply bitumen or polyurethane mastics using a sprayer or brush.

The concrete surface will develop a film that acts as a moisture barrier for many years after a certain amount of time.

A concrete roof pour needs to be completed with meticulous planning and execution. You can guarantee a strong and long-lasting roof by following the instructions, which include setting up the formwork and mixing and pouring the concrete.

Paying close attention to details is essential. It is imperative to mix concrete properly, pour it quickly, and allow it to cure sufficiently to prevent problems like weak spots and cracks. Recall that over time, the performance of the roof will be greatly impacted by the caliber of your work.

A sturdy and dependable roof is the result of spending money on high-quality materials and devoting sufficient time to the task. By taking this approach, you can improve the building’s structural integrity and feel more at ease knowing that the roof is resilient to different weather conditions.

Ultimately, pouring a concrete roof is a big job, but it can be done right and provide a sturdy, long-lasting roof that protects and enhances the value of your building.

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