Foam Module House Roof Prefabrication

The roof of foam module houses typically adopts a prefabricated modular installation method, completing the roof structure construction through steps such as factory prefabrication, on-site assembly, steel reinforcement, and concrete pouring.

The roof prefabrication and installation of foam module houses are part of an overall modular construction system. The core principle is similar to that of wall modular construction, but it requires special design for the mechanical properties of the roof. The specific construction process can be divided into the following steps:

1. Factory Prefabrication Stage
Roof modules are standardizedly produced in the factory according to design drawings, using high-density EPS (expanded polystyrene) or other lightweight insulation materials as the base material. They are processed into geometric shapes that meet mechanical requirements through CNC cutting equipment. The modules have pre-set steel reinforcement channels or connection holes inside. Some designs integrate insulation layers, waterproof layers, and roof decoration layers to form integrated components. For example, the thickness of EPS module roof components is usually designed to be 150-300mm according to span requirements, and the diameter and spacing of internal steel reinforcements need to be determined through structural calculations.

2. On-site Assembly Stage
After being transported to the construction site, the roof modules are positioned on top of the walls using lifting equipment and fixed to the wall modules with mortise-and-tenon or bolt-type connectors. During the assembly process, it is necessary to ensure that the vertical and horizontal deviations between modules do not exceed the allowable values specified in the standards (usually ≤3mm/m), and maintain structural stability through a temporary support system. For complex roof shapes (such as pitched roofs and curved roofs), shape adaptation needs to be achieved through module cutting or customized production.

3. Structural Reinforcement Stage
After the modules are assembled, longitudinal steel reinforcements need to be inserted into the pre-set steel reinforcement channels and form an overall load-bearing system with the steel reinforcements in the walls and floor slabs. The diameter of the steel reinforcements is usually Φ8-Φ12, and the spacing is determined according to the design load (generally ≤200mm). Then, fine aggregate concrete with a strength grade of C30 or above is poured into the modules and the assembly gaps using high-pressure grouting equipment to ensure that the concrete fully fills the module cavities and connection parts, forming a solid structure.

4. Waterproofing and Decoration Stage
After the concrete reaches the required curing standard, waterproof membranes need to be laid or waterproof coatings need to be applied on the roof to form a continuous waterproof layer. For integrated modules, roof tiles or metal sheets can be directly installed on the surface of the prefabricated layer; for non-integrated modules, additional decoration layers need to be constructed. The entire roof system must meet the requirements of standards such as the "Technical Code for Pitched Roof Engineering" (GB50693) to ensure structural safety and functionality.