AU2015224401C1

AU2015224401C1 - Textile reinforced membranes

Info

Publication number: AU2015224401C1
Application number: AU2015224401A
Authority: AU
Inventors: Mark James Hazlehurst
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-09-08
Filing date: 2015-09-08
Publication date: 2024-03-14
Anticipated expiration: 2035-09-08
Also published as: AU2015224401A1; AU2015224401B2

Abstract

Described herein is a textile reinforced membrane (TRM). The TRM contains a unique combination of surface preparation techniques, primers, adhesives, reinforcing mesh and elastomeric membrane that allows it to adhere to a wide range of materials and to provide a 5 highly durable weather-tight elastomeric seal. The TRM also minimises work needed to complete a repair, simplifies the installation process and avoids the need to further damage the area being repaired as may be required for other methods. 28 3 \ ~ 4 2 FIGURE 1 FIGURE 2 1/3

Description

\ ~ 4 2

FIGURE

1

FIGURE 2

1/3

TEXTILE REINFORCED MEMBRANES RELATED APPLICATIONS

This application derives priority from New Zealand patent application number 630461

incorporated herein by reference.

TECHNICAL FIELD

Described herein is a textile reinforced membrane (TRM). The TRM contains a unique

combination of surface preparation methodology, primers, adhesives and reinforced

membrane that allows the TRM to adhere to a wide range of building materials so as to provide

a highly durable elastometric waterproof seal between diverse building elements.

BACKGROUND ART

Textile reinforced membranes (TRMs) are used in the art to seal junctions in building

construction between disparate building elements. TRMs are used in the art on both new and

existing structures although, at least in New Zealand, sealing junctions in structures has taken more prominence in the wake of the so-called 'leaky building' issues and the Christchurch

earthquake sequence that caused extensive damage to existing structures. A need exists to

face seal the junction between for example, window perimeters and their surrounding

cladding as well seal around penetrations through claddings, over and around saddle flashings,

scupper outlets and overflows from decks, balconies and gutters. TRM's have the capacity to

remove or limit the need to replace a building component or rebuild or re-clad a structure.

Typically TRM's minimise the amount of work needed to correct a defect and render a building

component, window, disparate material junction, or penetration weather tight.

Existing methods of sealing the junction between a window perimeter and its adjacent

cladding involve:

1). Paint;

2). A painted sealant bead;

3). The cutting back of the cladding from around the window perimeter and the

installation of uPVC flashings and the application of in-fill plaster or installation of polystyrene and plaster coating to flush out to the same plane as the existing cladding, thus requiring the wall to be overclad with a reinforced modified plaster system to cover the junction between the existing and new in-fill plaster.

Alternatively, the junction between new and old plaster could be covered with a

plant-on pre-meshed polystyrene moulding;

4). The insertion of a surface adhered PVC flashing tucked behind the window flange,

thus requiring the wall to be overclad with a reinforced plaster system to cover the

exposed leg of the uPVC flashing.

For options 1) and 2) above, the application of paint or sealant and paint fails to meet a

cladding system's Durability requirement of 15years under Clause B2 of the New Zealand

Building Code:1992 and thereby fails to attract building consent approval as a component of a

code compliant cladding system.

Option 3) above, requires the existing cladding to be to cut back from the edge of the window

approximately 50mm to 75mm and the installation of uPVC jamb and sill flashings and the

installation of an in-fill plaster or polystyrene strip which is over-plastered with a modified

plaster reinforced with mesh in order to cover the junction between the existing and new plaster installed around the windows. As may be appreciated, this method is difficult, time

consuming, noisy, dusty and comparatively expensive. Further, particularly with solid plaster

claddings, the solid plaster overlaps the flanges of the aluminium window and as such tends to

leave a scratched 'tide mark' on the surface of the aluminium window on both the jambs and

the sills of the window, which is covered by the application of the TRM. Without TRM,

windows with scratched 'tide-marks' require stripping and re-spraying or replacing.

Option 4) above, often requires the surface of the exterior cladding to be ground back to allow

the face fixed uPVC flashing to fit in behind the flush mounted window flange risking damage

to the edge of the window or the window flange has to be 'levered' out in order to ease the

leading edge of the uPVC flashing behind the window flange. Having inserted the uPVC

flashing and glued it to the existing cladding surface the wall requires overcladding with a fibre

glass mesh reinforced plaster to cover the exposed leg of the face fixed uPVC flashing. Further,

particularly with solid plaster claddings, the solid plaster overlaps the flanges of the aluminium

window and as such tends to leave a scratched/pitted 'tide mark' on the surface of the

aluminium window on the jambs and the sills of the window, which is covered by the

application of the TRM. Without TRM, windows with scratched and pitted 'tide-marks' require re-spraying or replacement.

The application of sealant and paint, if deemed to be part of the cladding system, is required to

meet the same NZ Building Code:1992 Clause B2 Durability requirement as the cladding

system (15 years). Sealant and paint have a Durability requirement under Clause B2 of 5 years

and therefore fail to meet the cladding's 15year Durability requirement. The installation of the

surface mounted uPVC flashings or the cutting back of the cladding to retro-fit uPVC flashing

are Alternative Solutions under the NZ Building Code:1992 and therefore require territorial

authority endorsement if a building consent is to be approved.

It should be appreciated that it may be useful to provide a textile reinforced membrane

solution (TRM) that addresses the above problems, meets the objectives, functional and

performance of the NZ Building Code:1992 Clauses B2 and E2 and provides building owner's

with a an economical remedial methodology or at least provides the public with a choice.

Further aspects and advantages of TRM's and their method of application will become

apparent from the ensuing description that is given by way of example only.

SUMMARY

Described herein is a textile reinforced membrane (TRM). The TRM system contains a unique

amalgam of surface preparation, primers, adhesives and membrane that allows TRM to adhere

to a wide range of disparate building materials to provide a highly durable weather-tight

elastomeric seal. TRM also minimises work needed to complete a repair, simplifies the

installation process and avoids the need to further damage to the area being repaired as may

be required for art methods.

In a first aspect, there is provided a textile reinforced membrane (TRM) comprising:

an intermediate layer of an textile mesh embedded within a mixture of elastomeric

resin and cement, the elastomeric resin being a fibre reinforced styrene-acrylic ester copolymer;

and

a primer coating on each side of the intermediate layer substantially sealing the first

layer within the coating, the primer being a styrene-acrylic ester copolymer.

In a second aspect, there is provided a method of applying a textile reinforced membrane (TRM)

to a building material surface, the method comprising the steps: a. prepare the surface to which the TRM is to be applied; b. apply a coat of primer to the surface, the primer being a styrene-acrylic ester copolymer; c. apply an intermediate layer of textile mesh embedded within an elastomeric resin and cement mixture to the primer, the elastomeric resin being a fibre reinforced styrene acrylic ester copolymer; and d. apply a further coat of the primer to the intermediate layer.

Advantages of the above TRM and method of application includes the ability to adhere the

membrane to a wide range of materials and to provide a highly durable elastomeric seal. The

TRM described has shown unexpected durability providing a weather-tight seal over almost all

typical building materials tested including powder coated or anodised aluminium, stainless

steel, ZincalumeiM, galvanised steel, copper, ColorsteelI, wood, plywood, solid plaster,

modified plaster, concrete, concrete block, fibre cement sheet, acrylic paint, membrane,

ceramic and porcelain tiles, thermoplastic olefin (TPO) and torch-on membrane, synthetic butyl

rubber such as ButynolI, and uPVC. Art TRM solutions in the inventor's experience, do not

have this variety and versatility of substrate application, durability or warranties.

The TRM also minimises work needed to complete a repair, simplifies the installation process

and avoids the need to further damage to the area being repaired as may be required for other

methods.

In the case of so-called 'leaky buildings' and earthquake strengthened historic buildings, TRM

and methods described herein have the potential to save thousands of dollars on repairs as

complete re-cladding or replastering are avoided since leaking sections or window/door

cladding junctions can be remediated, obviating the need to remove and re-install or replace

exterior joinery components. The same technique may be used for a wide variety of other

scenarios such as seismically damaged structures, restoration of historic building facades and

weathered structures needing remedial sealing repairs.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the textile reinforced membrane and method of application will become

apparent from the following description that is given by way of example only and with

reference to the accompanying drawings in which:

Figure 1 is a photograph showing a crack repair around windows about to commence with

the repair area having had a primer layer applied;

Figure 2 is a photograph showing in more detail the priming of the window frame in

preparation for the application of the textile reinforced membrane to seal the

junction between the window frame and the cladding;

Figure 3 is a photograph showing the intermediate layer (including the reinforcing mesh)

being applied to the repair area;

Figure 4 is a photograph showing the final coat of primer ready for the application of two

acrylic paint coats;

Figure 5 is a photograph showing the installation of a retrofitted uPVC diverter prior to TRM

application; and,

Figure 6 is a photograph showing the uPVC diverter installed and TRM coatings over the

uPVC, Colorsteel'" apron flashings and TRM weatherproofing the timber

fascia/solid plaster intersection.

DETAILED DESCRIPTION

As noted above, described herein is a textile reinforced membrane (TRM). The TRM contains a

unique combination of surface preparation techniques, primers, adhesives, reinforcing mesh

and elastomeric membrane that allows it to adhere to a wide range of materials and to provide

a highly durable weather-tight elastomeric seal. The TRM also minimises work needed to

complete a repair, simplifies the installation process and avoids the need to further damage the

area being repaired as may be required for other methods.

For the purposes of this specification, the term 'about' or 'approximately' and grammatical

variations thereof mean a quantity, level, degree, value, number, frequency, percentage,

dimension, size, amount, weight or length that varies by as much as 30, 25, 20, 15, 10, 9, 8, 7, 6,

5, 4, 3, 2, or 1% to a reference quantity, level, degree, value, number, frequency, percentage,

dimension, size, amount, weight or length.

The term 'substantially' or grammatical variations thereof refers to at least about 50%, for

example 75%, 85%, 95% or 98%.

The term 'comprise'and grammatical variations thereof shall have an inclusive meaning - i.e.

that it will be taken to mean an inclusion of not only the listed components it directly

references, but also other non-specified components or elements.

and

layer within the coating, the primer being a styrene-acrylic ester copolymer.

The textile mesh may be a woven mesh. The textile mesh may be a polyester mesh. The mesh

may provide a structural base for the TRM and helps to retain the different compounds

together. The mesh may also be alkali resistant to withstand the alkali compounds used to form

the TRM.

As noted above, the textile mesh is embedded within the elastomeric resin. Embedded refers

to the mesh being fully encapsulated and covered by the elastomeric resin.

The elastomeric resin is a fibre reinforced styrene-acrylic ester copolymer. Historically, resins of

this nature may have been used on their own but in the inventor's experience, this resin alone does not provide the durability needed, particularly across the range of substrates, which the

present TRM can adhere to nor do these individual applications carry a warranty. A key feature

of the resin is a very high flexibility - in fact the resin alone once dried can be stretched to at

least 1.5 times its normal shape or more and return to its original size without ripping or

splitting.

In one embodiment, the elastomeric resin may be a modified sterol-butadien-stirol (SBS)

polymer.

Fibre reinforcement for the elastomeric resin may be provided by a synthetic fibre - one

example being polyacrylonitril fibres.

The elastomeric resin may also comprise at least one clay or mineral. Example clays or minerals

may comprise: quartz, calcium carbonate and combinations thereof.

One specific elastomeric resin that the inventor has found useful may comprise the following:

Water <12.5%

Quartz 20%

Styrene-acrylic ester copolymer 57% in water >30%

Calcium carbonate 10%

Polyacrylonitril fibres <1.5%

Cement as noted above, may be used as a curing agent to help dry and set the mixture. The

inventor has found that an optimum speed of drying and durability ratio of elastomeric resin to

cement may be a ratio of approximately 6, or 7, or 8, or 9, or 10 parts resin to approximately 1

part cement. Ratios outside the ranges described may also be used to suit manufacturer's

recommendations and differing compounds/compositions used.

The primer (termed below interchangeably as the TRM primer) may be a styrene-acrylic ester

copolymer. In one embodiment, the TRM primer may be a modified sterol-butadien-stirol (SBS)

polymer.

The TRM primer may also comprise at least one clay or mineral. Example clays or minerals may

comprise: quartz, limestone, calcium carbonate, talcum, titanium dioxide, and combinations

thereof.

One specific TRM primer may comprise the following:

Water <25%

Quartz <10%

Limestone >10%

Styrene-acrylic ester copolymer 50% in water <20%

Calcium carbonate 20%

Talcum <5%

Titanium dioxide >5%

to a building material surface, the method comprising the steps:

a. prepare the surface to which the TRM is to be applied;

b. apply a coat of primer to the surface, the primer being a styrene-acrylic ester

copolymer;

c. apply an intermediate layer of textile mesh embedded within an elastomeric resin and

cement mixture to the primer, the elastomeric resin being a fibre reinforced styrene acrylic ester copolymer; and d. apply a further coat of the primer to the intermediate layer.

The textile reinforced membrane may be applied to a surface selected from: powder coated or

anodised aluminium, stainless steel, ZincalumeM, galvanised steel, copper, ColorsteelIM, wood,

plywood, solid plaster, modified plaster, concrete, concrete block, brick, fibre cement sheet,

acrylic paint, acrylic membrane, glazed and unglazed ceramic tiles and porcelain tiles,

thermoplastic olefin (TPO) and torch-on membrane, synthetic butyl rubber membrane such as

ButynolI, uPVC, and combinations thereof. As should be appreciated, this list represents a

significant range of building materials that might be seen or observed. In the applicant's

experience, the TRM described may be used on many materials and achieve the desired level of

sealing and durability unlike art TRM solutions that might only be sufficiently durable for a one

of or a small range of materials.

The TRM once applied may be painted over or plastered over. This allows the repair to be

effectively hidden and give a clean finish to the surface of the building structure.

Surface preparation in step (a) of the method noted above may comprise the step of

roughening or keying the surface. The term 'roughening or keying' as used herein refers to the step of increasing surface adhesion through abrasion methods or other steps. As should be

appreciated, the exact method of roughening or keying the surface may vary depending on the

surface material to which TRM is to be applied.

By way of example, surface preparation for an aluminium surface may include the steps of:

i. keying/scouring the surface with a diamond encrusted pad or grinding the surface

abutting the window/door frame to ensure it provides a secure adhesion surface;

ii. cleaning the surface with a solvent;

iii. applying an etching primer (e.g. Wattyl Super EtchT M ) to the keyed surface;

iv. applying a coat of TRM primer.

Surface preparation for a wall to concrete junction may include the steps of:

i. cutting a blade width slot (3mm deep approx.) with a diamond saw [40mm (approx.)

out from the wall] to drop the leading edge of the reinforcing mesh into the slot or stop

the mesh just short of the slot and use the slot to protect the leading edge of the TRM;

ii. keying the concrete surface with either a carbide blade or a grinder;

iii. applying a coat of TRM primer.

For metal surfaces, the preparation steps may include:

i. scuffing the metal surface with a diamond pad;

ii. cleaning the bonding surfaces with a solvent;

iii. applying an etching primer to the bonding surfaces;

iv. applying a coat of TRM primer.

For wooden surfaces, preparation steps may include:

i. using a carbide scraper, flat scraping the bonding surface, then

ii. using the sharp edge of the carbide blade, cutting shallow grooves in the timber surface

to make a diamond pattern (5mm to 10mm spacing) or similar process to key the

timber surface so that it is rough to the touch;

iii. applying an etching primer to the prepared surface;

iv. applying a coat of TRM primer.

For uPVC surfaces, preparation steps may include:

i. flat scraping the bonding surface using wet and dry sandpaper or a carbide scraper,

then; ii. cutting shallow grooves in the uPVC surface using the sharp edge of a carbide blade and making a diamond pattern that is rough to touch;

iii. apply etching primer to the prepared surface;

iv. applying a coat of TRM primer.

The uPVC surfaces may also be further roughened or 'livened up' by application of thinners such

as the product Valspar IKM thinners or similar products and, once the thinners have flashed off TM but the surface of the uPVC is still tacky, applying an etch primer such as Wattyl Super Etch or

similar products.

Optionally, a perimeter barrier such as masking tape may define the area to which the TRM is

applied. A secondary layer of masking tape may be applied adjacent to the roughened prepared

surface prior to application of the TRM to facilitate a neat straight edge to the TRM (i.e. double

tape lines).

Typically, each layer is left to dry before commencing placement of the additional layer. Step (c)

of the method above may only be applied for example once the TRM primer applied in step (b)

is fully dry. Further, step (d) may only commence once the elastomeric resin applied in step (c)

is fully dry.

Porous surfaces such as wood, fibre cement sheet, precast concrete, tiles, brick et al. may

require the application of a porous surface sealer (PSS) following the keying of the substrate

surface to ensure complete adhesion of the TRM. This is because these types of materials can

have a fine dust layer impregnated in the material that may need to be bound into the surface

before TRM application to maximise adhesion bond strength.

As noted above with respect to the TRM itself, the applicant has found that for ideal results with

respect to speed of drying and durability, the elastomeric resin and curing agent may be mixed

at a ratio of approximately 6, or 7, or 8, or 9, or 10 parts resin to approximately 1 part curing

agent. In one embodiment, the ratio may be approximately 8 parts resin to 1 part curing agent.

Ratios beyond the ranges described may also be used to suit manufacturer's recommendations

and differing compounds. The figures provided are for illustration only and should not be seen

as limiting. The mixing of the resin and curing agent may be completed immediately prior to the

time of application to the surface where the term 'immediately' refers to mixing occurring

within approximately 30, or 25, or 20, or 15, or 10, or 5, or 4, or 3, or 2, or 1 minute/s of

application.

The textile mesh may be embedded into the elastomeric resin and curing agent on the surface prior to the resin and agent hardening. For example, the resin and curing agent mixture may be

applied to the surface and the mesh pushed into and embedded into the mixture.

More than one intermediate layer (resin, cement and optionally mesh) may be used. For

example, once the first intermediate layer dries, a further intermediate layer or layers of

elastomeric resin/cement and optionally mesh may be applied before commencing step (d).

Additional steps may also be taken to suit particular conditions and materials. For example, it

may be advantageous in the case of aluminium joinery applications to apply a modified silicone

bead to the intersection of the exterior joinery frame and the abutting surface to accommodate

structural and thermal movement.

modified plaster, concrete, concrete block, brick, fibre cement sheet, acrylic paint, acrylic

membrane, glazed and unglazed ceramic tiles and porcelain tiles, thermoplastic olefin (TPO) and torch-on membrane, synthetic butyl rubber membrane such as ButynolIM, uPVC,and combinations thereof. Art TRM solutions in the inventor's experience do not have this durability.

and avoids the need to further damage the area being repaired as may be required for other

methods.

In the case of so-called 'leaky buildings' TRM and method described herein has the potential to

save thousands of dollars on repairs as complete re-cladding is avoided since leaking sections

can be remediated and not replaced. The same technique may be used for a wide variety of

other scenarios such as seismically damanged structures and weathered structures needing

sealing repairs.

The embodiments described above may also be said broadly to consist in the parts, elements

and features referred to or indicated in the specification of the application, individually or

collectively, and any or all combinations of any two or more said parts, elements or features.

Further, where specific integers are mentioned herein which have known equivalents in the art

to which the embodiments relate, such known equivalents are deemed to be incorporated herein as of individually set forth.

WORKING EXAMPLES

The above described textile reinforced membrane and method of application are now

described by reference to specific examples. Note that unless otherwise stated, the term

primer as used below refers to a styrene-acrylic ester copolymer primer and the term

elastomeric resin refers to a fibre reinforced styrene-acrylic ester copolymer.

EXAMPLE 1

In this example, a method of applying the membrane and adhesive to powder coated/anodised

aluminium and steel exterior joinery is described.

The method comprises the following steps:

a. Make sure the substrate abutting the window/door frame is sound

b. If required remove loose material and re-plaster before commencing the TRM process c. Key the surface with a carbide scraper or grind the surface abutting the window/door frame to ensure it provides a secure adhesion surface d. Apply masking tape lines ensuring that drain holes from aluminium extrusion are not covered - if drain holes are covered by the TRM they can be re-drilled or cut through the TRM once the TRM is fully dried e. Use a diamond pad to scour the joinery surfaces where adhesive will be applied f. Wipe the scoured joinery clean with solvent g. Apply an etching primer to etch the surface h. When the etch primer is dry, thumb nail scratch the etch primer to ensure that the etch has adhered to the surface i. Place secondary masking tape 3mm from preliminary tape line so when tapes are removed there is a 3mm band of etch primer to paint onto j. Apply a coat of TRM primer to both the exterior joinery and the abutting adjacent surface k. Apply a modified silicone bead to the intersection of the exterior joinery frame and the abutting surface (optional)

1. Whilst the modified silicone is still tacky but 'skinned off' and firm to touch, apply TRM

primer to the sealant surface

m. Mix elastomeric resin and cement at a ratio of 8 parts elastomer resin to 1 part cement

and apply to both the exterior joinery and the abutting surface

n. Lay the textile mesh in the wet elastomer resin ensuring it sits flat and is encapsulated

in the first elastomer resin coat

o. Once the first coat is dry, apply a second coat of elastomer resin

p. Apply TRM primer coating to all surfaces once the second coat of elastomer resin is fully

dry q. Remove masking tape leaving a 3mm wide band of the etch primer for the painter to

paint to the leading edge of the etch primer

r. Check work to ensure all junctions are sealed and that the leading edge of the

elastomer resin to ensure this edge will not lift

s. If necessary rub the leading edge of the elastomer resin to 'flatten' the leading edge

slightly so it 'rounds' the leading edge.

EXAMPLE 2

In this example, a method of applying the membrane and adhesive from a wall cladding onto an

adjacent concrete surface is described. For example where a dwelling wall abuts a path,

driveway or retaining wall and a seal is necessary about the junction.

The method comprises the following steps:

a. Make sure both surfaces are sound

b. Cut a slot with a diamond saw (40mm out from the wall a blade width and 3mm deep)

to drop the leading edge of the resin into

c. Key the concrete surface with either a carbide blade or a grinder

d. Tape a straight line of the masking tape along the edge of the slot cut into the concrete

e. TRM primer both the concrete and the wall surface

f. When the TRM primer coating is dry, it may be useful to apply a modified silicone at the

junction between the cladding and the adjacent concrete surface coated with TRM

primer whilst still tacky

g. Apply a first intermediate layer coat of elastomer resin and cement reinforced with

100mm wide textile mesh embedded in the elastomer resin and cement h. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and

cement to ensure the textile mesh is fully encapsulated in the elastomer resin and

cement mixture

i. When the elastomer resin/cement second coat is completely dry, apply a final coat of

TRM primer coating.

EXAMPLE 3

In this example, a method of applying the membrane and adhesive to metal surfaces is

described.

The method comprises the following steps:

a. Ensure the bonding surface is free of dust and deleterious/foreign material

b. Apply masking tape to form a primary line providing straight edges to the membrane

and adhesive perimeter

c. Scuff the metal surface with a diamond pad

d. Clean the bonding surfaces with a solvent

e. Apply an etch primer to the bonding surfaces up to the internal edges of the masking tape primary line f. After the etch primer has dried, ensure the etch primer has adhered to the metal surface by attempting to remove the etch primer by scraping the etch primer surface with a thumbnail g. If the etch primer has failed to adhere successfully repeat the process above h. When adhered, apply a secondary masking tape line approximately 3mm inside the primary tapeline. The secondary line masking tape should cover the etch primer surface by approximately 3mm. This allows the final paint coating to encapsulate the leading edge of the elastomer resin at the same time adhering the to the final coat of acrylic based resin applied over the elastomer resin.

i. Apply a first coat of TRM primer coating to the etched surface

j. Apply a first intermediate layer coat of elastomer resin and cement reinforced with

100mm wide textile mesh embedded in the elastomer resin and cement

k. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and

cement mixture 1. When the elastomer resin/cement second coat is completely dry, apply a final coat of

TRM primer coating.

m. Carefully remove the masking tape from the perimeter of the membrane and adhesive

coated area and flatten the leading edge of the membrane and adhesive by rubbing it

flat as required.

EXAMPLE 4

In this example, a method of applying the membrane and adhesive to wooden surfaces is

described. The wooden surfaces may be timber, timber profiles, plywood surfaces including

construction areas such as facings, soffit moulds, door jambs/heads and scuppers.

The method comprises the following steps:

a. Ensure the bonding surface is free of dust, oil and deleterious/foreign material

b. Establish the bonding area margins by marking the area out with a pencil line c. Cut a slot with a diamond saw (40mm out from the wall a blade width and 3mm deep)

to drop the leading edge of the resin into

d. Using a carbide scraper, flat scrap the bonding surface, then using the sharp edge of the

carbide blade, cut shallow grooves in the timber surface making a diamond pattern

(5mm to 10mm spacing). Upon completion, ensure the timber surface is rough to the

touch

e. Apply masking tape to form a primary line providing straight edges to the membrane

and adhesive perimeters

f. Apply a coat of porous surface sealer

g. Apply TRM primer coating to the keyed timber surfaces

h. Once the TRM primer coating is dry, test the primer coating for strength of bond to the

timber surface to ensure it is well bonded

i. Apply a secondary masking tape line approximately 3mm inside the primary tapeline. In

other words, cover the primer surface with the secondary masking tape by

approximately 3mm. This allows the final paint coating to encapsulate the leading edge

of the elastomer resin at the same time adhering the to the final coat of TRM primer.

n. When the TRM primer coating is dry, lightly sand the surface then apply a first

intermediate layer coat of elastomer resin and cement reinforced with 100mm wide

textile mesh embedded in the elastomer resin and cement.

o. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and cement to ensure the textile mesh is fully encapsulated in the elastomer resin and

cement mixture

j. When the second intermediate layer coat is completely dry, apply a final coat of TRM

primer, carefully remove the masking tape from the perimeter of the membrane and

adhesive coated area and flatten the leading edge of the membrane and adhesive by

rubbing it flat as required.

EXAMPLE 5

In this example, a method of applying the membrane and adhesive to PVC surfaces is described.

The method comprises the following steps:

b. Using wet and dry sandpaper or a carbide scraper, flat scrape the bonding surface, then

using the sharp edge of the carbide blade, cut shallow grooves in the timber surface making a diamond pattern (5mm to 10mm spacing)

c. Establish the bonding area margins by marking the area out with a pencil line

d. Apply masking tape to form a primary line providing straight edges to the membrane

and adhesive perimeters e. 'Liven up' the PVC surface with Valspar IKM or a similar product f. Once the thinners have flashed off but the surface of the PVC is still tacky, apply Wattyl

Super Etchi metch primer or a similar product

g. Apply a secondary masking tape line approximately 3mm inside the primary tapeline. In

other words, cover the etch primer surface with the secondary masking tape by

of the elastomer resin at the same time adhering the to the final coat of TRM primer

coating. Apply TRM primer coating to the keyed PVC etch primed surface

h. Once the TRM primer coating is dry, test the TRM primer for bond strength

i. Apply a first intermediate layer coat of elastomer resin and cement reinforced with

100mm wide textile mesh embedded in the elastomer resin and cement

j. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and

cement mixture

k. When the elastomer resin/cement second coat is completely dry, apply a final coat of

TRM primer coating. 1. Carefully remove the masking tape from the perimeter of the membrane and adhesive

coated area and flatten the leading edge of the membrane and adhesive by rubbing if

required.

EXAMPLE 6

In this example, a method of applying the membrane and adhesive to solid plaster and modified

plaster surfaces is described.

The method comprises the following steps:

b. Using a carbide scraper, flat scrape the bonding surface, then using the sharp edge of

the carbide blade, cut shallow grooves in the timber surface making a diamond pattern

(5mm to 10mm spacing)

c. Apply masking tape to form a primary line providing straight edges to the membrane

and adhesive perimeters

d. Apply a coat of TRM primer coating to the prepared plaster surface e. Once the TRM primer coating is dry, test the acrylic base primer for bond strength p. When the TRM primer coating is dry, apply a first intermediate layer coat of elastomer resin and cement reinforced with 100mm wide textile mesh embedded in the elastomer resin and cement q. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and cement to ensure the textile mesh is fully encapsulated in the elastomer resin and cement mixture r. When the elastomer resin/cement second coat is completely dry, apply a final coat of

TRM primer coating.

f. Carefully remove the masking tape from the perimeter of the membrane and adhesive

flat as required.

EXAMPLE 7

In this example, a method of applying the membrane and adhesive to fibre cement sheet

surfaces is described.

The method comprises the following steps:

b. Establish the bonding area margins by marking the area out with a pencil line

c. Cut a slot with a diamond saw (40mm out from the wall a blade width and 3mm deep)

to drop the leading edge of the resin into

carbide blade, cut shallow grooves in the fibre cement sheet surface making a diamond

pattern (5mm to 10mm spacing). Upon completion, ensure the fibre cement sheet

surface is rough to the touch

and adhesive perimeters

f. Apply a coat of porous surface sealer

g. Apply TRM primer coating to the keyed fibre cement sheet surfaces h. Once the TRM primer coating is dry, test the primer coating for strength of bond to the

fibre cement sheet surface to ensure it is well bonded

other words, cover the primer surface with the secondary masking tape by approximately 3mm. This allows the final paint coating to encapsulate the leading edge of the elastomer resin at the same time adhering to the final coat of TRM primer.

s. When the TRM primer coating is dry, lightly sand the surface then apply a first

textile mesh embedded in the elastomer resin and cement

t. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and

cement mixture

u. When the elastomer resin/cement second coat is completely dry, apply a final coat of

TRM primer coating.

j. Carefully remove the masking tape from the perimeter of the membrane and adhesive

flat as required.

EXAMPLE 8

Referring to the Figures, a repair to cladding 1 about a window frame 2 is illustrated. Figure 1 shows the window area 2 with repairs about to commence. Masking tape 3 and an applied

primer layer 4 define the repair area perimeter. Figure 2 shows the prepared area in more

detail. Figure 3 shows the intermediate layer 5 being applied to the repair area, in this case

with the mesh (not shown) already applied and the resin and cement being applied on over the

mesh. Figure 4 shows the final repaired surface 6 prior to final paint coats being applied over

the TRM illustrating how the repair is largely invisible and gives an aesthetically attractive result.

EXAMPLE 9

Figures 5 and 6 illustrate a retrofitted uPVC water diverter installation. The uPVC section has

been attached to a timber fascia and runs under Coloursteel" in order to divert water flow from

the roof away from the roof/wall junction. Figure 5 illustrates the uPVC diverter mounted to

the timber fascia and with the surfaces prepared for TRM application. Figure 6 illustrates the

finished assembly with the TRM coating applied to all three surfaces (wood, uPVC and

Coloursteel'" with all surfaces sealed and weather-tight. This example illustrates the versatility

of the TRM being able to adhere to three very different surfaces all in a close relationship and

accommodate the inherent structural and thermal movement between them.

EXAMPLE 10

Tests were completed by an independent testing authority to confirm the TRM strength,

adhesion, durability for use on pre-cast concrete substrates. The aim of the tests was to ensure

the TRM meets the performance requirements of Clause B2 of the New Zealand Building Code.

The test used the TRM as described above.

The test method used a pull off adhesion test, tested according to BTS Test Procedure 105,

reference standard: AS/NZS 1580.408.5. Average adhesion to the specified substrate shall be at

least 0.8MPa being a minimum adhesion level established by BEAL Testing based on experience

with similar products.

The results found were as shown in Table 1 below where:

C = failure mode by cohesive failure being a failure within a single coating layer (as opposed to

glue failure, adhesive failure and substrate failure).

S = substrate failure where the adhesive strength of the coating exceeds the tensile strength of

the substrate, causing the substrate to fail before adhesive failure.

G = glue failure between the adhesive used to glue the test rig dollies to the coating.

A = adhesive failure being a failure at the coating/substrate interface or between layers of

coatings.

Table 1- Pre-cast concrete test data:

Sample Number Area (mm 2) Failure Mode Adhesion Strength

(MPa)

S497-2 1963 90% C, 10% S 1.51

S497-3 1963 90% C, 10% S 1.47

S497-4 1963 50% G, 50% A 1.41

S497-5 1963 90% C, 10% S 1.47

Mean 1.47

S.D. 0.04

C.o.V. 2.7%

As can be seen from the above results, The TRM easily exceeded BEAL standards.

EXAMPLE 11

In this example, test results are shown using the same methods and testing regimes as that

described in Example 10, this time using substrates terracotta, unglazed porcelain, glazed

ceramic and glazed porcelain.

For terracotta, the test results are shown in Table 2 below where:

PSS = refers to additional use of a porous surface sealer prior to TRM application.

PK = the TRM as described above without a porous surface sealer.

glue failure, adhesive failure) and

the substrate, causing the substrate to fail before adhesive failure.

G glue failure between the adhesive used to glue the test rig dollies to the coating.

Table 2 - Terracottatest data

............... Tem- o, ta RSS 1,03 S3 7 1 ................................... ............... C 51,77-2 Tertac, )tl PSS' .1-10 C ----------------------- --------------------------------------------- ------------------------------------------------------------------ ----------------------------- PS5 1, 1 -7 C ............................ ............................... .............. ......................... .................... S'377-4 P SS 2,04 C --,377-5 T rf ac'.')tt PS S 1-97 C 1. 4 0 '50 ................................................................. .......... ...... .... ............. .................. '. NA A ......... ... ............................... . .. . .. 9 . . ......: . ...... ........... .: .. : .. :. : .. ...... .

......... .................. ............. ... ........ .......................... ... .... 4 xxxxxxxxx.. ............................................. .... ............... ..................................... ....... ...................... ............. .. ...... ...................... .. .. .. ... ... ... . .

.... .. . .... ........... . . . .. . . . .. . . . . . . . . . . . .. . . . ................ ............................... . .. ... ... .. .. .. ... ... . . . ..... .... . . . . . .. . .. ... .. ............................... ............................... . .. . .......... .. .... .. .. .. .. .. ...... ...... .. .. .. .. .. .. .. .. .. ... .............. .. .. . .... .... .. .... ..... . . . . . . . . . .. . . . . . . . . . ... . . . . .. . ...... . .. . .. . . . ...... ....... . . . . . .......... ....................................................................................... ....... .. . . . . . . . . . . .................. . ... . ... . .. ....... ......... ..

W ...........T......... ..................................P.K ..: : : : : ..... .... . .. .. .. .. .. .. .. .. . CI ............. .. .. . 1..,94 ........................ ........ ............. .... ................... ................ ...... ............................................. . .

.. ....................... ...................................... ............................................ .............. ... . .. . ........................ .. .. ..................................................................................................................................................................... ...................................................... .......... . . .. ............ .................... ................................ . ..................... .

......... ...... ................. W C.... .................. ....... ....... ................... ........... 2 '.% ............... .. .............. ......................... ...... ... .......................................... .... ..... ......... .. .. .. ................. ....................... .

............. .............. .... ........ ............. ........ ... .. .................................. . ............................... ............................................................. ......................... ......................... ............................. . ...................................... ..... . . .............................. .... ....... . ....................... .............. .. ... ... ... .. . ... ... ... ............. .. .. . . . . . . . .. ......... ..... ... .. ........ ..... ........ ................................................ .................... .. ... . .. ..... ....... ............................................................................... . .... . ... .. .. ....... . .. .. ... .. .. .. ... .. ... .................... .. . . .... .. .. .. . ..... ... .... .................. .. ..... . .. ..... ....... ........... . .

.... ...... .. . . ..... .. .............. ........ .. ......... 10 ...................PK .................... .................... C ............................... .. ... . ... ................... 50 . ..................................................................... .. .. xxxxxx : ............. ........... .

......... .

Note that the results for sample 5377-7 are not included in the analysis as this failure was the

result of a gluefailure between the test dolly and the TRM surface (a test equipmentfailure and

not TRM test).

For unglazed porcelain, the test results are shown in Table 3 below where:

PK = the TRM as described above without a porous surface sealer.

glue failure, adhesive failure) and

the substrate, causing the substrate to fail before adhesive failure.

Table 3 - Unglazed porcelain test data

15S

Note that theresultsfor sample 5378-6 are notincludedintheanalysisasthisfailurewasthe

result of aglue failure between the test dolly and the TRMsurface (a test equipment failure and not TRM test).

Forglazedceramic,the testresultsare shown inTable4belowwhere:

PK = the TRM as described above without a porous surface sealer.

glue failure, adhesive failure) and

the substrate, causing the substrate to fail before adhesive failure.

G =glue failure between the adhesive used to glue the test rig dollies to the coating.

Table 4 - Glazed ceramic test data

9 1 aedCer SL60 C S3792 G aZed Ceram c PSS 1,63 C 5379 3 G aed Ceram c PSS .169 C 5379-4 G azed Ceram c PSS 1,39 C S39- 6'4azd CefrI"Y P SS -1A C 1-56

For glazed porcelain, the test results are shown in Table 5below where:

PSS =refers to additional use of aporous surface sealer prior to TRM application.

PK =the TRM as described above without aporous surface sealer.

C =failure mode by cohesive failure being afailure within asingle coating layer (as opposed to glue failure, adhesive failure) and

S =substrate failure where the adhesive strength of the coating exceeds the tensile strength of the substrate, causing the substrate tofail beforeadhesive failure.

G =glue failure between the adhesive used to glue the test rig dollies tothe coating.

Table 5 - Glazed porcelain test data

5380-1 G az ed Force a :n PsS, 2,24 C 5380-2 G aze d Por-Ce a n PSS 1,97 C 5380- G a ed Por-elain PSS 2,03 C

53804 G Ua ed Porcela o PSS L980 C -0 01

As can be seen from the above results, the TRMexceeded standards in terms ofadhesion strength to several substrates. In addition, in the case ofthe testedsubstrates, surface preparation with aporous surface sealer did not makeany significant difference to the adhesion strength.

EXAMPLE12

In this example, strength adhesion results were tested for TRM as described above using the same methods and testing regimes as that described in Example 9and Example 10, this time using various substrates including:

• uPVC • Fibre cement • ZincalumeM • Stainless steel • Powder coating aluminium • Anodised aluminium • ColoursteelM • Aluminium • Electro galv • Copper

* Zinc (plain)

• Quartz zinc

• Galvanised steel

• Anthra zinc

• Timber weatherboard

• TPO

• Nuralite'TM TPE

• Sarnafil"

• ButynolIM

• Plywood • Polyethylene

The various substrates and TRM were also tested for adhesion strength post multiple freeze

thaw cycles. This was completed to confirm that naturally occurring weather extreme cycles

would not be detrimental to adhesion strength. Freeze thaw cycle testing was completed by

subjecting the samples to 20 freeze thaw cycles according to BS Test Procedure 108. Each cycle

had a duration of 12 hours and consisted of 3 hours at 70°C, 3 hours off, 3 hours at -20°C and

another 3 hours off. For brevity only a summary of results are provided below in Table 6.

Table 6- Multiple substrate test data

S33S PV 1-6

. . . . . . .. ... . .......: ........ ................... . ----- ---------------- ---- ---------------------

3,6 ............

Ascanbeseenfromtheboveresults.theTRreachedandexceedetheminimumadhesio srntsadr(.....a..forallsubstratestestedprovingthedurabilityoftheTR............described. 5~ ~ ~~~~~~~~~~~~~~..... heenFrhrtereehwetnasohwdhthT.deieteghnl susraetstdinotdegradew' 4-ithfeezthwcodiionngonfrmngtatheT. i w a hr ei tn ........................... ..

. Aspetsofhetxtilreiforcdmemranandmthoofaplicaionavebendscriedb ~~ 3 waofxmpenladisoudbaprcatdhamdiictonadadtinmab madetheretoithoutdepatingfromthecopeofthecaimsherein

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Claims

WHAT IS CLAIMED IS:

1. An elastomeric water proof cladding on a building substrate comprising:

a building substrate to or part thereof to be water proofed; and

a textile reinforced membrane (TRM) adhered to the substrate or part thereof, the

TRM comprising:

a first coating of elastomeric modified styrene-butadiene-styrene (SBS) thermoplastic elastomer on the substrate;

an intermediate layer on the first coating, the intermediate layer comprising

of woven fibre textile mesh embedded within a mixture of thermoplastic elastomer

and cement, the thermoplastic elastomer being a fibre reinforced modified styrene

butadiene-styrene (SBS) polymer, and wherein the ratio of thermoplastic elastomer

to cement in the intermediate layer is approximately 6 to 10 parts thermoplastic

elastomer to approximately 1 part cement; and

a second coating of elastomeric modified styrene-butadiene-styrene (SBS)

thermoplastic elastomer on the intermediate layer;

wherein the TRM once set having an adhesion strength on the substrate greater than

0.8MPa.

2. The textile reinforced membrane as claimed in claim 1 wherein the textile mesh is

manufactured from polyester fibres.

3. The textile reinforced membrane as claimed in any one of the above claims wherein the

textile mesh is manufactured from polyacrylonitril fibres.

4. The textile reinforced membrane as claimed in any one of the above claims wherein the

intermediate layer further comprises at least one clay or mineral.

5. The textile reinforced membrane as claimed in claim 4 wherein the clay or mineral is

selected from: quartz, calcium carbonate, and combinations thereof.

6. The textile reinforced membrane as claimed in any one of the above claims wherein the

first layer and/or second layer further comprises at least one clay or mineral.

7. The textile reinforced membrane as claimed in claim 6 wherein the clay or mineral is

selected from: quartz, limestone, calcium carbonate, talcum, titanium dioxide, and

combinations thereof.

8. A method of applying an elastomeric water proof cladding as claimed in any one of the

above claims to a building substrate, the method comprising the steps: a. prepare the substrate surface to which the TRM is to be applied; b. apply the first coating of elastomeric modified styrene-butadiene-styrene (SBS) polymer to the substrate; c. apply the intermediate layer to the first coating; and d. apply the second coating to the intermediate layer.

9. The method as claimed in claim 8 wherein the substrate is selected from: powder coated or anodised aluminium, stainless steel, ZincalumeM, galvanised steel, copper,

ColorsteelI, wood, plywood, solid plaster, modified plaster, concrete, concrete block,

brick, fibre cement sheet, acrylic paint, acrylic membrane, glazed and unglazed ceramic

tiles and porcelain tiles, thermoplastic olefin (TPO) and torch-on membrane, synthetic

butyl rubber membrane, uPVC, and combinations thereof.

10. The method as claimed in claim 8 or claim 9 wherein surface preparation in step (a)

comprises the step of roughening the surface.

11. The method as claimed in any one of claims 8 to 10 wherein step (c) only commences

once the first coating applied in step (b) is dry.

12. The method as claimed in any one of claims 8 to 11 wherein step (d) only commences

once the intermediate layer applied in step (c) is dry.