AU2019101218A4

AU2019101218A4 - Method of coating concrete

Info

Publication number: AU2019101218A4
Application number: AU2019101218A
Authority: AU
Inventors: Michael Burke
Original assignee: Specialised Pool Repairs Pty Ltd
Current assignee: Specialised Pool Repairs Pty Ltd
Priority date: 2019-10-04
Filing date: 2019-10-04
Publication date: 2019-11-28
Anticipated expiration: 2027-10-04

Abstract

Abstract A method of coating a concrete swimming pool is disclosed. The coating is created using a polymer resin containing crushed glass and white sand. It is applied in a thickness of about 5mm to 10mm to create a polymer barrier between the concrete swimming pool wall and the water.

Description

“METHOD OF COATING CONCRETE”

Field of the Invention [0001] The present invention relates to the coating of concrete. It is has been developed for use in coating the internal surface of concrete swimming pools, and this is its primary application. Nonetheless, it is considered that it may be usable in other situations.

Background to the Invention [0002] Concrete swimming pools are subject to degradation over time. This is caused through both chemical leaching from the concrete into the water, particularly of calcium, and also from abrasion of the concrete surface.

[0003] In order to repair the internal surface of a pool, it is generally necessary to sand or sand blast the surface back to a clean surface, and then to apply concrete render and/or plaster to finish the pool surface.

[0004] Alternatively, it is sometimes possible to use the concrete pool surface as a shell within which a fibreglass swimming pool can be located. Fibreglass surfaced pools are not subject to the same degradation factors, however are limited in their size and shape.

[0005] The present innovation seeks to provide a method of coating a concrete swimming pool which at least partially overcomes these disadvantages. Although it will be described with reference to swimming pools, it will be appreciated that the same coating method can be used on other concrete surfaces, such as in bathrooms, or indeed on other similar surfaces such as masonry.

Summary of the Invention [0006] According to one aspect of the present invention there is provided a method of coating a concrete surface, the method including the steps of:

(a) preparing the concrete surface;

2019101218 04 Oct 2019 (b) applying to the concrete surface a sealing coat primarily consisting of a polymer resin;

(c) mixing a coating, the coating including a polymer resin, crushed glass and sand;

(d) applying the mixed coating of step (c) to the sealed concrete surface of step (b); and (e) applying a finishing layer to the coated surface.

[0007] It is preferred that the sealing coat of step (b) is formed from a vinyl ester resin.

[0008] It is preferred that the polymer resin of the coating is a vinyl ester resin. It is further preferred that that the coating includes crushed glass and sand in the ratio 2:1.

[0009] The sand may be white quartz sand.

[0010] The coating may include glass pebbles to create a translucent effect.

[0011] The coating may include a pigment to add colour.

[0012] The finishing layer is preferably formed from a polymer resin, such as a vinyl ester. In a preferred embodiment the finishing layer is a clear gel coat.

[0013] The coating is preferably applied in step (d) in a thickness of between 5mm and 10mm.

[0014] The concrete surface may be the internal surface of a swimming pool.

[0015] The same method may be used on other surfaces instead of concrete, such as bricks or masonry more generally.

Detailed Description of Preferred Embodiments [0016] A typical application to a degraded concrete swimming pool will now be described.

2019101218 04 Oct 2019 [0017] The first task is to sand blast or otherwise abrade the internal surface of the pool back to clean plaster or concrete, removing any loose substrate.

[0018] Once the surface is clean, it is sealed using a vinyl ester resin sealing coat, such as one used in the construction of fibreglass swimming pools.

[0019] A coating can then be mixed and catalysed in suitable proportions. Typical proportions include: 2 parts crushed recycled glass to 1 part clean white quartz sand, together with glass pebbles or beads (typically 0.5 to 1mm in size) and, if desired, a pigment. These elements are mixed into a vinyle ester resin.

[0020] The coating can then be applied by trowel to the sealed pool surface. A coating thickness of 5mm to 10mm is considered preferable. The coating is allowed to cure.

[0021] Once the coating has cured, it can be sanded to a smooth finish if desired. A top coat finishing layer (typically a clear gel coat formed of a vinyl ester resin) can then be applied.

[0022] It will be appreciated that the coating is both physically and chemically superior to plaster coatings. The vinyl ester coating of the present invention is anticipated to be in the order of 2.5 times stronger than a plaster coating. It also has some flexibility and thus can withstand impacts by bending rather than breaking.

[0023] Chemically, the coating acts similarly to a fibreglass pool. It provides a barrier between the concrete wall of the pool and the water within the tool, preventing calcium leaching.

[0024] Unlike a fibreglass pool located within a concrete shell, the coating of the present invention is chemically bonded to the concrete wall rather than being physically attached. This makes is significantly more versatile, and less susceptible to damage.

2019101218 04 Oct 2019 [0025] Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.

Claims

Claims

1. A method of coating a concrete surface, the method including the steps of:

(a) preparing the concrete surface;

(b) applying to the concrete surface a sealing coat primarily consisting of a polymer resin;

(c) mixing a coating, the coating including a polymer resin, crushed glass and sand;

(d) applying the mixed coating of step (c) to the sealed concrete surface of step (b); and (e) applying a finishing layer to the coated surface.
2. A method of coating a concrete surface as claimed in claim 1, wherein the sealing coat of step (b) is formed from a vinyl ester resin.
3. A method of coating a concrete surface as claimed in claim 1 or claim 2, wherein the polymer resin of the coating is a vinyl ester resin.
4. A method of coating a concrete surface as claimed in any preceding claim, wherein the coating includes crushed glass and sand in the ratio 2:1.
5. A method of coating a concrete surface as claimed in any preceding claim, wherein the sand is white quartz sand.
6. A method of coating a concrete surface as claimed in any preceding claim, wherein the coating includes glass pebbles.
7. A method of coating a concrete surface as claimed in any preceding claim, wherein the finishing layer is formed from a polymer resin.
8. A method of coating a concrete surface as claimed in claim 7, wherein the finishing layer is a clear gel coat.
9. A method of coating a concrete surface as claimed in any preceding claim, wherein the coating is applied in step (d) in a thickness of between 5mm and 10mm.

2019101218 04 Oct 2019
10. A method of coating a concrete surface as claimed in any preceding claim, wherein the concrete surface is the internal surface of a swimming pool.
11. A method of coating a masonry surface, the method including the steps of:

(a) applying to the masonry surface a sealing coat primarily consisting of a polymer resin;

(b) mixing a coating, the coating including a polymer resin, crushed glass and sand;

(c) applying the mixed coating of step (b) to the sealed masonry surface of step (a); and (d) applying a finishing layer to the coated surface.