CA1046361A - Cement in a roll for application to the surface of a building - Google Patents
Cement in a roll for application to the surface of a buildingInfo
- Publication number
- CA1046361A CA1046361A CA226,709A CA226709A CA1046361A CA 1046361 A CA1046361 A CA 1046361A CA 226709 A CA226709 A CA 226709A CA 1046361 A CA1046361 A CA 1046361A
- Authority
- CA
- Canada
- Prior art keywords
- covering material
- cement
- matrix layer
- water
- cement mix
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/04—Portland cements
Abstract
ABSTRACT OF THE DISCLOSURE
A rolled, flexible covering material for finishing the surface of a building consists of a matrix layer covered with a water-curable composition consisting essentially of a cement mix and a polymeric binder therefor.
A rolled, flexible covering material for finishing the surface of a building consists of a matrix layer covered with a water-curable composition consisting essentially of a cement mix and a polymeric binder therefor.
Description
104~36~
CEMENT IN A ROLL FOR APPLICATION TO
T~E SURFACE OF A BUILDING
.~
BACKGROUND OF THE INVENTION
This invention relates to a composite covering material for finishing the surface of a building and to the use thereof to provide permanently adherent decorative cement-based surfaces on buildings.
The application of a finish to the surface of a building is often necessary because buildings are generally constructed from the most economical available materials selected for their load bearing and structural characteristics, without regard to their appearance. Thus, a finish is necessary to enhance the appearance of the building or to give protection against the elements, and the like.
Although cement has commonly been used as a finishing material for surfaces of buildings, the use of cement entails ..
several practical difficulties. Normally, cement is prepared at the job site and applied by troweling or spraying to the surface being covered. It will be apparent that the character-istics of surfaces obtained by troweling are almost exclusively ~ -dependent on the skill of the workman applying the cement, and that the decorative qualities of surfaces thus prepared are frequently of uneven quality. When cement is applied by spraying, the operation is objectionable owing to the need for masking sur-faces which are not to be covered and to the clean-up required as well as to the fact that hand finishing is often necessary.
Other objections to the practice of preparing and apply-ing cement at the job site include the lack of reproducibility am~ng several batches of purportedly identical cement mixes as well as the necessity of accurately predetermining the amount of ~emt~t which can be applied from a given batch, so that unused cement does not have to be discarded. ~-i~ -1- . ~ '~"`' '"' iO~ti3~
Another problem inherent in the application of cement compositions to structural surfaces is the poor adhesion qualities of cement to many of these surfaces. Thus, when cement as is commonly the case, is the adhesive between a structural member and the cement or other finishing material, the permanency of the finish depends on the "keying" or "locking" of cement paste in pores, cracks and crevices of the surface. Because the locking action of cement is relatively weak, a cement finish is -subject to delamination and may separate and fall away from the building surface under normal stresses of expansion, contraction, vibration and settling of buildings.
In the refurbishing of older buildings, it is usually very difficult to obtain a good bond between old cement surfaces and a new covering or finishing layer.
A further disadvantage of using cement as the finishing layer by the spraying or troweling techniques, is that several coats or layers may be required. This is not only time consuming and expensive, but adds unnecessary weight to the building so that stronger and more costly load bearing members must be used.
It is known in the art of finishing a surface of a building to apply thereto a fully processed veneer layer consist-ing of split natural crystalline stone bonded by a thermoplastic synthetic resin in a bearing layer, which is a textile or metallic net, as taught by Gurgui et al, in United States Patent No.
3,705,830. However, the deficiency of this method is that the veneer must be bonded to the surface using a mortar of hydraulic binder, such as cement or cement with lime, which has the objec-tionable properties pointed out above.
The difficulty of bonding hard ceramics, such as alumina- -based ceramics, to rubber or other organic resins is pointed out in ~eninga, United States Patent No. 3,666,613, and the problem is solved by metallizing the surface of the ceramic. It is clearly apparent that the expense inherent in this process
CEMENT IN A ROLL FOR APPLICATION TO
T~E SURFACE OF A BUILDING
.~
BACKGROUND OF THE INVENTION
This invention relates to a composite covering material for finishing the surface of a building and to the use thereof to provide permanently adherent decorative cement-based surfaces on buildings.
The application of a finish to the surface of a building is often necessary because buildings are generally constructed from the most economical available materials selected for their load bearing and structural characteristics, without regard to their appearance. Thus, a finish is necessary to enhance the appearance of the building or to give protection against the elements, and the like.
Although cement has commonly been used as a finishing material for surfaces of buildings, the use of cement entails ..
several practical difficulties. Normally, cement is prepared at the job site and applied by troweling or spraying to the surface being covered. It will be apparent that the character-istics of surfaces obtained by troweling are almost exclusively ~ -dependent on the skill of the workman applying the cement, and that the decorative qualities of surfaces thus prepared are frequently of uneven quality. When cement is applied by spraying, the operation is objectionable owing to the need for masking sur-faces which are not to be covered and to the clean-up required as well as to the fact that hand finishing is often necessary.
Other objections to the practice of preparing and apply-ing cement at the job site include the lack of reproducibility am~ng several batches of purportedly identical cement mixes as well as the necessity of accurately predetermining the amount of ~emt~t which can be applied from a given batch, so that unused cement does not have to be discarded. ~-i~ -1- . ~ '~"`' '"' iO~ti3~
Another problem inherent in the application of cement compositions to structural surfaces is the poor adhesion qualities of cement to many of these surfaces. Thus, when cement as is commonly the case, is the adhesive between a structural member and the cement or other finishing material, the permanency of the finish depends on the "keying" or "locking" of cement paste in pores, cracks and crevices of the surface. Because the locking action of cement is relatively weak, a cement finish is -subject to delamination and may separate and fall away from the building surface under normal stresses of expansion, contraction, vibration and settling of buildings.
In the refurbishing of older buildings, it is usually very difficult to obtain a good bond between old cement surfaces and a new covering or finishing layer.
A further disadvantage of using cement as the finishing layer by the spraying or troweling techniques, is that several coats or layers may be required. This is not only time consuming and expensive, but adds unnecessary weight to the building so that stronger and more costly load bearing members must be used.
It is known in the art of finishing a surface of a building to apply thereto a fully processed veneer layer consist-ing of split natural crystalline stone bonded by a thermoplastic synthetic resin in a bearing layer, which is a textile or metallic net, as taught by Gurgui et al, in United States Patent No.
3,705,830. However, the deficiency of this method is that the veneer must be bonded to the surface using a mortar of hydraulic binder, such as cement or cement with lime, which has the objec-tionable properties pointed out above.
The difficulty of bonding hard ceramics, such as alumina- -based ceramics, to rubber or other organic resins is pointed out in ~eninga, United States Patent No. 3,666,613, and the problem is solved by metallizing the surface of the ceramic. It is clearly apparent that the expense inherent in this process
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~ 104636~
precludes its use except under very exceptional circumstances.
Wagner, in United States Patent No. 3,030,258, teaches the preparation of an improved mortar composition containing an organic resin, but it will be understood that Wagner contemplates mixing the mortar and applying it at the point of use.
Thus, in the field of finishing the surfaces of buildings, there is a continuing need for an economical, convenient, clean method of applying cementitious compositions to interior and exterior surfaces so that the cementitious coverings will bond permanently to any kind of surface, be available in a wide variety of textures and finishes, and be of uniform quality.
In accordance with this invention, it has been found that unset cement fabricated in the form of a roll or sheet can be applied economically, conveniently and neatly to surfaces of buildings and bonded permanently to any kind of surface. The cement rolls of this invention further provide a wide variety of aesthetically pleasing surfaces not otherwise readily avail-able and provide ceme~t coverings of a reliable quality regardless of the ultimate point of application.
SUMMARY OF THE INVENTION ;
More particularly in one broad aspect the invention comprehends a flexible covering material suitable for finishing a surface of a building which covering material includes a matrix layer covered with and at least partially embedded in water-curable composition. The water curable includes a combination of a polymer binder and a cement mix wherein the cement mix is from 85~ to 95~ of the water-curable composition and the covering material has sufficient flexiblity to be rolled into a roll -or transporting.
The invention further comprehends a flexible wall cover-ing material suitable for finishing a surface of a building which comprises a flexible matrix layer covered with and at least partially embedded in water-curable composition. The composition ; ~ includes a combin~tion of a polymer binder and a Portland cement l ~ -3 - " ~
10~6361 mix wherein the cement mix is from 85% to 95% by weight of the water-curable composition. The Portland cement mix includes from zero to about 70% by weight of a filler. The composition produces a planar substantially uniform layer by being deposited on the matrix layer with a solvent therein which is substantially removed. The covering material having sufficient flexibility to be rolled into a roll for transporting and subsequently unrolled for being applied to a surface without the composition separating from the matrix layer or cracking.
The invention in another aspect comprehends a method for preparing a flexible cementitious covering material for the surface of a building which comprises the steps of applying to a matrix layer a covering composition consisting of from about 85 to about 95 parts by weight of a cement mix and from about 15 parts to about 5 parts by weight of a polymeric binder and --from about 10 to about 30 parts by weight of an organic solvent, and removing the organic solvent by evaporation.
A still further aspect of the invention relates to a method for permanently covering a surface of a building which comprises adhering thereto a flexible cementitious covering material by bonding a matrix layer of the covering material to the surface of the building. The covering material consists of the matrix layer covered with and at least partially embedded in a water-curable composition which includes the combination of a polymer binder and a cement mix wherein the cement mix is from 85~ to 95% of the water-curable composition. The covering material having sufficient flexibility to be rolled into a roll for transporting.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of this invention will become apparent from the description and drawings below, in which - . ~ . , . . ~.. ,:
, . . - . . . .
10~636~
Figures l and 2 show magnified views of cross sections of the cement rolls of this invention, Figure 3 shows an installation for making the cement rolls of this invention, and Figure 4 shows application of the cement in a roll to a structural surface. ~ :
DESCRIPTION OF THE PREFERRED EMBODIMENT -THE CEMENT MIX -"Cement mix", as used herein, refers to a combination of Portland cement, fillers and admixtures used in the cement rolls of this invention. Fillers usable in the cement mix of -this invention include aggregates such as sand, limestone, glass chips, marble dust, talc, clay, mica, carbon black, bentonite, perlite and gravel. Suitable admixtures include those which will improve product hardness, impart color, reduce sagging, reduce shrinkage, or decrease foaming during processing. Other admix-tures appropriate for the cement mixes of this invention include reinforcing filamentary fibers, such as whiskers of glass, asbestos or metal for exceptionally high structural strength, resistance to weathering and corrosion, and decreased thermal conductivity. When glass fibers are used in the cement mixes of this invention, the fibers should be treated to resist the alkali -present in the cement.
The amount of cement mix including fillers in *he paste or slurry will generally consist of from 70% to 82~ by weight of the total slurry. The slurry includes the cement mix, a polymeric binder, a plasticizer, and a solvent and dispensing agent. After the organic solvent is removed by drying, the cement mix remaining generally consist of from 85% to 95% and the polymeric binder consists of 5% to 15% by weight excluding, of course, the weight of the matrix layer.
For economy, the cement rolls of this invention, the higher amounts of cement mix, especially amounts above about 90%
~B ~ ~
` 10a~t;361 by weight of the combination, are preferred.
The fillers used in the cement mixes for the cement rolls and sheets of this invention will generally be of small particle size, of the range below about 0.5 millimeters, and preferably below about 0.2 millimeters. The amount of filler, or combination of fillers, usable in the cement mixes of this invention can be as high as about 70% by weight of the cement mixture, that is, up to about as much as 65% by weight of the combin~d cement mix-binder combination. If higher amounts of fillers are used, the resulting water-cured cement product tends to crumble owing to the low level of true cement bonds in the final composite.
Portland cement is a powdered material which, when mixed with water, forms a paste which hardens slowly to bond intermixed crushed rock, gravel, sand or other fillers into ;
concrete of rock-like hardness. Portland cement is made by sintering a mixture of raw materials, one of which is primarily calcium carbonate, i.e., limestone, and the other of which is primarily aluminum silicates, e.g., clay or shale. The sinter-ing process causes the occurrence of chemical changes which produce nodules, known as clinkers, consisting mainly of calcium ;`
silicates and aluminates. Portland cement of commerce is the foregoing clinker pulverized with a small amount of calcium sulfate. Portland cement is differentiated from other types of commercial cements by the different phases of which it is formed and by fulfillment of certain standards established by regulatory and testing authorities. See, generally, R. H. Bogue, "Cement"
in Kirk-Othmer, "Encyclopedia of Chemical Technology" II, Volume 4, Interscience Publishers, New York (1964) after 684.
. : .
104~;3f;1 Although Specification C 150-63 of the American Society for Testing and Materials (A.S.T.M.) differentiates Portland cements into five types, Type I, which is designated for use in general concrete construction when the special properties of Types II, III, IV and V are not required, will generally be the preferred type of Portland cement for the practice of this invention. It will be appreciated that special use Portland cements, such as Types II, III, IV and V can also be used in the practice of this invention.
THE POLYMERIC BINDER
"Polymeric binder", as used in the specification and claims, means a thermoplastic polymer, whether in the form of a solution, dispersion, latex, or solid, which will adhere the cement mixes of the present invention to the flexible matrix layer and which will maintain the uncured cement mixes in a flexible condition during extended periods of storage prior to use at a building site.
Typical of the thermoplastic polymers which can be used as binders in the practice of this invention are polyvinyl-acetals, Polyacrylates, polyvinyl chloride, alkyd resins, andcellulosic resins, such as cellulose acetate and isobutyrate.
Preferred thermoplastic resins for the purposes of this invention are polyvinylacetals, such as polyvinylbutyral, and acrylate resins. Typical of the polyvinylacetal resins preferred ~ -for the practice of this invention is polyvinylbutyral, such as a 25~ solution known commerically as Butyral Solution L-7124, obtained from Raffi and Swanson, Inc.
Typical of the acrylic resins suitable for the practice of this invention is polymethyl methacrylate such as ACRYLOID~
B-50 or ACRYLOID~ B-48N, manufactured by the Rohm and Haas Co.
When an acrylic polymer is used in the binding compcsition of this invention, it is frequently desirable to use a plasticizer in order to improve the flexibility of the resulting composite material. Typical of the plasticizers which can be used are ester plasticizers, such as PARAPLEX ~ G-30, commercially available from the Rohm and Haas Co., and SA~TICIZERS ~ 160, 261 and 262, supplied by the Monsanto Chemical Corp.
Acrylic polymers used in the water-curable compositions of this invention may also be combined with other resins, such as conventional solvent grade acrylic resins, alkyd resins, vinyl resins and cellulosic resins. A combination of an acrylic resin with a second resin, such as polyvinyl chloride, and a plasticizer may also be used.
The amount of polymeric binder used in the water-curable compositions of this invention will be from about 5% to about 15% by weight after curing of the cement mix-polymeric binder total, including any plasticizer. Use of binder in amounts below 5% by weight gives a cement roll product in which the cement mix does not adhere well either to itself or to the matrix layer. Use of polymeric binder in amounts above abo~t 15~ by weight gives no substantial improvement in properties over a lower level of polymeric binder, which is the more expensive component of the cement mix-polymeric binder ~: combination.
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THE ~ATRIX LAYER
The matrix layer or supporting material for the cement rolls and sheets of this invention may be any natural or syn-thetic woven or non-woven fabric or mesh. The basic material may be paper, fiber glass, flexible metal mesh, polyester, poly-olefins, polystyrene and the like, as well as natural fibers or ~ ~
asbestos. ~-The material chosen as the matrix layer should be characterized by ease of handling and cutting, good workability, ;~
high strength, low flammability, and resistance to deleterious atmospheric conditions. The material can be treated to impart resistance to fungi and rodents. Normally, the cost and avail-ability of a material will be important considerations.
Typical of the matrix layers suitable for the cement rolls of this invention is non-woven polypropylene cloth as is often used as backing for indoor-outdoor carpeting. Woven fiberglass scrim material is equally suitable. Fiber reinforced paper or woven kraft paper are quite useful as matrix layers, ;-as is open weave polyester scrim cloth.
A porous flexible support material i9 preferred for the matrix layer of these cement rolls because it provides a good surface for adhesion to the cement mix-polymeric binder being applied thereto and partially embedded therethrough. Thus, an open weave mesh material allows the cement mix-polymeric binder combination to penetrate and at least partially encapsulate the support material so that the cement is integrated _g_ .
104~3~1 :
into the product. Of the acceptable maxtrix materials, woven -and loosely knit materials, such as woven kraft paper, woven fiberglass, and open weave polyester scrim cloth are preferred.
In Figure 1 is shown a cross-sectional view of a typical embodiment of the cement rolls of this invention. The rolls consist of a flexible matrix layer, e.g., woven kraft paper, ~ -(1) which is bonded to and which is partially embedded (5) in the water-curable combination (2) consisting of cement mix and polymeric binder. The surface of the water-curable combination may be decorated as at (3) or level as at (4).
In another embodiment of this invention, shown in Figure 2, the matrix layer (11) is a loosely knit fabric, coated -~
with a water-curable composition (12) containing glass fibers (13) for reinforcement. Macroscopic aggregate particles (14) are embedded in the water-curable composition distal to the matrix layer.
Preparation of the- Cement Rolls The cement rolls of this invention are prepared by depositing on and partially through the matrix layer a covering 20 composition consisting of cement mix, a polymeric binder, and an -inert organic solvent and removing the inert organic solvent.
.
By "covering composition" is meant a paste or thick slurry consisting of from about 85 parts to about 95 parts by weight of cement mix, from about 15 parts to about 5 parts by weight of a polymeric binder, and from about 10 parts to about 30 parts by weight of inert organic solvent.
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104~3ti1 Inert organic solvents which are useful for this purpose include ethanol, toluene, isopropyl alcohol, Methyl acetate, benzene, xylene, acetone, methyl isobutyl ketone, and the like.
The amount of solvent used will generally and preferably be such as to give the covering composition being applied to the matrix layer a viscosity from about 40,000 to about 60,000 centi-poises at room temperature. It will be understood that covering compositions of higher or lower viscosities can be handled if specialized equipment is available.
After the covering composition has been applied to the surface of the matrix layer and partially embedded therein, solvent is removed, usually by heating. Generally, the heating will be below about 200 degrees F. because this is often the softening point of the thermoplastic binders used in the covering compositions.
A typical installation for making the cement rolls of this invention is shown in Figure 3, wherein matrix layer (21) is passed over rollers (22) while covering composition ~23) is applied from a hopper or other applicator device. The surface of the covering composition is leveled and made smooth by a doctor blade or any other suitable device (24) before the com-posite material is passed into a drier (25) which may be equipped with a condenser (26) for the recovery of organic solvent. The product is collected in the form of a roll (27).
In another typical installation, the doctor blade may be supplemented by an embossing tool to provide a product with any desired texture or design. ~
: ' ' 104~361 When a product is to be prepared with macroscopic aggregate particles embedded in the surface of the water-curable composition distal to the matrix layer, an installation similar to that in Figure 3 can be used, provided that an additional feed device for macroscopic particles, usually of the order of 0.5-5 millimeters grain size, is provided between the feed device for the covering composition and the drier.
The dried product may be stored in rolls, as illustrated in Figure 3, or may be cut into sheets, which can be stacked.
Either product can be conveniently shipped to the site of use.
Application of the Cement Roll The method of applying the cement in a roll to the sur-face of a building is illustrated in Figure 4. Adhesive mater-ial (32~ is applied either to the surface being covered (31) which is pressed against the building surface until good adhesion is obtained or to the back surface of the roll. Curing of the water-curable composition (34) of the cement roll will be accom-plished by exposure to moisture in the air. However, it is frequently desirable to spray the cement roll, after application to the surface of a building, with a fine mist of water to pro-vide water for the cure.
There is a wide variety of various latex adhesives that are suitable for use in the present invention. However, a polyvinyl acetate water emulsion has perfor~ed admirably because of its ease of formulation, price and ultimate physical proper-ties. Other later adhesives which are also suitable include:
vinyl-acetate-ethylene copolymers, polyvinyl chloride, polymers or copolymers of acrylic acid, acrylonitrile-butadiene copolymers, I chlorinated rubber, neoprene, polyisobutylene, SB-R rubber, ¦ 30 Butyl rubber.
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' It will be apparent that sheets of material prepared according to this invention are applied in the same fashicn.
The adhesive layer used to bond the cement roll of this invention to the building surface being coated will be selected according to the nature of the surface and the nature of the matrix layer used.
The following examples of covering compositions of this invention are presented only as typical of the compositions of this invention and not as limitative thereof.
Example 1 Pounds Component 100 Cement mix--50% Portland cement Type I
50% sand 18 Polyvinylbutyral solution (25% solids) (binder) 16 Isopropyl alcohol (99%) (solvent) Cement rolls obtained from this composition produces a cured product which is relatively resistant to water and is stable to weather and atmospheric conditions.
Example 2 Pounds Component 100 Cement mix--40% Portland cement Type I
60% carbon black Acrylic polymer--ACRYLOID ~ ~-50 (binder) (44-46~ solids) 18 Toluene (solvent) Cement roll prepared using this composition was somewhat less flexible than the roll produced from the composition of Example 1 and showed a tendency to crack.
Example 3 Pounds Component 100 Cement mix--40% Portland cement Type I
60% carbon black j ~A
L .. . . . ~
6 Acrylic polymer--ACRYLOID ~ B-50 (binder) 6 Plasticizer--PARAPLEX ~ G-30 17 Toluene (solvent) Cement roll prepared using this composition produced a cured product with excellent weathering properties. The roll had the same flexibility as those prepared using the composition of Example 1 and showed no tendency to crack before use. ,~ .
Example 4 Pounds Component 100 Cement mix--35% Portland cement Type I
65% crushed limestone 4 Acrylic resin--ACRYLOID ~ B-50 (binder) 4 Polyvinyl chloride--VYRAM ~ 28100 (binder) 4 Plasticizer--PARAPLEX ~ G-30 17 Toluene (solvent) Example 5 Pounds Component 100 Cement mix--40% Portland cement Type I
60% silica -8.5 Acrylic polymer--ACRYLOID ~ C-lOLV (binder) 4 Plasticizer--SANTICIZER ~ 261 Isopropyl alcohol (solvent) ~ ~ -Example 6 Pounds Component 100 Cement mix--50% cement 45% sand 5% yellow pigment -8 Acrylic polymer--ACRYLOID ~ B-48N (binder) 2 Plasticizer-SANTICIZER ~ 262 Methyl acetate (solvent) Cement rolls can be obtained from compositions of Examples 4 - 6 which exhibit satisfactory flexibility, stability on storage, and ease of application to building surfaces.
While a preferred embodiment of the invention has been IA
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-` 104~;361 described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
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~ 104636~
precludes its use except under very exceptional circumstances.
Wagner, in United States Patent No. 3,030,258, teaches the preparation of an improved mortar composition containing an organic resin, but it will be understood that Wagner contemplates mixing the mortar and applying it at the point of use.
Thus, in the field of finishing the surfaces of buildings, there is a continuing need for an economical, convenient, clean method of applying cementitious compositions to interior and exterior surfaces so that the cementitious coverings will bond permanently to any kind of surface, be available in a wide variety of textures and finishes, and be of uniform quality.
In accordance with this invention, it has been found that unset cement fabricated in the form of a roll or sheet can be applied economically, conveniently and neatly to surfaces of buildings and bonded permanently to any kind of surface. The cement rolls of this invention further provide a wide variety of aesthetically pleasing surfaces not otherwise readily avail-able and provide ceme~t coverings of a reliable quality regardless of the ultimate point of application.
SUMMARY OF THE INVENTION ;
More particularly in one broad aspect the invention comprehends a flexible covering material suitable for finishing a surface of a building which covering material includes a matrix layer covered with and at least partially embedded in water-curable composition. The water curable includes a combination of a polymer binder and a cement mix wherein the cement mix is from 85~ to 95~ of the water-curable composition and the covering material has sufficient flexiblity to be rolled into a roll -or transporting.
The invention further comprehends a flexible wall cover-ing material suitable for finishing a surface of a building which comprises a flexible matrix layer covered with and at least partially embedded in water-curable composition. The composition ; ~ includes a combin~tion of a polymer binder and a Portland cement l ~ -3 - " ~
10~6361 mix wherein the cement mix is from 85% to 95% by weight of the water-curable composition. The Portland cement mix includes from zero to about 70% by weight of a filler. The composition produces a planar substantially uniform layer by being deposited on the matrix layer with a solvent therein which is substantially removed. The covering material having sufficient flexibility to be rolled into a roll for transporting and subsequently unrolled for being applied to a surface without the composition separating from the matrix layer or cracking.
The invention in another aspect comprehends a method for preparing a flexible cementitious covering material for the surface of a building which comprises the steps of applying to a matrix layer a covering composition consisting of from about 85 to about 95 parts by weight of a cement mix and from about 15 parts to about 5 parts by weight of a polymeric binder and --from about 10 to about 30 parts by weight of an organic solvent, and removing the organic solvent by evaporation.
A still further aspect of the invention relates to a method for permanently covering a surface of a building which comprises adhering thereto a flexible cementitious covering material by bonding a matrix layer of the covering material to the surface of the building. The covering material consists of the matrix layer covered with and at least partially embedded in a water-curable composition which includes the combination of a polymer binder and a cement mix wherein the cement mix is from 85~ to 95% of the water-curable composition. The covering material having sufficient flexibility to be rolled into a roll for transporting.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features and advantages of this invention will become apparent from the description and drawings below, in which - . ~ . , . . ~.. ,:
, . . - . . . .
10~636~
Figures l and 2 show magnified views of cross sections of the cement rolls of this invention, Figure 3 shows an installation for making the cement rolls of this invention, and Figure 4 shows application of the cement in a roll to a structural surface. ~ :
DESCRIPTION OF THE PREFERRED EMBODIMENT -THE CEMENT MIX -"Cement mix", as used herein, refers to a combination of Portland cement, fillers and admixtures used in the cement rolls of this invention. Fillers usable in the cement mix of -this invention include aggregates such as sand, limestone, glass chips, marble dust, talc, clay, mica, carbon black, bentonite, perlite and gravel. Suitable admixtures include those which will improve product hardness, impart color, reduce sagging, reduce shrinkage, or decrease foaming during processing. Other admix-tures appropriate for the cement mixes of this invention include reinforcing filamentary fibers, such as whiskers of glass, asbestos or metal for exceptionally high structural strength, resistance to weathering and corrosion, and decreased thermal conductivity. When glass fibers are used in the cement mixes of this invention, the fibers should be treated to resist the alkali -present in the cement.
The amount of cement mix including fillers in *he paste or slurry will generally consist of from 70% to 82~ by weight of the total slurry. The slurry includes the cement mix, a polymeric binder, a plasticizer, and a solvent and dispensing agent. After the organic solvent is removed by drying, the cement mix remaining generally consist of from 85% to 95% and the polymeric binder consists of 5% to 15% by weight excluding, of course, the weight of the matrix layer.
For economy, the cement rolls of this invention, the higher amounts of cement mix, especially amounts above about 90%
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` 10a~t;361 by weight of the combination, are preferred.
The fillers used in the cement mixes for the cement rolls and sheets of this invention will generally be of small particle size, of the range below about 0.5 millimeters, and preferably below about 0.2 millimeters. The amount of filler, or combination of fillers, usable in the cement mixes of this invention can be as high as about 70% by weight of the cement mixture, that is, up to about as much as 65% by weight of the combin~d cement mix-binder combination. If higher amounts of fillers are used, the resulting water-cured cement product tends to crumble owing to the low level of true cement bonds in the final composite.
Portland cement is a powdered material which, when mixed with water, forms a paste which hardens slowly to bond intermixed crushed rock, gravel, sand or other fillers into ;
concrete of rock-like hardness. Portland cement is made by sintering a mixture of raw materials, one of which is primarily calcium carbonate, i.e., limestone, and the other of which is primarily aluminum silicates, e.g., clay or shale. The sinter-ing process causes the occurrence of chemical changes which produce nodules, known as clinkers, consisting mainly of calcium ;`
silicates and aluminates. Portland cement of commerce is the foregoing clinker pulverized with a small amount of calcium sulfate. Portland cement is differentiated from other types of commercial cements by the different phases of which it is formed and by fulfillment of certain standards established by regulatory and testing authorities. See, generally, R. H. Bogue, "Cement"
in Kirk-Othmer, "Encyclopedia of Chemical Technology" II, Volume 4, Interscience Publishers, New York (1964) after 684.
. : .
104~;3f;1 Although Specification C 150-63 of the American Society for Testing and Materials (A.S.T.M.) differentiates Portland cements into five types, Type I, which is designated for use in general concrete construction when the special properties of Types II, III, IV and V are not required, will generally be the preferred type of Portland cement for the practice of this invention. It will be appreciated that special use Portland cements, such as Types II, III, IV and V can also be used in the practice of this invention.
THE POLYMERIC BINDER
"Polymeric binder", as used in the specification and claims, means a thermoplastic polymer, whether in the form of a solution, dispersion, latex, or solid, which will adhere the cement mixes of the present invention to the flexible matrix layer and which will maintain the uncured cement mixes in a flexible condition during extended periods of storage prior to use at a building site.
Typical of the thermoplastic polymers which can be used as binders in the practice of this invention are polyvinyl-acetals, Polyacrylates, polyvinyl chloride, alkyd resins, andcellulosic resins, such as cellulose acetate and isobutyrate.
Preferred thermoplastic resins for the purposes of this invention are polyvinylacetals, such as polyvinylbutyral, and acrylate resins. Typical of the polyvinylacetal resins preferred ~ -for the practice of this invention is polyvinylbutyral, such as a 25~ solution known commerically as Butyral Solution L-7124, obtained from Raffi and Swanson, Inc.
Typical of the acrylic resins suitable for the practice of this invention is polymethyl methacrylate such as ACRYLOID~
B-50 or ACRYLOID~ B-48N, manufactured by the Rohm and Haas Co.
When an acrylic polymer is used in the binding compcsition of this invention, it is frequently desirable to use a plasticizer in order to improve the flexibility of the resulting composite material. Typical of the plasticizers which can be used are ester plasticizers, such as PARAPLEX ~ G-30, commercially available from the Rohm and Haas Co., and SA~TICIZERS ~ 160, 261 and 262, supplied by the Monsanto Chemical Corp.
Acrylic polymers used in the water-curable compositions of this invention may also be combined with other resins, such as conventional solvent grade acrylic resins, alkyd resins, vinyl resins and cellulosic resins. A combination of an acrylic resin with a second resin, such as polyvinyl chloride, and a plasticizer may also be used.
The amount of polymeric binder used in the water-curable compositions of this invention will be from about 5% to about 15% by weight after curing of the cement mix-polymeric binder total, including any plasticizer. Use of binder in amounts below 5% by weight gives a cement roll product in which the cement mix does not adhere well either to itself or to the matrix layer. Use of polymeric binder in amounts above abo~t 15~ by weight gives no substantial improvement in properties over a lower level of polymeric binder, which is the more expensive component of the cement mix-polymeric binder ~: combination.
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.... . .. . . . ....... , .. . , . . - .. .
THE ~ATRIX LAYER
The matrix layer or supporting material for the cement rolls and sheets of this invention may be any natural or syn-thetic woven or non-woven fabric or mesh. The basic material may be paper, fiber glass, flexible metal mesh, polyester, poly-olefins, polystyrene and the like, as well as natural fibers or ~ ~
asbestos. ~-The material chosen as the matrix layer should be characterized by ease of handling and cutting, good workability, ;~
high strength, low flammability, and resistance to deleterious atmospheric conditions. The material can be treated to impart resistance to fungi and rodents. Normally, the cost and avail-ability of a material will be important considerations.
Typical of the matrix layers suitable for the cement rolls of this invention is non-woven polypropylene cloth as is often used as backing for indoor-outdoor carpeting. Woven fiberglass scrim material is equally suitable. Fiber reinforced paper or woven kraft paper are quite useful as matrix layers, ;-as is open weave polyester scrim cloth.
A porous flexible support material i9 preferred for the matrix layer of these cement rolls because it provides a good surface for adhesion to the cement mix-polymeric binder being applied thereto and partially embedded therethrough. Thus, an open weave mesh material allows the cement mix-polymeric binder combination to penetrate and at least partially encapsulate the support material so that the cement is integrated _g_ .
104~3~1 :
into the product. Of the acceptable maxtrix materials, woven -and loosely knit materials, such as woven kraft paper, woven fiberglass, and open weave polyester scrim cloth are preferred.
In Figure 1 is shown a cross-sectional view of a typical embodiment of the cement rolls of this invention. The rolls consist of a flexible matrix layer, e.g., woven kraft paper, ~ -(1) which is bonded to and which is partially embedded (5) in the water-curable combination (2) consisting of cement mix and polymeric binder. The surface of the water-curable combination may be decorated as at (3) or level as at (4).
In another embodiment of this invention, shown in Figure 2, the matrix layer (11) is a loosely knit fabric, coated -~
with a water-curable composition (12) containing glass fibers (13) for reinforcement. Macroscopic aggregate particles (14) are embedded in the water-curable composition distal to the matrix layer.
Preparation of the- Cement Rolls The cement rolls of this invention are prepared by depositing on and partially through the matrix layer a covering 20 composition consisting of cement mix, a polymeric binder, and an -inert organic solvent and removing the inert organic solvent.
.
By "covering composition" is meant a paste or thick slurry consisting of from about 85 parts to about 95 parts by weight of cement mix, from about 15 parts to about 5 parts by weight of a polymeric binder, and from about 10 parts to about 30 parts by weight of inert organic solvent.
-10- ' . -rA -:
.. ~... ..... .. . . ...... . . ~ . . ........... ... ~ . . ..
............ . . . .. .. .. .... .. ... ~ . . . ..
104~3ti1 Inert organic solvents which are useful for this purpose include ethanol, toluene, isopropyl alcohol, Methyl acetate, benzene, xylene, acetone, methyl isobutyl ketone, and the like.
The amount of solvent used will generally and preferably be such as to give the covering composition being applied to the matrix layer a viscosity from about 40,000 to about 60,000 centi-poises at room temperature. It will be understood that covering compositions of higher or lower viscosities can be handled if specialized equipment is available.
After the covering composition has been applied to the surface of the matrix layer and partially embedded therein, solvent is removed, usually by heating. Generally, the heating will be below about 200 degrees F. because this is often the softening point of the thermoplastic binders used in the covering compositions.
A typical installation for making the cement rolls of this invention is shown in Figure 3, wherein matrix layer (21) is passed over rollers (22) while covering composition ~23) is applied from a hopper or other applicator device. The surface of the covering composition is leveled and made smooth by a doctor blade or any other suitable device (24) before the com-posite material is passed into a drier (25) which may be equipped with a condenser (26) for the recovery of organic solvent. The product is collected in the form of a roll (27).
In another typical installation, the doctor blade may be supplemented by an embossing tool to provide a product with any desired texture or design. ~
: ' ' 104~361 When a product is to be prepared with macroscopic aggregate particles embedded in the surface of the water-curable composition distal to the matrix layer, an installation similar to that in Figure 3 can be used, provided that an additional feed device for macroscopic particles, usually of the order of 0.5-5 millimeters grain size, is provided between the feed device for the covering composition and the drier.
The dried product may be stored in rolls, as illustrated in Figure 3, or may be cut into sheets, which can be stacked.
Either product can be conveniently shipped to the site of use.
Application of the Cement Roll The method of applying the cement in a roll to the sur-face of a building is illustrated in Figure 4. Adhesive mater-ial (32~ is applied either to the surface being covered (31) which is pressed against the building surface until good adhesion is obtained or to the back surface of the roll. Curing of the water-curable composition (34) of the cement roll will be accom-plished by exposure to moisture in the air. However, it is frequently desirable to spray the cement roll, after application to the surface of a building, with a fine mist of water to pro-vide water for the cure.
There is a wide variety of various latex adhesives that are suitable for use in the present invention. However, a polyvinyl acetate water emulsion has perfor~ed admirably because of its ease of formulation, price and ultimate physical proper-ties. Other later adhesives which are also suitable include:
vinyl-acetate-ethylene copolymers, polyvinyl chloride, polymers or copolymers of acrylic acid, acrylonitrile-butadiene copolymers, I chlorinated rubber, neoprene, polyisobutylene, SB-R rubber, ¦ 30 Butyl rubber.
-:
' It will be apparent that sheets of material prepared according to this invention are applied in the same fashicn.
The adhesive layer used to bond the cement roll of this invention to the building surface being coated will be selected according to the nature of the surface and the nature of the matrix layer used.
The following examples of covering compositions of this invention are presented only as typical of the compositions of this invention and not as limitative thereof.
Example 1 Pounds Component 100 Cement mix--50% Portland cement Type I
50% sand 18 Polyvinylbutyral solution (25% solids) (binder) 16 Isopropyl alcohol (99%) (solvent) Cement rolls obtained from this composition produces a cured product which is relatively resistant to water and is stable to weather and atmospheric conditions.
Example 2 Pounds Component 100 Cement mix--40% Portland cement Type I
60% carbon black Acrylic polymer--ACRYLOID ~ ~-50 (binder) (44-46~ solids) 18 Toluene (solvent) Cement roll prepared using this composition was somewhat less flexible than the roll produced from the composition of Example 1 and showed a tendency to crack.
Example 3 Pounds Component 100 Cement mix--40% Portland cement Type I
60% carbon black j ~A
L .. . . . ~
6 Acrylic polymer--ACRYLOID ~ B-50 (binder) 6 Plasticizer--PARAPLEX ~ G-30 17 Toluene (solvent) Cement roll prepared using this composition produced a cured product with excellent weathering properties. The roll had the same flexibility as those prepared using the composition of Example 1 and showed no tendency to crack before use. ,~ .
Example 4 Pounds Component 100 Cement mix--35% Portland cement Type I
65% crushed limestone 4 Acrylic resin--ACRYLOID ~ B-50 (binder) 4 Polyvinyl chloride--VYRAM ~ 28100 (binder) 4 Plasticizer--PARAPLEX ~ G-30 17 Toluene (solvent) Example 5 Pounds Component 100 Cement mix--40% Portland cement Type I
60% silica -8.5 Acrylic polymer--ACRYLOID ~ C-lOLV (binder) 4 Plasticizer--SANTICIZER ~ 261 Isopropyl alcohol (solvent) ~ ~ -Example 6 Pounds Component 100 Cement mix--50% cement 45% sand 5% yellow pigment -8 Acrylic polymer--ACRYLOID ~ B-48N (binder) 2 Plasticizer-SANTICIZER ~ 262 Methyl acetate (solvent) Cement rolls can be obtained from compositions of Examples 4 - 6 which exhibit satisfactory flexibility, stability on storage, and ease of application to building surfaces.
While a preferred embodiment of the invention has been IA
~,.
.`.- - ~. .; , ~ , ~ . . . ..
-` 104~;361 described using specific terms, such description is for illustrative purposes only, and it is to be understood that changes and variations may be made without departing from the spirit or scope of the following claims.
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Claims (15)
1. A flexible covering material suitable for finishing a surface of a building comprising a matrix layer covered with and at least partially embedded in water-curable composition, including a combination of a polymer binder and a cement mix wherein said cement mix is from 85% to 95% of said water-curable composition and said covering material having sufficient flexibility to be rolled into a roll for transporting.
2. The covering material as set forth in claim 1, wherein said polymeric binder is from 5% to 15% by weight of the water-curable composition.
3. The covering material of claim 1, wherein the cement mix includes up to about 70% by weight of a filler.
4. The covering material of claim 1, 2 or 3 wherein the polymeric binder is a resin to which a plasticizer has been added.
5. The covering material of claim 1, 2 or 3 wherein the poly-meric binder consists of an acrylic resin and at least one other polymeric resin.
6. A method for permanently covering a surface of a building which comprises adhering thereto a flexible cementitious covering material by bonding a matrix layer of the covering material to the surface of the building, wherein said covering material consists of the matrix layer covered with and at least partially embedded in a water-curable composition, including a combination of a polymer binder and a cement mix wherein said cement mix is from 85% to 95% of said water-curable composition, the covering material having sufficient flexibility to be rolled into a roll for transporting.
7. The method of claim 6 wherein said covering material is sprayed with water after being adhered to said surface.
8. The method of claim 6 or 7 wherein said covering material consists essentially of the matrix layer covered by and at least partially embedded in the water-curable composition, and wherein decorative macroscopic aggregate particles are embedded in the surface of said water-curable composition distal to said matrix layer.
9. A method for preparing a flexible cementitious covering material for the surface of a building which comprises the steps of applying to a matrix layer a covering composition consisting of from about 85 to about 95 parts by weight of a cement mix and from about 15 parts to about 5 parts by weight of a polymeric binder and from about 10 to about 30 parts by weight of an organic solvent and removing the organic solvent by evaporation.
10. The method of claim 9, wherein the covering composition applied to the matrix layer has a viscosity from about 40,000 to about 60,000 centipoises at room temperature.
11. The method of claim 9, wherein macroscopic aggregate particles are embedded in said covering composition distal to said matrix layer prior to removal of said organic solvent by evaporation.
12. The method of claim 9, 10 or 11 wherein the polymeric binder contains a plasticizer.
13. The method of claim 9, 10 or 11 wherein the cement mix contains up to about 70 parts by weight of a filler.
14. The method of claim 9, 10 or 11 wherein the flexible cementitious covering is rolled following the step of removing said organic solvent by evaporation.
15. A flexible wall covering material suitable for finishing a surface of a building comprising a flexible matrix layer covered with and at least partially embedded in water-curable composition, including a combination of a polymer binder and a Portland cement mix wherein said cement mix is from 85% to 95%
by weight of said water-curable composition, said Portland cement mix includes from zero to about 70% by weight of a filler, said composition producing a planar substantially uniform layer by being deposited on said matrix layer with a solvent therein which is substantially removed, said covering material having sufficient flexibility to be rolled into a roll for transporting and subsequently unrolled for being applied to a surface without said composition separating from said matrix layer or cracking.
by weight of said water-curable composition, said Portland cement mix includes from zero to about 70% by weight of a filler, said composition producing a planar substantially uniform layer by being deposited on said matrix layer with a solvent therein which is substantially removed, said covering material having sufficient flexibility to be rolled into a roll for transporting and subsequently unrolled for being applied to a surface without said composition separating from said matrix layer or cracking.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US47436174A | 1974-05-30 | 1974-05-30 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1046361A true CA1046361A (en) | 1979-01-16 |
Family
ID=23883187
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA226,709A Expired CA1046361A (en) | 1974-05-30 | 1975-05-12 | Cement in a roll for application to the surface of a building |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1046361A (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0790370A1 (en) * | 1996-02-16 | 1997-08-20 | Hans Peter Böe | Half-product building element for coating surfaces |
| WO2012038099A1 (en) | 2010-09-23 | 2012-03-29 | Wacker Chemie Ag | Flexible waterproof roof coatings |
| WO2012038302A1 (en) | 2010-09-23 | 2012-03-29 | Wacker Chemie Ag | Coating agents for producing waterproof infrastructure coatings |
| GR1008164B (en) * | 2012-11-27 | 2014-04-08 | Αθανασιος Ηλια Τετωρος | Flexible, decorative, slow-burning builidng material with heat, sound and humidity insulation properties - use of same in floors or in interior and exterior walls |
| GR1009005B (en) * | 2016-02-17 | 2017-04-04 | Παναγιωτης Κωνσταντινου Ζαφειρακης | Waterproof thermally-insulating stone-like sheet destined for the easy coating of whatever surface - production method thereof |
| US11946257B2 (en) | 2013-03-14 | 2024-04-02 | Avi Feuer | Roofing method and apparatus |
-
1975
- 1975-05-12 CA CA226,709A patent/CA1046361A/en not_active Expired
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0790370A1 (en) * | 1996-02-16 | 1997-08-20 | Hans Peter Böe | Half-product building element for coating surfaces |
| WO1997030246A1 (en) * | 1996-02-16 | 1997-08-21 | Boee Hans Peter | Semi-finished surface-cladding component |
| WO2012038099A1 (en) | 2010-09-23 | 2012-03-29 | Wacker Chemie Ag | Flexible waterproof roof coatings |
| WO2012038302A1 (en) | 2010-09-23 | 2012-03-29 | Wacker Chemie Ag | Coating agents for producing waterproof infrastructure coatings |
| DE102010041292A1 (en) | 2010-09-23 | 2012-03-29 | Wacker Chemie Ag | Flexible, waterproof roof coatings |
| DE102010041291A1 (en) | 2010-09-23 | 2012-03-29 | Wacker Chemie Ag | Coating composition for the production of water-bearing infrastructure coatings |
| US9249060B2 (en) | 2010-09-23 | 2016-02-02 | Wacker Chemie Ag | Flexible watertight roof coatings |
| GR1008164B (en) * | 2012-11-27 | 2014-04-08 | Αθανασιος Ηλια Τετωρος | Flexible, decorative, slow-burning builidng material with heat, sound and humidity insulation properties - use of same in floors or in interior and exterior walls |
| US11946257B2 (en) | 2013-03-14 | 2024-04-02 | Avi Feuer | Roofing method and apparatus |
| GR1009005B (en) * | 2016-02-17 | 2017-04-04 | Παναγιωτης Κωνσταντινου Ζαφειρακης | Waterproof thermally-insulating stone-like sheet destined for the easy coating of whatever surface - production method thereof |
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