CA1055270A - Composite panel structure for building constructions and process for preparing the panel structure - Google Patents
Composite panel structure for building constructions and process for preparing the panel structureInfo
- Publication number
- CA1055270A CA1055270A CA261,568A CA261568A CA1055270A CA 1055270 A CA1055270 A CA 1055270A CA 261568 A CA261568 A CA 261568A CA 1055270 A CA1055270 A CA 1055270A
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- Prior art keywords
- percent
- weight
- copolymer
- foam
- styrene
- 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
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
- B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B13/12—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
- E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
- E04D3/351—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material
- E04D3/352—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation at least one of the layers being composed of insulating material, e.g. fibre or foam material at least one insulating layer being located between non-insulating layers, e.g. double skin slabs or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D2350/00—Pretreatment of the substrate
- B05D2350/30—Change of the surface
- B05D2350/33—Roughening
- B05D2350/35—Roughening by chemical means
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
- B05D3/12—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by mechanical means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/50—Multilayers
- B05D7/51—One specific pretreatment, e.g. phosphatation, chromatation, in combination with one specific coating
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Structural Engineering (AREA)
- Civil Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Wood Science & Technology (AREA)
- Laminated Bodies (AREA)
- Panels For Use In Building Construction (AREA)
- Paints Or Removers (AREA)
Abstract
Abstract of the Disclosure This invention relates to roof structures comprising a water barrier layer placed on a roof deck, a waterproof closed cell foam insulation placed over the water barrier layer and a protective layer of an inorganic mortar placed on the foam insulation. More particularly, the present invention is directed to roof structures of this type which utilize a specified styrene--butadiene as the protective layer. The improved roofing system has excellent resistance to weatherability, fire and mechanical damage and has unexpectedly enhanced resistance to delamination of the protective layer from the foam insulation.
Description
l~5SZ70 The invention resides in a roof structure; a composite panel for building constructions, and in a process for promoting adhesion of a cementitious material to a foam material. More particularly the invention resides in a composite building panel comprising a main body portion of a closed cell generally smooth skinned foam material having along at least one surface thereof a protective cementitious facing material adhered thereto;
such panels being particularly adapted for use in roofing and curtain wall construction.
Particularly preferred results are obtained with a styrene-butadiene-1,3 copolymer modified portland cement which is a shrinkage compensating portland cement and wherein such cement contains sufficient reinforcement to provide restraint against expansion.
U. S. Patent 3,411,256 discloses and claims roofing structures of the general type as utilized herein.
Such prior known structures consist essentially of a roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck supporting a water impermeable membrane having its lower face generally adjacent the roof deck, a closed cell foam insulating layer adjacent the upper face of the water permeable membrane, such foam insulating 1~355Z70 layer being comprised of a plurality of individual closed cell foam insulating members defining fissures between adjacent members, and a protective layer of an inorganic material, such as mortar, disposed on the surface of the insulating members. Such prior known roofing structures - suffer, however, from ineffective bonding of the pro-tective layer to the surface of the insulating members with resultant delamination of such layers during normal handling and/or exposure to the elements. Such delamination is believed to be due primarily to the poor bond of the protective layer to closed cell, generally smooth skinned foam insulation, taken with the normal shrinkage of the prior known protective layers, resulting in the development of stress at the foam-mortar interface. Another factor believed to be a cause of such delamination is temperature cycling during cure of the protective layer due to the differences in the coefficient of expansion between the foam and mortar.
Significantly improved resistance to delamination of the protective layer from the foam layer is achieved by utilizing roof structures of the type as described in U.S.P. 3,411,256, where a water or vapor barrier layer is placed on a roof deck, a waterproof closed cell, generally smooth skinned foam insulation is placed over the water barrier layer and a cementitious protective layer is placed on the foam insulation wherein the cementitious protective layer is modified by a styrene-butadiene-1,3 copolymer.
The invention resides in a composite building panel comprising a main body portion of a closed cell, 1q~5SZ70 generally smooth skinned foam material having adhered along at least one surface thereof a protective cementi-tious facing material consisting essentially of an admix-ture of portland cement, mineral aggregate and from 5 to 25 percent based on the weight of said cement of a styrene--butadiene-1,3 copolymer having a styrene to butadiene weight ratio of 30:70 to 70:30, water in amount of from 25 to 65 percent based on the weight of said cement, and based on the weight of said copolymer, (a) from 2 to 10 percent of non-ionic surfactant, (b) from 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is a sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1.
The invention also resides in a building panel comprising a main body portion of a closed cell, generally smooth skinned styrene polymer foam material having a surface containing one or more regions having indentations therein, said surface having applied thereto a substantially continuous binder coating of a styrene-butadiene copolymer latex consisting essentially of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non--ionic surfactant, (b) from about 0.75 to 7.5 percnet of anionic surfactant, at least about 15 percent of which is .,? ~
1~3S5Z70 sodium alkyl sulfate in which the alkyl groups contain 9 to 17 carbon atoms, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1, and adhered to said binder coating a pro-tective cementitious facing material, a portion of which is contained in said indentations, said facing material consisting essentially of an admixture of portland cement, mineral aggregate and from about 5 to about 25 percent based on the weight of said cement of a styrene-butadiene--1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, water in amount of from about 25 to 65 percent based on the weight of said cement, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is a sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from about 0.1 to 5 percent of a polyorganosiloxane foam depres-sant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1.
The invention also resides in a process for promoting the adhesion of the cementitious material to the surface of the foam material to form a building ~J
-3a-1~55270 panel, said process comprising the sequential steps of (1) applying to said foam material surface a substantially continuous coating of a thermoplastic styrene-butadiene copolymer latex consisting essentially of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is sodium alkyl sulfate in which the alkyl groups contain 9 to 17 carbon atoms, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1, (2) applying the cementitious material to the coated surface prior to substantial dehydration of said coating, and (3) allowing said cementitious material to harden.
The invention also resides in a roof structure consisting essentially of a roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck supporting a water or vapor impermeable membrane, the impermeable membrane having an upper face and a lower face being gener-ally adjacent the roof deck, and a plurality of the building panels disposed adjacent the upper face of the water impermeable membrane, the foam material in said plurality of panel members defining fissures between adjacent members and wherein the surface of said foam insulating layer adjacent said cementitious protective layer contains a plurality of individual indentations therein said indentations ~ -4-~L~355Z70 containing a portion of said cementitious protective layer.
The invention also resides in a roof structure consisting essentially of a roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck support-ing a water or vapor impermeable membrane, the impermeable membrane having an upper face and a lower face being gen-erally adjacent the roof deck, a closed cell generally smooth skinned water impermeable styrene polymer foam in-sulating layer disposed adjacent the upper face of the water impermeable membrane, said insulating layer compris-ing a plurality of insulating members said members defining fissures between adjacent members, and a protective layer of an inorganic material disposed on the surface of the insulating members remote from the roof decX, the improve-ment consisting of (1) utilizing as said protective layer an admixture of a portland cement, mineral aggregate, from about 5 to about 25 percent based on the weight of said cement of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, water in amount of from about s25 to 65 percent based on the weight of said cement; and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non--ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from about 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and `` 1~55270 the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1, and (2) wherein the surface of said insulating layer adjacent said protective layer contains a plurality of individual indentations therein, said indentations containing a portion of said protective layer.
The basic roof structure designs as contemplated by the present invention are schematically set forth in Figures 1 and 2 of U.S.P. 3,411,256. A wide variety of materials may be employed in the preparation of such roofs, e.g. the roof deck or roof support means may be prepared from steel, wood, laminated wood, cardboard, cement, asbestos board, planking and the like. The roof deck may be supported in any convenient manner such as being firmly affixed to the rafters by means of nails, screws or bolts.
The roof decking may be of panels and readily inserted into suitable recesses in a framework and prepared by like methods well known to the art. The water impermeable membrane may comprise or consist of a wide variety of water impermeable materials including conven--5a-tional asphaltic and bituminous compositions employed for roofing as well as laminates of the bituminous material with fibrous products such as roofing felt employing organic or inorganic fibers. Beneficially such felt and bituminous materials may be applied in alternating layers to provide a water impermeable membrane of the desired thickness and mechanical strength to re-sist movement of the roof deck and associated supporting structure. In certain instances, a water or vapor impermeable membrane can be formed of synthetic resinous film or sheet such as polyethylene, polyvinyl chloride, polyurethane, butyl rubber, polyisobutylene and the like with or without the presence of vapor impermeable materials such as aluminum foil, which is adhered to the roof deck by a suit-able adhesive. One or more layers of such material may be employed depending on the characteristics which are desired from the finished structure.
The foam insulating layer, employed in the practice of the present invention, is a closed cell, generally smooth skinned material which is substantially water impermeable. Particularly beneficial and advantageous are cellular plastic foams of a closed cell configuration including styrene polymer foams, styrene-acrylonitrile copolymer foams and styrene-methylmethacrylate copolymer foams, polyvinylchloride foams, polyurethane foams, poly-ethylene foams, phenolic foams and other water impermeable materials available in cellular foam form which are well known to the art. Exemplary of such other materials which may be used are the ceramic foams and foam glass.
~S5270 For obtainment of optimum bonding with the herein described latex modified cementitious protective layer, the prescribed foam insulation layer is beneficlally provided with indentations along one or more surfaces, such indentations being of a wide variety of shapes, sizes and frequency. More particularly, the surface of the closed cell foam may be punched, drilled, stamped, milled, routed, scored or cut to provide such indentations. Further heated projections of varying configuration may be used to form indentations by melting a portion of such foam in-sulation. A particularly useful means for placing indentations in the closed cell foam insulation is to pass such foam along a forwarding roll having longitudinal projections thereon. This method is particularly useful for placing indentations in styrene polymer foam due to the inherent resiliency of such foam material. Thus, such foam is initially compressed under a projection, having a sub-stantially square contact area, then pushed in a forward direction. The resulting combination of compression and resiliency causes the foam to tear away from the edge of the initial hole, thereby making a hole larger in diameter at the bottom than at the top. The shape of the hole thus resembles a trapezoid with the short parallel side of the hole opening at the foam surface.
Particularly useful cementitious protective layers utilized by the present invention are comprised essentially of an admixture of a shrinkage compensating portland cement, mineral aggregate, from 5 to 25 percent based on the weight of said cement of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of ~6355270 30:70 to 70:30, water in the amount of from 25 to 65 percent based on the weight of said cement; and based on the weight of said copolymer, (a) from 2 to 10 percent of nonionic surfactan', (b) from 0.75 to 7.5 percent of anionic surfactant, at least 15 percent of which is a sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding 11 percent by weight of the copolymer and the weight ratio of (a) to (b) being within the range of 0.7:1 to 10:1; and reinforcement to provide restraint against expansion.
The shrinkage compensating cements utilized are as follows:
Type K: This is a mixture of portland cement compounds, anhydrous calcium sulfoaluminate (4Ca0.3A12O3.SO3), calcium sulfate (CaSO4), and lime (CaO). The anhydrous calcium sulfoaluminate is a component of a separately burned clinker that is interground or blended with port-land cement clinker. Alternatively, it may be formed simultaneously with the portland clinker compounds.
Type M: Either a mixture of portland cement, calcium aluminate cement and calcium sulfate or an inter-ground product made with portland cement clinker, calcium aluminate clinker and calcium sulfate.
Type S: A portland cement containing a large tricalcium aluminate content and modified by an excess of calcium sulfate above usual amounts found in other portland cements.
~ 1~55;~70 The styrene-butadiene-1,3 copolymer latexes employed can be prepared in accordance with known procedures. For example, the styrene and butadiene monomers can be mixed in the proportions corresponding to the composition of the desired copolymer in water con-taining an emulsifying agent or agents and heated with agitation in the presence of a peroxide catalyst to initiate copolymerization as known in the art.
The concentration of the styrene-butadiene-1,3 copolymer solids in the cement composition is, however, critical for the obtainment of the desired combination of properties required by the present invention. In this regard, concentrations less than 5 percent based on the weight of cement used, do not provide improved mechanical properties such as flexibility, abrasion resistance, and adherence. Further, total latex solids concentrations in excess of 25 percent based on the weight of cement significantly reduce the mechanical properties of the composition.
Utilization of such copolymer latexes in conventional portland cement, mortar compositions is known, e.g. as disclosed in USP 3,043,790.
If the modified shrinkage compensating cement compositions are not properly restrained, they literally expand themselves apart so that their potential strength is seriously impaired or totally lost. In general, any conventional reinforcing material such as, for example, deformed bar, rods, or wire mesh, in the proper amounts and properly installed will provide restraint sufficient to maintain compositional strength and integrity. Fiber reinforcing materials, such as steel fibers or alkali resistant glass fibers, also provide sufficient restraint.
Fibrous types can be added to the composition during the mixing stage and hence, will be evenly dispersed and be-come an integral constituent of the composition. These fibers are randomly oriented and will provide three dimensional restraint.
It has been found that the combination of alkali resistant glass fiber reinforcement and the herein pre-scribed latex modification creates an unexpectedly beneficial effect.
It has also been found that properly restrained modified shrinkage compensating cement compositions possess significantly increased freeze-thaw resistance, flexural strengths and water absorption characteristics.
The amount of water employed in preparing the shrinkage compensating cement compositions is also important with regard to providing compositions of optimum workability.
In this regard at least 25 percent water, based on the weight of expansive cement, is required with an amount from 35 to 65 percent being preferred.
Some or all of the non-ionic and anionic sur-factants employed in the cement compositions of the invention can be present while effecting copolymerization of the styrene and butadiene. Ordinarily, however, it is preferred to follow the practices used in making styrene-butadiene emulsions for use in preparing latex paints. Thus, some but not necessarily all of the anionic surfactant is introduced to aid in effecting the desired dispersion and emulsification in carrying out the copolymerization of butadiene and styrene, and the non-ionic surfactant is subsequently added to stabilize the resulting polymer dispersion. The polyorganosiloxane foam depressant and such additional quantities of non-ionic surfactant and anionic surfactant, as are required to complete the cement composition, are subsequently introduced.
Illustrative of non-ionic surfactants are, for example: fatty acid esters such as glycerol mono-stearate, diethyleneglycol laurate, propyleneglycol mono-stearate, sorbitol monolaurate, and pentaerythritol mono-stearate, acid derivatives of ethylene oxide products such as the reaction product of six moles of ethylene oxide with one of oleic acid; condensation products of ethylene oxide with alcohols such as stearyl alcohol; and condensation products of ethylene oxide with phenols, naphthols, and alkyl phenols such as di-t-butylphenoxynonaoxyethylene--ethanol. Preferred are the condensation products of ethylene oxide with alkyl phenols.
Illustrative of anionic surfactants are, for example: the alkyl aryl sulfonates such as dodecylbenzene sodium sulfonate; sulfate derivatives of higher fatty alcohols (i.e., alcohols of at least nine carbon atoms and ordinarily not more than seventeen carbon atoms) such as sodium lauryl sulfate; the sulfonated animal and vegeta-ble oils such as sulfonated fish and castor oils; sulfonated acyclic hydrocarbons; and the like. As pointed out here-tofore, at least 15 percent of the anionic surfactant com-ponent of the cement additive of the invention should be a sodium higher alkyl sulfate such as sodium lauryl sulfate and preferably the anionic surfactant component consists lOS5Z70 of a mixture of an alkyl aryl sulfonate surfactant and such sodium alkyl sulfate.
Illustrative of the polyorganosiloxanes are the condensation products resulting from polymerization of organo silane diols, as represented by the formula R R
HO- SiO - S OH
R' R' n where R and R', in the above formula, represent organic radicals such as alkyl, aryl, aralkyl and alkaryl or heterocyclic groups, and n is one or more. Also useful are polymerization products of organo silane diols in the presence of an organo silane monol, and condensation pro-ducts obtained from mixtures of organo silane triols, diols, and monols.
Preferably the organo substituent of the siloxanes is lower alkyl (i.e., methyl, ethyl, propyl), cyclohexyl or phenyl. Most preferably it is methyl, and accordingly, the preferred polyorganosiloxanes are those which are condensation products of methyl silicols, and most preferably condensation products of dimethyl silane diol.
Polyorganosiloxanes are commercially available in several forms which are designated in the trade as "silicone fluids", "silicone emulsions" and "silicone com-pounds", the latter being siloxanes modified by the addition of a small percentage of finely divided silica or other inert divided solid. Any of these forms can be used in the practice of this invention.
- lOSSZ70 It has further been found to be beneficial, for purposes of obtaining optimum adhesion of the cementitious facing material to the foam surface to coat the foam surface with a substantially continuous coating of the styrene-butadiene-1,3 latex, as described supra, prior to the application of the cementitious facing material.
In this regard, the latex coating is preferably not substantially dehydrated prior to application of the cementitious material.
The aggregate employed in the cementitious protective layer may be any conventionally employed manufactured aggregate or naturally occurring mineral aggregate, such as sand and a mixture of sand with gravel, crushed stone, or equivalent materials.
The cement compositions are made by simply adding the additives to the expansive cement with mixing to obtain a cement mix of desired flow and consistency.
While it is generally convenient to prepare the cement compositions as a unitary product by pre-combining the styrene-butadiene copolymer, non-ionic and anionic surfactant, and polyorganosiloxane foam depressant, and then introducing the resulting mixture into the cement--aggregate mixture in making cement, mortar, or concrete mixes, it will be understood, of course, that it is not necessary that all the various components of the additive be so premixed. For example, equivalent cement, mortar, or concrete mixes are obtained by separate addition of the requisite quantity of styrene-butadiene copolymer emulsion containing sufficient of the anionic and non--ionic surfactants to avoid coagulation of the latex, the polyorganosiloxane foam depressant and such additional non-ionic and anionic surfactants as are necessary.
In preparation of the roof structures of the present invention, usually the water resistant membrane is applied to the roof deck, for example by applying a layer of bituminous material thereto, applying a suitable roofing felt to the bituminous material and providing the repeated applications of roofing felt and bituminous material until a suitable membrane is formed.
Advantageously the foam insulating layer is joined to the water impermeable membrane by the use of the same or a different bituminous composition employed in preparing the water resistant membrane while the bituminous material is in a heat plastified condition.
Pressing planks or sheets of the heat insulating material into the bituminous layer provides a suitable bond.
It is necessary, however, that the bituminous material does not have a temperature sufficiently high to destroy a large portion or proportion of such cellular material.
For example, when foamed polystyrene sheets are utilized as the insulating layer, it is generally desirable that the bi~uminous material have a temperature not greatly in excess of about 100 Centigrade, to prevent distortion or melting of such polystyrene foam material. It is essential to the practice of the present invention, that the insulating layer be of a closed cell configuration. The particular density or physical strength of such insulating material need only be sufficient to meet the mechanical demands of the particular installation. Generally, foamed polystyrene sheets having a density of about 1.5 pounds per cubic foot ~05527~
are adequate providing the protective layer is of sufficient thickness to resist mechanical damage. Thus, in a region where little or no foot traffic is expected on a roof, a protective layer having a thickness of about 1/8 of an inch provides adequate protection. However, in regions where frequent or heavy foot traffic occurs, it is often desirable to employ a layer of cementitious material of from about 1/4 to about 3/8 of an inch or more.
It is not essential that the protective layer be resistant to the passage of moisture, nor is it essential the insulating layer have a surface which prevents moisture from contacting the water resistant membrane.
In another embodiment of the present invention, bonding of the foam insulating layer to the latex modified cementitious layer can be further enhanced by applying a substantially continuous coating of the styrene-butadiene latex described herein (but absent the polyorganosiloxane foam depressant), to the foam insulation, followed by application thereto of the protective layer prior to substantial dehydration of such latex coating.
Roof structures, in accordance with the invention, do not appear subject to damage by freezing of water in spaces between adjacent foam insulating elements. The foam insulating elements appear to have sufficient resilience to resist rupturing by the expansion of freezing water in crevices. Furthermore, in installations on a heated building the temperature adjacent the water resistant membrane usually does not reach freezing temperatures. In buildings having a roof applied in accordance with the present invention, little or no tendency is observed for moisture to condense on the inner surface of the roof deck.
1C~5S270 By way of further illustration, a plurality of blocks of closed cell, generally smooth skinned poly-styrene foam measuring about 1 1/4 inches in thickness,
such panels being particularly adapted for use in roofing and curtain wall construction.
Particularly preferred results are obtained with a styrene-butadiene-1,3 copolymer modified portland cement which is a shrinkage compensating portland cement and wherein such cement contains sufficient reinforcement to provide restraint against expansion.
U. S. Patent 3,411,256 discloses and claims roofing structures of the general type as utilized herein.
Such prior known structures consist essentially of a roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck supporting a water impermeable membrane having its lower face generally adjacent the roof deck, a closed cell foam insulating layer adjacent the upper face of the water permeable membrane, such foam insulating 1~355Z70 layer being comprised of a plurality of individual closed cell foam insulating members defining fissures between adjacent members, and a protective layer of an inorganic material, such as mortar, disposed on the surface of the insulating members. Such prior known roofing structures - suffer, however, from ineffective bonding of the pro-tective layer to the surface of the insulating members with resultant delamination of such layers during normal handling and/or exposure to the elements. Such delamination is believed to be due primarily to the poor bond of the protective layer to closed cell, generally smooth skinned foam insulation, taken with the normal shrinkage of the prior known protective layers, resulting in the development of stress at the foam-mortar interface. Another factor believed to be a cause of such delamination is temperature cycling during cure of the protective layer due to the differences in the coefficient of expansion between the foam and mortar.
Significantly improved resistance to delamination of the protective layer from the foam layer is achieved by utilizing roof structures of the type as described in U.S.P. 3,411,256, where a water or vapor barrier layer is placed on a roof deck, a waterproof closed cell, generally smooth skinned foam insulation is placed over the water barrier layer and a cementitious protective layer is placed on the foam insulation wherein the cementitious protective layer is modified by a styrene-butadiene-1,3 copolymer.
The invention resides in a composite building panel comprising a main body portion of a closed cell, 1q~5SZ70 generally smooth skinned foam material having adhered along at least one surface thereof a protective cementi-tious facing material consisting essentially of an admix-ture of portland cement, mineral aggregate and from 5 to 25 percent based on the weight of said cement of a styrene--butadiene-1,3 copolymer having a styrene to butadiene weight ratio of 30:70 to 70:30, water in amount of from 25 to 65 percent based on the weight of said cement, and based on the weight of said copolymer, (a) from 2 to 10 percent of non-ionic surfactant, (b) from 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is a sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1.
The invention also resides in a building panel comprising a main body portion of a closed cell, generally smooth skinned styrene polymer foam material having a surface containing one or more regions having indentations therein, said surface having applied thereto a substantially continuous binder coating of a styrene-butadiene copolymer latex consisting essentially of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non--ionic surfactant, (b) from about 0.75 to 7.5 percnet of anionic surfactant, at least about 15 percent of which is .,? ~
1~3S5Z70 sodium alkyl sulfate in which the alkyl groups contain 9 to 17 carbon atoms, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1, and adhered to said binder coating a pro-tective cementitious facing material, a portion of which is contained in said indentations, said facing material consisting essentially of an admixture of portland cement, mineral aggregate and from about 5 to about 25 percent based on the weight of said cement of a styrene-butadiene--1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, water in amount of from about 25 to 65 percent based on the weight of said cement, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is a sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from about 0.1 to 5 percent of a polyorganosiloxane foam depres-sant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1.
The invention also resides in a process for promoting the adhesion of the cementitious material to the surface of the foam material to form a building ~J
-3a-1~55270 panel, said process comprising the sequential steps of (1) applying to said foam material surface a substantially continuous coating of a thermoplastic styrene-butadiene copolymer latex consisting essentially of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is sodium alkyl sulfate in which the alkyl groups contain 9 to 17 carbon atoms, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1, (2) applying the cementitious material to the coated surface prior to substantial dehydration of said coating, and (3) allowing said cementitious material to harden.
The invention also resides in a roof structure consisting essentially of a roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck supporting a water or vapor impermeable membrane, the impermeable membrane having an upper face and a lower face being gener-ally adjacent the roof deck, and a plurality of the building panels disposed adjacent the upper face of the water impermeable membrane, the foam material in said plurality of panel members defining fissures between adjacent members and wherein the surface of said foam insulating layer adjacent said cementitious protective layer contains a plurality of individual indentations therein said indentations ~ -4-~L~355Z70 containing a portion of said cementitious protective layer.
The invention also resides in a roof structure consisting essentially of a roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck support-ing a water or vapor impermeable membrane, the impermeable membrane having an upper face and a lower face being gen-erally adjacent the roof deck, a closed cell generally smooth skinned water impermeable styrene polymer foam in-sulating layer disposed adjacent the upper face of the water impermeable membrane, said insulating layer compris-ing a plurality of insulating members said members defining fissures between adjacent members, and a protective layer of an inorganic material disposed on the surface of the insulating members remote from the roof decX, the improve-ment consisting of (1) utilizing as said protective layer an admixture of a portland cement, mineral aggregate, from about 5 to about 25 percent based on the weight of said cement of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, water in amount of from about s25 to 65 percent based on the weight of said cement; and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non--ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from about 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and `` 1~55270 the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1, and (2) wherein the surface of said insulating layer adjacent said protective layer contains a plurality of individual indentations therein, said indentations containing a portion of said protective layer.
The basic roof structure designs as contemplated by the present invention are schematically set forth in Figures 1 and 2 of U.S.P. 3,411,256. A wide variety of materials may be employed in the preparation of such roofs, e.g. the roof deck or roof support means may be prepared from steel, wood, laminated wood, cardboard, cement, asbestos board, planking and the like. The roof deck may be supported in any convenient manner such as being firmly affixed to the rafters by means of nails, screws or bolts.
The roof decking may be of panels and readily inserted into suitable recesses in a framework and prepared by like methods well known to the art. The water impermeable membrane may comprise or consist of a wide variety of water impermeable materials including conven--5a-tional asphaltic and bituminous compositions employed for roofing as well as laminates of the bituminous material with fibrous products such as roofing felt employing organic or inorganic fibers. Beneficially such felt and bituminous materials may be applied in alternating layers to provide a water impermeable membrane of the desired thickness and mechanical strength to re-sist movement of the roof deck and associated supporting structure. In certain instances, a water or vapor impermeable membrane can be formed of synthetic resinous film or sheet such as polyethylene, polyvinyl chloride, polyurethane, butyl rubber, polyisobutylene and the like with or without the presence of vapor impermeable materials such as aluminum foil, which is adhered to the roof deck by a suit-able adhesive. One or more layers of such material may be employed depending on the characteristics which are desired from the finished structure.
The foam insulating layer, employed in the practice of the present invention, is a closed cell, generally smooth skinned material which is substantially water impermeable. Particularly beneficial and advantageous are cellular plastic foams of a closed cell configuration including styrene polymer foams, styrene-acrylonitrile copolymer foams and styrene-methylmethacrylate copolymer foams, polyvinylchloride foams, polyurethane foams, poly-ethylene foams, phenolic foams and other water impermeable materials available in cellular foam form which are well known to the art. Exemplary of such other materials which may be used are the ceramic foams and foam glass.
~S5270 For obtainment of optimum bonding with the herein described latex modified cementitious protective layer, the prescribed foam insulation layer is beneficlally provided with indentations along one or more surfaces, such indentations being of a wide variety of shapes, sizes and frequency. More particularly, the surface of the closed cell foam may be punched, drilled, stamped, milled, routed, scored or cut to provide such indentations. Further heated projections of varying configuration may be used to form indentations by melting a portion of such foam in-sulation. A particularly useful means for placing indentations in the closed cell foam insulation is to pass such foam along a forwarding roll having longitudinal projections thereon. This method is particularly useful for placing indentations in styrene polymer foam due to the inherent resiliency of such foam material. Thus, such foam is initially compressed under a projection, having a sub-stantially square contact area, then pushed in a forward direction. The resulting combination of compression and resiliency causes the foam to tear away from the edge of the initial hole, thereby making a hole larger in diameter at the bottom than at the top. The shape of the hole thus resembles a trapezoid with the short parallel side of the hole opening at the foam surface.
Particularly useful cementitious protective layers utilized by the present invention are comprised essentially of an admixture of a shrinkage compensating portland cement, mineral aggregate, from 5 to 25 percent based on the weight of said cement of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of ~6355270 30:70 to 70:30, water in the amount of from 25 to 65 percent based on the weight of said cement; and based on the weight of said copolymer, (a) from 2 to 10 percent of nonionic surfactan', (b) from 0.75 to 7.5 percent of anionic surfactant, at least 15 percent of which is a sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding 11 percent by weight of the copolymer and the weight ratio of (a) to (b) being within the range of 0.7:1 to 10:1; and reinforcement to provide restraint against expansion.
The shrinkage compensating cements utilized are as follows:
Type K: This is a mixture of portland cement compounds, anhydrous calcium sulfoaluminate (4Ca0.3A12O3.SO3), calcium sulfate (CaSO4), and lime (CaO). The anhydrous calcium sulfoaluminate is a component of a separately burned clinker that is interground or blended with port-land cement clinker. Alternatively, it may be formed simultaneously with the portland clinker compounds.
Type M: Either a mixture of portland cement, calcium aluminate cement and calcium sulfate or an inter-ground product made with portland cement clinker, calcium aluminate clinker and calcium sulfate.
Type S: A portland cement containing a large tricalcium aluminate content and modified by an excess of calcium sulfate above usual amounts found in other portland cements.
~ 1~55;~70 The styrene-butadiene-1,3 copolymer latexes employed can be prepared in accordance with known procedures. For example, the styrene and butadiene monomers can be mixed in the proportions corresponding to the composition of the desired copolymer in water con-taining an emulsifying agent or agents and heated with agitation in the presence of a peroxide catalyst to initiate copolymerization as known in the art.
The concentration of the styrene-butadiene-1,3 copolymer solids in the cement composition is, however, critical for the obtainment of the desired combination of properties required by the present invention. In this regard, concentrations less than 5 percent based on the weight of cement used, do not provide improved mechanical properties such as flexibility, abrasion resistance, and adherence. Further, total latex solids concentrations in excess of 25 percent based on the weight of cement significantly reduce the mechanical properties of the composition.
Utilization of such copolymer latexes in conventional portland cement, mortar compositions is known, e.g. as disclosed in USP 3,043,790.
If the modified shrinkage compensating cement compositions are not properly restrained, they literally expand themselves apart so that their potential strength is seriously impaired or totally lost. In general, any conventional reinforcing material such as, for example, deformed bar, rods, or wire mesh, in the proper amounts and properly installed will provide restraint sufficient to maintain compositional strength and integrity. Fiber reinforcing materials, such as steel fibers or alkali resistant glass fibers, also provide sufficient restraint.
Fibrous types can be added to the composition during the mixing stage and hence, will be evenly dispersed and be-come an integral constituent of the composition. These fibers are randomly oriented and will provide three dimensional restraint.
It has been found that the combination of alkali resistant glass fiber reinforcement and the herein pre-scribed latex modification creates an unexpectedly beneficial effect.
It has also been found that properly restrained modified shrinkage compensating cement compositions possess significantly increased freeze-thaw resistance, flexural strengths and water absorption characteristics.
The amount of water employed in preparing the shrinkage compensating cement compositions is also important with regard to providing compositions of optimum workability.
In this regard at least 25 percent water, based on the weight of expansive cement, is required with an amount from 35 to 65 percent being preferred.
Some or all of the non-ionic and anionic sur-factants employed in the cement compositions of the invention can be present while effecting copolymerization of the styrene and butadiene. Ordinarily, however, it is preferred to follow the practices used in making styrene-butadiene emulsions for use in preparing latex paints. Thus, some but not necessarily all of the anionic surfactant is introduced to aid in effecting the desired dispersion and emulsification in carrying out the copolymerization of butadiene and styrene, and the non-ionic surfactant is subsequently added to stabilize the resulting polymer dispersion. The polyorganosiloxane foam depressant and such additional quantities of non-ionic surfactant and anionic surfactant, as are required to complete the cement composition, are subsequently introduced.
Illustrative of non-ionic surfactants are, for example: fatty acid esters such as glycerol mono-stearate, diethyleneglycol laurate, propyleneglycol mono-stearate, sorbitol monolaurate, and pentaerythritol mono-stearate, acid derivatives of ethylene oxide products such as the reaction product of six moles of ethylene oxide with one of oleic acid; condensation products of ethylene oxide with alcohols such as stearyl alcohol; and condensation products of ethylene oxide with phenols, naphthols, and alkyl phenols such as di-t-butylphenoxynonaoxyethylene--ethanol. Preferred are the condensation products of ethylene oxide with alkyl phenols.
Illustrative of anionic surfactants are, for example: the alkyl aryl sulfonates such as dodecylbenzene sodium sulfonate; sulfate derivatives of higher fatty alcohols (i.e., alcohols of at least nine carbon atoms and ordinarily not more than seventeen carbon atoms) such as sodium lauryl sulfate; the sulfonated animal and vegeta-ble oils such as sulfonated fish and castor oils; sulfonated acyclic hydrocarbons; and the like. As pointed out here-tofore, at least 15 percent of the anionic surfactant com-ponent of the cement additive of the invention should be a sodium higher alkyl sulfate such as sodium lauryl sulfate and preferably the anionic surfactant component consists lOS5Z70 of a mixture of an alkyl aryl sulfonate surfactant and such sodium alkyl sulfate.
Illustrative of the polyorganosiloxanes are the condensation products resulting from polymerization of organo silane diols, as represented by the formula R R
HO- SiO - S OH
R' R' n where R and R', in the above formula, represent organic radicals such as alkyl, aryl, aralkyl and alkaryl or heterocyclic groups, and n is one or more. Also useful are polymerization products of organo silane diols in the presence of an organo silane monol, and condensation pro-ducts obtained from mixtures of organo silane triols, diols, and monols.
Preferably the organo substituent of the siloxanes is lower alkyl (i.e., methyl, ethyl, propyl), cyclohexyl or phenyl. Most preferably it is methyl, and accordingly, the preferred polyorganosiloxanes are those which are condensation products of methyl silicols, and most preferably condensation products of dimethyl silane diol.
Polyorganosiloxanes are commercially available in several forms which are designated in the trade as "silicone fluids", "silicone emulsions" and "silicone com-pounds", the latter being siloxanes modified by the addition of a small percentage of finely divided silica or other inert divided solid. Any of these forms can be used in the practice of this invention.
- lOSSZ70 It has further been found to be beneficial, for purposes of obtaining optimum adhesion of the cementitious facing material to the foam surface to coat the foam surface with a substantially continuous coating of the styrene-butadiene-1,3 latex, as described supra, prior to the application of the cementitious facing material.
In this regard, the latex coating is preferably not substantially dehydrated prior to application of the cementitious material.
The aggregate employed in the cementitious protective layer may be any conventionally employed manufactured aggregate or naturally occurring mineral aggregate, such as sand and a mixture of sand with gravel, crushed stone, or equivalent materials.
The cement compositions are made by simply adding the additives to the expansive cement with mixing to obtain a cement mix of desired flow and consistency.
While it is generally convenient to prepare the cement compositions as a unitary product by pre-combining the styrene-butadiene copolymer, non-ionic and anionic surfactant, and polyorganosiloxane foam depressant, and then introducing the resulting mixture into the cement--aggregate mixture in making cement, mortar, or concrete mixes, it will be understood, of course, that it is not necessary that all the various components of the additive be so premixed. For example, equivalent cement, mortar, or concrete mixes are obtained by separate addition of the requisite quantity of styrene-butadiene copolymer emulsion containing sufficient of the anionic and non--ionic surfactants to avoid coagulation of the latex, the polyorganosiloxane foam depressant and such additional non-ionic and anionic surfactants as are necessary.
In preparation of the roof structures of the present invention, usually the water resistant membrane is applied to the roof deck, for example by applying a layer of bituminous material thereto, applying a suitable roofing felt to the bituminous material and providing the repeated applications of roofing felt and bituminous material until a suitable membrane is formed.
Advantageously the foam insulating layer is joined to the water impermeable membrane by the use of the same or a different bituminous composition employed in preparing the water resistant membrane while the bituminous material is in a heat plastified condition.
Pressing planks or sheets of the heat insulating material into the bituminous layer provides a suitable bond.
It is necessary, however, that the bituminous material does not have a temperature sufficiently high to destroy a large portion or proportion of such cellular material.
For example, when foamed polystyrene sheets are utilized as the insulating layer, it is generally desirable that the bi~uminous material have a temperature not greatly in excess of about 100 Centigrade, to prevent distortion or melting of such polystyrene foam material. It is essential to the practice of the present invention, that the insulating layer be of a closed cell configuration. The particular density or physical strength of such insulating material need only be sufficient to meet the mechanical demands of the particular installation. Generally, foamed polystyrene sheets having a density of about 1.5 pounds per cubic foot ~05527~
are adequate providing the protective layer is of sufficient thickness to resist mechanical damage. Thus, in a region where little or no foot traffic is expected on a roof, a protective layer having a thickness of about 1/8 of an inch provides adequate protection. However, in regions where frequent or heavy foot traffic occurs, it is often desirable to employ a layer of cementitious material of from about 1/4 to about 3/8 of an inch or more.
It is not essential that the protective layer be resistant to the passage of moisture, nor is it essential the insulating layer have a surface which prevents moisture from contacting the water resistant membrane.
In another embodiment of the present invention, bonding of the foam insulating layer to the latex modified cementitious layer can be further enhanced by applying a substantially continuous coating of the styrene-butadiene latex described herein (but absent the polyorganosiloxane foam depressant), to the foam insulation, followed by application thereto of the protective layer prior to substantial dehydration of such latex coating.
Roof structures, in accordance with the invention, do not appear subject to damage by freezing of water in spaces between adjacent foam insulating elements. The foam insulating elements appear to have sufficient resilience to resist rupturing by the expansion of freezing water in crevices. Furthermore, in installations on a heated building the temperature adjacent the water resistant membrane usually does not reach freezing temperatures. In buildings having a roof applied in accordance with the present invention, little or no tendency is observed for moisture to condense on the inner surface of the roof deck.
1C~5S270 By way of further illustration, a plurality of blocks of closed cell, generally smooth skinned poly-styrene foam measuring about 1 1/4 inches in thickness,
2 feet in width and about 4 feet long, were forwarded along a roll having individual projections thereon, which projections were about 1/2" apart in both directions and about 1/8" by 1/8" in cross sectional area and 3/16" in height. Such projections produced a plurality of inden-tations in the foam which indentations were in the shape of a trapezoid with the short parallel side of the hole opening at the surface of the foam. Thereafter, the surface of the foam having such indentations was coated with a substantially continuous coating of a styrene-butadiene latex composed essentially of an aqueous emulsion of about 48 weight percent of a solid copolymer of about 66 per cent by weight styrene and 34 percent by weight butadiene--1,3; and based on the copolymer weight, about 4.65 percent of the non-ionic surfactant di-t-butylphenoxy-nonaethylene-ethanol; and about 0.78 percent of a mixture of anionic surfactants comprising predominant amounts of sodium lauryl sulfate and correspondingly lesser amounts of dodecyl-benzene sulfonate.
A 1/2 inch coating of a cementitious protective layer was then cast on the coated surface of the foam, prior to significant dehydration of the latex coating. The cemen-titious protective material used was prepared by admixing a Type K shrinkage compensating cement with sufficient water to form water to cement ratios of 0.29 to 0.635, a sharp mason sand in amount to provide a sand to cement ratio of about 2.75-1, to 3-1, the styrene-butadiene latex previously described in amount to provide about 15 percent latex solids based on the weight of cement, a polymethyl-siloxane foam depressant in amount to provide about 0.4 percent by weight active silicon based on the weight of latex solids, and with about 4 pounds of 1/2" long alkali--resistant glass fibers per 94 pounds of cement, to furnish restraint. The Type K compensating cement was a mixture of portland cement compounds, anhydrous calcium sulfoaluminate tCaO)4(A12O3)3(SO3), calcium sulfate (CaSO4), and lime (CaO).
The cementitious protective layer was then vibrated to remove entrapped air and to seat a portion of such cementi-tious layer in the indentations present in the foam.
The so-formed panels were then cured under ambient temperatures.
The cured panels were characterized by being exceptionally resistant to delamination. More particularly, delamination did not occur following 300 temperature cycles of from 15F to 85F or following 500 temperature cycles of from 50F to 140F.
Further, the cured panels were characterized by a freeze-thaw value of greater than 300 cycles, as determined by ASTM Test No. C-666, i.e. such panels were not significantly deteriorated following such temperature cycling.
By way of further illustration of the exceptional binding produced by the use of Latex A as prescribed by the invention, in each of a series of experiments one of a series of latex materials were cast as the substantially continu-ous coating on a block of a closed cell, generally smooth skinned polystyrene foam. The latex materials used were as follows:
lOSSZ70 Latex A -- (as described supra) Latex B -- As per Latex A but additionally containing a polymethylsiloxane foam depressant in amount to provide about 0.4 percent by weight active silicone, based on the weight of latex solids.
Latex C (For Comparison) A blend of (1) about 25 percent by weight of Latex A above with (2) about 75 percent by weight of a latex com-posed of an aqueous emulsion of about 75 percent by weight vinylidene chloride, about 20 percent by weight vinyl chloride, about 3 percent by weight ethyl acrylate and about 2 percent by weight methyl methacrylate.
Latex D (For Comparison) As per Latex C but additionally containing small amounts of a polymethylsiloxane foam depressant.
Each coated foam sample was tested for tensile bond strength by adhering the coated foam sample between opposed wooden blocks via an epoxy adhesive. The tensile bond strength was obtained by drawing the wooden blocks apart and moving the point of separation. The following Table illustrates the samples used and the results obtained.
TAsLE
Latex Coating Tensile Type of Used Strength (PSI) Fracture A 73-76 Wood to Foam B 69-70 Film to Foam C 24-28 Film to Foam D 25-32 Film to Foam The above data illustrate the unexpectedly greater bond strength achieved using Latex A. Panels prepared as lOSSZ70 described herein are particularly useful in building construction, e.g., as roofing panels or panels used for sidewall construction. By way of comparison, panels prepared as described herein but utilizing (a) a non-latex modified, non-reinforced conventional portland cement or (b) a non-latex modified, fiber reinforced shrinkage compensating cement of the type as specifically disclosed herein; were both characterized by significant deter-ioration following about 200 temperature cycles.
A roof structure was prepared using the panels as prescribed by the present invention by mopping a wooden roof deck with a roofing grade asphalt followed by the application of a roofing felt thereto. The procedure was repeated until a water resistant membrane was formed.
A plurality of the cement coated foam panels were then adhered (with the cementitious layer on top) to the upper surface of the waterproof membrane by means of hot bitumen having a temperature of about 100 Centigrade.
The resulting roof structure was characterized by having a weight of less than about 5 pounds per square foot and was free from delamination of the cementi-tious layer from the foam even when exposed to repeated temperature cycles of about 100F and total temperature differences of up to 200F. Such roof structure was fur-ther characterized by having a Class A fire rating, the capability of sustaining foot traffic and normal loads or impacts without cracking and of being light in color and thus capable of reflecting sunlight to prevent excessive temperature rise in the insulation.
" ~OSSZ70 Further, after an extended period of exposure, portions of the membrane were removed and evaluated for resiliency. The membrane disposed underneath the cement latex modified cement coated foam polystyrene installation was in excellent condition and exhibited no indication of undue hardening. By way of comparison, a similar membrane covered with gravel and having a 2 inch layer of cellular styrene disposed beneath the roof deck showed marked deterioration.
By way of further illustration, the following comparative examples serve to emphasize the exceptional bonding properties obtained with a styrene-butadiene-1,3 copolymer when used as a modifying agent in the cement and when used as a primer coating on a perforated or indented generally closed cell styrene polymer foam in-sulating layer.
Example 1 A cementitious composition was prepared from a mixture of the following:
3000 grams of mason sand (ASTM C-144) 1000 grams of Type 1 cement (ASTM C-150) and 231 grams of water.
The cement composition was mixed and poured into a plurality of cup shaped molds, each having a diameter of
A 1/2 inch coating of a cementitious protective layer was then cast on the coated surface of the foam, prior to significant dehydration of the latex coating. The cemen-titious protective material used was prepared by admixing a Type K shrinkage compensating cement with sufficient water to form water to cement ratios of 0.29 to 0.635, a sharp mason sand in amount to provide a sand to cement ratio of about 2.75-1, to 3-1, the styrene-butadiene latex previously described in amount to provide about 15 percent latex solids based on the weight of cement, a polymethyl-siloxane foam depressant in amount to provide about 0.4 percent by weight active silicon based on the weight of latex solids, and with about 4 pounds of 1/2" long alkali--resistant glass fibers per 94 pounds of cement, to furnish restraint. The Type K compensating cement was a mixture of portland cement compounds, anhydrous calcium sulfoaluminate tCaO)4(A12O3)3(SO3), calcium sulfate (CaSO4), and lime (CaO).
The cementitious protective layer was then vibrated to remove entrapped air and to seat a portion of such cementi-tious layer in the indentations present in the foam.
The so-formed panels were then cured under ambient temperatures.
The cured panels were characterized by being exceptionally resistant to delamination. More particularly, delamination did not occur following 300 temperature cycles of from 15F to 85F or following 500 temperature cycles of from 50F to 140F.
Further, the cured panels were characterized by a freeze-thaw value of greater than 300 cycles, as determined by ASTM Test No. C-666, i.e. such panels were not significantly deteriorated following such temperature cycling.
By way of further illustration of the exceptional binding produced by the use of Latex A as prescribed by the invention, in each of a series of experiments one of a series of latex materials were cast as the substantially continu-ous coating on a block of a closed cell, generally smooth skinned polystyrene foam. The latex materials used were as follows:
lOSSZ70 Latex A -- (as described supra) Latex B -- As per Latex A but additionally containing a polymethylsiloxane foam depressant in amount to provide about 0.4 percent by weight active silicone, based on the weight of latex solids.
Latex C (For Comparison) A blend of (1) about 25 percent by weight of Latex A above with (2) about 75 percent by weight of a latex com-posed of an aqueous emulsion of about 75 percent by weight vinylidene chloride, about 20 percent by weight vinyl chloride, about 3 percent by weight ethyl acrylate and about 2 percent by weight methyl methacrylate.
Latex D (For Comparison) As per Latex C but additionally containing small amounts of a polymethylsiloxane foam depressant.
Each coated foam sample was tested for tensile bond strength by adhering the coated foam sample between opposed wooden blocks via an epoxy adhesive. The tensile bond strength was obtained by drawing the wooden blocks apart and moving the point of separation. The following Table illustrates the samples used and the results obtained.
TAsLE
Latex Coating Tensile Type of Used Strength (PSI) Fracture A 73-76 Wood to Foam B 69-70 Film to Foam C 24-28 Film to Foam D 25-32 Film to Foam The above data illustrate the unexpectedly greater bond strength achieved using Latex A. Panels prepared as lOSSZ70 described herein are particularly useful in building construction, e.g., as roofing panels or panels used for sidewall construction. By way of comparison, panels prepared as described herein but utilizing (a) a non-latex modified, non-reinforced conventional portland cement or (b) a non-latex modified, fiber reinforced shrinkage compensating cement of the type as specifically disclosed herein; were both characterized by significant deter-ioration following about 200 temperature cycles.
A roof structure was prepared using the panels as prescribed by the present invention by mopping a wooden roof deck with a roofing grade asphalt followed by the application of a roofing felt thereto. The procedure was repeated until a water resistant membrane was formed.
A plurality of the cement coated foam panels were then adhered (with the cementitious layer on top) to the upper surface of the waterproof membrane by means of hot bitumen having a temperature of about 100 Centigrade.
The resulting roof structure was characterized by having a weight of less than about 5 pounds per square foot and was free from delamination of the cementi-tious layer from the foam even when exposed to repeated temperature cycles of about 100F and total temperature differences of up to 200F. Such roof structure was fur-ther characterized by having a Class A fire rating, the capability of sustaining foot traffic and normal loads or impacts without cracking and of being light in color and thus capable of reflecting sunlight to prevent excessive temperature rise in the insulation.
" ~OSSZ70 Further, after an extended period of exposure, portions of the membrane were removed and evaluated for resiliency. The membrane disposed underneath the cement latex modified cement coated foam polystyrene installation was in excellent condition and exhibited no indication of undue hardening. By way of comparison, a similar membrane covered with gravel and having a 2 inch layer of cellular styrene disposed beneath the roof deck showed marked deterioration.
By way of further illustration, the following comparative examples serve to emphasize the exceptional bonding properties obtained with a styrene-butadiene-1,3 copolymer when used as a modifying agent in the cement and when used as a primer coating on a perforated or indented generally closed cell styrene polymer foam in-sulating layer.
Example 1 A cementitious composition was prepared from a mixture of the following:
3000 grams of mason sand (ASTM C-144) 1000 grams of Type 1 cement (ASTM C-150) and 231 grams of water.
The cement composition was mixed and poured into a plurality of cup shaped molds, each having a diameter of
3.92 inches or an equivalent surface area of 12.07 square inches. The cup shaped molds, with the cement mixture therein, were inverted onto a closed cell, generally smooth--skinned polystyrene foam backing and the cement was allowed to set and cure thereon. After 24 hours, the cement was sufficiently cured so that the molds could be lOS5270 removed leaving a disc-shaped cement block adhered to the foam backing. The cement was then allowed to cure for another 6 days. A load was applied to the composite disc-shaped block and gradually increased until a separation of the cement block from the foam backing was obtained.
The load obtained at separation of the cement block from the foam backing was recorded and readily converted into pounds per square inch. The following results were obtained:
TABLE I
Total LoadLoad (in pounds Test No. (in pounds)per square inch) 1 32 2.65 2 28 2.31 3 31.5 2.61
The load obtained at separation of the cement block from the foam backing was recorded and readily converted into pounds per square inch. The following results were obtained:
TABLE I
Total LoadLoad (in pounds Test No. (in pounds)per square inch) 1 32 2.65 2 28 2.31 3 31.5 2.61
4 31 2.54 An average load of 2.54 pounds per square inch was obtained in this test series attesting to the low bonding strength between the cement blocks and their foam backings.
Example la A series of tests, similar to the tests in Example 1 were conducted with a cement composition comprising a mixture of the following:
30 pounds of mason cement (ASTM C-144) 10 pounds of Peereless Type I cement ~ASTM C-150) and 5.1 pounds of water.
A load was applied to each of a plurality of cement blocks of this composition adhered to their respective foam backing. The following results were obtained:
lOS5Z70 TABLE Ia Total Load Load (in pounds Test No. (in pounds)per square inch) 1 27 2.24 2 29.5 2.44 3 20.5 1.70 An average load of only 2.13 pounds per square inch was obtained in this test series again attesting to the low bonding strength of a cement block when adhered to a smooth-skinned STYROFOAM backing without the benefit of a styrene-butadiene copolymer latex as a cement modifier or primer coating on the foam board.
Example 2 The tests conducted with the cement composition of Example la were repeated except that the smooth-skinned closed cell plastic foam board was first provided with a substantially continuous primer coating of the styrene--butadiene-1,3 copolymer latex described herein (but absent the polyorganosiloxane foam depressant). The cement com-position was allowed to cure on the primer coated foam board for 7 days. The following load test results were recorded:
TABLE II
Total Load Load (in pounds Test No. (in pounds)per square inch) 1 153 12.7 2 100 8.3 3 253 21.0 4 163 13.5 250 20.7 lOSSZ70 An average load of 15.2 pounds per square inch was obtained in this test series indicating a substantial improvement in the load capacity obtained with the specified latex primer coating between a foam backing and a cement molding.
Example 3 A series of tests with the cement composition of Example la were conducted except that the cement composition was modified with a 15%, by weight, styrene-butadiene-1,3 copolymer latex of the composition described herein (including the polyorganosiloxane foam depressant). The latex composi-tion being calculated on a latex solids content of 48% with respect to the cement. The latex modified cement composition contained the following amounts:
30 pounds mason sand 10 pounds Peereless Type I cement 3,19 pounds of the styrene-butadiene-1,3 copolymer latex (48% solids) 2.13 pounds of water.
The following load test results were recorded:
TABLE III
Total Load Load (in pounds Test No. (in pounds)per square inch) 1 305 25.26 2 110 9.11 3 213 17.65 4 240 19.88 220 18.22 An average load of 18.0 pounds per square inch was obtained in this test series attesting to a further improvement in bonding strength obtained with the latex modified cement as compared to the test series conducted in Example 2.
111~55~70 Example 4 A series of tests were conducted with the same latex modified cement mixture of Example 3 with the further proviso that the foam board was first provided with a sub-stantially continuous coating of the styrene-butadiene-1,3 copolymer latex binder (without the polyorganosiloxane foam depressant). The cement composition was allowed to cure simultaneously with the primer coating for 7 days. The following results were recorded.
TABLE IV
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 340 28.2 2 340 28.2 3 358 29.7 4 357 29.6 340 28.2 An average load of 28.8 pounds per square inch was obtained before separation of the foam board from the cement blocks occurred. The load results are much superior to the test results of Examples 2 and 3 and also indicate a high degree of consistency. This consistency is ascribed to the fact that the load figures approach the tensile strength of the foam backing itself. Separation between each concrete block and foam backing was not always observed to be a clean separation between the two members but often resulted in breakage of the foam backing rather than separation at the interface between the concrete block and backing.
Example 5 A further test series was conducted using a 7 1/2~, by weight, of the styrene-butadiene latex binder `~ in the cement mixture of Example 3. Thus, the cement mixture contained the following amounts:
30 pounds mason sand 10 pounds Peereless Type I cement 723.5 grams of the styrene-butadiene-1,3 copolymer latex (48~ solids) and 1650 grams of water.
The following results were recorded:
TABLE V
Total LoadLoad (in pounds Test No. (in pounds)per s~uare inch) 1 43 3.56 2 80 6.62 3 13 1.07 4 25 2.07 48 3.98 An average load of 3.46 pounds per square inch was obtained which indicated that the use of about 1/2 of the amount of the latex binder in the cement composition was substantially less effective than the results obtained with the 15~, by weight, latex modified cement composition of Example 3.
Example 6 The test series of Example 5 was repeated except that the foam board was first provided with a substantially con-tinuous coating of the styrene-butadiene-1,3 copolymer latex binder and allowed to cure with the cement composition for 7 days. The following results were recorded:
TABLE VI
Total LoadLoad (in pounds Test No. (in pounds)per square inch) 1 180 14.9 2 165 13.7 3 215 17.8 4 175 14.5 213 17.6 An average load of 15.7 pounds per square inch was obtained which indicates a substantial improvement over the unprimed foam board of Example 5. The results also indicate that substantially better results are obtained with the 15%, by weight, latex modified cement of Example 4.
Example 7 Molded cement blocks were prepared in accordance with the procedure of Example 1. The cement blocks were prepared from an admixture of the following:
3000 grams of mason sand 1000 grams of Type I cement and 510 grams of water.
The foam board was provided with a plurality of indentations by means of a plurality of 1/8 inch diameter brass pins mounted in a staggered relationship on a plate having a surface area of 64 square inches. With 98 pins being provided on the plate, a total pin area of 1.2 square inches was calculated. With this arrangement 21 impressions or indentations were made in a 12.07 square inch surface area of the foam backing covered by the circular cement block. The depth of the indentations into the foam board was held to 0.085 inches. The following results were recorded:
lOSSZ70 TABLE VII
Total LoadLoad (in pounds Test No. (in pounds)per square inch) 1 19.8 1.6 2 ` 45 3.7 3 16 1.3 4 8 0.6 An average of only 1.8 pounds per square inch was obtained in this test series with a perforated indented foam board. The test did not show any improvement over the results obtained in the test of Example 1, even though an increase in the bonding of the cement block to the foam board could reasonably have been expected due to the provisions of the indentations in the foam board.
Example 8 A series of tests similar to the test of Example 7 were conducted except that the foam board was first provided with a substantially continuous coating of the styrene--butadiene-1,3 copolymer latex binder (without the foam depressant). The same number of indentations having first been applied to the foam board to an average depth of about 0.085 in. The following results were recorded:
TABLE VIII
Total Load Load (in pounds Test No. (in pounds)per square inch) 1 112 9.3 2 99 8.2 3 131 10.8 4 97 8.0 107 8.9 lS~SSZ70 An average load of 9.1 pounds per square inch was obtained which indicated a substantial improvement in the load capacity over the tests conducted in Example 7.
Surprisingly, the primed perforated foam board did not show any improvement over the primed but unperforated foam board of Example 2.
Example 9 A latex modified cement mixture was prepared in accordance with Example 5. The foam board was provided with indentations as in Example 7. However, the indentations were only applied to an average depth of 0.034 inch. The following test results were recorded.
TABLE IX
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 70 5.80 2 55 4.56 3 63 5.22 4 50 4.14 4.14 An average load of 4.77 pounds per square inch was obtained which indicated a slight improvement over the unperforated board of Example 5.
Example 10 Example 9 was repeated'except that the foam board was first provided with a substantially continuous coating of the styrene-butadiene-1,3 copolymer latex binder (without the foam depressant). The following results were recorded:
-2~-1~55~70 TABLE X
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 170 14.1 2 248 20.5 3 225 18.6 4 178 14.7 165 13.7 An average load of 16.3 pounds per square inch was obtained which indicates a substantial improvement in the load capacity over the unprimed foam board of Example 9.
Example 11 A series of tests were conducted in which latex modified cement moldings were prepared from the following admixture:
3000 grams of mason sand 1000 grams of Type I cement 319 grams of the styrene-butadiene-1,3 copolymer latex (48% solids) and 287 grams of water.
The admixture contained 15%, by weight latex solids in the cement. A closed cell generally smooth-skinned polystyrene foam board was provided with indentations to a depth of 0.85 in. substantially by the same procedure as in Example 7. The foam backing was not provided, however, with a latex primer coating. The following test results were recorded:
~ -29-1055~70 TABLE XI
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 293 24.3 2 390 32.3 3 237 19.6 4 293 24.3 267 22.1 An average load of 24.5 pounds per square inch was obtained, indicating a substantial improvement over the tests conducted with the unperforated foam board of Example 3.
Example 12 A final series of tests were conducted similar to the tests of Example 11 except that the foam board was also provided with a substantially continuous coating of the styrene-butadiene-1,3 copolymer latex binder. The following results were recorded:
TABLE XII
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 365 30.2 2 317 26.3 3 332 27.5 4 372 30.8 370 30.6 An average load of 29.1 pounds per square inch was obtained indicating a slightly better performance over the 15%, by weight, latex modified cement moldings and primer coated foam board (but unperforated foam board) given in Example 4.
~55Z'70 All of the foregoing tests were conducted at a temperature of 73F and 50% relative humidity in a con-stant temperature room. In each instance, the mold was removed after 24 hours and after the cement had set to allow for an even curing of the cement blocks for an additional 6 days.
Although slight improvements only are obtained with the tests of Example 12 over the tests conducted in Example 4, they do not in any way detract from the desira-bility of providing the foam boards with indentations since they provide substantial lateral support for the cement layer.
As is apparent from the foregoing specification, the present invention is susceptible of being embodied with various alterations and modification which may differ particularly from those that have been described in the preceding specification and description. For this reason, it is to be fully understood that all of the foregoing is intended to be merely illustrative and is not to be construed or interpreted as being restrictive or otherwise limiting of the present invention, excepting as it is set forth and defined in the hereto appended claims.
Example la A series of tests, similar to the tests in Example 1 were conducted with a cement composition comprising a mixture of the following:
30 pounds of mason cement (ASTM C-144) 10 pounds of Peereless Type I cement ~ASTM C-150) and 5.1 pounds of water.
A load was applied to each of a plurality of cement blocks of this composition adhered to their respective foam backing. The following results were obtained:
lOS5Z70 TABLE Ia Total Load Load (in pounds Test No. (in pounds)per square inch) 1 27 2.24 2 29.5 2.44 3 20.5 1.70 An average load of only 2.13 pounds per square inch was obtained in this test series again attesting to the low bonding strength of a cement block when adhered to a smooth-skinned STYROFOAM backing without the benefit of a styrene-butadiene copolymer latex as a cement modifier or primer coating on the foam board.
Example 2 The tests conducted with the cement composition of Example la were repeated except that the smooth-skinned closed cell plastic foam board was first provided with a substantially continuous primer coating of the styrene--butadiene-1,3 copolymer latex described herein (but absent the polyorganosiloxane foam depressant). The cement com-position was allowed to cure on the primer coated foam board for 7 days. The following load test results were recorded:
TABLE II
Total Load Load (in pounds Test No. (in pounds)per square inch) 1 153 12.7 2 100 8.3 3 253 21.0 4 163 13.5 250 20.7 lOSSZ70 An average load of 15.2 pounds per square inch was obtained in this test series indicating a substantial improvement in the load capacity obtained with the specified latex primer coating between a foam backing and a cement molding.
Example 3 A series of tests with the cement composition of Example la were conducted except that the cement composition was modified with a 15%, by weight, styrene-butadiene-1,3 copolymer latex of the composition described herein (including the polyorganosiloxane foam depressant). The latex composi-tion being calculated on a latex solids content of 48% with respect to the cement. The latex modified cement composition contained the following amounts:
30 pounds mason sand 10 pounds Peereless Type I cement 3,19 pounds of the styrene-butadiene-1,3 copolymer latex (48% solids) 2.13 pounds of water.
The following load test results were recorded:
TABLE III
Total Load Load (in pounds Test No. (in pounds)per square inch) 1 305 25.26 2 110 9.11 3 213 17.65 4 240 19.88 220 18.22 An average load of 18.0 pounds per square inch was obtained in this test series attesting to a further improvement in bonding strength obtained with the latex modified cement as compared to the test series conducted in Example 2.
111~55~70 Example 4 A series of tests were conducted with the same latex modified cement mixture of Example 3 with the further proviso that the foam board was first provided with a sub-stantially continuous coating of the styrene-butadiene-1,3 copolymer latex binder (without the polyorganosiloxane foam depressant). The cement composition was allowed to cure simultaneously with the primer coating for 7 days. The following results were recorded.
TABLE IV
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 340 28.2 2 340 28.2 3 358 29.7 4 357 29.6 340 28.2 An average load of 28.8 pounds per square inch was obtained before separation of the foam board from the cement blocks occurred. The load results are much superior to the test results of Examples 2 and 3 and also indicate a high degree of consistency. This consistency is ascribed to the fact that the load figures approach the tensile strength of the foam backing itself. Separation between each concrete block and foam backing was not always observed to be a clean separation between the two members but often resulted in breakage of the foam backing rather than separation at the interface between the concrete block and backing.
Example 5 A further test series was conducted using a 7 1/2~, by weight, of the styrene-butadiene latex binder `~ in the cement mixture of Example 3. Thus, the cement mixture contained the following amounts:
30 pounds mason sand 10 pounds Peereless Type I cement 723.5 grams of the styrene-butadiene-1,3 copolymer latex (48~ solids) and 1650 grams of water.
The following results were recorded:
TABLE V
Total LoadLoad (in pounds Test No. (in pounds)per s~uare inch) 1 43 3.56 2 80 6.62 3 13 1.07 4 25 2.07 48 3.98 An average load of 3.46 pounds per square inch was obtained which indicated that the use of about 1/2 of the amount of the latex binder in the cement composition was substantially less effective than the results obtained with the 15~, by weight, latex modified cement composition of Example 3.
Example 6 The test series of Example 5 was repeated except that the foam board was first provided with a substantially con-tinuous coating of the styrene-butadiene-1,3 copolymer latex binder and allowed to cure with the cement composition for 7 days. The following results were recorded:
TABLE VI
Total LoadLoad (in pounds Test No. (in pounds)per square inch) 1 180 14.9 2 165 13.7 3 215 17.8 4 175 14.5 213 17.6 An average load of 15.7 pounds per square inch was obtained which indicates a substantial improvement over the unprimed foam board of Example 5. The results also indicate that substantially better results are obtained with the 15%, by weight, latex modified cement of Example 4.
Example 7 Molded cement blocks were prepared in accordance with the procedure of Example 1. The cement blocks were prepared from an admixture of the following:
3000 grams of mason sand 1000 grams of Type I cement and 510 grams of water.
The foam board was provided with a plurality of indentations by means of a plurality of 1/8 inch diameter brass pins mounted in a staggered relationship on a plate having a surface area of 64 square inches. With 98 pins being provided on the plate, a total pin area of 1.2 square inches was calculated. With this arrangement 21 impressions or indentations were made in a 12.07 square inch surface area of the foam backing covered by the circular cement block. The depth of the indentations into the foam board was held to 0.085 inches. The following results were recorded:
lOSSZ70 TABLE VII
Total LoadLoad (in pounds Test No. (in pounds)per square inch) 1 19.8 1.6 2 ` 45 3.7 3 16 1.3 4 8 0.6 An average of only 1.8 pounds per square inch was obtained in this test series with a perforated indented foam board. The test did not show any improvement over the results obtained in the test of Example 1, even though an increase in the bonding of the cement block to the foam board could reasonably have been expected due to the provisions of the indentations in the foam board.
Example 8 A series of tests similar to the test of Example 7 were conducted except that the foam board was first provided with a substantially continuous coating of the styrene--butadiene-1,3 copolymer latex binder (without the foam depressant). The same number of indentations having first been applied to the foam board to an average depth of about 0.085 in. The following results were recorded:
TABLE VIII
Total Load Load (in pounds Test No. (in pounds)per square inch) 1 112 9.3 2 99 8.2 3 131 10.8 4 97 8.0 107 8.9 lS~SSZ70 An average load of 9.1 pounds per square inch was obtained which indicated a substantial improvement in the load capacity over the tests conducted in Example 7.
Surprisingly, the primed perforated foam board did not show any improvement over the primed but unperforated foam board of Example 2.
Example 9 A latex modified cement mixture was prepared in accordance with Example 5. The foam board was provided with indentations as in Example 7. However, the indentations were only applied to an average depth of 0.034 inch. The following test results were recorded.
TABLE IX
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 70 5.80 2 55 4.56 3 63 5.22 4 50 4.14 4.14 An average load of 4.77 pounds per square inch was obtained which indicated a slight improvement over the unperforated board of Example 5.
Example 10 Example 9 was repeated'except that the foam board was first provided with a substantially continuous coating of the styrene-butadiene-1,3 copolymer latex binder (without the foam depressant). The following results were recorded:
-2~-1~55~70 TABLE X
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 170 14.1 2 248 20.5 3 225 18.6 4 178 14.7 165 13.7 An average load of 16.3 pounds per square inch was obtained which indicates a substantial improvement in the load capacity over the unprimed foam board of Example 9.
Example 11 A series of tests were conducted in which latex modified cement moldings were prepared from the following admixture:
3000 grams of mason sand 1000 grams of Type I cement 319 grams of the styrene-butadiene-1,3 copolymer latex (48% solids) and 287 grams of water.
The admixture contained 15%, by weight latex solids in the cement. A closed cell generally smooth-skinned polystyrene foam board was provided with indentations to a depth of 0.85 in. substantially by the same procedure as in Example 7. The foam backing was not provided, however, with a latex primer coating. The following test results were recorded:
~ -29-1055~70 TABLE XI
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 293 24.3 2 390 32.3 3 237 19.6 4 293 24.3 267 22.1 An average load of 24.5 pounds per square inch was obtained, indicating a substantial improvement over the tests conducted with the unperforated foam board of Example 3.
Example 12 A final series of tests were conducted similar to the tests of Example 11 except that the foam board was also provided with a substantially continuous coating of the styrene-butadiene-1,3 copolymer latex binder. The following results were recorded:
TABLE XII
Total Load Load (in pounds Test No. (in pounds) per square inch) 1 365 30.2 2 317 26.3 3 332 27.5 4 372 30.8 370 30.6 An average load of 29.1 pounds per square inch was obtained indicating a slightly better performance over the 15%, by weight, latex modified cement moldings and primer coated foam board (but unperforated foam board) given in Example 4.
~55Z'70 All of the foregoing tests were conducted at a temperature of 73F and 50% relative humidity in a con-stant temperature room. In each instance, the mold was removed after 24 hours and after the cement had set to allow for an even curing of the cement blocks for an additional 6 days.
Although slight improvements only are obtained with the tests of Example 12 over the tests conducted in Example 4, they do not in any way detract from the desira-bility of providing the foam boards with indentations since they provide substantial lateral support for the cement layer.
As is apparent from the foregoing specification, the present invention is susceptible of being embodied with various alterations and modification which may differ particularly from those that have been described in the preceding specification and description. For this reason, it is to be fully understood that all of the foregoing is intended to be merely illustrative and is not to be construed or interpreted as being restrictive or otherwise limiting of the present invention, excepting as it is set forth and defined in the hereto appended claims.
Claims (18)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A composite building panel comprising a main body portion of a closed cell, generally smooth-skinned foam material having adhered along at least one surface thereof a protective cementitious facing material con-sisting essentially of an admixture of portland cement, mineral aggregate and from 5 to 25 percent based on the weight of said cement of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of 30:70 to 70:30, water in amount of from 25 to 65 percent based on the weight of said cement, and based on the weight of said copolymer, (a) from 2 to 10 percent of non-ionic surfactant, (b) from 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is a sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of 0.7:1 to 10:1.
2. The building panel of Claim 1 wherein said foam material is a styrene polymer foam.
3. The building panel of Claim 1, wherein a surface of said foam material adjacent said cementitious material contains one or more regions having indentations therein, said indentations ultimately containing a portion of said facing material.
4. A building panel comprising a main body portion of a closed cell, generally smooth skinned styrene polymer foam material having a surface containing one or more regions having indentations therein, said surface having applied thereto a substantially continuous binder coating of a styrene-butadiene copolymer latex consisting essentially of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is sodium alkyl sulfate in which the alkyl groups contain 9 to 17 carbon atoms, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1, and adhered to said binder coating a protective cementitious facing material, a portion of which is contained in said indentations, said facing material consisting essentially of an admixture of portland cement, mineral aggregate and from about 5 to about 25 percent based on the weight of said cement of a styrene-butadiene-1,3 copolymer having a styrene to buta-diene weight ratio of about 30:70 to 70:30, water in amount of from about 25 to 65 percent based on the weight of said cement, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 per-cent of which is a sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from about 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyogranosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1.
5. The building panel of Claim 4 wherein the indentations in said foam are undercut indentations which are generally in the shape of a trapezoid with the short parallel side of the indentations opening at the foam surface.
6. The building panel of Claim 4 wherein the non--ionic surfactant in said cementitious material is di-t-butyl--phenoxynonaoxyethylene-ethanol, the anionic surfactant com-prises a mixture of an alkyl aryl sulfonate and a sodium alkyl sulfate and the polyorganosiloxane foam depressant is poly-methylsiloxane.
7. The building panel of Claim 6 wherein the alkyl aryl sulfonate is dodecylbenzene sodium sulfonate, and the sodium alkyl sulfate is sodium lauryl sulfate.
8. The building panel of Claim 4 wherein the copolymer in said cementitious material is a copolymer of about 66 percent styrene and about 34 percent butadiene.
9. The building panel of Claim 4 wherein the port-land cement is a shrinkage compensating cement.
10. The building panel of Claim 4 wherein the cemen-titious material contains sufficient reinforcement to provide restraint against expansion.
11. The building panel of Claim 10 wherein the reinforcement is alkali resistant glass fibers.
12. A process for promoting the adhesion of the cementitious material to the surface of the foam material to form the building panel of Claim 1, said process comprising the sequential steps of (1) applying to said foam material surface a substantially continuous coating of a thermoplastic styrene-butadiene copolymer latex consisting essentially of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is sodium alkyl sulfate in which the alkyl groups contain from 9 to 17 carbon atoms, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1, (2) applying the cementitious material to the coated surface prior to substantial dehydration of said coating, and (3) allowing said cementitious material to harden.
13. The process of Claim 12, including the step of providing in said foam surface a plurality of indentations.
14. The process of Claim 13 wherein said cementi-tious material is a shrinkage compensating portland cement protective covering and said foam material is a styrene polymer foam material, including the step of vibrating the portland cement after application to the coated foam surface as a means of seating a portion of such protective covering within said indentations.
15. A roof structure consisting essentially of a roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck supporting a water or vapor impermeable membrane, the impermeable membrane having an upper face and a lower face being generally adjacent the roof deck, and a plurality of the building panels of Claim 1 disposed adjacent the upper face of the water impermeable membrane, said plurality of panel members defining fissures between adjacent members, and wherein the surface of said foam insulating layer adja-cent said cementitious protective layer contains a plurality of individual indentations therein, said indentations con-taining a portion of said cementitious protective layer.
16. The roof structure according to Claim 15, wherein said protective layer comprises an admixture of a shrinkage compensating cement containing alkali resistant glass fiber reinforcement mineral aggregate.
17. The roof structure of Claim 16, wherein the surface of said foam insulating layer is coated prior to application thereto of said cementitious protective layer, with a substantially continuous coating of the styrene--butadiene copolymer latex consisting essentially of a styrene-butadiene-1,3 copolymer having a styrene to buta-diene weight ratio of about 30:70 to 70:30, and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is sodium alkyl sulfate in which the alkyl groups con-tain 9 to 17 carbon atoms, the sum of (a) and (b) not exceed-ing about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0.7:1 to 10:1.
18. A roof structure consisting essentially of a roof support means having a roof deck, the roof deck having an upper surface and a lower surface, the upper surface of the roof deck supporting a water or vapor impermeable mem-brane, the impermeable membrane having an upper face and a lower face being generally adjacent the roof deck, a closed cell generally smooth skinned water impermeable styrene polymer foam insulating layer disposed adjacent the upper face of the water impermeable membrane, said insulating layer comprising a plurality of insulating members said members defining fissures between adjacent members, and a protective layer of an inorganic material disposed on the surface of the insulating members remote from the roof deck, the improve-ment consisting of (1) utilizing as said protective layer an admixture of a portland cement, mineral aggregate, from about 5 to about 25 percent based on the weight of said cement of a styrene-butadiene-1,3 copolymer having a styrene to butadiene weight ratio of about 30:70 to 70:30, water in amount of from about 25 to about 65 percent based on the weight of said cement; and based on the weight of said copolymer, (a) from about 2 to about 10 percent of non-ionic surfactant, (b) from about 0.75 to 7.5 percent of anionic surfactant, at least about 15 percent of which is sodium alkyl sulfate in which the alkyl group contains 9 to 17 carbon atoms, and (c) from about 0.1 to 5 percent of a polyorganosiloxane foam depressant based on the weight of active polyorganosiloxane, the sum of (a) and (b) not exceeding about 11 percent by weight of said copolymer and the weight ratio of (a) to (b) being within the range of about 0,7:1 to 10:1, and (2) wherein the surface of said insulating layer adjacent said protective layer contains a plurality of individual indenta-tions therein, said indentations containing a portion of said protective layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| ES504306A ES504306A0 (en) | 1976-09-20 | 1981-07-27 | A PROCEDURE TO MANUFACTURE A COMPOSITE PANEL FOR BUILDING. |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US61733275A | 1975-09-24 | 1975-09-24 | |
| US05/617,333 US4054691A (en) | 1975-09-24 | 1975-09-24 | Process for promoting the adhesion of cementitious material to closed cell generally smooth skinned foam materials |
| US05/617,334 US4067164A (en) | 1975-09-24 | 1975-09-24 | Composite panels for building constructions |
| US67963776A | 1976-04-22 | 1976-04-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1055270A true CA1055270A (en) | 1979-05-29 |
Family
ID=27505139
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA261,568A Expired CA1055270A (en) | 1975-09-24 | 1976-09-20 | Composite panel structure for building constructions and process for preparing the panel structure |
Country Status (4)
| Country | Link |
|---|---|
| JP (1) | JPS6025265B2 (en) |
| AU (1) | AU498305B2 (en) |
| BE (1) | BE889818Q (en) |
| CA (1) | CA1055270A (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS6090749A (en) * | 1983-10-25 | 1985-05-21 | 積水化成品工業株式会社 | Manufacture of flame-retarded synthetic resin foam |
| JPS60154125U (en) * | 1984-03-26 | 1985-10-14 | 松元 重徳 | Cement composite board using styrofoam board as core material |
| US4559263A (en) * | 1985-02-11 | 1985-12-17 | The Dow Chemical Company | Cement-foam composite board |
-
1976
- 1976-09-16 AU AU17844/76A patent/AU498305B2/en not_active Expired
- 1976-09-20 CA CA261,568A patent/CA1055270A/en not_active Expired
- 1976-09-24 JP JP51114578A patent/JPS6025265B2/en not_active Expired
-
1981
- 1981-07-31 BE BE0/205549A patent/BE889818Q/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| AU498305B2 (en) | 1979-03-01 |
| JPS6025265B2 (en) | 1985-06-17 |
| JPS5259621A (en) | 1977-05-17 |
| BE889818Q (en) | 1982-02-01 |
| AU1784476A (en) | 1978-03-23 |
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