CA2006970A1 - Flame retardant asphalt coating - Google Patents
Flame retardant asphalt coatingInfo
- Publication number
- CA2006970A1 CA2006970A1 CA002006970A CA2006970A CA2006970A1 CA 2006970 A1 CA2006970 A1 CA 2006970A1 CA 002006970 A CA002006970 A CA 002006970A CA 2006970 A CA2006970 A CA 2006970A CA 2006970 A1 CA2006970 A1 CA 2006970A1
- Authority
- CA
- Canada
- Prior art keywords
- cut
- asphaltic
- type base
- additive
- weight
- 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.)
- Abandoned
Links
Landscapes
- Paints Or Removers (AREA)
- Compositions Of Macromolecular Compounds (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
The invention features an additive for a mastic coating comprising a cut-back asphaltic base material used in roof and construction applications. The additive comprising sodium bicarbonate in a range by weight of between 2 and 8 parts per 1 part of the cut-back, asphaltic-type base material, has the dual purpose of accelerating the curing time and improving flame retardancy of the mastic coating.
The invention features an additive for a mastic coating comprising a cut-back asphaltic base material used in roof and construction applications. The additive comprising sodium bicarbonate in a range by weight of between 2 and 8 parts per 1 part of the cut-back, asphaltic-type base material, has the dual purpose of accelerating the curing time and improving flame retardancy of the mastic coating.
Description
2ai0697() FI~ME RETARDANT ASPH~L~ COATING
Field of the Invention The invention relates to mastic coatings ~or roofing and highway construction, and more particularly to a flame retardant asphalt coating for built-up-roofing applications.
BACKGROUND OF THE INVENTION
Cut-back asphalts are in current use as mastic coatings for highway construction and built-up-roofing tBUR) applications. Such cut-back asphalts are usually prepared by adding mineral spirits ~naphtha) to an asphaltic base.
Used as a mastic coating ~or insulating and weather-proofing roof membranes, these cut-back asphalts have several advantages, one of which is the ease of application~
They are usually mopped or sprayed in a cold (ambient) state over roof membranes, and then allowed to dry. An additional layer o~ granules or qravel can be applied over the mastic-coated membrane to provide protection ~rom heat and ultraviolet radiation, as taught in U.S. Patent No.
4,521,478; issued: June 4, 1985 to John P. Hageman.
Docket No. H-117 - 1 -, .' , . .
..... . ~
~ .
, ,, , ,,, ~" . ,, ,,",,, 200697(~
While cut-back asphalts have gained commercial acceptance in roofing applications and construction, they have not achieved their complete potential dua to several drawbacks and disadvantages, such as:
1. Cut-back asphalts remain tacky from 3 to 4 weeks after application, causing considerable delays in completion of the construction project. Roofs cannot be walked upon and inspected until the asphalt is dry.
Field of the Invention The invention relates to mastic coatings ~or roofing and highway construction, and more particularly to a flame retardant asphalt coating for built-up-roofing applications.
BACKGROUND OF THE INVENTION
Cut-back asphalts are in current use as mastic coatings for highway construction and built-up-roofing tBUR) applications. Such cut-back asphalts are usually prepared by adding mineral spirits ~naphtha) to an asphaltic base.
Used as a mastic coating ~or insulating and weather-proofing roof membranes, these cut-back asphalts have several advantages, one of which is the ease of application~
They are usually mopped or sprayed in a cold (ambient) state over roof membranes, and then allowed to dry. An additional layer o~ granules or qravel can be applied over the mastic-coated membrane to provide protection ~rom heat and ultraviolet radiation, as taught in U.S. Patent No.
4,521,478; issued: June 4, 1985 to John P. Hageman.
Docket No. H-117 - 1 -, .' , . .
..... . ~
~ .
, ,, , ,,, ~" . ,, ,,",,, 200697(~
While cut-back asphalts have gained commercial acceptance in roofing applications and construction, they have not achieved their complete potential dua to several drawbacks and disadvantages, such as:
1. Cut-back asphalts remain tacky from 3 to 4 weeks after application, causing considerable delays in completion of the construction project. Roofs cannot be walked upon and inspected until the asphalt is dry.
2. Cut-back asphalts present a dangerou~ fire hazard because of their highly flammable nature. Cut-back asphalts have a low flash point of approximately 50 degrees F. ~open cup~
.~ ,. :! :
In ordér to decrease the ~lammability of the asphalt, flame retardant ~illers such as asbestos have been utilized.
However, asbestos has been coming into increasing disrepute as a carcinogen, and its use in the building trades is on the wane. In addition, asbestos does nothing to improve the ~ -, drying characteristics of the asphalt, and is also a fairly expensive component.
,,.~ , . '' .
Docket No. ~-117 - 2 -~ , ~06970 The invention seeks to provide an asphalt additive which retards flammability, and is inexpensive.
The invention also ha~ as one of its objectives to provide an additive which will decrease the drying time of the mastic coat.
SUMMARY OF THE INVENTION
The invenkion features an additive for a mastic coating, which has flame retardant capabilities. Mastic coatings which are the concern of~this invention comprise a base of asphalt, coal tar or bitumen that is made more li~uefiable and free-flowing by fluxing with suitable distillates, such as mineral spirits (naphtha).
The mastic coating of the invention generally features the cut-back asphaltic base combined with a sodium bicarbonate (bicarbonate of soda) additive in a range of ratios of between 8:1 and 2:1 parts by weight.
~,~
The sodium bicarbonate (NaHCO2) when mixed with a cut-back asphalt produces a mastic coating with excellent flame retardancy.
:, ' ' ' ', ? Docket No. H-117 - 3 -. . .
.I~r ,, r ~
:' , , '; . ~' ~ .. "' ":
`' ': , , ;~
In addition, the use of the sodium bicarbonate accelerates the curing time of the coating, such that the mastic will dry in approximately 1/4 to 1/3 of the normal curing time.
One other une~pected result of using this additive is its ability to make the cut-back asphalt thixotropic in the uncured state, i.e., the coating fills-in depressions in the roof surface when it is wet, and upon drying provides a more level and uniform coated surface.
.. ~ ' In addition to the sodium bicarbonate, the ~lame retardant additive may also comprise between 5% and 15%
antimony trioxide by weight.
.
' DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
.,', '' . :' ' Generally speaking, the invention pertains to mastic coatings for use in highway and roo~ing construction. The ................................................................. .
mastic coating comprises an asphaltic base, which can contain either asphalt, coal tar or bitumen that has been cut-back with appropriate distillates, such as mineral spirits (naphtha).
.' . ' .
Docket No. H-lI7 - 4 -. ~ :. .
. .
", , r~
: ;~()0~97~
Mastic coatings of the type mentioned herein can be purchased from the Karnak Chemical Company of Clark, New Jersey; Tremco of Cleveland, Ohio; and Gardner Asphalt Company of Hoboken, New Jersey, to name a few.
In their commercial state, such mastic coatings are highly flammable, and provide appropriate ~warnings of the fire hazard when purchased.
The invention seeks to reduce the flammability of the mastic coatings by the addition of powdered sodium bicarbonate (NiaHCO2). The sodium bicarbonate is purchased in commercial or U~S.P. grade from any one of a number of companies, such as: Fluka Chemical Corporation of Ronkonkoma, New York; or Church and Dwight Company, Incorporated of New York, New York.
The powdered sodium bicarbonate is added in a range o~
ratios from 1 gallon (8 lbs) of mas~ic to 1 lb of NaHCO2;
~:i and 1/~ gallon (2 lbs) of mastic to l lb of NaHCO2.
The sodium bicarbonate is added to the mastic and blended therewith by stirring ~or approximately 10 to 15 minut2s at a low speed of 5 to lO r.p.m. in an appropriate sized vat.
, Docket No. H-117 - 5 -'' ' '' ~ ..
. : . ; . ~,: .
-, ., ,. . ~ , ~ .. .
~ 2t)0~970 ~
The mastic mixture is then spray or mop coated over a roof membrane or other suitable surface and allowed to dry.
.- :,.. ~ .
Normally, the mastic has a drying time of approximately 3 to 4 weeks before it can be inspected or walked upon.
': ' One of the unexpected results of using the sodium bicarbonate as a flame retardant in admixture, was the discovery that the curing time of the coating was accelerated, such that a typical coating layer cured in approximately 5 to 7 days.
. ;' ~, Another unexpected result of the aforementioned admixture was the observation that the coating developed a thixotropic character when spread upon the work sureace.
The admixture was noticed to fill-in the depressions and void areas, thus providing a more uniform and even surface.
Exam~le 1:
,.!
~- To a gallon of cut-back, asbestos-filled asphalt, 1 .
pound of powdered sodium bicarbonate was added. The mixture was stirred for 15 minutes at 10 r.p.m. to provide a uniform :~ .
blend. The admixture was then coated upon a roof surface and allow0d to cure for 1 week. , Docket No. H-117 - 6 -.,~ : , '~f ~`'' `' .,. , ~' ,.
, ~ 2al~970 .
When the admixture was dry, the coated surface was uniformly heated to incandescency by a blow torch for several minutes.
It was observed that the mastic coatillg did not burn, and a red hot, intumescent layer was formed on the surface of the coating. Also observed was the release of carbon dioxide which bubbled the asphalt into the aforementioned intumescent tchar) layer. The release of the carbon dioxide quickly extinguished any flames before they could spread over the surface of the coating.
.. .. . .
Example 2:
The experiment of Example 1 was repeated using an admixture of 1 gallon of cut-back asphalt to 2 pounds of powdered sodium bicarbonate.
The same result was observed upon torching the cured coating with the further observation of an enhanced abilLty to extinguish the spread o~ the flames.
Example 3:
., .
.
Docket No. H-117 - 7 -: ~"
_,. ..... ~, - ' ' ~ ' , '~ ' -~, ' ' ' ' ' ' ~ ' ,' ` : .
200697~
The experiment of Example 2 was repeated using an admixture o 1 gallon of cut-back asphalt and between 3 to 4 lbs of powdered sodium bicarbonate.
The same results were observed with a still greater enhancement of the flame retardancy characteristic.
It is contemplated by this invention that the sodium ~ - -bicarbonate can be used as a supplemental filler to improve the flame retardancy of asbestos filled, cut-back asphalt, ;
or preferably as an additive without the use o~ asbestos.
.: .
It is further contemplated that small amounts o~
antimony trioxide, of approximately between 5~ to 15% by weight be additionally added to the admixture.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered lim.ited to the examples chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
~', .
' Docket No. ~-117 - 8 -' , ,, . ~, ''
.~ ,. :! :
In ordér to decrease the ~lammability of the asphalt, flame retardant ~illers such as asbestos have been utilized.
However, asbestos has been coming into increasing disrepute as a carcinogen, and its use in the building trades is on the wane. In addition, asbestos does nothing to improve the ~ -, drying characteristics of the asphalt, and is also a fairly expensive component.
,,.~ , . '' .
Docket No. ~-117 - 2 -~ , ~06970 The invention seeks to provide an asphalt additive which retards flammability, and is inexpensive.
The invention also ha~ as one of its objectives to provide an additive which will decrease the drying time of the mastic coat.
SUMMARY OF THE INVENTION
The invenkion features an additive for a mastic coating, which has flame retardant capabilities. Mastic coatings which are the concern of~this invention comprise a base of asphalt, coal tar or bitumen that is made more li~uefiable and free-flowing by fluxing with suitable distillates, such as mineral spirits (naphtha).
The mastic coating of the invention generally features the cut-back asphaltic base combined with a sodium bicarbonate (bicarbonate of soda) additive in a range of ratios of between 8:1 and 2:1 parts by weight.
~,~
The sodium bicarbonate (NaHCO2) when mixed with a cut-back asphalt produces a mastic coating with excellent flame retardancy.
:, ' ' ' ', ? Docket No. H-117 - 3 -. . .
.I~r ,, r ~
:' , , '; . ~' ~ .. "' ":
`' ': , , ;~
In addition, the use of the sodium bicarbonate accelerates the curing time of the coating, such that the mastic will dry in approximately 1/4 to 1/3 of the normal curing time.
One other une~pected result of using this additive is its ability to make the cut-back asphalt thixotropic in the uncured state, i.e., the coating fills-in depressions in the roof surface when it is wet, and upon drying provides a more level and uniform coated surface.
.. ~ ' In addition to the sodium bicarbonate, the ~lame retardant additive may also comprise between 5% and 15%
antimony trioxide by weight.
.
' DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
.,', '' . :' ' Generally speaking, the invention pertains to mastic coatings for use in highway and roo~ing construction. The ................................................................. .
mastic coating comprises an asphaltic base, which can contain either asphalt, coal tar or bitumen that has been cut-back with appropriate distillates, such as mineral spirits (naphtha).
.' . ' .
Docket No. H-lI7 - 4 -. ~ :. .
. .
", , r~
: ;~()0~97~
Mastic coatings of the type mentioned herein can be purchased from the Karnak Chemical Company of Clark, New Jersey; Tremco of Cleveland, Ohio; and Gardner Asphalt Company of Hoboken, New Jersey, to name a few.
In their commercial state, such mastic coatings are highly flammable, and provide appropriate ~warnings of the fire hazard when purchased.
The invention seeks to reduce the flammability of the mastic coatings by the addition of powdered sodium bicarbonate (NiaHCO2). The sodium bicarbonate is purchased in commercial or U~S.P. grade from any one of a number of companies, such as: Fluka Chemical Corporation of Ronkonkoma, New York; or Church and Dwight Company, Incorporated of New York, New York.
The powdered sodium bicarbonate is added in a range o~
ratios from 1 gallon (8 lbs) of mas~ic to 1 lb of NaHCO2;
~:i and 1/~ gallon (2 lbs) of mastic to l lb of NaHCO2.
The sodium bicarbonate is added to the mastic and blended therewith by stirring ~or approximately 10 to 15 minut2s at a low speed of 5 to lO r.p.m. in an appropriate sized vat.
, Docket No. H-117 - 5 -'' ' '' ~ ..
. : . ; . ~,: .
-, ., ,. . ~ , ~ .. .
~ 2t)0~970 ~
The mastic mixture is then spray or mop coated over a roof membrane or other suitable surface and allowed to dry.
.- :,.. ~ .
Normally, the mastic has a drying time of approximately 3 to 4 weeks before it can be inspected or walked upon.
': ' One of the unexpected results of using the sodium bicarbonate as a flame retardant in admixture, was the discovery that the curing time of the coating was accelerated, such that a typical coating layer cured in approximately 5 to 7 days.
. ;' ~, Another unexpected result of the aforementioned admixture was the observation that the coating developed a thixotropic character when spread upon the work sureace.
The admixture was noticed to fill-in the depressions and void areas, thus providing a more uniform and even surface.
Exam~le 1:
,.!
~- To a gallon of cut-back, asbestos-filled asphalt, 1 .
pound of powdered sodium bicarbonate was added. The mixture was stirred for 15 minutes at 10 r.p.m. to provide a uniform :~ .
blend. The admixture was then coated upon a roof surface and allow0d to cure for 1 week. , Docket No. H-117 - 6 -.,~ : , '~f ~`'' `' .,. , ~' ,.
, ~ 2al~970 .
When the admixture was dry, the coated surface was uniformly heated to incandescency by a blow torch for several minutes.
It was observed that the mastic coatillg did not burn, and a red hot, intumescent layer was formed on the surface of the coating. Also observed was the release of carbon dioxide which bubbled the asphalt into the aforementioned intumescent tchar) layer. The release of the carbon dioxide quickly extinguished any flames before they could spread over the surface of the coating.
.. .. . .
Example 2:
The experiment of Example 1 was repeated using an admixture of 1 gallon of cut-back asphalt to 2 pounds of powdered sodium bicarbonate.
The same result was observed upon torching the cured coating with the further observation of an enhanced abilLty to extinguish the spread o~ the flames.
Example 3:
., .
.
Docket No. H-117 - 7 -: ~"
_,. ..... ~, - ' ' ~ ' , '~ ' -~, ' ' ' ' ' ' ~ ' ,' ` : .
200697~
The experiment of Example 2 was repeated using an admixture o 1 gallon of cut-back asphalt and between 3 to 4 lbs of powdered sodium bicarbonate.
The same results were observed with a still greater enhancement of the flame retardancy characteristic.
It is contemplated by this invention that the sodium ~ - -bicarbonate can be used as a supplemental filler to improve the flame retardancy of asbestos filled, cut-back asphalt, ;
or preferably as an additive without the use o~ asbestos.
.: .
It is further contemplated that small amounts o~
antimony trioxide, of approximately between 5~ to 15% by weight be additionally added to the admixture.
Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered lim.ited to the examples chosen for purposes of disclosure, and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.
~', .
' Docket No. ~-117 - 8 -' , ,, . ~, ''
Claims (17)
1. An additive for a mastic coating material useful in roofing and construction, comprising a cut-back, asphaltic-type base, said additive having the dual purpose of providing both an acceleration of curing time and flame retardancy for said mastic coating material, said additive comprising sodium bicarbonate which is added to said mastic coating material in a range of ratios from approximately between 1:8 to about 1:2 parts by weight.
2. The additive of claim 1, wherein said sodium bicarbonate is added in a ratio of approximately 3:8 parts by weight.
3. The additive of claim 1, further comprising approximately between 5 and 15% by weight, antimony trioxide.
4. The additive of claim 2, further comprising approximately between 5 and 15% by weight, antimony trioxide.
5. The additive of claim 1, wherein said cut-back, asphaltic-type base contains asbestos.
6. The additive of claim 1, wherein said cut-back, asphaltic-type base is asbestos free.
7. The additive of claim 1, wherein said cut-back asphaltic-type base is selected from a group consisting of:
asphalt, coal tar and bitumen.
asphalt, coal tar and bitumen.
8. In combination, a mastic coating comprising:
1 part by weight of a cut-back, asphaltic-type base material; and between 2 and 8 parts by weight of sodium bicarbonate.
1 part by weight of a cut-back, asphaltic-type base material; and between 2 and 8 parts by weight of sodium bicarbonate.
9. The mastic coating of claim 8, further comprising approximately between 5 and 15% by weight, antimony trioxide.
10. The mastic coating of claim 8, wherein said cut-back asphaltic-type base material is selected from a group consisting of: asphalt, coal tar and bitumen.
11. The mastic coating of claim 8, wherein said cut-back asphaltic-type base material contains asbestos.
12. The mastic coating of claim 8, wherein said cut-back, asphaltic-type base material is asbestos free.
13. A method of accelerating the curing time and improving the flame retardancy of a cut-back, asphaltic-type base material utilized as a mastic coating in roofing and construction applications, comprising the step of:
adding approximately between 2 and 8 parts by weight, sodium bicarbonate to 1 part by weight of said asphaltic-type base material.
adding approximately between 2 and 8 parts by weight, sodium bicarbonate to 1 part by weight of said asphaltic-type base material.
14. The method of claim 13, further comprising the step of adding approximately between 5 and 15% by weight, antimony trioxide to further improve the flame retardancy.
15. The method of claim 13, wherein said cut-back, asphaltic-type base material is selected from a group consisting of: asphalt, coal tar and bitumen.
16. The method of claim 13, wherein said cut-back asphaltic-type base material contains asbestos.
17. The method of claim 13, wherein said cut-back asphaltic-type base material is asbestos free.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002006970A CA2006970A1 (en) | 1988-11-28 | 1990-01-02 | Flame retardant asphalt coating |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US07/276,517 US4925494A (en) | 1988-11-28 | 1988-11-28 | Flame retardant asphalt coating |
| CA002006970A CA2006970A1 (en) | 1988-11-28 | 1990-01-02 | Flame retardant asphalt coating |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2006970A1 true CA2006970A1 (en) | 1991-07-02 |
Family
ID=25673856
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002006970A Abandoned CA2006970A1 (en) | 1988-11-28 | 1990-01-02 | Flame retardant asphalt coating |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2006970A1 (en) |
-
1990
- 1990-01-02 CA CA002006970A patent/CA2006970A1/en not_active Abandoned
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Discontinued |