CA2022151C - Flame retardant bitumen - Google Patents

Flame retardant bitumen Download PDF

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Publication number
CA2022151C
CA2022151C CA 2022151 CA2022151A CA2022151C CA 2022151 C CA2022151 C CA 2022151C CA 2022151 CA2022151 CA 2022151 CA 2022151 A CA2022151 A CA 2022151A CA 2022151 C CA2022151 C CA 2022151C
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CA
Canada
Prior art keywords
styrene
composition
butadiene
roofing
component
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 - Lifetime
Application number
CA 2022151
Other languages
French (fr)
Other versions
CA2022151A1 (en
Inventor
Louis L. Grube
Stanley P. Frankoski
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
GAF Building Materials Corp
Original Assignee
GAF Building Materials Corp
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Filing date
Publication date
Application filed by GAF Building Materials Corp filed Critical GAF Building Materials Corp
Publication of CA2022151A1 publication Critical patent/CA2022151A1/en
Application granted granted Critical
Publication of CA2022151C publication Critical patent/CA2022151C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09KMATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
    • C09K21/00Fireproofing materials
    • C09K21/06Organic materials
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L95/00Compositions of bituminous materials, e.g. asphalt, tar, pitch
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/02Roof covering by making use of flexible material, e.g. supplied in roll form of materials impregnated with sealing substances, e.g. roofing felt

Abstract

This invention relates to a stabilized, flame retardant roofing mat or sheeting impregnated with a composition comprising, modified asphalt and between about 9 and about 50 wt % of colemanite. The invention also relates to the novel flame retardant composition which can be employed for treating roofing reinforcement and building siding material.

Description

~o~~~~~

FLAME RETARDANT BTTUMEN
BACKGROUND OF THE INVENTION
Roofing sheets are generally supplied in rolled up form for use in the formation of roofing membranes wherein overlapping sections of the material are used to form one or more plies of the finished roofing membranes. In addition they may be used on sidewalls of buildings. Such roofing membranes and systems are used primarily on commercial buildings ox buildings of low slope by reason of their durability and comparatively low cost. One type of roofing sheet which is in demand for economical installations is a modified asphalt sheet. However, since modified asphalt is not fire resistant, it has been the practice to manufacture the sheet with a glass mat reinforcement and to cover it with a separate flame retardant composition such as a glass cap sheet or coating. Obviously, this procedure reguires several time consuming steps to complete the roofing installation.
Accordingly, it is an object of thus invention to simplify the aperation necessary for providing a fire retardant roofing membrane.
Another object is to eliminate the necessity for a glass mat reinforcement either alone or in addition to the polyester reinforcment in the sheet and to provide a fire reta~dant roef covering with a material which incorporates fire r~tardancy, thus eliminating the need for membranes of different composition and top coating operations.
These and other objects will become apparent from those skilled in the art from the following description and disclosure.
THE INVENTION
In accordance with this invention there is provided a modified asphalt sheet which is impregnated, i.e. saturated or coated on its upper and/or lower surfaces with a composition comprising (a) between about 35 and about 60 wt. o petroleum asphalt or an asphaltic blend having a Brookfield viscosity at 210°F. of between about 500 and about 4000 cps, a penetration at 77°F. (100 g., 5 seconds, mm/10) of from about 20 to about 350 dmm and a softening point of from about 80° to about 200°F; (b) between about 2 and about 30 wt. o of a thermoplastic copolymeric styrene modifier and (c) between about 35 and about 50 wt. o of colemanite, combined to provide 1000 composition.
In the above composition, the asphaltic component is more desirably used in a concentration of from about 45 to about 60 wt. % and is preferably one having a viscosity of from about 1500 to about 3000 cps; a penetration of from about 80 to about 200 dmm and a softening point of from about 100° to about 150°F.
Such asphalts include roofing flux, straight reduced, thermal and air blown asphalts, mopping asphalt, liquid cut-back asphalts, etc. It will be apparent that asphalts of relatively lower penetration and higher viscosity can be employed when diluted with a cutting oil, such as for example, gas oil, to provide the asphaltic component having properties within the above ranges.
Suitable modifier components are those conventionally employed for saturation of polyester roofing mat, and include from about 5%-95o to about 40%-60o by weight blends of isotactic polypropylene having a melt flow of from about 2 to 200 and atactic polypropylene homopolymer or copolymer containing up to 40% ethylene comonomer. An alternate modifier component which can be employed in the present composition is a synthetic polymer such as polyisobutylene, polybutylene or blends thereof.
These modifiers generally comprise between about 2 and about 30 wt. % of the flame retardant composition. Still another alternate is a styrene-butadiene, styrene-ethylene-butadiene-styrene, styrene-butadiene-styrene block copolymers or styrene-butadiene-rubber containing from about 10 to about 50 wt. % styrene, preferably from about 25 to about 35 wt.
% styrene. When the styrene containing modifier is selected, the copolymer generally comprises between about 2 and about 20 wt. %, preferably between about 8 and about 15 wt. % of the composition.
Colemanite is a natural blend of hydrated oxides as represented by a particular type of calcium borate generally containing between about 30 and about 55%
B203 and between about 20 and about 35% CaO. This mineral may also contain up to about 12% other oxides such as silicon dioxide, aluminum oxide and magnesium oxide.
The colemanite is preferably used in the present composition in a concentration of from about 10 to about 50% and is generally employed as granular material having a mesh size of from about 75% to about 80% minus 200 mesh screen.
A particular advantage of colemanite is its high cost effectiveness and availability over other borate compounds and compositions containing colemanite within the above ranges can be easily applied to polyester mats to achieve a Class A rating in the ASTM E-108 and UL 790 fire tests. Consequently, it is not necessary to apply a separate fire retardant top coating to the modified asphalt membrane. Also, the need for glass mat reinforcement is completely eliminated. Thus, the cost of the completed roof is greatly reduced and greater fire protection is afforded by coverage with the present inherently fire resistant roofing ply or plies. It is to be understood, however, that the present composition is also suitable for coating or impregnation of other reinforcing mats such as glass mats, glass/polyester composites, etc. Typically a roofing material may comprise about 40 to 95 wt. o of a composition of the invention.
The roofing membrane can be a mono or multi ply structure depending on the desired thickness of the roof covering. Generally, a thickness of from about 0.07 to about one inch is sufficient to provide good weathering preferably from about 0.07 to 0.25 inch, particularly between about 0.12 and about 0.2 inch.
The method of coating a reinforcing mat is conventional and includes dipping, spraying, soaking or mechanical coating with a doctor blade or similar device. When coating a surface of the mat, the present composition is generally applied in a thickness of from about 0.05 to about 0.5 inch. Saturation of the mat provides inherent fire retardant throughout the felt.
The present composition is easily prepared by mixing the components in any order at a temperature of from about 100 to about 500°F. for a period of from about 1 to 24 hours, preferably at about 325-400°F. for 2 to 6 hours. The composition is then applied to the mat at about the same temperature to provide a product suitable for installation. The roofing sheet obtained shows no deterioration in flexibility so that it can be easily unrolled for overlaying a roof deck and can be easily handled in roofing construction.
Many methods of roofing can be employed for the purposes of this invention. For example, the present roofing sheet can be utilized as the sole roof covering over the entire deck or a base and top covering with instant roofing sheet can be combined with intermediate roofing layers of a different composition, e.g. an impregnated or non-impregnated glass mat.

4a Also, alternate layers of roof covering can be employed. The specific roofing procedure for installation is conventional and need not be further discussed.

.. g Having generally described the invention, reference is now had to the following examples which are provided to illustrate preferred embodiments but which are not to be construed as limiting to the scope of the invention as more broadly discussed above and as defined in the appended claims.

The following ingredients for the flame retardant composition were introduced into a metal container and mixed for 4 hours at 380 °F.
Ingredients wt. %
(1) AC-5 Asphalt 57.5 Isotactic polypropylene 3.5 (melt flow 60-90) Atactic polypropylene/polyethylene blend 20.0 Polyethylene (melt flow 75-35) 6.0 Colemanite 13.0 (1) Per ASTM D3381 Table 2 The above melt was applied to a 12x20 inch sheet of polyester roofing mat (0.038" thick) by coating an a 2 roll mill to build a thickness of 0.157". The resulting product was then subjectedwto a flame test which comprised subjecting a 4x8 inch sample of the above, mounted on a 1''/ft slope to the frame of a propane burner fox 90 seconds. The results of this test are as reported in Table I.

A full sized roll of roofing sheet having the above composition was prepared and sent to Underwriters Laboratories (Northbrook, Illinois) for fire retardancy testing and quality classification The above formulation was assigned a Class A rating, indicating minimal flame and char damage, substantially no sheet flow coupled with high flame extinguishing properties.
When 7 wt. % polyisobutylene is substituted for isotactic polypropylene in the above composition, the resulting product has substantially the same beneficial properties.
L'Y~MDT.F 7 The following ingredients for the flame retardant composition were introduced into a metal container and mixed for 4 hours at 380 °F.
Ingredients wt.
(2) Asphalt (Penetration 130 dmm) 52.1 (3) Krat~n*1101 4~9 ( 4 ) Kraton~ 1102 3 . 0 Colemanite 40.00 (2) softening point 120°F. (3) 31/69 styrene-butadiene copolymer, 0.94 specific gravity, Brookfield viscosity (toluene solution) at 77°F, 4,000 cps (25 wt.% polymer) (4) 28/72 styrene-butadiene copolymer, 0.94, Brookfield viscosity (toluene solution) at 77°F, 1,200 cps (25 wt. %
polymer).
*Trade-mark _ 7 _ The above melt was applied to a 12x20 inch sheet of polyester roofing mat (0.038 " thick) by coating on a 2 roll mill to build a thickness of 0.157 inch. The resulting product was then subjected to a flame test which comprised sujecting a 4x8 inch sample of the above, mounted on a 1"/ft slope to the flame of a propane burner for a 90 seconds. The results of this test are as reported in Table I.
A full sized roll of roofing sheet having the above composition was prepared and the was then tested for fire retardancy by Underwriters Laboratory as described above. This sheet was given a Class A rating.
TABLE I
90 Second Burn Test Product Tested Char Formation Flow Example 1 excellent none Example 2 very good very slight Commercial Sample excellent ncne Manville Dynakap*FR SBS
Commercial Sample very good none Siplast*Paradiene*FR SBS
*Trade-mark

Claims (12)

1. A flame retarding composition which comprises:
(a) between about 35 and about 60 wt.% of a petroleum asphalt or asphaltic blend having a Brookfield viscosity of from about 500 to 4000 cps, a penetration of from about 20 to 350 dmm and a softening point of from about 80° to 200°F.;
(b) between about 2 and about 30 wt. % of a thermoplastic copolymeric styrene modifier and (c) between about 35 and about 50 wt.% of colemanite, combined to provide 100% composition.
2. The composition of claim 1 wherein said component (a) has a viscosity of from about 1500 to 3000 cps; a penetration of from about 80 to 200 dmm and a softening point of from about 100°
to 150°F.
3. The composition of claim 1 wherein said component (b) is selected from the group of styrene-butadiene-styrene and styrene-ethylene butadiene-styrene block polymers and blends thereof.
4. The composition of claim 1 wherein said component (b) is a rubber and is selected from the group of styrene-butadiene, styrene-butadiene-rubber, styrene-ethylene-butadiene-styrene and styrene-butadiene-styrene block copolymers containing from about to about 50 wt. % styrene.
5. The composition of claim 1 wherein said component (b) is an elastomeric styrene-butadiene-styrene block copolymer.
6. The composition of any one of claims 1 to 5 wherein between about 2 and about 20 wt. % of said copolymer is present in the composition.
7. A roofing material containing between about 40 and about 95 wt. % of the composition of any one of claims 1 to 6.
8. The roofing material of claim 7 wherein said material is a polyester roofing felt and having a thickness of from about 0.07 to about 0.25 inch.
9. The roofing material of claim 7 wherein said material is a glass mat and having a thickness of from about 0.07 to about 0.25 inch.
10. A roof deck overlaid with a layer of the material of claim 7.
11. A building siding covered with a layer of the material of claim 7.
12. A polyester roofing felt installation containing between about 40 and about 50 wt. % of the composition which comprises:
(a) between about 35 and 60 wt. % of a petroleum asphalt or asphaltic blend having a Brookfield viscosity of from about 500 to 4000 cps, a penetration of from about 20 to 350 dmm and a softening point of from about 80° to 200°F;

(b) between about 2 and about 30 wt. % of a thermoplastic copolymeric styrene modifier and (c) between 35 and about 50 wt. % of colemanite, combined to provide 100% composition.
CA 2022151 1989-08-17 1990-07-27 Flame retardant bitumen Expired - Lifetime CA2022151C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US39489289A 1989-08-17 1989-08-17
US394,892 1989-08-17

Publications (2)

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CA2022151A1 CA2022151A1 (en) 1991-02-18
CA2022151C true CA2022151C (en) 2001-12-04

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CA 2022151 Expired - Lifetime CA2022151C (en) 1989-08-17 1990-07-27 Flame retardant bitumen

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CA (1) CA2022151C (en)
MX (1) MX170763B (en)
WO (1) WO1991002776A1 (en)

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5278207A (en) * 1992-11-06 1994-01-11 Shell Oil Company Asphalt amine functionalized polymer composition
FR2701502B1 (en) * 1993-02-11 1995-05-24 Roger Vallon Improved fire and flame resistance of cellulose and bitumen-based roofs.
US5437923A (en) * 1993-06-09 1995-08-01 Gs Roofing Products Company, Inc. Halogen-free flame-retardent bitumen roofing composition
US6133350A (en) * 1996-08-13 2000-10-17 Shell Oil Company Oil free compounds of styrenic block copolymers, amorphous polyolefins, and carbon black
CN103805024B (en) * 2013-10-21 2015-11-25 溧阳市浙大产学研服务中心有限公司 A kind of technique of steel construction being carried out to frie retardant coating application
CN104292024A (en) * 2014-10-24 2015-01-21 柳州市天姿园艺有限公司 Foliage application fertilizer for pot flowers
CN104927520A (en) * 2015-06-10 2015-09-23 柳州弘天科技有限公司 Non-intumescent latex fireproof coating
CN104927490A (en) * 2015-06-10 2015-09-23 柳州弘天科技有限公司 Solvent-based non-expansive fire retardant coating
CN108102397A (en) * 2017-12-04 2018-06-01 杭州睿琦化工科技有限公司 Modified pitch and bituminous concrete

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4008095A (en) * 1969-03-12 1977-02-15 Nichireki Kagaku Kogyo Co., Ltd. Paving compositions and method for producing the same
GB1421334A (en) * 1972-08-07 1976-01-14 Magnesium Elektron Ltd Flame retardant materials
US3897387A (en) * 1973-05-23 1975-07-29 Shaughnessy James D O Fire retardant agent
US4659381A (en) * 1986-03-28 1987-04-21 Manville Corporation Flame retarded asphalt blend composition
JPH0665620B2 (en) * 1986-12-18 1994-08-24 日本特殊塗料株式会社 Vibration control sheet for vehicles

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CA2022151A1 (en) 1991-02-18
MX170763B (en) 1993-09-13
WO1991002776A1 (en) 1991-03-07

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