Classifications

• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L59/00—Thermal insulation in general
  • F16L59/02—Shape or form of insulating materials, with or without coverings integral with the insulating materials
  • F16L59/021—Shape or form of insulating materials, with or without coverings integral with the insulating materials comprising a single piece or sleeve, e.g. split sleeves; consisting of two half sleeves; comprising more than two segments
  • F16L59/025—Shape or form of insulating materials, with or without coverings integral with the insulating materials comprising a single piece or sleeve, e.g. split sleeves; consisting of two half sleeves; comprising more than two segments comprising more than two segments
• • C—CHEMISTRY; METALLURGY
  • C03—GLASS; MINERAL OR SLAG WOOL
  • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
  • C03C11/00—Multi-cellular glass ; Porous or hollow glass or glass particles
  • C03C11/007—Foam glass, e.g. obtained by incorporating a blowing agent and heating
• • C—CHEMISTRY; METALLURGY
  • C03—GLASS; MINERAL OR SLAG WOOL
  • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
  • C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
  • C03C17/22—Surface treatment of glass, not in the form of fibres or filaments, by coating with other inorganic material
• • C—CHEMISTRY; METALLURGY
  • C03—GLASS; MINERAL OR SLAG WOOL
  • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
  • C03C27/00—Joining pieces of glass to pieces of other inorganic material; Joining glass to glass other than by fusing
  • C03C27/06—Joining glass to glass by processes other than fusing
  • C03C27/10—Joining glass to glass by processes other than fusing with the aid of adhesive specially adapted for that purpose
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/08—Fats; Fatty oils; Ester type waxes; Higher fatty acids, i.e. having at least seven carbon atoms in an unbroken chain bound to a carboxyl group; Oxidised oils or fats
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/24—Macromolecular compounds
  • C04B24/36—Bituminous materials, e.g. tar, pitch
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B24/00—Use of organic materials as active ingredients for mortars, concrete or artificial stone, e.g. plasticisers
  • C04B24/40—Compounds containing silicon, titanium or zirconium or other organo-metallic compounds; Organo-clays; Organo-inorganic complexes
  • C04B24/42—Organo-silicon compounds
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L58/00—Protection of pipes or pipe fittings against corrosion or incrustation
  • F16L58/02—Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
  • F16L58/04—Coatings characterised by the materials used
  • F16L58/06—Coatings characterised by the materials used by cement, concrete, or the like
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
  • C04B2103/60—Agents for protection against chemical, physical or biological attack
  • C04B2103/65—Water proofers or repellants
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
  • C04B2111/00672—Pointing or jointing materials
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
  • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
  • C04B2111/00706—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like around pipelines or the like
• • C—CHEMISTRY; METALLURGY
  • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
  • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/20—Resistance against chemical, physical or biological attack
  • C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials

Definitions

• the present invention relates to insulation for structures including roofing and pipes, and more particularly, to systems and methods that avoid problems associated with intrusion of moisture occurring between adjacent segments of insulation.
• Cellular glass insulation is often fabricated into sections for insulating industrial and commercial structures.
• Cellular glass also called foam glass or foamed glass
• foam glass or foamed glass is a preferred choice for certain insulation applications due to its ability to maintain its shape under strenuous conditions and its closed-cell makeup, making it impermeable to water vapor.
• cellular glass performs the necessary purpose of energy conservation or process control, other problems may arise when using cellular glass insulation due to its closed cell nature. For instance, corrosion under insulation (CUI) may occur under cellular glass insulation where moisture has been trapped or otherwise allowed to migrate between the insulation and the surface of the pipe or structure, which are often composed of metal. This includes liquid water that is trapped under the insulation and has not been allowed to evaporate or be removed from the system.
• CTI corrosion under insulation
• the general inventive concepts are based, in part, on the discovery that conventional porous adhesives (also called cements) may allow for unwanted moisture infiltration between adjacent segments of pipe insulation, which can lead to corrosion of the underlying substrate.
• conventional porous adhesives also called cements
• a waterproof (or otherwise moisture resistant) fabrication adhesive for insulation applications that use cellular glass including those that are exposed to the elements and/or operate at low temperature (e.g., cryogenic applications).
• the general inventive concepts contemplate a cellular glass insulation system.
• the cellular glass insulation system comprises a plurality of cellular glass insulation segments and a modified gypsum cement.
• the cellular glass insulation segments comprise side joint sections, and end joint sections.
• the modified gypsum cement is positioned on a joint section at the interface between adjacent cellular glass insulation segments.
• the modified gypsum cement comprises a solid component and a liquid component.
• the solid component comprises a gypsum cement base and the liquid component comprises a waterproofing element and water.
• the waterproofing element and the water are pre-combined to form the liquid component.
• the solid component and the liquid component are combined in a ratio of about 1 : 1 to 3 : 1, including about 2: 1 by weight.
• the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element present in an amount of 5% to 40% by weight of the gypsum cement base.
• the general inventive concepts contemplate a method of insulating a pipe.
• the method comprises mixing a gypsum cement base, water, and a waterproofing element to form a modified gypsum cement, wherein the waterproofing element displaces a portion of the water; providing a plurality of cellular glass insulation segments, each cellular glass insulation segment comprising a length, side joint sections extending the length of the cellular glass insulation segment, and end joint sections; applying the modified gypsum cement to at least one side joint section; and positioning the cellular glass insulation system about the exterior of a pipe.
• the general inventive concepts contemplate a method of insulating a structure.
• the method comprises mixing a gypsum cement base, water, and a waterproofing element to form a modified gypsum cement, wherein the waterproofing element displaces a portion of the water; providing a plurality of cellular glass insulation segments, each cellular glass insulation segment comprising a length, side joint sections extending the length of the cellular glass insulation segment, and end joint sections; applying the modified gypsum cement to at least one side joint section; and positioning the cellular glass insulation system about the exterior of the structure.
• Figure 1 shows an illustration of a conventional cellular glass insulation segment.
• Figure 2 shows an example of a conventional cellular glass insulation positioned around a pipe.
• Figure 3 shows an illustration of a cellular glass roof insulation system including a modified gypsum cement adhesive.
• Figure 4 shows a plot of weight change over time for a control gypsum cement adhesive (Hydrocal Bl l) compared to a modified cement made with a wax emulsion waterproofing element according to the general inventive concepts.
• Figure 5 shows a plot of weight change over time for a control cement compared to two cements made with silicon emulsion waterproofing element.
• Figure 6 shows a plot of weight change over time for a control cement compared to a series of cements made with a series of waterproofing elements.
• Figure 7 shows an SEM image of the control gypsum cement without a waterproofing element.
• the image shows the typical open porosity of the cement which leads to a high moisture permeability.
• Figure 8 is an SEM image of the control cement formulated with a wax emulsion (i.e., a modified gypsum cement) showing the closed pore structure with a paraffin wax particle addition.
• a wax emulsion i.e., a modified gypsum cement
• Figure 9 is an SEM image of the control gypsum cement without a waterproofing element.
• Figure 10 is an SEM image of gypsum cement with a silicon emulsion waterproofing element (i.e., a modified gypsum cement).
• Figure 11 A is an SEM image showing paraffin wax emulsion size and shape with an average particle size of between 0.5 to 20 microns in diameter.
• Figure 1 IB is a magnified view of the paraffin wax shown in Figure 11 A, showing paraffin wax particles with an average particle size of between 1 to 5 microns in diameter.
• gypsum cement base refers to the dry ingredients of a conventional gypsum cement (e.g., the solid component).
• a conventional gypsum cement e.g., the solid component
• Hydrocal Bl 1 sold by U.S. Gypsum.
• gypsum cement mixture refers to the combination of a solid component and a liquid component (e.g., gypsum cement base and water).
• modified gypsum cement refers to a gypsum cement mixture, optional water, and a waterproofing element, according to the general inventive concepts.
• the solid component and the liquid component are combined in a ratio of about 1 : 1 to 3 : 1, including about 2: 1 by weight.
• waterproofing element refers to a chemical composition that reduces the permeability and permeance of a gypsum cement mixture by displacing a portion of the water that would otherwise make up the liquid portion of the gypsum cement mixture.
• the term “displacing a portion of the water” as used herein, refers to a modification of the ingredient formula for making a gypsum cement mixture or modified gypsum cement mixture.
• the modification entails replacing a portion of the water (or otherwise liquid portion) that would conventionally be used to make a gypsum cement mixture with an amount of a waterproofing element.
• the total amount of water and waterproofing element is about 50% by weight based on the gypsum cement base.
• a solid component, 100 g gypsum base is mixed with a liquid component, 50 g of water.
• a mixing procedure for a modified gypsum cement comprises 100 g gypsum base + 25 g of wax emulsion + 25 g of water are mixed to form a modified gypsum cement.
• the wax emulsion is made up of approximately 50% wax, with the remainder water.
• the total amount of wax is between 5% and 15% of the modified gypsum cement mixture.
• the liquid component i.e., the water and the wax emulsion
• the general inventive concepts contemplate the combination of a solid component (i.e., the gypsum base) and a liquid component (comprising the e.g., wax emulsion (comprising wax and water) and water).
• a mixing procedure for a modified gypsum cement comprises mixing 100 g gypsum base with 50 g of a mixture of water and the wax emulsion (this is similar to the previous example, but the wax and water components are already in one component).
• a modified gypsum cement comprises 100 g of gypsum cement base (solid component) and 50 g of a liquid component comprising a diluted wax emulsion.
• the wax itself makes up about 25% by weight of the liquid component of the adhesive/cement and this is equivalent to approximately 8-9% wax in the total adhesive solids of mix.
• the liquid component would comprise from about 10% to about 40% wax, including about 20% to about 30% wax, and including about 25% wax.
• the general inventive concepts relate to systems for and methods of insulating a structure (e.g., a roof) or pipe.
• a structure e.g., a roof
• the intrusion of moisture into the region or space between an insulation system and the underlying substrate can cause significant complications to an industrial facility or a building owner.
• the ingress of water can promote corrosion under the insulation as well as degrade the desired insulating properties of the system.
• Corrosion under insulation (CUI) is a major issue within systems operating at temperatures where water may exist in a liquid state. For example, even high temperature equipment may show CUI when the liquid water cycles onto the equipment surface during shutdowns or system cycling.
• Cellular glass (sometimes called foamed glass or foam glass) is a rigid, non- porous insulation material.
• One use for cellular glass is insulation of pipes, especially in high temperature work (e.g., above 400 °F) through the entire temperature range to cryogenic temperature environments.
• cellular glass is not flexible, in order to form customized insulation products, cellular glass must be formed or otherwise shaped into fabricated sections (e.g., half sections, quarter sections, or segments) that fit around the exterior of the pipe.
• the foam glass pipe insulation is typically fabricated using a cement to seal discrete foam glass sections together. Intrusion of moisture into insulation systems can cause a variety of issues such as corrosion of a pipe or other structure.
• Gypsum cements made by combining a gypsum cement powder and water, are a conventional cement for adhering foam glass sections to one another.
• the conventional gypsum cement used to fabricate the foam glass insulation is porous, which allows for water intrusion over time.
• the waterproofing element is one of a wax emulsion and a silicon emulsion.
• the waterproofing element is a chemical composition that reduces gypsum porosity and thus water vapor permeability according to the ASTM E 96 Test Method.
• the wax emulsion comprises a paraffin wax particulate with an average particle size of 0.5 to 20 microns in diameter.
• the general inventive concepts contemplate a new cement composition for fabricating cellular glass insulation systems and a method of reducing the permeability of a cellular glass cement adhesive.
• the new formulation comprises a gypsum cement base combined with water and a waterproofing element that displaces a portion of the water that would otherwise make up the conventional cement mixture.
• Particular embodiments of the waterproofing element include a silicon emulsion and a wax emulsion.
• the waterproofing element e.g., emulsified wax in the liquid portion of the mixture substantially reduces the porosity and pore size in the gypsum cement after curing (without wishing to be bound by theory, it is Applicant’s belief that the emulsified wax particles can effectively fill the pores that would otherwise be present in the cement in a manner that cannot be achieved by application of conventional waterproofing aids to a cement).
• a particular particle size range for the wax component of the waterproofing element (the particles suspended in the emulsion) provides surprising performance with respect to reduction of water vapor permeability of the modified gypsum cement.
• the particle size is less than 20 microns, including an average particle size of about 0.1 microns to about 15 microns, including an average particle size of about 0.1 microns to about 10 microns, including an particle size average of about 0.1 microns to about 9 microns, including an average particle size of about 0.1 microns to about 8 microns, including an average particle size of about 0.1 microns to about 7 microns, including an average particle size of about 0.1 microns to about 6 microns, including an average particle size of about 0.5 microns to about 7 microns, including an average particle size of about 1 micron to about 7 microns, including an average particle size of about 1 microns to about 6 microns, including an average particle size of about 1 micron to about 5 microns, including an average particle size of about 2 micron to about 5 microns.
• the method of the general inventive concepts involves replacing a portion of the water used to mix the gypsum cement base with a volume of the waterproofing element (e.g., a wax emulsion).
• the cement is then applied to the cellular glass in a substantially conventional manner.
• the cellular glass for use according to the general inventive concepts is characterized by a low water vapor permeability and generally lower porosity.
• This in conjunction with the modified gypsum cement’s ability to adhere and seal the cellular glass section through temperature cycles that include cryogenic temperatures (e.g., -50°C to 50°C) provides an improved cellular glass insulation system which resists CUI.
• the waterproofing element is present in the modified gypsum cement in an amount of less than 40% by weight based on the weight of the gypsum cement base.
• the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element in an amount of 5% by weight of the gypsum cement base to 40% by weight of the gypsum cement base.
• the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element in an amount of 5% by weight of the gypsum cement base to 35% by weight of the gypsum cement base.
• the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element in an amount of 5% by weight of the gypsum cement base to 30% by weight of the gypsum cement base. In certain exemplary embodiments, the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element in an amount of 5% by weight of the gypsum cement base to 25% by weight of the gypsum cement base.
• the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element in an amount of 5% by weight of the gypsum cement base to 20% by weight of the gypsum cement base. In certain exemplary embodiments, the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element in an amount of 5% by weight of the gypsum cement base to 15% by weight of the gypsum cement base.
• the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element in an amount of 5% by weight of the gypsum cement base to 10% by weight of the gypsum cement base.
• the waterproofing element is present in the modified gypsum cement in an amount of about 8% to about 10% by weight of the gypsum cement base.
• the amount of water and waterproofing element together is from about 40% to about 60% by weight of the gypsum cement base.
• the waterproofing element makes up nearly the entire nongypsum cement base portion (i.e., the liquid portion) of the modified cement, with only a small amount of water needed for formulating the modified gypsum cement.
• the waterproofing element is present in the modified gypsum cement in an amount of 2.5% by weight to 20% by weight of the modified gypsum cement. In certain exemplary embodiments, the waterproofing element is present in the modified gypsum cement in an amount of 5% by weight to 20% by weight of the modified gypsum cement.
• the waterproofing element is present in the modified gypsum cement in an amount of 7% by weight to 20% by weight of the modified gypsum cement. In certain exemplary embodiments, the waterproofing element is present in the modified gypsum cement in an amount of 8% by weight to 15% by weight of the modified gypsum cement. In certain exemplary embodiments, the amount of water and waterproofing element together is from about 8% to about 12% by weight of the modified gypsum cement.
• the modified gypsum cement has a water vapor transmission rate of less than 0.02 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor transmission rate of less than 0.01 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor transmission rate of less than 0.005 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor transmission rate of less than 0.002 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor transmission rate of less than 0.001 perm-inch.
• the modified gypsum cement has a water vapor transmission rate of 0.02 perm-inch to 0.0001 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor transmission rate of 0.02 perminch to 0.0002 perm-inch. In certain exemplary embodiments, the modified gypsum cement has a water vapor transmission rate of 0.02 perm-inch to 0.0005 perm-inch.
• the general inventive concepts contemplate a method of insulating a pipe.
• the method comprises mixing a gypsum cement base, water, and a waterproofing element to form a modified gypsum cement, wherein the waterproofing element displaces a portion of the water; providing a plurality of cellular glass insulation segments, each cellular glass insulation segment comprising a length, side joint sections extending the length of the cellular glass insulation segment, and end joint sections; applying the modified gypsum cement to at least one side joint section; and positioning the cellular glass insulation system about the exterior of a pipe.
• Figure 1 shows an exemplary 14 segment of cellular glass pipe insulation 100. While the segment is illustrated herein as a quarter segment, those of ordinary skill will understand that a variety of segment combinations are contemplated and would be suitable for the general inventive concepts. Accordingly, it is not intended that the general inventive concepts be limited to those specific embodiments described herein.
• the cellular glass pipe insulation is defined by a length L, side joint sections 110, an inner pipe bore 120, and end joint sections 130.
• the inner pipe bore 120 defines the area in which the pipe will by positioned between the cellular glass pipe insulation segments and is adapted for fitting around an arc of the exterior of the pipe.
• the end joint sections 130 are substantially flat and extend the length of the cellular glass pipe insulation segment 100 between the inner pipe bore 120 and the exterior of the cellular glass pipe insulation segment 100.
• a sealant/adhesive such as a gypsum cement
• FIG. 2 shows a conventional cellular glass pipe insulation system.
• pipe 300 is substantially surrounded by two segments of cellular glass insulation 200.
• the interface where the cellular glass segments 200 meet is joined with a cement/ adhesive 400.
• the cement 400 is conventionally a gypsum-based cement. Because the purpose of the adhesive is to close off the joint between adjacent foam glass segments 200, the adhesive 400 is generally applied to the joint sections, which are then mated together around the pipe.
• the purpose of the adhesive is to join the individual segments of foam glass together and to form a barrier to prevent water intrusion at the joints.
• blocks of cellular glass insulation may be assembled on a roof or other structure to provide insulation including both thermal insulation and protection from moisture.
• Conventional cellular glass roof insulation is made up of blocks of cellular glass and a bitumen-based adhesive.
• the cellular glass blocks are assembled on the roof, often with a layer of adhesive applied to the top/exterior surface of the cellular glass, at an interface or joint between adjacent segments of cellular glass, and/or between the cellular glass and the surface of the roof.
• the smooth surface of metal-clad roofing can complicate installation without an effective adhesive between the cellular glass segments and the roof.
• Bitumen adhesives while displaying many beneficial temperature-related properties, have known drawbacks regarding human health and safety regulations and installation. Thus, an adhesive for replacing bitumen must demonstrate good thermal characteristics, good adhesion to metal surfaces, while avoiding the drawbacks of bitumen adhesives.
• the general inventive concepts contemplate a cellular glass insulation system.
• the cellular glass insulation system comprises a plurality of cellular glass insulation segments and a modified gypsum cement.
• the cellular glass insulation segments comprising a length, side joint sections, and end joint sections.
• the modified gypsum cement is positioned on a joint section at the interface between adjacent cellular glass insulation segments.
• a layer or coating of the modified gypsum cement is applied to the surface of the roof.
• a layer or coating of the modified gypsum cement is applied to an exposed surface of the insulation system.
• the modified gypsum cement comprises a gypsum cement base, water, and a waterproofing element as discussed herein.
• FIG. 3 shows an embodiment of a cellular glass insulation system installed on a roof or other building structure 320.
• two segments of cellular glass insulation 300 are positioned on the structure.
• the interface 305 where the cellular glass segments 300 meet is joined with a cement/adhesive 310 according to the general inventive concepts.
• the cement/adhesive 310 is a modified gypsum cement. Because one function of the adhesive is to close off each joint between adjacent cellular glass segments 300, the adhesive 310 is generally applied to the joint sections (i.e., the sides of the cellular glass block that will be mated together), which are then brought together on the surface of the structure 320 to form the cellular glass insulation system.
• the modified gypsum cement may be applied to the interface 330 between the cellular glass segments 300 and the structure 320 (e.g., an interior surface of the cellular glass segment) .
• the modified gypsum cement may be applied as a coating layer 340 to an exterior surface of the cellular glass segments 300.
• the roof surface is comprised of metal.
• Example 1 water vapor permeability test.
• a series of gypsum-based cements were prepared and tested according to ASTM E96, “Standard Test Methods for Water Vapor Transmission of Materials.”
• 100 grams gypsum powder are mixed with 10 g waterproofing element and 30 grams water.
• the combination is mixed well and spread an even layer onto one cellular glass surface and then a second cellular glass surface is mated to the first.
• the two pieces are gently moved to make sure the cement spreads evenly; let it sit over night before cutting into shape for testing.
• Figure 4 shows the results of a conventional gypsum cement compared to a modified cement including a wax emulsion.
• Example 2 water vapor permeability test. Similar to Example 1, Figure 5 shows the results of a series of gypsum-based cements tested according to ASTM E96. Figure 5 shows the results of a conventional gypsum cement compared to a modified cement including C9 silicone emulsion and C20 silicone emulsion. As can be seen from the graph, inclusion of the silicone emulsion significantly reduces the water vapor transmission relative to the conventional gypsum cement adhesive, Hydrocal B 11.
• Example 3 water vapor permeability test. Similar to Example 1, Figure 6 shows the results of a series of gypsum-based cements tested according to ASTM E96. Figure 6 shows the results of a conventional gypsum cement compared to three separate waterproofing elements. The purple data is for Aqualite 070, Green is forNuvaN2155, and Red is for Mi chem 67235. As can be seen from the graph, inclusion of the wax emulsion significantly reduces the water vapor transmission relative to the conventional gypsum cement adhesive, Hydrocal B 11.
• Example 4 SEM images show pore size reduction.
• Two formulations of gypsum cement were prepared, a conventional cement made up of Hydrocal B 11 (Fig. 7, control) and a modified gypsum cement including Bl 1 with a wax emulsion and water (e.g., a 50% mixture of water and wax) (Fig. 8).
• the modified gypsum cement comprised 30 g gypsum, 12 g wax emulsion, and 3g water.
• the images show a difference in porosity with the latter showing obvious pore reduction/blockage relative to the conventional cement, due to incorporation of the wax emulsion.
• Example 4 cont’d SEM images show pore size reduction.
• Two formulations gypsum cement were prepared: a conventional cement made up of Hydrocal Bl l (Fig. 9, control) and a modified gypsum cement including Bl l with a silicon emulsion (Fig. 10). The images show a difference in porosity with Fig. 10 showing obvious pore reduction/blockage relative to the conventional cement, due to incorporation of the wax emulsion.
• Example 5 Temperature Cycle Testing of Roof Sections. In this test a modified gypsum cement was applied to the interfaces between cellular glass sections; a cellular glass section and concrete; and cellular glass and metal. A top coating was also applied to the surface of the cellular glass segment. The samples were then subjected to thermal cycle testing as follows:
• modified gypsum cement i.e., comprising up to 20% paraffinic wax emulsion
• the modified gypsum cement i.e., comprising up to 20% paraffinic wax emulsion
• Example 6 Corrosion testing. Conventional gypsum cement and a modified gypsum cement according to the general inventive concepts were tested for whether they contributed to corrosion on a metal surface (a proxy for a metal roof). Conventional gypsum cement failed the corrosion test, whereas the metal surface with the modified gypsum cement did not show signs of corrosion.
• Example 7 A series of modified gypsum cement adhesives were made using waterproofing elements to displace a portion of the water that would otherwise be used to make the gypsum cement.
• the modified gypsum cements were tested for water vapor permeability.
• a conventional cement made from Hydrocal Bl 1 gypsum cement was also tested as a control. Table 1 shows the results of the permeability test.
• Example 8 Modified gypsum cement mixtures were made without water and their water vapor permeability was measured. A conventional cement made from Hydrocal Bl l gypsum cement and water was also tested as a control. Table 2 shows the results of the permeability test.
• Example 9 A series of modified gypsum cement adhesives were made using waterproofing elements in an amount of 20% by weight based on the gypsum cement base (e.g., the solid portion). The modified gypsum cements were tested for water vapor permeability. A conventional cement made from Hydrocal B 11 gypsum cement was also tested as a control. Table 3 shows the results of the permeability test.
• Example 10 A 50:50 wax emulsion and 50:50 silicon emulsion waterproofing elements were used to make a series of modified gypsum cement adhesives in weight % of 10 to 40% by weight of the gypsum cement base.
• the modified gypsum cements were tested for water vapor permeability.
• a conventional cement made from Hydrocal Bl l gypsum cement was also tested as a control.
• Table 4 shows the results of the permeability test. Table 4
• Example 11 A series of samples of modified gypsum cement were fabricated according to the general inventive concepts. The samples were tested for requirement of MIL- DTL-24244D, ASTM C795 and NRC Req. Guide 136. Further modified gypsum cement samples were compared to a control group comprising conventional gypsum cement made according to manufacturers’ specifications in a 28-day corrosion test. The conventional gypsum cement failed the corrosion testing, whereas the inventive modified gypsum cement made with a wax waterproofing element (in an amount of 8-9% by weight of the modified gypsum cement) passed the corrosion testing as well as MIL-DTL-24244D(SH), ASTM C795 and NRC Req. Guide 136.
• Example 12 A series of samples were fabricated and subjected to ignition testing in the presence of liquid oxygen.
• the modified gypsum cement according to the general inventive concepts passed ASTM G86-17 Standard Test Method for Determining Ignition Sensitivity of Materials to Mechanical Impact in Ambient Liquid Oxygen and Pressurized Liquid and Gaseous Oxygen Environments (LOXMIS per ASTM G86).
• a series of samples of FOAMGLAS insulation fabricated with a modified gypsum cement according to the general inventive concepts also passed ASTM G86-17 Standard Test Method for Determining Ignition Sensitivity of Materials to Mechanical Impact in Ambient Liquid Oxygen and Pressurized Liquid and Gaseous Oxygen Environments (LOXMIS per ASTM G86).
• the service temperature range for the modified gypsum cements according to the general inventive concepts encompasses temperatures from below about -200°C to above about 400°C.
• the decrease in the porosity of the adhesive provides more effective sealing (and water impermeability) to the insulation system, while not sacrificing the insulative properties of the system overall.
• the modified gypsum cement does not sacrifice the adhesive or temperature performance properties of conventional gypsum cement (i.e., cement without the waterproofing element).
• the cellular glass compositions, and corresponding methods of the present disclosure can comprise, consist of, or consist essentially of the essential elements and limitations of the disclosure as described herein, as well as any additional or optional ingredients, components, or limitations described herein or otherwise useful in foam glass composition applications.
• the cellular glass compositions of the present disclosure may also be substantially free of any optional or selected ingredient or feature described herein, provided that the remaining composition still contains all of the required elements or features as described herein.
• the term “substantially free” means that the selected composition contains less than a functional amount of the optional ingredient, typically less than 0.1% by weight, and also including zero percent by weight of such optional or selected essential ingredient.

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