GB2190385A

GB2190385A - A coating material

Info

Publication number: GB2190385A
Application number: GB08711222A
Authority: GB
Inventors: James Green
Original assignee: WYRE PLASTERERS AND BUILDERS L
Current assignee: WYRE PLASTERERS AND BUILDERS L
Priority date: 1986-05-13
Filing date: 1987-05-13
Publication date: 1987-11-18
Also published as: GB8711222D0; GB8611668D0; GB2190385B

Abstract

A coating material for walls or floors comprises crushed, washed, bleached and graded sea shells combined with an adhesive material as a binding agent. The adhesive material can be white cement, styrene butadene rubber or modified styrene/acrylate co-polymer emulsion. The coating material can also include an amalgam of fused metal silicates in a contrived fragmented format for example toughened glass granules and although the shells and the binder are preferably pre-mixed before application, the binder may be applied separately and the shells embedded or pressed therein before it hardens.

Description

SPECIFICATION A coating material This invention relates to a coating material specifically a coating for a building's internal and external elevations including both horizontal and vertical surfaces.

If the finished walls of a building are of a plain or, for some reason, of an undesirable appearance it is common practice to apply a coating to the wall. This coating often takes the form of a mixture of pebbles in a cement base and is known as pebble dashing. The application of such a coating can greatly enhance the apperance of, for example, a plain concrete wall. Furthermore the pebble dashing provides the wall with protection against erosion by the wind and rain. It is, of course, far easier to renew or repair the pebble dashing in the event of damage than it is to repair the wall itself.

This particular form of coating has several disadvantages. Firstly the pebbles required have a maximum usable size and therefore have to be mechanically graded to remove very large pebbles. Secondly because the average size of pebbles is relatively large the cement layer has to be thick enough to anchor the pebbles to the wall and this factor increases the cost of the pebble dashing.

Finally although the appearance of a pebble dashed wall is more pleasing than a plain wall the aesthetic properties of the pebble dashing would be enhanced if the pebbles themselves were more colourful.

An object of the present invention is therefore to provide a coating material which is inexpensive to produce, can be spread thinly whilst still retaining a basic toughness and is more pleasing in appearance than heretofore possible.

With this object in view the pressent invention provides a coating material including, as a binding agent, an adhesive material and further including a quantity of crushed sea shells.

Preferably the crushed sea shells are washed, bleached and graded to ensure a substantially uniform size and a clean appearance.

Advantageously the adhesive material is white cement which is preferably applied to a wall or other surface and into which the crushed sea shells are pressed. Alternatively the white cement can be premixed with the crushed sea shells and then applied to the wall.

Preferably the adhesive material is or includes either styrene butadene rubber or modified styrene/acrylate co-polymer emulsion.

Advantageously hydrated lime is added to the coating material.

Preferably the coating material also includes an amalgam of fused metal silicates in a contrived fragmented format. Advantageously this is in the form of granules of toughened glass.

The invention also provides a method of making a coating material comprising the steps of crushing a quantity of sea shells, adding the crushed sea shells to an adhesive binding agent to form the coating material.

Preferably the method further includes the step of applying the mixed coating material to a surface such as a wall or floor.

Advantageously the method includes the step of applying the adhesive binding agent to a surface prior to the addition of the crushed sea shells.

The invention will be described further by way of example with reference to a number of preferred embodiments, it being understood that the following description is not limitative of the scope of the invention.

A first preferred embodiment of the invention is intended for use as a dry dash material. First a coating of white cement, hydrated lime and clean sharp washed pit sand mixed in the proportions of 1:1:5 by weight is applied to a surface for example a wall. Before this coat is allowed to dry a dry dash material comprising crushed, washed, bleached and graded scallop and mussel shells and grannules of toughened glass (known as Cullite) is pressed into the cement coat to complete the coating material. The dry dash material comprises 75%-95% crushed shell aggregate and 25%-5% toughened glass granules.

A second preferred embodiment of the invention is intended as a trowel application to produce a smooth, flat surface coat to prepared wall surfaces. An aggregate of crushed, washed, bleached and graded scallop and mussel shells is mixed with a binder of either styrene butadene rubber or modified styrene/acrylate co-polymer emulsion in the ratio of 6 parts shell aggregate to 1 part binder. The shell aggregate and the binder are thoroughly mixed using a paddle type mixer.

The resultant coating material is applied by trowel to the desired surface to a thickness of between 4mm-20mm as required. A tough, durable, pleasing multi-coloured surface results, the wearing properties of which can be increased by applying either by brush or spray a protective coating of acrylate co-polymer emulsion.

A third embodiment of the invention is intended for spray application to wall surfaces.

A crushed washed and bleached aggregate of multi-coloured shells is finely graded and mixed with cement, hydrated lime and modified styrene/acryiate co-polymer emulstion.

Coloured tints may also be added if so desired. The mix is in the proportion of 22 parts shell aggregate, 1 part cement, 1 part hydrated lime and 1 part styrene/ acrylate. Fine grade Cullite can also be added.

The resultant coating material is sprayed onto a firm dry wall surface and the overall thickness of the coating can be nuilt up in layers from 2mm to 16mm as desired to form a textured, stipple effect. Such a spray coating material can also be formed by omitting the cement and the lime and mixing the shell aggregate with styrene butadene rubber or styrene/acrylate co-polymer emulsion.

A fourth preferred embodiment of the invention is for use as a floor coating material and comprises an aggregate of crushed, washed, bleached and graded shells to which is added 5% to 20% of toughened glass granules. The grade of the shell aggregate and the glass granules should be approcimately 0.5mm to 12mm. The shell aggregate/granule mix is mixed with a binder of cement and either styrene butadene rubber or modified styrene/acrylate co-polymer emulsion in the proportion of 22 parts shell/granules, 1 part cement and between 1 and 2 parts of rubber/co-polymer emulsion. The proportion of the rubber/copolymer emulsion is varied to provide a mix of the correct 'slump' for the required method of application.The base concrete of the floor is first primed with styrene butadene rubber or styrene acrylate co-polymer emulsion and then the coating material is applied to a desired thickness of 5mm to 30mm. The coating material surface is finished with a wood or steel float and when it has hardened sufficiently the surface is ground with a mechanical grinder and polished to produce a smooth marble-like surface.

The invention is not limited to the foregoing description and variations may be made thereto. For example a waterproofing agent may be added to the coating material to improve its weather resisting properties. The styrene butadene rubber or the modified styrene/acrylate co-polymer emulsion can be replaced by any suitable polymer and the compositions of the mixtures specified can be varied as may the uses for each specific composition. For example a higher proportion of shells or glass granules may be used or the amount of adhesive material relative to the shell aggregate can be increased depending on the desired performance characteristics of the coating material's surface. Other variations are also possible.

Claims

1. A coating material including, as a binding agent, an adhesive material and further including a quantity of crushed sea shells.

2. A coating material as claimed in claim 1 wherein the crushed sea shells are washed bleached and graded before inclusion in the coating material.

3. A coating material as claimed in claims 1 or 2 wherein the adhesive material includes white cement.

4. A coating material as claimed in claims 1, 2 or 3 wherein the adhesive material includes styrene butadene rubber.

5. A coating material as claimed in claims 1, 2 or 3 wherein the adhesive material includes modified styrene/acrylate co-polymer emulsion.

6. A coating material as claimed in claim 3 wherein the adhesive material further includes hydrated lime.

7. A coating material as claimed in any preceding claim further including an amalgam of fused metal silicates in a contrived fragmented format.

8. A coating material as claimed in claim 7 wherein the amalgam is toughened glass granules.

9. A method of making a coating material comprising the steps of crushing a quantity of sea shells and adding the crushed sea shells to an adhesive binding agent.

10. A method as claimed in claim 9 further including the step of applying the mixed coating material to a surface.

11. A method as claimed in claim 9 including the step of applying the adhesive binding agent to a surface prior to the addition of the crushed sea shells.

12. A coating material substantially as hereinbefore described.