GB2615882A

GB2615882A - A waterproofing composition and a process for its preparation

Info

Publication number: GB2615882A
Application number: GB2219652.1A
Authority: GB
Inventors: Mitra Suman; Chaudhari Ramesh; C Vinay Govindhan
Original assignee: Asian Paints Ltd
Current assignee: Asian Paints Ltd
Priority date: 2021-12-29
Filing date: 2022-12-23
Publication date: 2023-08-23
Also published as: WO2023126805A1; GB202219652D0

Abstract

A waterproofing composition comprising [i] an acrylic binder, such as butyl acrylate, methyl methacrylate; [ii] at least one silicone based emulsion, such as silane-siloxane emulsion; [iii] a crystalline additive, such as a double salt of tartaric acid; [iv] at least one performance additive, such as biocide, a defoamer, a thickener, a pH regulator, a dispersing agent, a surfactant, an anti-efflorescence additive, a coalescing solvent; [v] at least one pigment; and [vi] water. Also disclosed is a process for the preparation of a waterproofing composition. The waterproofing composition of the present disclosure is effective against dampness and efflorescence. The waterproofing composition of the present disclosure is capable of forming a breathable yet water tight film which does not allow transport of water and salts through the film.

Description

A WATERPROOFING COMPOSITION AND A PROCESS FOR ITS PREPARATION

FIELD

The present disclosure relates to a waterproofing composition and a process for ts preparation.

DEFINITION

As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.

Efflorescence refers to a deposit of salts, usually white, formed on a surface, having migrated in solution from within either concrete or masonry and subsequently precipitated by evaporation. It occurs most readily in porous concrete near the surface.

Crystalline additive refers to the special category of crystal forming chemicals which react with concrete/cementitious matter in the presence of water to form insoluble crystal structures in the capillaries.

Performance additive refers to an additive that brings unique properties to products and compounds.

BACKGROUND

The background information herein below relates to the present disclosure but is

not necessarily prior art.

Protective coatings are capable of imparting high hydrophobicity to a variety of substrates are desirable to reduce exposure or deterioration of the surface. One source of deterioration is moisture A highly hydrophobic coating may protect the surface by causing water to form droplets rather than penetrating into the substrate When surfaces such as concrete, brick, masonry, stone, and the like are applied with waterproofing sealer compositions, the surfaces get overall protection from corrosion and general deterioration. The treatment reduces the rate of water absorption considerably. thereby preventing water related damages.

There are many conventional water repellent sealers available in the market.

The conventional water repellent sealers are generally based on silane siloxane emulsion which can be used on all types of concrete and masonry surfaces. The conventional water repellent sealers reduce the absorption of surface water and the formation of efflorescence. However, they fail to work on damp or moist surfaces where the surface moisture is greater than 50%.

Therefore, there is felt a need to develop a waterproofing composition which obviates the drawbacks mentioned herein above or at least provides a useful alternative.

OBJ ECTS

Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.

An object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.

Another object of the present disclosure is to provide a waterproofing 20 composition Yet another object of the present disclosure is to provide a waterproofing composition that is effective against dampness and efflorescence.

Still another object of the present disclosure is to provide a waterproofing composition that can be used on damp substrates.

Yet another object of the present disclosure is to provide a waterproofing composition that is capable of forming a breathable yet water tight film.

Still another object of the present disclosure is to provide a simple and an environment friendly process for the preparation of a waterproofing composition.

Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present

disclosure.

SUMMARY

The present disclosure relates to a waterproofing composition comprising an acrylic binder; at least one silicone based emulsion, at least one crystalline additive; at least one performance additive; at least one pigment, and water.

The present disclosure further relates to a process for the preparation of a waterproofing composition. The process comprises the step of mixing a predetermined amount of at least one first performance additive in a predetermined amount of water to obtain a mixture followed by adding a crystalline additive under stirring at a first predetermined speed at a first predetermined temperature for a first predetermined time period to obtain a first slurry. Predetermined amounts of at least one pigment and at least one second performance additive are added to the first slurry under stirring at a second predetermined speed at a second predetermined temperature for a second predetermined time period to obtain a second slurry. The second slurry is ground at a third predetermined temperature for a third predetermined time period to obtain a homogeneous slurry. The homogeneous slurry is stabilized by adding at least one third performance additive under stirring at a third predetermined speed at a fourth predetermined temperature for a fourth predetermined time period to obtain a stabilized slurry. The stabilized slurry is thinned by adding an acrylic binder and at least one silicone based emulsion under stirring at a fourth predetermined speed at a predetermined pH and at a fifth predetermined temperature for a fifth predetermined time period to obtain the waterproofing composition.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

The present disclosure will now be described with the help of the accompanying drawing, in which.

Figure I (a) Illustrates a mortar panel coated with the waterproofing composition of Example 1 (test assembly) before Anti-dampness and Anti-efflorescence test, Figure 1 (b) illustrates a failed control panel showing presence of efflorescence (salt deposit) after 3 days of exposure, Figure 1 (c) illustrates a surface moisture content on the mortar panel coated with the waterproofing composition of Example 1 after 90 days of exposure showing 10 <6% reading on Moisture Meter arid no efflorescence; Figure 2 (a) illustrates a SEM micrograph of control mortar panel having porous structure and no crystal growth; Figure 2 (b) illustrates a mortar panel coated with the waterproofing composition of Example 1 after 28 days of exposure showing uniform crystal growth, and Figure 2 (c) illustrates a mortar panel coated with the waterproofing composition of Example 1 after 28 days of exposure showing pore blocking.

DETAILED DESCRIPTION

Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.

Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," "including," and "having," are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

A highly hydrophobic coating may protect the surface by causing water to form droplets rather than penetrating into the substrate. When surfaces such as concrete, brick, masonry, stone, and the like are coated with waterproofing sealer compositions, the surfaces get overall protection from corrosion and general deterioration. The treatment of the substrate with the waterproofing sealer compositions, reduces the rate of water absorption considerably, thereby preventing water related damages.

There are many water repellent sealers available in the market. The conventional water repellent sealers are generally based on silane siloxane emulsion which can be used on all types of concrete and masonry surfaces These conventional sealers reduce the absorption of surface water and the formation of efflorescence.

However, the conventional sealers fail to work on damp or moist surfaces where surface moisture is greater than 50%.

The present disclosure provides a waterproofing composition and a process for ts preparation.

In an aspect, the present disclosure provides a waterproofing composition comprising: i. an acrylic binder; ii. at least one silicone based emulsion; iii. at least one crystalline additive; iv. at least one performance additive; v. at least one pigment; and vi. water.

In an embodiment of the present disclosure, the waterproofing composition comprises: i. 60 mass% to 80 mass% of the acrylic binder; ii. 3 mass% to 15 mass% of the silicone based emulsion; iii. 0.1 mass% to 2 mass% of the crystalline additive; iv. 2 mass% to 15 mass% of the performance additive; v. 0.1 mass% to 2 mass% of the pigment; and vi, ci.s water.

In another embodiment of the present disclosure, the waterproofing composition comprises: i. 70 mass% to 78 mass% of the acrylic binder; mass% to 10 mass% of the silicone based emulsion; iii. 0.1 mass% to I mass% of the crystalline additive; iv. 5 mass% to 10 mass% of the performance additive; v. 0.5 mass% to 1.5 mass% of the pigment; and vi. q. s water The mass% of each component is with respect to the total mass of the composition.

The acrylic binder is an acrylic emulsion (Primal AC 3001). In an embodiment, the acrylic emulsion is 100% acrylic polymer of butyl acrylate (BA), methyl methacrylate (MMA) and other functional co-monomers.

The silicone based emulsion is at least one selected from a silane-siloxane emulsion (Tegosivin HE 328) and a mixture of triethoxy(octyl)silane, siloxanes and silicones (Dowsil IF 6694). In an exemplary embodiment of the present disclosure, the silicon based emulsion is a combination of the silane-siloxane emulsion (Tegosivin HE 328) and the mixture of triethoxy(octyl)silane, siloxanes and silicones (Dowsil IF 6694) The crystalline additive is a double salt of tartaric acid. In an exemplary embodiment of the present disclosure, the double salt of tartaric acid is sodium potassium tartrate.

Crystalline additives are special category of crystal forming chemicals which react with concrete/cementitious matter in the presence of water to form insoluble crystal structures in the capillaries. These insoluble crystal structures blocks the pores and results in watertight concrete/ waterproofing. This process continues until all the chemicals have reacted with cementitious matrix The performance additive can be at least one selected from a biocide, a defoamer, a thickener, a pH regulator, a dispersing agent, a surfactant, an anti-efflorescence additive and a coalescing solvent.

The biocide is at least one selected from iodopropynyl butylcarbamate (Troy PI 30), a mixture of chlormethyl-/methylisothiazolone and formaldehyde (Rocima 623), a blend of 1,2-benzisothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Thor MBS), 2-octy1-4-isothiazolin-3-one (OIT), 4,5-dichloro-2-octy1-4-isothiazolin-3-one (DCOIT) and carbendazim In an exemplary embodiment of the present disclosure, the biocide is a combination of iodopropynyl butylcarbamate (Troy PI 30), a mixture of chlormethyl-/methylisothiazolone and formaldehyde (Rocima 623), and a blend of 1,2-benzisothiazolin-3-one and 2-methy1-4-i sothiazolin-3-one (Thor MBS).

The defoamer is at least one selected from hydrocarbon oil-based defoamer. The commercially available hydrocarbon oil-based defoamers are selected from AM 15 1512A, Tego Foamex 1(3 and Dapro DF 7010. In an exemplary embodiment of the present disclosure, the hydrocarbon oil-based defoamer is AM 1512A.

The thickener is at least one selected from hydrous sodium lithium magnesium silicate (Laponite RD) and aqueous polyurethane thickener (Coapur 3020). In an exemplary embodiment of the present disclosure, the thickener is a combination of hydrous sodium lithium magnesium silicate (Laponite RD) and aqueous polyurethane thickener (Coapur 3020).

The pH regulator is 2-amino-2-methyl-1-propanol (AMP 95).

The dispersing agent is a solution of modified styrene maleic acid copolymer (Disperbyk 190) The surfactant is polyoxyethylene (9) synthetic primary Cm/Cis alcohol (Synperonic A9).

The anti-efflorescence additive is rosin modified with fatty acid derivative (Elotex ERA 200) The coalescing solvent is 2,2,4-trimethy1-1,3-pentaned ol monoisobutyrate (Texanol).

The water repellent is encapsulated triethoxyoctylsilane (El otex Seal 200) The pigment is titanium dioxide.

The conventional water repellent sealers penetrate inside the surface of the concrete where they chemically react to develop water repellency within the pores. They reduce the absorption of surface water and the formation of efflorescence. However, the conventional sealers fail to work on damp or moist surfaces where surface moisture is greater than 50%. In contrast to the conventional sealers, the waterproofing composition of the present disclosure comprising a blend of at least one acrylic binder, silane-siloxane emulsion and at least one crystalline additive, works effectively on any masonry surfaces having up to 70% moisture level.

The waterproofing composition of the present disclosure works synergistically, wherein the acrylic binder forms a tough and breathable film on the masonry substrates and silane-siloxane emulsion penetrates through the substrates and thus, helps in hydrophobization of the interstices, pores and voids present in the masonry substrates. Thus, resulting in an effective waterproofing performance on the damp surfaces. Further, the crystalline additive present in the composition, enables pore blocking through needle shaped crystal formation, thereby increasing the effectiveness of the composition.

In another aspect, the present disclosure provides a process for the preparation of a waterproofing composition The process comprises the following steps: a. mixing a predetermined amount of at least one first performance additive in a predetermined amount of water to obtain a mixture followed by adding a crystalline additive under stirring at a first predetermined speed at a first predetermined temperature for a first predetermined time period to obtain a first slurry; b adding predetermined amounts of at least one pigment and at least one second performance additive to the first slurry under stirring at a second predetermined speed at a second predetermined temperature for a second predetermined time period to obtain a second slurry; c. grinding the second slurry at a third predetermined temperature for a third predetermined time period to obtain a homogeneous slurry, d stabilizing the homogeneous slurry by adding at least one third performance additive under stirring at a third predetermined speed at a fourth predetermined temperature for a fourth predetermined time period to obtain a stabilized slurry, and e. thinning the stabilized slurry by adding an acrylic binder and at least one silicone based emulsion under stirring at a fourth predetermined speed at a predetermined pH and at a fifth predetermined temperature for a fifth predetermined time period to obtain the waterproofing composition.

The process for the preparation of the waterproofing composition is described in detail herein below.

In a first step, a predetermined amount of at least one first performance additive is mixed in a predetermined amount of water to obtain a mixture followed by adding a crystalline additive under stirring at a first predetermined speed at a first predetermined temperature for a first predetermined time period to obtain a first slurry.

The first performance additive can be at least one selected from a biocide, a defoamer, a thickener, a pH regulator, a dispersing agent and a surfactant.

The predetermined amount of the first performance additive is in the range of 2 mass% to 10 mass% with respect to the total mass of the waterproofing composition The biocide is at least one selected from iodopropynyl butylcarbamate (Troy PI 30), a mixture of chlormethyl-/methylisothiazolone and formaldehyde (Rocima 623), a blend of 1,2-benzisothiazolin-3-one and 2-methyl-4-isothiazolin-3-one (Thor MBS), 2-octy1-4-isothiazolin-3-one (OIT), 4,5-dichloro-2-octy1-4-isothiazolin-3-one (DCOIT) and carbendazim In an exemplary embodiment of the present disclosure, the biocide is a combination of iodopropynyl butylcarbamate (Troy PI 30), a mixture of chlormethyl-/methylisothiazolone and formaldehyde (Rocima 623), and a blend of 1,2-benzisothiazolin-3-one and 2-methy1-4-i sothiazolin-3-one (Thor MBS).

The pH regulator is 2-amino-2-methyl-l-propanol (AMP 95).

The crystalline additive is a double salt of tartaric acid In an exemplary embodiment of the present disclosure, the double salt of tartaric acid is sodium potassium tartrate.

The predetermined amount of the crystalline additive is in the range of 0.1 mass% to 2 mass% with respect to the total mass of the waterproofing composition.

The first predetermined stirring speed is in the range of 500 rpm to 1000 rpm. In an exemplary embodiment of the present disclosure, the first predetermined stirring speed is 700 rpm.

The first predetermined temperature is in the range of 20 °C to 40 °C. In an exemplary embodiment of the present disclosure, the first predetermined temperature is 30 °C.

The first predetermined time period is in the range of 5 minutes to 15 minutes. In an exemplary embodiment of the present disclosure, the first predetermined time period is 10 minutes.

In a second step, predetermined amounts of at least one pigment and at least one second performance additive are added to the first slurry under stirring at a second predetermined speed at a second predetermined temperature for a second predetermined time period to obtain a second slurry.

The second performance additive can be at least one selected from an anti-efflorescence additive and a water repellent The predetermined amount of the second performance additive is in the range of 0.1 mass% to 1 mass% with respect to the total mass of the waterproofing composition The anti-efflorescence additive is rosin modified with fatty acid derivative (Elotex 25 ERA 200).

The water repellent is encapsulated triethoxyoctylsilane (Elotex Seal 200).

The pigment is titanium dioxide. The predetermined amount of the pigment is in the range of 0.1 mass% to 1.5 mass% with respect to the total mass of the waterproofing composition.

The second predetermined stirring speed is in the range of 1500 rpm to 2000 rpm In an exemplary embodiment of the present disclosure, the second predetermined stirring speed is 1700 rpm.

The second predetermined temperature is in the range of 40 °C to 60 °C. In an exemplary embodiment of the present disclosure, the second predetermined temperature is 50 °C.

The second predetermined time period is in the range of 30 minutes to 80 minutes.

In an exemplary embodiment of the present disclosure, the second predetermined time period is 50 minutes In a third step, the second slurry is ground at a third predetermined temperature for a third predetermined time period to obtain a homogeneous slurry.

The third predetermined temperature is in the range of 40 °C to 60 °C. In an exemplary embodiment of the present disclosure, the third predetermined temperature is 50 °C.

The third predetermined time period is in the range of 10 minutes to 20 minutes.

In an exemplary embodiment of the present disclosure, the third predetermined time period is 15 minutes.

In a fourth step, the homogeneous slurry is stabilized by adding at least one third performance additive under stirring at a third predetermined speed at a fourth predetermined temperature for a fourth predetermined time period to obtain a stabilized slurry.

The third performance additive can be at least one selected from a coalescing solvent and a biocide.

The predetermined amount of the third performance additive is in the range of 0.1 mass% to 5 mass% with respect to the total mass of the waterproofing composition The coalescing solvent is 2,2,4-trimethy1-1,3-pentaned ol monoisobutyrate (Texanol) The third predetermined stirring speed is in the range of 500 rpm to 1000 rpm In an exemplary embodiment of the present disclosure, the third predetermined stirring speed is 700 rpm.

The fourth predetermined temperature is in the range of 40 °C to 60 °C. In an exemplary embodiment of the present disclosure, the fourth predetermined temperature is 50 °C.

The fourth predetermined time period is in the range of 5 minutes to 15 minutes. In an exemplary embodiment of the present disclosure, the fourth predetermined time period is 10 minutes.

In a fifth step, the stabilized slurry is thinned by adding an acrylic binder and at least one silicone based emulsion under stirring at a fourth predetermined speed at a predetermined pH and at a fifth predetermined temperature for a fifth predetermined time period to obtain the waterproofing composition.

The predetermined amount of the acrylic binder is in the range of 60 mass% to 80 mass% with respect to the total mass of the waterproofing composition.

The silicone based emulsion is at least one selected from a silane-siloxane emulsion (Tegosivin HE 328) and a mixture of triethoxy(octyl)silane, siloxanes and silicones (Dowsil IE 6694). In an exemplary embodiment of the present disclosure, the silicon based emulsion is a combination of silane-siloxane emulsion (Tegosivin HE 328) and a mixture of triethoxy(octyl)silane, siloxanes and silicones (Dowsil lE 6694) The predetermined amount of the silicone based emulsion is in the range of 3 mass% to 15 mass% with respect to the total mass of the waterproofing composition The fourth predetermined stirring speed is in the range of 500 rpm to 1000 rpm. In an exemplary embodiment of the present disclosure, the first predetermined stirring speed is 700 rpm.

The fifth predetermined temperature is in the range of 40 °C to 60 °C. In an exemplary embodiment of the present disclosure, the fifth predetermined temperature is 50 °C.

The fifth predetermined time period is in the range of 10 minutes to 30 minutes. In an exemplary embodiment of the present disclosure, the fifth predetermined time period is 20 minutes.

The predetermined pH is in the range of 8 to 11. In an exemplary embodiment of the present disclosure, the predetermined p1-1 is 9.

The process for the preparation of a waterproofing composition in accordance with the present disclosure is simple, economic, efficient and environmental 20 friendly.

The present disclosure provides the waterproofing composition that: * is effective against dampness and efflorescence; * can be used on damp substrates having up to 70% moisture level, * is capable of forming a breathable yet water tight film which doesn't allow transport of water and salts through the film; * can be used either as a preventive or as a curative treatment for water related damages; and * has brushable paint like consistency and hence, is easy to apply.

The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.

The present disclosure is further described in light of the following experiments which are set forth for illustration purpose only and not to be construed for limiting the scope of the disclosure. The following experiments can be scaled up to industrial/commercial scale and the results obtained can be extrapolated to industrial scale.

EXPERIMENTAL DETAILS

Experiment 1: Preparation of the waterproofing composition in accordance with the present disclosure General process: In a high speed disperser (HSD), a predetermined amount of at least one first performance additive was mixed in a predetermined amount of water to obtain a mixture followed by adding a crystalline additive under stirring at 700 rpm at 30 °C for 10 minutes to obtain a first slurry. The stirring speed was increased up to 1700 rpm. Predetermined amounts of at least one pigment and at least one second performance additive were added to the first slurry under stirring at 1700 rpm at 50 °C and the stirring was continued for 50 minutes to obtain a second slurry. The second slurry was ground at 50 °C for 15 minutes to obtain a homogeneous slurry. The stirring speed was decreased up to 700 rpm. The homogeneous slurry was stabilized by adding at least one third performance additive under stirring at 700 rpm at 50 °C for 10 minutes to obtain a stabilized slurry. The stabilized slurry was thinned by adding an acrylic binder and at least one silicone based emulsion under stirring at 700 rpm at 50 °C for 20 minutes by maintaining a pH of 9 to obtain the waterproofing composition.

Examples 1 to 7 and comparative examples 1 and 2: The waterproofing compositions of Examples 1 to 7 and comparative examples 1 to 2 were prepared by following the general process as disclosed herein above, with variable components and their amounts as summarized in Table 1 herein below.

Table 1: Variable components and their amounts Sr. In gredients Examp Examp le-2 Examp le-3 Examp le-4 Examp le-5 Examp le-6 Examp le-7 Compa Compar No. le-1 rative ative

Examp Example

le-1 -2 1. Water 11.55 13.55 14.05 9.05 6.55 11.3 10.8 7 88 2. Sodium Crystalli -additive 0.25 0.25 0.25 0.25 0.25 0.5 1.0 0 0 Potassium I artrate 3. Rocima Biocides 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0 4. Tro PI 30 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0 5. Thor NIBS 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0 6. AM 1512A Defoamer 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0 7. Laponite Thickener 0_2 0.2 0.2 0.2 0.2 0.2 0_2 0.2 0

RD

8. Coapur 1 1 1 1 1 1 1 1 o 9. AMP 95 pII 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0 regulator 10. Disperbyk Dispersing 0_3 0.3 0.3 0.3 0.3 0.3 0_3 0.3 0 agent 11. Sy nperonie * . 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0 A9 Stufactant 12. Elotex Anti 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0 ERA 200 Effloresce nee Additive 13. Texanol Coalescing 2 2 2 2 7 2 2 2 0 solvent 14. Elotex Seal Water 0_5 0.5 0.5 0.5 0.5 0.5 0_5 0.5 0 repellent 15. Wacker ES 0 0 0 0 0 0 0 2.5 0 16. TiO2 R- White 1 1 1 1 1 1 1 1.5 0 902 Plus Pigment 17. Talc 10 Extender 0 0 0 0 0 0 0 4 0 Microns 18. Marble 0 0 0 0 0 0 0 4 0 powder 500 mesh 19. Si I quest A Adhesion promoter (Epoxy functional silanes) 0 0 0 0 0 0 0 0.3 0 1S7 20. Primal AC Acrylic 74.5 74.5 74.5 74.5 74.5 74.5 74.5 75 0 3001 Emulsion 21. Tegosivin Silicon 5) 2.5 7.5 10) ) 0 10 1 JE 328 based emulsion 22. Dowsil IF, 2 0 2 2 i -, 2 0,-) Total 100 100 100 100 100 100 100 100 100 Experiment 2: Determination of the performance properties of the waterproofing compositions of Examples I to 7 and comparative examples 1 to 2 prepared in Experiment 1 in accordance with the present disclosure A. Anti-efflorescence and anti-dampness tests: For anti-efflorescence and anti-dampness tests, the method followed is as given below: 1:5 Cement to M-sand mortar panels (1ft X lft X 25mm) were prepared and cured for 28 days (9 panels were prepared). Then the panels were dipped into water for 24 hours. After 24 hours, these panels were taken out of water and the waterproofing compositions of Examples 1 to 7 and comparative examples 1 to 2 (prepared in Experiment 1) were coated by brush and roller (Coverage 50 scift/litre) when moisture on panels was 70% by moisture meter reading (Protimeter Mini Model no. BLD2000). The coating was dried overnight. Then levelling Putty (Asian Wall Putty, Cement based) and Topcoats (Asian Paints Tractor Emulsion) were applied one after another as per regular painting process and dried overnight. Post that panels were immersed 1/3 deep in 20% w/w Sodium Chloride (NaCI) solution. Moisture meter reading was taken periodically and when it showed > 20%, system was considered as failed in the test. Also, visual appearance of salts as white deposit on surface was considered as efflorescence. One control mortar panel without any waterproofing coating but with putty and topcoat was also kept for exposure as control. When the control panel was exposed in water, the appearance of efflorescence was observed on the control panel as illustrated in Figure 1(b). Figure 1(a) illustrates a mortar panel coated with the waterproofing composition of Example 1 (test assembly) before subjecting to Anti-dampness and Anti-efflorescence test. Figure 1 (c) illustrates a surface moisture content on the mortar panel coated with the waterproofing composition of Example 1 after 90 days of exposure showing <6% reading on Moisture Meter and no visual observation of efflorescence on the surface.

The results for anti-efflorescence and anti-dampness tests are summarized in Table 2.

B. Stability Study: The coating compositions of Examples 1 to 7 and comparative examples 1 to 2 prepared in Experiment 1 were subjected to accelerated stability study to understand their in-can stability and shelf-life performance. After 30 days at 55°C, the coating compositions of Examples 1 to 7 were found to be stable as no significant pickup in viscosity was observed. The coating compositions of Examples 1 to 7 didn't show any phase separation or coagulation post accelerated stability test. However, slight syneresis was observed which could be easily mixed.

C. Other properties: Neaative water permeability Density Non-volatile matter and Drying time Other properties such as Negative water permeability, Density, Non-volatile matter and Drying time of the coating compositions of Examples 1 to 7 and comparative examples 1 to 2 prepared in Experiment 1 were studied. The results are summarized in Table 2.

D. Scanning Electron Microscopy (SEM) analysis: To understand the effect of Sodium Potassium Tartrate on Pore blocking performance, Scanning Electron microscopy was conducted, and the formation of crystal growth were monitored with time. The mortar panel coated with the waterproofing composition of Example 1 and the control mortar panel without any waterproofing coating (after 28 days of exposure to moisture) were immersed in water (part of Anti-dampness testing) and taken out after specific periods and were subjected to SEM analysis to monitor Crystal growth. The SEM micrographs are illustrated in Figures 2(a) to 2(c). It was observed that Crystal growth started after 7days of water exposure and optimum growth was observed after 28 days of exposure. After 28 days, no meaningful growth in Crystals was observed.

Figure 2(a) shows the SEM micrograph of the control mortar panel having porosity and no formation of crystals on the surface; whereas Figures 2(b) and 2(c) show SEM micrographs of the mortar panel coated with the waterproofing composition of Example 1 after 28 days of exposure to water where crystals are clearly visible with substantial pore blocking as evident from the micrograph images in Figures 2(b) and 2(c). Figure 2 (b) illustrates a mortar panel coated with the waterproofing composition of Example 1 after 28 days of exposure showing uniform crystal growth and Figure 2 (c) illustrates a mortar panel coated with the waterproofing composition of Example 1 after 28 days of exposure showing pore blocking.

Table 1: performance properties of the waterproofing compositions of Examples 1 to 7 and comparative examples 1 to 2 prepared in Experiment 1

in accordance with the present disclosure

NA: Not Applicable; * Measured by B4 Cup method; ND: Not detected in this method; I -Failure criteria is surface moisture > 20% 5;:^ "1. teri.

Inference of Table 2: The composition of comparative example I comprising only acrylic emulsion along with performance additives without the use of Silane Siloxane emulsion and Sodium Potassium Tartrate, didn't perform beyond 14 days in anti-dampness testing and efflorescence appeared on the panel.

Since Silane and Siloxane emulsion-based products are available in the market for water repellent application, a comparative example 2 was designed with a blend of 10% Silane Siloxane emulsion (Tegosivin HE 328) and 2% Dowsil IF 6694 (Silicone emulsion). However, it showed inferior performance on panels having 70% moisture as it failed after 7 days of exposure. It showed good performance when it was applied on a dry panel (moisture level <5%). Thus, it was concluded that in absence of the acrylic binder and crystalline additive, Silane / Siloxane based emulsion is not capable of providing anti-damp performance over a moist (70%) masonry substrate.

In Example I, all ingredients (acrylic binder, silicone based emulsion, crystalline additive and performance additives) were used together to produce the synergistic effect. The waterproofing composition of Example I showed the best performance as it didn't fail even after 90 days of exposure to water. Surface moisture remained below 6% even after 90 days of exposure (Figure-1 c) Thus, the role of each ingredient (acrylic binder, silicone based emulsion, crystalline additive and performance additives) is critical for the overall performance of the waterproofing composition. Acrylic emulsion forms the breathable watertight film whereas Tegosivin HE 328 penetrates inside the cavities of masonry substrate and effectively blocks the capillary water transport which is main mechanism of efflorescence formation. Anti-efflorescence additive Elotex Era-200 act by reduction of capillary connectivity, size reduction of efflorescence forming crystals and reduction of water permeability. In case of Crystalline additive Sodium Potassium Tartrate, it is mainly acting as a pore blocker by forming insoluble crystalline precipitate.

Further, the waterproofing composition of Example 2 only without Silicone emulsion (Dowsil 1E 6694) didn't perform like the waterproofing composition of Example 1 and failed after 35 days. This shows that the ingredients perform in synergistic manner and all the ingredients are necessary to provide superior performance.

The waterproofing composition of Examples 3 to 5 were prepared by varying the amount of silane-siloxane emulsion (Tegosivin HE 328) as 2.5 mass%, 7.5 mass% and 10 mass% to check the effect of the quantity of silane-siloxane emulsion on the performance of the waterproofing composition of Example 1. At 2.5 mass% of silane-siloxane emulsion, performance was inferior, and the mortar panels didn't pass for more than 21 days (Example 3). However, there was no difference in the performance observed for the waterproofing compositions comprising 7.5 mass% of silane-siloxane emulsion (Example 4) and 10 mass% of silane-siloxane emulsion (Example 5) in anti-dampness test, which implied that the best performance was observed at 5 mass% Silane/Siloxane emulsion.

Similarly, Sodium Potassium Tartrate quantity was also varied from 0.25 mass% (Example 1) to 0.5 mass% (Example 6) and 1 mass% (Example 7). No difference in anti-dampness and anti-efflorescence performance was observed at higher dosage and 0.25 mass% was finalized as an optimized quantity.

TECHNICAL ADVANCEMENTS

The present disclosure described herein above has several technical advantages including, but not limited to, the realization of -a waterproofing composition that; * is effective against dampness and efflorescence; * can be used on damp substrates having up to 70% moisture level; * is capable of forming a breathable yet water tight film which doesn't allow transport of water and salts through the film, and * is economic, and a process for the preparation of a waterproofing composition that; * is simple, economic, efficient and environmental friendly.

Throughout this specification the word "comprise", or variations such as "comprises" or "comprising, will be understood to imply the inclusion of a stated element, integer or step," or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications of such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

The use of the expression "at least" or "at least one" suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the

specification specific to the contrary.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

Claims: 1. A waterproofing composition comprising: i. an acrylic binder; ii. at least one silicone based emulsion; hi. a crystalline additive; iv. at least one performance additive; v. at least one pigment; and vi. water.
2 The composition as claimed in claim 1 comprises: i. 60 mass% to 80 mass% of said acrylic binder; ii. 3 mass% to 15 mass% of said silicone based emulsion; 0.1 mass% to 2 mass% of said crystalline additive; iv. 2 mass% to 15 mass% of said performance additive; v. 0.1 mass% to 2 mass% of said pigment; and vi. ci.s water, wherein said mass% of each component is with respect to the total mass of said composition.
3. The composition as claimed in claim 1 comprises i. 70 mass% to 78 mass% of said acrylic binder; ii. 5 mass% to 10 mass% of said silicone based emulsion; iii. 0.1 mass% to 1 mass% of said crystalline additive; iv. 5 mass% to 10 mass% of said performance additive; v. 0.5 mass% to 1.5 mass% of said pigment; and vi. q.s water, wherein said mass% of each component is with respect to the total mass of said composition.
4 The composition as claimed in claim 1, wherein said acrylic binder is an acrylic emulsion wherein said acrylic emulsion is 100% acrylic polymer of butyl acrylate (BA), methyl methacrylate (MMA) and other functional co-monomers 5. The composition as claimed in claim 1, wherein said silicone based emulsion is at least one selected from a silane-siloxane emulsion and a mixture of triethoxy(octyl)silane, siloxanes and silicones.6. The composition as claimed in claim 1, wherein said crystalline additive is a double salt of tartaric acid.7 The composition as claimed in claim 1, wherein said performance additive is at least one selected from a biocide, a defoamer, a thickener, a pH regulator, a dispersing agent, a surfactant, an anti-efflorescence additive and a coalescing solvent.8 The composition as claimed in claim 7, wherein said biocide is at least one selected from iodopropynyl butylcarbamate, a mixture of chlormethyl/methylisothiazolone and formaldehyde, a blend of 1,2-benzisothiazolin-3-on e and 2-m ethyl -4-i sothi azol i n-3 -one, 2-octyl -4-i sothi azol i n-3 -on e (01T), 4,5-di chl oro-2-octy1-4-i sothi azol in-3 -one (DC OTT) and carbendazim 9 The composition as claimed in claim 7, wherein said defoamer is a hydrocarbon oil-based defoamer) The composition as claimed in claim 7, wherein said thickener is at least one selected from hydrous sodium lithium magnesium silicate and aqueous polyurethane solution 11 The composition as claimed in claim 7, wherein said pH regulator is 2-amino-2-methyl-l-propanol; said dispersing agent is a solution of modified styrene maleic acid copolymer; and said surfactant is polyoxyethylene (9) synthetic primary Cm/C15 alcohol.12. The composition as claimed in claim 7, wherein said anti-efflorescence additive is rosin modified with fatty acid derivative; said coalescing solvent is 2,2,4-trimethy1-1,3-pentanediol monoisobutyrate; and said water repellent is encapsulated triethoxyoctylsilane 13. The composition as claimed in claim 1, wherein said pigment is titanium dioxide.14. A process for the preparation of a waterproofing composition, said process comprises the following steps: a. mixing a predetermined amount of at least one first performance additive in a predetermined amount of water to obtain a mixture followed by adding a crystalline additive under stirring at a first predetermined speed at a first predetermined temperature for a first predetermined time period to obtain a first slurry, b. adding predetermined amounts of at least one pigment and at least one second performance additive to said first slurry under stirring at a second predetermined speed at a second predetermined temperature for a second predetermined time period to obtain a second slurry; c. grinding said second slurry at a third predetermined temperature for a third predetermined time period to obtain a homogeneous slurry; d. stabilizing said homogeneous slurry by adding at least one third performance additive under stirring at a third predetermined speed at a fourth predetermined temperature for a fourth predetermined time period to obtain a stabilized slurry; and thinning said stabilized slurry by adding an acrylic binder and at least one silicone based emulsion under stirring at a fourth predetermined speed at a predetermined pH at a fifth predetermined temperature for a fifth predetermined time period to obtain said waterproofing composition.15. The process as claimed in claim 14, wherein said predetermined amounts of said: i) acrylic binder is in the range of 60 mass% to 80 mass%; ii) silicone based emulsion is in the range of 3 mass% to 15 mass%; iii) crystalline additive is in the range of 0 1 mass% to 1 mass%; first, second and third performance additives are in the range of 2 mass% to 10 mass%; v) pigment is in the range of 0.1 mass% to 1.5 mass%; and vi) q.s water, wherein said mass% of each component is with respect to the total mass of said waterproofing composition.16. The process as claimed in claim 14, wherein said acrylic binder is an acrylic emulsion, wherein said acrylic emulsion is 100% acrylic polymer of butyl acrylate (BA), methyl methacrylate (MMA) and other functional co-monomers.17 The process as claimed in claim 14, wherein said silicone based emulsion is at least one selected from a silane-siloxane emulsion and a mixture of triethoxy(octyl)silane, siloxanes and silicones.18 The process as claimed in claim 14, wherein said crystalline additive is a double salt of tartaric acid 19 The process as claimed in claim 14, wherein said first performance additive is at least one selected from a biocide, a defoamer, a thickener, a pH regulator, a dispersing agent and a surfactant; said second performance additive is at least one selected from an anti-efflorescence additive and a water repellent, and said third performance additive is at least one selected from a coalescing solvent and a biocide.The process as claimed in claim 19, wherein said biocide is at least one selected from iodopropynyl butylcarbamate, a mixture of chlormethyl- /methylisothiazolone and formaldehyde, a blend of 1,2-benzisothiazolin-3-one and 2-methyl-4-isothiazolin-3-one, 2-octy1-4-isothiazolin-3-one (OTT), 4,5-dichloro-2-octy1-4-isothiazolin-3-one (DC OTT) and carbendazim.21. The process as claimed in claim 19, wherein said defoamer is a hydrocarbon oil-based defoamer.22. The process as claimed in claim 19, wherein said thickener is at least one selected from hydrous sodium lithium magnesium silicate and aqueous polyurethane solution.23. The process as claimed in claim 19, wherein said pH regulator is 2-amino- 2-methyl-1 -propanol; said dispersing agent is a solution of modified styrene maleic acid copolymer; and said surfactant is polyoxyethylene (9) synthetic primary Cu/C15 alcohol 24. The process as claimed in claim 19, wherein said anti-efflorescence additive is rosin modified with fatty acid derivative; said coalescing solvent is 2,2,4-trimethy1-1,3-pentanediol monoisobutyrate; and said water repellent is encapsulated triethoxyoctylsilane.25. The process as claimed in claim 14, wherein said pigment is titanium dioxide.26 The process as claimed in claim 14, wherein said first predetermined temperature is in the range of 20 °C to 40 °C; said second predetermined temperature, said third predetermined temperature, said fourth predetermined temperature and said fifth predetermined temperature are independently in the range of 40 °C to 60 °C 27 The process as claimed in claim 14, wherein said first predetermined speed, said third predetermined speed and said fourth predetermined speed are independently in the range of 500 rpm to 1000 rpm; and wherein said second predetermined speed is in the range of 1500 rpm to 2000 rpm.28. The process as claimed in claim 14, wherein said * first predetermined time period is in the range of 5 minutes to 15 minutes, * second predetermined time period is in the range of 30 minutes to 80 minutes, * third predetermined time period is in the range of 10 minutes to 20 minutes; * fourth predetermined time period is in the range of 5 minutes to 15 minutes, and * fifth predetermined time period is in the range of 10 minutes to 30 minutes.29. The process as claimed in claim 14, wherein said predetermined pH is in the range of 8 to 11.