MXPA98006946A - Lamina asphalt protection section - Google Patents

Abstract

A protective layer is described for use in a waterproof or roofing system and a method for making the protective layer in a laminable form. The protective layer includes a felt core matrix and a typical saturated asphalt in many roofing products. The protection layer also includes a single coating applied to the matrix. The coating comprises a mixture of asphalt waste, a relatively soft asphalt and a filler. The addition of the coating to the mixture results in a product that is flexible enough to allow the product to be laminated without cracking, yet be sufficiently puncture and rub resistant to adequately protect an underlying membrane.

Description

LAMINABLE ASPHALT PROTECTION SECTION BACKGROUND OF THE INVENTION A. Field of the Invention The invention relates to materials used as barriers to protect waterproof membranes or roofing from damage during and after the installation of these membranes. More particularly, the invention relates to a protection section that can be supplied and stored in a rolled form that is made using cut asphalt roofing.

B. Background In the manufacturing of roofing and waterproof, sheet membranes are usually installed in areas where they are exposed to environments that can puncture, break or otherwise damage the integrity of the sheet. For example, waterproof membranes are applied to almost all low-level portions of base walls, beach platforms and bridge platforms. A puncture of a waterproof membrane may require expensive excavation and extensive repair or replacement work on the damaged portion to restore the integrity of the waterproof system. Generally, a protective section is installed above or adjacent to the membrane surface to prevent punctures and allow work to proceed up or adjacent to the membrane. Similarly, the protection section is used above the ground to protect the membranes from damage at most construction sites. The protection sections have been manufactured from a variety of materials including asphalt and bituminous compositions. It is important that a stretch of protection is strong and resistant to punctures to help prevent damage to the underlying membrane. As such, the protection sections have typically been manufactured as rigid cartons. The boards are laid on top of, or adjacent to, the waterproof membranes in areas where the membrane installation is complete. An additional protective cardboard is installed as more membrane is installed. A tester cuts each cardboard as required to completely cover and protect the installed membrane. Protection cartons are typically of normal sizes, either 0.9144 m by 1.52 m, or 1.27 m by 2.43 m, and may have a thickness of 0.317 cm or 0.635 cm (which are normal sizes in the industry). The cartons are stacked and sold as a unit. The maximum coverage area of a commercial unit of rigid protection cardboard is at least 2,972 m2, not representing the amount of usable cardboard lost when the cardboard is cut to be fixed to an application. A disadvantage in the existing protection sections is that the rigid form of the cartons makes transport and storage uncomfortable. The installation of rigid cartons is insufficient. Since waterproof and roofing membranes can be rolled or applied as a liquid, cartons must be individually carried from the storage area resulting in additional work and time. Also, during application, much of the surface of the usable protective board can be lost when the boards are cut to be fixed to the application. A separate problem in the roofing industry is the problem of how to dispose waste materials from the production of new asphalt roofing products, and the removal of used or cut materials when removing asphalt gravel or similar roofing materials. Asphaltic roofing products typically include organic mat (felted) or inorganic (glass fiber) saturated with asphalt to make the roofing product is waterproof additional protective coatings which are added as asphalt surface and mineral. The gravel is produced in flat sheets or strips designed for easy installation. Generally, gravel includes tabs, or cuts, which provides flexibility and improves the appearance of the portion of the gravel that is exposed after installation. To produce asphalt gravel with tabs, a flat sheet or strip is manufactured and then cut and separated into the final shape that generates the waste material. In the past, this waste material was not reused in the product sold and presented a waste problem. The application of laminated roof, which is similar in composition to asphalt gravel, has been known in the industry. The sheet roofing is usually applied to a substrate through a heating process or using adhesives. Laminated roofing is used in ceilings and as decking. Recently, laminated roofing has been used as a protection section. It is difficult to use laminated roof type products as a protection section, since hot and adhesive application procedures can have dangerous effects on waterproof membranes and can result in very expensive membrane fafas. In addition, if the laminated product is not adhered, it is subjected to lamination due to the asphalt "memory" of its laminated condition. Finally, the barrier can be displaced by construction traffic leaving the membrane exposed and subjected to puncture.

COMPENDIUM OF THE INVENTION The present invention overcomes the problems with the roofing and waterproofing industries by providing a protective section made of asphalt gravel and roof trimming in a laminated form. The laminated protection section can be transported, stored and used in an efficient way through the roof and waterproofing markets. In addition, the invention reduces the waste expense and the new material costs by using waste materials. More specifically, the invention reduces the time and work involved with the installation of a protection section. This is especially useful in waterproof applications of intense work such as bases, platforms and bridge platforms. An applicator can easily follow the installation of the membrane by unwinding the protection section as a barrier to preserve the membrane. As one area is completed, the applicator only needs to cut the end of the roll, and store the roll when the next application is to begin. Asphalt "memory" in the protection barrier is reduced by preventing lamination after installation As such, the use of adhesives or application of heat is unnecessary with the laminated protection section of the present invention. The protection section also increases the usable area per commercial unit, For example, while a commercial unit of rigid protection board generally covers almost 2,972 m2, the laminated protection section of the present invention covers approximately 9,290 m2 with a thickness of 0.3175 cm and approximately 4.64 m2 in a thickness of 0.635 cm In this way, while the total size of a commercial unit of the laminated protection section is smaller than the size of a corresponding commercial unit of rigid cardboard, the laminated protection section unit provides a Greater coverage area.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a cross-sectional view of a laminated asphalt protection section. Figure 2 is a cross-sectional view of a typical application of the invention. Figure 3 is a cross-sectional view of another typical application of the invention.

DESCRIPTION OF THE PREFERRED MODALITIES The product of the present invention includes a felt layer. The felt can be a common felt in the roofing and waterproofing industry, and can be organic or inorganic. Different felt sizes can be used depending on the thickness of the desired final product. For example, in one embodiment of the present invention, a 65 gauge felt can be used to produce a laminated protection section having a nominal thickness of 635 cm. In another embodiment, a 40 gauge felt is used to produce the laminated protection section of the invention having a nominal thickness of 0.3175 cm.

Other felts with variable thicknesses can be used, depending on the desired strength and flexibility of the final product. The felt is impregnated with saturating asphalt. To form a matrix, it is understood in the roof formation and water approval industries that the felt must be fully and completely saturated for a better function. Ideally, the entire surface area of the felt, and all openings between the fibers, will be coated through the saturating asphalt to produce a solid, waterproof matrix. Soft asphalts have been very successful for this use. However, soft asphalts generally have a relatively low melting point, making the saturated felt ineffective because it has been easily worn and punctured. Therefore, at least one coating of a relatively hard asphalt material is added. This makes the product suitable for storage, handling and installation. The coating asphalt has a higher softening point and is more resistant to wear and puncture. Referring to Figure 1, the laminated asphalt protection section 10 of the present invention uses an original combination of roofing waste, filler, and asphalt to form a coating mixture 12. This mixture 12 is used to coat the saturated felt matrix 14 and produce a stretch. of protection or barrier that is different in its ability to laminate without cracking and is highly resistant to puncture. The granular layer 16 can be added to the upper part of the protective section 10 to act as a separating layer for the invention in its laminated form. Other suitable materials can be used as the separation layer. The waste of asphalt gravel, either from the cleaning cut generated by the production and cutting of new gravels or "detached" gravels removed from faulty or worn gravel roofs, varies in size and composition. The composition of the gravel is not considered important, since the asphalt felt and the coating combination are relatively similar from gravel to gravel and from manufacturer to manufacturer. The built-in waste product can be another waste of roofing having a composition similar to asphalt gravel, such as rolling roof. The method for making the laminated protection section includes grinding, spraying or otherwise reducing the roofing waste to a particle size that allows the roofing waste to be used in the new composition. Any type of conventional grinding mill, spray equipment or other grinding equipment can be used if the result is fine particles. Preferably, the maximum size of the roofing waste particles after milling is not greater than 1.27 cm. Grinding to a finer consistency, such as essentially a powder, is acceptable and can improve mixing. A filler product added to the mix increases flexibility in the final product. The filler also extends the amount of protection section produced using a given amount of waste. In one embodiment, limestone can be used as the filler, although other fillers common in the roofing industry can be used such as dolomite, ash dust, silica, granite, rhyolite, syenite, basalt, diabase, green rock, slate, kettle scum, and others. The virgin asphalt is included in the coating mixture. The virgin asphalt reduces the viscosity of the mixture. The flow of roofing or other soft asphalt formation is preferred. Generally, the asphalt can be heated to a soft state before the waste particles and the filler are added.

The waste of asphalt roof formation commonly contains a high percentage of asphalt grade of coating which is relatively hard. If the coating grade asphalt is not tempered with the flow of softer roofing or soft asphalt, the protective section may crack when rolled. Accordingly, it is desired to utilize the roof formation flow having a softening point approximately between 26.6 and 40.5 ° C. However, asphalts with softening points as high as 65.5 ° C can be used. The amount of waste, filler and asphalt in the mix is important to obtain various characteristics. In a preferred embodiment, the protection section includes approximately 53% of the waste of the asphalt rusted roof, approximately 27% of new asphalt, and approximately 20% of the limestone filler. These percentages are given as an example of a possible mixture that can be used to produce a commercially acceptable product. It has been found that the listed percentages result in a coating for the protection section that allows the final product to be produced in the form of a sheet, to roll up and unwind at a cold temperature, and not to soften at higher temperatures. In general, a scale of asphalt roof waste of between 45% and 60% is preferred, and a soft asphalt scale of between 15% to 35%, with the remaining percentage being filler. However, a section of protection that can work can be created using a scale of waste of asphalt roof of between 1% and 70%. Other percentages, and other fillers will result in products having different characteristics of flexibility, puncture resistance and temperature stability. These changes are necessary to meet the demands of many different applications. By varying the percentages, the present invention can be used for a variety of applications, each having its own particular blend of material capabilities. After the appropriate percentages of ingredients have been added, these can be mixed together. Any common mixing equipment can be used, however, it is beneficial to use a high shear mixer, since the size of any remaining large waste particle can be reduced during mixing. The coating mixture should be at a substantially uniform temperature and at a substantially uniform consistency when mixing is complete. When the coating mixture is complete, it is added to the saturated felt using a conventional manufacturing method, such as gravity drop of the coating on the surface. The coating is extended or scraped to achieve the desired uniform thickness. Granules can be added for additional rubbing resistance and thickness. Afterwards, the protection section is cooled and laminated. The product is typically manufactured in rolls with a width of 91.44 cm. The laminated protection section of the present invention covers 0.0092 m2 in a thickness of 0.317 cm, and 4.64 m2 in a thickness of 0.635 cm. The difference in coverage area is a result of a consistent roll size designed for easy commercial handling and storage. The roll thickness of 0.635 cm and 0.317 cm will be a similar size and weight. As illustrated in Figure 2, the protection section 10 of the present invention is used as part of a sheet waterproof system in the same manner as other commercially available protection sections. After the waterproof sheet 20 is adhered to the structure being waterproofed 30, the protective section 10 is applied adjacent to the waterproof sheet 20 to protect the waterproof sheet. of puncture caused by construction trafficfilling, or the addition of an upper structure 32. In the case of vertical water proof applications, as illustrated in Figure 3, the protection section 10 is directly attached to the surface of the water protection sheet 20 using any variety of adhesive materials, an asphalt-based adhesive as a typical choice. The most common use for the protection section product described is in horizontal waterproof systems to avoid damage by construction traffic. In this application, the protection section is placed on top of the foil waterproof membrane. The description of the present invention is intended to be an example of some embodiments of the invention and not limitations. Many variations can be made to the described embodiments without departing from the scope and spirit of the present invention. For example, since the above description is directed to a composite material of specific protection section having certain characteristics of flexibility and softening, the present invention is applicable to reuse many forms of roof waste to create protection sections having variable characteristics. The present invention is intended to be limited only by the scope and spirit of the following claims.

Claims (8)

1. - A barrier material comprising: a) a matrix, the matrix having two opposite sides and including a felt and a saturating asphalt applied to the felt; b) a coating applied to both sides of the matrix, the coating including the mixture of asphaltic waste material, a relatively soft asphalt and a filler; and c) a granule material attached to an opposite side.

2. The barrier according to claim 1, wherein the asphaltic waste material is roof-forming particles.

3. The barrier according to claim 2, wherein the roof forming particles are ground.

4. The barrier according to claim 2, wherein the coating is mixed using a high shear mixer or other mixer that reduces the roof formation particles.

5. The barrier according to claim 1, wherein the filler is limestone. 6.- A method for making a protection section that includes the steps of: a) reducing the waste of asphalt to small particles; b) heating a soft asphalt; c) add small particles of asphalt waste to hot soft asphalt; d) mix the hot soft asphalt and small particles of asphalt waste to a mixture of substantially uniform consistency; e) add a filler to the mix; f) coating a mixture of felt and asphalt with the mixture to produce a sheet; g) cooling the sheet; and h) laminating the cooled sheet. 7. The method according to claim 6, wherein the asphalt waste comprises cut-out of asphalt roof. 8. A coating mixture comprising: a) approximately 45% to 60% waste of asphalt roof reduced to fine particles; b) approximately 15% to 35% soft asphalt; and c) approximately 5% to 40% filler.