RU2189411C2 - Method of manufacturing layered roofing and waterproofing material - Google Patents

Abstract

FIELD: manufacture of building materials. SUBSTANCE: manufacture of layered coating is characterized by than bitumen or polymer-bitumen binder is applied onto fibrous support simultaneously over upper and lower layers, which are also separated from each other by a polymer film at temperature 120-150 C, followed by doubling material at pressure 0.5-2.0 kg/cu.cm and subsequent cooling to 15-30 C. Strength of roofing and waterproofing material is enhanced owing to reduced internal stresses in material and to increased crack resistance thereof. EFFECT: increased technical and economic characteristics. 6 ex

Description

 The invention relates to the building materials industry and can be used to protect various building structures and structures mainly as roofing and waterproofing materials.

 The present invention is a method of manufacturing a layered material, which consists of two outer and one inner layers, the outer layers are made of a fibrous base impregnated with a bitumen composition, the inner one is made of a polymer film.

 Currently, laminated materials are widely used in various fields of industry. It is known the use of layered material in honeycomb structures (RF patent 2126327), in the manufacture of elastic gaskets (RF patent 2009891). Various layer structures using various materials and impregnating compositions are described. So in the patent EP 0414143 A1, E 04 D 5/12, 1991 described material containing at least three layers (carrier, adhesive and decorative), quite expensive due to the use of a special adhesive layer. In a number of patents (WO 98/05495, 32B 11/04, EP 0 287 078 L2, 32B 11/10/10, 1988) multilayer materials are proposed, including substrate layers, bitumen layers, as well as cushioning and protective layers.

 The disadvantage of such materials is the presence in their composition of bitumen layers, which without modifiers are quite fragile, with low crack resistance.

 RU 2117578 describes a multilayer material containing a substrate coated on both sides with bitumen layers and an upper protective layer preliminarily prepared from melt-mixed components of a composition consisting of at least a thermoplastic and rubber powder and applied to the molten bitumen at a temperature.

 The disadvantage of this material is the preliminary molding of the upper layer of the material in the molten components. This is an independent technological process that requires appropriate equipment and development of technological modes. In addition, the preformed layer upon joining with molten bitumen cannot form a monolithic material and internal stresses appear at the boundary of such layers, which reduce the strength of the material as a whole.

 Along with the finished multilayer material, multilayer coatings are known that are formed from individual materials directly on the surface to be protected (roofing, etc.). So in the patent RU 2085674 C1, cl. E 04 D 5/00, 1997, a multilayer roofing is proposed, made in the form of canvases, consisting of a base and bituminous compositions containing a styrene-butadiene-styrene copolymer for the lower layer and atactic polypropylene for the upper layer, and a plastic film or quartz sand. The described material is the closest analogue of the invention and is selected by the authors as a prototype.

 The disadvantage of this multilayer coating is the time-consuming operation of laying its layers: lower, intermediate and upper, which provides for the melting of the tar layers along the entire surface of the joint, while the degree of melting of the polyethylene film strip should be 40-50%. In the application of quartz sand, an additional laborious operation is introduced to apply and fix it on the lower layer and dock the upper layer with it. This technology of forming a multilayer coating does not guarantee uniformity of properties over the entire surface, which can lead to stress concentrators and a decrease in the coating strength.

 Modern roofing and waterproofing roll materials from a fibrous base and a bitumen-containing binder are obtained by impregnating the base and applying a binder consisting of bitumen, polymer, plasticizer and mineral filler on it from 2 sides. The roofing and waterproofing of this material is produced, as a rule, in 2 layers. The rolled web is laid with an overlap in length and fastened at the joints and with the top layer by fusing the joined surfaces and subsequent pressing with special devices.

 The aim of the invention is to develop a method of manufacturing such a rolled roofing and waterproofing material for roofing and waterproofing carpet, which would meet modern requirements for roofing and waterproofing coatings, operated in various climatic conditions, and performed the functions of both the upper and lower layers. This may be a multilayer material, including a set of layers that provide requirements for roofing and waterproofing coatings. A multilayer coating simplifies roofing and waterproofing by eliminating the process of applying a second layer. The connection of the lower and upper layers is carried out in the process of manufacturing a multilayer material, which allows for its monolithicity, minimal internal stress and high strength of the material. And to increase the crack resistance of the multilayer material with this technology of connecting the layers, an introduction of a polymer layer between them, which acts as a damping medium capable of stopping the process of crack development, is provided.

 The proposed method of manufacturing a multilayer material provides a monolithic composition consisting of two layers of a fibrous base, impregnated with a bitumen-containing composition, and a polymer film placed between them. The outer surfaces of the material are protected by a coating made of a plastic film or a dust-like powder, and on the top instead of the above, a coarse-grained powder can be used.

 The proposed method for producing material with desired characteristics as any bitumen and bitumen-polymer binders can be any binders based on this.

 The following examples show the properties of the material obtained by the described method.

 Example 1

The glass fabric base of both layers is impregnated with a binder of the following composition, wt.%:
Oil bitumen, construction, BN 70/30 brand GOST 6617-76 - 70
Industrial oil, GOST 26799-88, rev. 1-4. - 2
Mineral powder, GOST 16557-78 - 28
Between the layers laid a plastic film 90 microns thick. The outer surfaces are coated with kaolin. The resulting material has the following physical and mechanical characteristics:
heat resistance - 78 ^o C;
flexibility on a beam with a diameter of 25 mm - minus 7 ^o C;
breaking strength - 50 kgf;
water resistance is absolute.

 Example 2

Two layers of polyester fiber are impregnated and coated on both sides with a binder of the following composition, wt.%:
Oil bitumen, road, BND 60/90 brand, GOST 22245-90. - 63
Thermoelastoplast divinyl styrene, grade DST-30R-01, TU 3840327- 90 - 8
Mineral powder, GOST 16557-78 - 29
Between the layers laid a plastic film with a thickness of 80 microns. A protective coating of a 7 mm thick polyethylene film is applied to the lower surface, and coarse-grained vermiculite topping is applied to the upper surface. Physico-mechanical characteristics:
heat resistance - 85 ^o C;
flexibility on a beam with a diameter of 25 mm - minus 15 ^o C;
breaking strength - 60 kgf;
water resistance is absolute.

 Example 3

The glass fabric base of the lower layer is impregnated with a binder, described in example 1, and the upper - binder, described in example 2. A polymer layer of 90 mm thick is laid between the layers. A protective coating of kaolin is applied on the lower surface, and coarse-grained granite chips on the upper surface. Physico-mechanical characteristics:
heat resistance - 85 ^o C;
flexibility on a beam with a diameter of 25 mm - minus 10 ^o C;
water resistance is absolute.

 Example 4

The glass fabric base of both layers is impregnated with a binder of the following composition, wt.%:
Oil bitumen, construction, BN 70/30 brand, GOST 6617-76 - 68
High pressure polyethylene, ground, GOST-16337-77 - 5
Industrial oil I-40A, GOST 26799-88 rev. 1-4 - 3
Mineral powder, GOST 16557-78 - 24
Between the layers laid a plastic film with a thickness of 80 microns. A protective coating of kaolin is applied to the lower surface, and coarse-grained sprinkling of vermiculite is applied to the upper surface. Physico-mechanical characteristics:
heat resistance - 90 ^o C;
flexibility on a beam with a diameter of 25 mm - minus 15 ^o C;
breaking strength - 70 kgf;
water resistance is absolute.

 The proposed method allows one material to use a fibrous base of various chemical nature, change the binder formulation and combine different layer formulations and thus vary the properties of the multilayer material in accordance with its purpose.

 A method of manufacturing the proposed material is as follows.

The fibrous base of the layers is passed through a bathtub filled with a bitumen binder, through a system of rolls installed at different levels. The binder-impregnated base is fed to squeezing rolls, where the excess of the binder is pressed. After squeezing rolls, a polymer film is laid between the layers along the entire width of the layer. Then, on special rolls, the layers are joined. The duplicated material is passed through a system of tension rolls, where at a temperature of 120-150 ^o C and a pressure of 0.5-2.0 kgf / cm ^{2 the} final formation of the material. Before the tension rolls, a protective coating is applied to the outer layer of the material in the form of a film, dusty or coarse-grained dusting. Cooled to a temperature of 15-30 ^o With the material wound into rolls.

 The described method allows to obtain a material with a different binder formulation for the lower and upper layers, for which the binder is impregnated in different baths. Next, the process of forming the material is carried out as described above.

 Example 5

Two layers of the fibrous base are passed through an impregnating bath with a binder, described in example 1, at a temperature of 140 ^o C, through a system of rolls installed at two levels in height for the lower and upper layers. After squeezing the rolls from a special roller, a plastic film 80 microns thick is wound and laid between the impregnated layers. The layers are connected on special rolls, kaolin is applied to the lower surface, vermiculite is applied to the upper surface, then the material enters the tension roll system, where it is formed at a pressure of 1.8 kgf / cm ² , and then to the cooling rolls. The material, cooled to 20 ^o C, is wound into rolls.

 Example 6

The process of obtaining the material is similar to that described in example 5, but the lower layer is impregnated with a binder of the formulation described in example 1, the upper one is made with the binder described in example 2, duplication is carried out at a temperature of 130 ^o C and a pressure of 1.0 kgf / cm ² .

 The material obtained by the proposed method has the following advantages.

 The use of a multilayer monolithic material that combines the functions of the lower and upper layers increases the strength of the roof and waterproofing by reducing internal stresses and reducing the area of the connecting surface.

 Composite material, consisting of two fibrous layers, impregnated and coated with a binder, and one intermediate of a polymer film 70-100 microns thick, helps to repay cracks and, therefore, increases the crack resistance of coatings.

 The multilayer material excludes the laying of the second layer, which ensures high technical and economic indicators.

Literature
1. RF patent 2009891, cl. B 32 B 7/04, 1991

 2. RF patent 2119513, cl. C 08 L 95/00, 1998

 3. RF patent 2117578, cl. B 32 B 11/04, 1998

 4. RF patent 2126327, cl. B 32 B 5/26, 1993

 5. Patent EP 0414143 A, E 04 D 5/12, 1991

 6. Patent EP 0287078 L2, 32V 11/10, 1998

 7. A.A. Valyukhov. Roofing and waterproofing material "Luberit". J. Construction materials, 12/97.

 8. Patent RU 2085674, cl. E 04 D 5/00, 1997

Claims (1)

A method of manufacturing a multilayer roofing and waterproofing material, including the impregnation of the fibrous base of the upper and lower layers with a bituminous or bitumen-polymer binder, laying an intermediate layer of polyethylene film between them, applying protective coatings on the outer surfaces of the material in the form of a polyethylene film, dust or coarse-grained dusting, followed by joining the layers at a temperature and cooling, characterized in that the connection of the layers is carried out between a pair of rolls at a temperature of 120-150 ^o With and a pressure of 0.5-2.0 kgf / cm ² .