WO2012015336A1

WO2012015336A1 - Method for the pollution-free repair of a bitumen-polymer composite roof covering

Info

Publication number: WO2012015336A1
Application number: PCT/RU2011/000539
Authority: WO
Inventors: Сергей Иванович КОВАЛЕВ
Original assignee: Kovalev Sergey Ivanovich
Priority date: 2010-07-29
Filing date: 2011-07-21
Publication date: 2012-02-02

Abstract

The method for the pollution-free repair of a bitumen-polymer composite roof covering is used for restoring roof coverings and/or for manufacturing new coverings directly on the roofs of structures. The method comprises, in a single technological cycle, removing the roof covering containing bitumen, roofing felt and mineral and other impurities, pulverizing said materials and subsequently loading them into the working chamber of a device in which the components of the mixture are processed and mixed with added plasticizers and modifiers specified under technical regulations. The roof covering is prepared in a single device by means of thermomechanical action on the material mixture, said action resulting in improved plastic, water-repellent and adhesive properties while also removing excess water from the bitumen-polymer composite material mass undergoing mixing.

Description

METHOD FOR NON-WASTE REPAIR OF BITUMINO-POLYMERIC

COMPOSITE ROOF COVERING

A non-waste repair method for a bitumen-polymer composite roofing is used in construction to restore and / or create new bitumen roofing coatings applied to flat roofs on buildings and structures for various purposes.

A known method of non-waste recycling of roofing material (“Roofing systems, materials and technologies”, LLC “Stroyinform”, publ. “Phoenix”, 2006, p. 17), which consists in the fact that the old roof is removed and crushed, melted in a heat generator with electric heating to 180 ° C, after which the mass is laid on the roof, sometimes fresh bitumen is added.

The disadvantage of this method is that the old roofs were made of materials on oxidized bitumen without modifying additives with heat resistance of 80 ° C, which requires the protection of the upper layers of gravel in light colors.

A known method of restoring roofs from bitumen-containing materials (patent RU2203373). The method is used in the restoration of old and / or manufacturing of new roofs from the material of old soft roofs made of bitumen-containing materials. The cleaned roof is treated with a molten primer on a bitumen basis. The old ruberoid coating is crushed, mixed with heating and dehydrated at the same time. The finished mass is applied to the primed surface, after which this surface is treated with molten bitumen. After cooling, the surface is rolled up with a manual or mechanical roller. To protect against direct sunlight and heating, an additional layer of material with low light absorption is applied.

The disadvantage of this method is that the main defect of the old roof is not eliminated - the bitumen material is old, i.e. the balance between the maltes and asphaltenes of the dispersed bitumen system remains the same. Remelting instantly and for a short time eliminates cracking and water saturation of bituminous roofing material without restoring the resource of its water resistance. Thin layers of primer and an external coating of fresh (standard) bitumen do not solve the problem of the durability of such a coating.

A known method of restoring roofs from bitumen-containing materials (patent RU2145374). In the method of restoring roofs from bitumen-containing materials, including cleaning the roof from the old coating and the subsequent application of bitumen-containing material, when cleaning the roof, all layers of the old coating are removed, bitumen is separated from the base of the old coating by melting and draining it. Bitumen is separated from the base of the old coating and the preparation of mastic is carried out at the site of roofing in a mobile unit having a heating chamber of the old coating with a grate basket for the base installed in it. The base is crushed in a grinding chamber until a particle cross section of 0.01-2.0 mm is reached, at least 25% of the obtained particles are combined with fused and / or new bitumen, mixed in a mixing chamber when heated to form a paste-like mastic, which is applied to the roof at least one layer 3–25 mm thick, followed by rolling. In this case, the base can be crushed to achieve a length of 0.05-3.0 mm for at least 25% of the obtained particles. The content of bitumen or base in the mastic is by weight 0.9-1.1% of their content in the bituminous material of the old coating. After applying mastic to the roof, it is rolled by exposure to a roller weighing 50-70 kg directly or through a layer of rolled or sheet roofing material, which becomes the top layer of the restored coating.

The disadvantage of this method is that the method includes a large set of technical devices having a narrow functional purpose: installation for the separation of bitumen from the base; grinding chamber; mixing chamber; skating rink, as well as a large number of technological operations: removal of the old roofing; its preliminary grinding for loading into the installation for separation of bitumen; separation of bitumen from the base; grinding the base; the preparation of mastic by mixing bitumen and crushed base; applying mastic to the roofing surface; mastic coating with rolled or sheet roofing material; rolling the roof with a skating rink. The method does not take into account the difference between new bitumen and old bitumen from the restored roof, which does not provide a stable quality of the roofing.

A known method and installation for the processing and disposal of roofing bitumen-containing materials (patent RU2244731), according to which the waste is crushed, loaded into a boiler with a furnace part to melt the bitumen and separate it from the cardboard base in the presence of a liquid contact coolant (waste oils and / or low-quality oil products) . Waste heating is carried out in several stages: in the first of which the waste is heated to a temperature of 100-110 ° C for 2 hours, kept in the second stage for 1 hour to remove 80% moisture, in the third stage the waste is heated to 180-235 ° C for 30-60 minutes, the molten bitumen and cardboard pulp are cooled to 140 ° C, the cardboard pulp is washed in a dissolving bitumen reagent (kerosene or white spirit with diesel fuel )

The disadvantage of this method is the complexity of the process of processing roofing waste; receiving at the process outlet not a finished product, but only a semi-finished product that requires further processing; use in the process of processing standard commercial components - kerosene or white spirit with diesel fuel; the need for separation and collection of processed products, the use of related processing materials separately: bituminized cardboard for the production of roofing materials and / or as a combustion material, the liquid phase in the production of bitumen varnish, soot in the manufacture of rubber products or as a dye or as a pigment. Used oils and / or low-quality petroleum products are used only as a liquid contact coolant.

There is a method of processing bitumen roofing materials (patent RU2251456), which includes grinding bitumen roofing materials, sorting the crushed material into bitumen powder and bituminized cardboard, using at the stage of grinding water in an amount of 1-15% by weight of the processed material (detergent can be dissolved in water ), while providing a high-speed rotation of the knives to create a fine droplet mist enveloping crushed material, excluding its sticking on the inner surface of the chambers grinder, capture the dusty bitumen formed during the grinding process, which, together with the bitumen powder, is subjected to remelting simultaneously with its dehydration. As a result of recycling, the following materials are obtained: secondary bitumen - 60%; bituminized cardboard - 30%; bitumen-mineral sludge - 10%.

The disadvantage of this method is: obtaining at the output of the process not a finished product, but only a semi-finished product that requires further processing; the use of equipment whose dimensions do not allow it to be placed in the area of repair work (on the roof), the need to sort the crushed material into bituminous powder, bituminized cardboard and mineral residue; as well as the need for transportation, warehousing and accumulation of the obtained components before putting them into production.

The task to be solved by the claimed method is aimed at creating an all-weather method for non-waste repair of bitumen-polymer composite roofing coatings, implemented using a multifunctional device installed directly on the roofing surface, in which waste-free and low-cost processing of raw materials from long-standing heterogeneous bitumen-containing roofing coatings is carried out, which are previously dismantled and ground by known methods, through their stepwise thermomechanical processing to a high degree of uniformity, phased application in the mixed material of special additives (ingredients) - modifiers and plasticizers ators for restoring the plastic, hydrophobic, adhesive and strength properties of a bitumen-polymer composite material to standard values, its unloading, and also the formation of a bulk seamless roofing from it by known methods.

The weighted average group composition of spent bitumen roofing is given in table 1.

Table 1

The problem is solved due to the fact that the inventive method of repairing a bitumen-polymer composite roofing includes removal (special treatment of the roof surface after dismantling of the coating is not performed) and grinding of the old roofing by known methods, its phased thermomechanical processing using a multifunctional mixing device that implements technological functions mixing and dispersing, melting, dehydration and removal of other gases from the working chamber of mixing, plasticization, modif cation and bulk (dispersed) reinforcement within the framework of a single technological cycle (redistribution) according to the conditional scheme: loading of component 1 - exposure1 (stage1), - loading of component 2 - exposure2 (stage2), exposure3 (stage3), - - loading of the component - exposureM ( stage H), including:

loading the plasticizer (oil fraction) in an amount of 10-H5% by weight of the coarsely ground roofing (hereinafter referred to as the raw material) that is gradually loaded into the mixing device and its simultaneous activation by stirring in any direction and raising the temperature to + 60 ° C at the end of the stage (the plasticizer performs the function liquid coolant); loading (phased) raw materials in portions of 1/3 of the effective volume of the mixing chamber with increasing temperature of the mixture (the first portion of the raw material is up to 10 minutes at a temperature of the mixture from +60 to + 90 ° C; the second is up to 10 minutes at a temperature mixes from +90 to + 120 ° С; 3rd — up to 10 minutes at a temperature of the mixture from +120 to + 140 ° С) with continuous reverse stirring (at least 1 minute in one direction) from the moment of loading the 1st portion raw materials (at this stage begins: the melting of old bitumen and the restoration of its colloidal system initiated by a plasticizer, the evaporation of water, sintegration of ruberoid base fragments, dispersion of the emulsion and dispersion components of the molten bitumen mixture; dispersed reinforcement of the molten bitumen with cellulose fibers);

increase in heat exposure from +140 to + 175 ° С with periodic reverse stirring (up to 10 minutes stirring - up to 10 minutes break: 1 cycle of processing the mixture) for at least 5 cycles (at this stage the melting of bitumen ends); loading of the modifier (elastomers) in an amount of 2.5% by weight of the loaded raw material with a preliminary decrease in the temperature of the mixture to + 140 ° C with periodic reverse stirring (at least 2 minutes of mixing - up to 8 minutes break: 1 cycle of processing the mixture) for at least 3 cycles;

loading modifier (polyolefins) in an amount of 1 6% by weight of the loaded raw materials, with a simultaneous increase in the temperature of the mixture to + 150 + 170 ° C at the end of the stage with periodic reverse stirring (at least 2 minutes of mixing - up to 8 minutes break: 1 cycle of processing the mixture ) for at least 4 cycles (at this stage the removal of gases from the mixture, modification of bitumen, plasticization and volumetric structuring of the mixture ends);

unloading and applying the finished mixture (bitumen-polymer composite material) to the roof surface is carried out in the form of a bulk seamless coating with a thickness of 15 + 30 mm (the thickness of the new coating depends on the amount of processed raw materials and additional ingredients introduced into the mixture).

The total time of the technological cycle for the production of a bitumen-polymer composite material and the application of a bulk roofing from it depends on the environmental conditions.

As a secondary raw material, a material of a damaged roof covering made by the claimed method can be used.

The term of use of the roofing made by this method in a device that implements the function of volumetric structural reinforcement of composite material increases approximately 2 times.

The technical result from the creation of the method is to reduce the integral resource and energy consumption of repair of flat roofs through the use of non-waste thermomechanical processing of secondary resources - dismantled bitumen roofing, degraded bitumen roofing, old reinforced materials, plasticizers and modifiers from secondary resources and / or production waste, using one multifunctional mixing device that implements intensive mixing, dispersion and of the ingredients of the mixture and volume reinforcement of the mixture to a high degree of uniformity directly on the spot and by the time of its use,

in restoring the plastic, hydrophobic, adhesive and strength properties of a bitumen-polymer composite material to standard values and unloading it and applying the finished material to the roof by known methods in the form of a seamless filler coating with a thickness of at least 15 mm in a single technological cycle.

Claims

FORMULA

A method for non-waste repair of a bitumen-polymer composite roofing, including the removal and grinding of old roofing containing bitumen in crushing devices, their loading and processing in mixing devices, unloading and applying the finished bitumen-polymer composite material in a mastic state to the roofing surface, characterized the fact that step-by-step thermomechanical waste-free processing into a new roofing material, raw materials from a random set of roofing, including degraded bitumen, reinforcing materials, mineral and organic ingredients, as well as plasticizers and modifiers from recycled materials added according to the preparation technology, are carried out in one multifunctional device, in which they are intensively mixed and dispersed, melted, dehydrated and removed gases, plasticized, modified and bulk (dispersed) reinforcement in a single technological cycle, in which the plasticizer (oil fraction) is loaded in stages in an amount of 10 1 5% by weight of the coarsely ground roofing (hereinafter referred to as the raw material) gradually loaded into the mixing device and its simultaneous activation by stirring in any direction and raising the temperature to + 60 ° C at the end of the stage;

stage-by-stage loading of raw materials in portions of 1/3 of the useful volume of the mixing chamber with increasing temperature of the mixture (the first portion of the raw material is up to 10 minutes at a temperature of the mixture from +60 to + 90 ° C; the second is up to 10 minutes at a temperature of the mixture from +90 to + 120 ° С; 3rd - up to 10 minutes at a temperature of the mixture from +120 to + 140 ° С) with continuous reverse stirring (at least 1 minute in one direction) from the moment of loading the 1st portion of raw materials; increase in heat exposure from +140 to + 175 ° С with periodic reverse stirring (up to 10 minutes stirring - up to 10 minutes break: 1 cycle of processing the mixture) for at least 5 cycles;

loading modifier (elastomers) in an amount of 2 5% by weight of the loaded raw materials with a preliminary decrease in the temperature of the mixture to + 140 ° C with periodic reverse stirring (at least 2 minutes of mixing - up to 8 minutes break: 1 cycle of processing the mixture) for at least 3 cycles;

loading modifier (polyolefins) in an amount of 1 6% by weight of the loaded raw materials, while increasing the temperature of the mixture to +150 170 ° C at the end of the stage with periodic reverse stirring (at least 2 minutes of mixing - up to 8 minutes break: 1 cycle of processing the mixture) for at least 4 cycles;

Bitumen-polymer composite material is unloaded directly on the roofing surface in place and by the time of its use,

application of a bitumen-polymer composite material is carried out in the form of a seamless bulk coating with a thickness of at least 15 mm.