WO2019185459A1 - A method for producing a pre-formed bituminous waterproofing membrane - Google Patents

A method for producing a pre-formed bituminous waterproofing membrane Download PDF

Info

Publication number
WO2019185459A1
WO2019185459A1 PCT/EP2019/057190 EP2019057190W WO2019185459A1 WO 2019185459 A1 WO2019185459 A1 WO 2019185459A1 EP 2019057190 W EP2019057190 W EP 2019057190W WO 2019185459 A1 WO2019185459 A1 WO 2019185459A1
Authority
WO
WIPO (PCT)
Prior art keywords
aqueous
waterproofing membrane
modified bitumen
polymer modified
polymer
Prior art date
Application number
PCT/EP2019/057190
Other languages
French (fr)
Inventor
Romel MORALES
Carlos Garcia
Claudia VARGAS
Dario Martinez
Original Assignee
Sika Technology Ag
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sika Technology Ag filed Critical Sika Technology Ag
Priority to BR112020015689-2A priority Critical patent/BR112020015689A2/en
Priority to MX2020009995A priority patent/MX2020009995A/en
Publication of WO2019185459A1 publication Critical patent/WO2019185459A1/en

Links

Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00—Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/02—Roof covering by making use of flexible material, e.g. supplied in roll form of materials impregnated with sealing substances, e.g. roofing felt
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B11/00—Layered products comprising a layer of bituminous or tarry substances
    • B32B11/04—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B11/046—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B11/00—Layered products comprising a layer of bituminous or tarry substances
    • B32B11/04—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B11/06—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B11/00—Layered products comprising a layer of bituminous or tarry substances
    • B32B11/04—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B11/08—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B11/00—Layered products comprising a layer of bituminous or tarry substances
    • B32B11/10—Layered products comprising a layer of bituminous or tarry substances next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/082—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising vinyl resins; comprising acrylic resins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/085—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B32B15/09—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N5/00—Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch
    • D06N5/003—Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch coated with bitumen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/12—Coating on the layer surface on paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/04—Cellulosic plastic fibres, e.g. rayon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/103—Metal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/14—Mixture of at least two fibres made of different materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/06—Roofs, roof membranes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L95/00—Compositions of bituminous materials, e.g. asphalt, tar, pitch
    • C08L95/005—Aqueous compositions, e.g. emulsions

Definitions

  • the invention relates to pre-formed bitumen-based waterproofing membranes, which can be used for waterproofing of underground and above ground
  • constructions in particular for waterproofing of roofing structures.
  • Pre-formed waterproofing membranes used for waterproofing of roof structures are typically provided as single-ply roofing membranes composed of one single waterproofing (barrier) layer or as multi-ply roofing membranes composed of multiple waterproofing (barrier) layers of same or different materials.
  • Pre-formed waterproofing membranes used of waterproofing of underground structures are typically single-ply systems.
  • thermoplastics such as plasticized polyvinylchloride (PVC-p), thermoplastic olefins (TPE-O, TPO), elastomers such as ethylene-propylene diene monomer (EPDM), as well as bitumen/asphalt compositions.
  • PVC-p plasticized polyvinylchloride
  • TPE-O thermoplastic olefins
  • EPDM ethylene-propylene diene monomer
  • bitumen/asphalt compositions bitumen/asphalt compositions.
  • Pre-formed waterproofing membranes are typically delivered to a construction site in rolls, transferred to the place of installation, unrolled, and adhered to the substrate to be waterproofed by using mechanical, and/or adhesive, and/or thermal bonding means.
  • the substrate on which the membrane is adhered may be comprised of variety of materials depending on the installation site.
  • the roof substrate may be, for example, a concrete, metal, or wood deck, or it may include an insulation board or recover board and/or an existing membrane.
  • Bituminous materials are also commonly used in waterproofing applications since they provide good resistance against environmental factors combined with relatively low costs compared to thermoplastic polymer materials.
  • Bitumen compositions used for producing waterproofing membranes are typically modified with synthetic polymers to increase UV-resistance, toughness, and flexibility at low temperatures. These modified bitumen compositions are commonly known as polymer modified bitumen (PMB).
  • Typical polymers mixed with the bitumen for producing waterproofing membranes include atactic polypropylenes (APP), amorphous poly-alpha-olefins (APAO), styrene block copolymers, in particular SBS and SEBS, as well as elastomers, in particular EPDM.
  • APP atactic polypropylenes
  • APAO amorphous poly-alpha-olefins
  • SBS styrene block copolymers
  • SEBS styrene block copolymers
  • EPDM elastomers
  • the synthetic polymers In production of bitumen membranes, the synthetic polymers have to be mixed with bitumen in a molten state. This increases the production costs of bitumen membranes since the preferred polymers typically have high melting temperatures, such as above 180°C.
  • Coagulum-forming liquid compositions of bitumen emulsions and polymer dispersions, in particular rubber lattices, have also been used for in situ
  • Such compositions are applied in liquid form on a surface of a substrate to be waterproofed by brushing, rolling, or troweling followed by curing (coagulation) of the composition by air- drying at ambient temperature or by application of heat.
  • the coagulum-forming liquid compositions can also be chemically cured by using a coagulating agent, which is able to break the emulsion resulting in coagulation of the bitumen and polymer parts and separation of water.
  • the coagulating agent and the polymer modified bitumen composition are simultaneously applied on a surface of a substrate, for example by spraying.
  • the coagulating agent and the composition can be contacted and mixed with each other on the surface of the substrate or during the spraying step.
  • the water separated from the de-emulsified composition is eventually removed, for example by drying.
  • Waterproofing layers and coatings obtained by application of liquid compositions on a surface to be waterproofed are also known as“liquid-applied waterproofing membranes (LAM)”. These are fundamentally different from the pre-formed waterproofing membranes discussed above since the waterproofing layer is formed in situ, i.e. on the surface to be waterproofed, whereas pre-formed waterproofing membranes have been formed before being applied on the surface to be waterproofed.
  • LAM liquid-applied waterproofing membranes
  • waterproofing membranes include, for example, the relatively high production costs resulting from high amount of heat energy required for preparing the polymer-bitumen blends.
  • the water-based emulsions of polymer modified bitumen can be produced without melting of the polymers but the liquid-applied
  • waterproofing coatings typically have low mechanical performance compared to waterproofing membranes based on polymer modified bitumen. Furthermore, the water-based bitumen emulsions have to be applied to a surface of a substrate to be waterproofed at the construction site, which means that the formed
  • the subject of the present invention is a method for producing a pre-formed waterproofing membrane as defined in claim 1.
  • aqueous bitumen emulsions modified with a specific synthetic polymer composition can be used for producing pre-formed bitumen-based waterproofing membranes having excellent waterproofing and mechanical properties.
  • bitumen-based pre-formed waterproofing membranes can be produced with significantly lower costs compared to the State-of-th e-Art production methods based on the use of polymer modified bitumen.
  • Another advantage is that since the aqueous bitumen emulsions are used for producing pre-formed waterproofing membranes instead of in-situ formed waterproofing coatings, the inherent limitations of water-based systems related to the application temperatures no longer apply.
  • the subject of the present invention is a method for producing a pre-formed waterproofing membrane comprising simultaneously spraying a first aqueous coagulant composition and first aqueous emulsion of polymer modified bitumen to a first surface of a support sheet to effect coagulation of the first aqueous emulsion and formation of a solid layer of the sprayed material on the first surface of the support sheet.
  • poly designate substances which formally contain, per molecule, two or more of the functional groups occurring in their names.
  • a polyol refers to a compound having at least two hydroxyl groups.
  • a polyether refers to a compound having at least two ether groups.
  • polymer designates a collective of chemically uniform macromolecules produced by a polyreaction (polymerization, polyaddition, polycondensation) where the macromolecules differ with respect to their degree of polymerization, molecular weight and chain length.
  • the term also comprises derivatives of said collective of macromolecules resulting from polyreactions, that is, compounds which are obtained by reactions such as, for example, additions or substitutions, of functional groups in predetermined macromolecules and which may be chemically uniform or chemically non-uniform.
  • (meth)acrylic designates both methacrylic or acrylic. Accordingly, the term“(meth)acrylate designates both acrylates and methacrylates.
  • molecular weight refers to the molar mass (g/mol) of a molecule or a part of a molecule, also referred to as“moiety”.
  • average molecular weight refers to number average molecular weight (M n ) of an oligomeric or polymeric mixture of molecules or moieties. The molecular weight may be determined by gel permeation chromatography.
  • bitumen designates blends of heavy hydrocarbons, having a solid consistency at room temperature, which are normally obtained as vacuum residue from refinery processes, which can be distillation (topping or vacuum) and conversion (thermal cracking and visbreaking) processes of suitable crude oils. Furthermore, the term“bitumen” also designates natural and synthetic bitumen as well as bituminous materials obtained from the extraction of tars and bituminous sands.
  • bitumen also designates natural and synthetic bitumen as well as bituminous materials obtained from the extraction of tars and bituminous sands.
  • emulsion designates stable mixtures of two immiscible liquids, in which the other one is dispersed as fine droplets in the other. Typically an emulsifier, such as soap, is required to obtain a stable emulsion in which the liquid phases do not separate.
  • The“amount or content of at least one component X” in a composition refers to the sum of the individual amounts of all polyols contained in the composition.
  • the composition comprises 20 wt.-% of at least one polyol
  • the sum of the amounts of all polyols contained in the composition equals 20 wt.-%.
  • the term“room temperature” designates a temperature of 23°C.
  • the method for producing a pre-formed waterproofing membrane comprises a first step of simultaneously spraying a first aqueous coagulant composition and a first aqueous emulsion of polymer modified bitumen to a first surface of a support sheet. During the spraying step, the coagulant composition is contacted and mixed with the polymer modified bitumen emulsion, which results in coagulation
  • pre-formed waterproofing membrane refers in the present disclosure to sheet-like solid articles, which have been formed before being applied on a surface of a substrate to be waterproofed.
  • pre-formed waterproofing membrane refers to sheet-like articles, which have not been formed in situ, i.e. not been formed on the surface of the substrate to be waterproofed.
  • Such pre-formed waterproofing membranes are fabricated at a location that is typically remote from the construction site, brought to the site, for example, in the form of a roll and laid on a surface of a substrate to be waterproofed.
  • the term“pre-formed waterproofing membrane” does not encompass layers of coatings, sealants, and the like that are formed in situ by applying a liquid composition on a surface of a substrate to be waterproofed and allowing the composition to harden and/or cure.
  • the term“liquid” is understood to mean a material that flows at normal room temperature and has a pour point of less than 20°C.
  • the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are simultaneously sprayed on the first surface of the support sheet in a manner that the solid layer of the sprayed material formed on the first surface of the support sheet has a thickness of at least 0.1 mm, preferably at least 0.25 mm, more preferably at least 0.35 mm, even more preferably at least 0.5 mm.
  • the solid layer of the sprayed material formed on the first surface of the support sheet has a thickness in the range of 0.15 - 15 mm, preferably 0.25 - 10 mm, more preferably 0.35 - 5 mm.
  • the method for producing a pre-formed waterproofing membrane comprises a second step of subjecting the wet waterproofing membrane containing the support sheet obtained from the first step to a drying step to remove at least part of the water separated from the first aqueous emulsion of polymer modified bitumen.
  • the drying step is preferably conducted by drawing the wet waterproofing membrane through a pair of calender rolls and/or by heating in an oven, heating by air stream, or heating with infrared (IR)-radiation.
  • the method for producing a pre-formed waterproofing membrane comprises a third step of subjecting the dried
  • waterproofing membrane obtained from the second step to one or more post- treatment steps preferably selected from the group consisting of rolling up the dried membrane into a roll, preferably with an inert divider layer, such as a release liner, cutting the dried waterproofing membrane into desired lengths, and applying one or more additional layers of material on at least one of the outer surfaces of the dried waterproofing membrane.
  • the 1 st , 2 nd , and 3 rd steps of the method for producing a pre-formed waterproofing membrane are performed in their given numerical order.
  • the support sheet is preferably a sheet-like element having first and second surfaces, i.e. top and bottom surfaces, defined by peripheral edges and defining a thickness of the element there between.
  • sheet-like element refers in the present document to elements having a length and width at least 25 times, preferably at least 50 times, more preferably at least 100 times greater than the thickness of the element.
  • the type of the support sheet is not particularly restricted.
  • the reinforcing layers commonly used for improving the dimensional stability of waterproofing and roofing membranes can be used as the support sheet.
  • the support sheet comprises at least one layer of fiber material.
  • fiber material designates in the present disclosure materials composed of fibers.
  • Suitable fibers to be used in the support sheet can comprise or consist of organic, inorganic or synthetic organic materials or any combination thereof.
  • Suitable organic fibers include, for example, cellulose fibers, cotton fibers, and protein fibers.
  • Suitable synthetic organic fibers include, for example, fibers composed of polyester, homopolymers and copolymers of ethylene and/or propylene, viscose, nylon, and polyamides.
  • Fiber materials composed of inorganic fibers are also suitable, in particular, those composed of mineral fibers, such as glass fibers, aramid fibers, wollastonite fibers, and carbon fibers.
  • Inorganic fibers, which have been surface treated, for example, with silanes, may also be used.
  • the fiber material can comprise short fibers, long fibers, spun fibers (yarns), or filaments.
  • the fibers can moreover be aligned or drawn fibers. It may also be advantageous to use a combination of different types of fibers, both in terms of geometry and composition.
  • the at least one layer of fiber material has a mass per unit weight of not more than 500 g/m 2 , more preferably not more than 350 g/m 2 , even more preferably not more than 250 g/m 2 , still more preferably not more than 150 g/m 2 , most preferably not more than 100 g/m 2 .
  • the at least one layer of fiber material has a mass per unit weight in the range of 5 - 350 g/m 2 , preferably 15 - 250 g/m 2 , more preferably 25 - 150 g/m 2 , even more preferably 25 - 100 g/m 2 , most preferably 25 - 75 g/m 2 .
  • the fiber material of the at least one layer of fiber material is preferably selected from the group consisting of non-woven fabrics, woven fabrics, and non-woven scrims.
  • the term“non-woven fabric” designates in the present disclosure materials composed of fibers, which are bonded together by using chemical, mechanical, or thermal bonding means, and which are neither woven nor knitted.
  • Non-woven fabrics can be produced, for example, by using a carding or needle punching process, in which the fibers are mechanically entangled to obtain the nonwoven fabric.
  • chemical binders such as adhesive materials are used to hold the fibers together in a non-woven fabric.
  • non-woven scrim designates in the present disclosure web-like non- woven products composed of yarns, which lay on top of each other and are chemically bonded to each other.
  • Typical materials for non-woven scrims include metals, fiberglass, and plastics, in particular polyester, polypropylene,
  • polyethylene and polyethylene terephthalate (PET).
  • the support sheet comprises at least one non-woven fabric layer composed of inorganic fibers, preferably having a mass per unit weight in the range of 5 - 300 g/m 2 , preferably 15 - 200 g/m 2 , more preferably 25 - 150 g/m 2 , even more preferably 25 - 125 g/m 2 , most preferably 25 - 100 g/m 2 .
  • the expression“composed of inorganic fibers” is understood to mean in the context of the present invention that the fiber base of the non-woven fabric layer is composed of inorganic fibers, wherein the fabric layer itself may contain further components, such as the chemical binders that hold the fibers together in the non- woven fabric layer.
  • the inorganic fibers are selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers.
  • the support sheet comprises at least one non-woven fabric layer composed of synthetic organic fibers, preferably having a mass per unit weight in the range of 5 - 250 g/m 2 , preferably 15 - 150 g/m 2 , more preferably 25 - 125 g/m 2 , even more preferably 25 - 100 g/m 2 , most preferably 25 - 75 g/m 2 .
  • the expression“composed of synthetic organic fibers” is understood to mean in the context of the present invention that the fiber base of the non-woven fabric layer is composed of synthetic organic fibers, wherein the fabric layer itself may contain further components, such as the chemical binders that hold the fibers together in the non-woven fabric layer.
  • the synthetic organic fibers are selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers.
  • the support sheet comprises at least one non-woven scrim composed of multifilament yarns of polyester, polypropylene, polyethylene, polyethylene terephthalate (PET), or glass fibers.
  • the support sheet comprises at least one non-woven fabric layer composed of inorganic or synthetic organic fibers and at least one non-woven scrim composed of multifilament yarns of polyester, polypropylene, polyethylene, polyethylene terephthalate (PET), or glass fibers.
  • the support sheet is a non-woven fabric layer composed of inorganic fibers, wherein the non-woven fabric preferably has a mass per unit weight in the range of 5 - 300 g/m 2 , preferably 15 - 200 g/m 2 , more preferably 25 - 150 g/m 2 , even more preferably 25 - 125 g/m 2 , most preferably 25 - 100 g/m 2 , wherein the inorganic fibers are preferably selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers.
  • the support sheet is a non-woven fabric layer composed of synthetic organic fibers, wherein the non-woven fabric preferably has a mass per unit weight in the range of 5 - 250 g/m 2 , preferably 15 - 150 g/m 2 , more preferably 25 - 125 g/m 2 , even more preferably 25 - 100 g/m 2 , most preferably 25 - 75 g/m 2 , wherein the synthetic organic fibers are preferably selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers.
  • the temperature of the first aqueous emulsion of polymer modified bitumen and/or the first aqueous coagulant composition during the spraying step is not particularly restricted. It may be preferable that the temperature of the first aqueous emulsion of polymer modified bitumen and/or the first aqueous coagulant composition during the spraying step is not more than 80°C, more preferably not more than 60°C, most preferably not more than 40°C.
  • the weight ratio of the amount of the first aqueous emulsion of polymer modified bitumen to the amount of the first aqueous coagulant composition simultaneously sprayed to the first surface of the support sheet is not particularly restricted.
  • the weight ratio of the amount of the first aqueous emulsion of polymer modified bitumen to the amount of the first aqueous coagulant composition is in the range of from 20:1 to 2:1 , preferably from 15:1 to 3:1 , more preferably from 15:1 to 5:1 , most preferably from 10:1 to 5:1.
  • the first aqueous coagulant composition comprises at least one coagulating agent selected from the group consisting of salts of alkali and earth alkali metals, organic acids, inorganic acids, metal sulfates, and polyamines.
  • the term“aqueous composition” refers in the present disclosure to a composition in which water is the primary dissolving medium or solvent.
  • the“aqueous composition” refers to a composition, in which water is the only dissolving medium or solvent.
  • the coagulating agent is selected from the group consisting of calcium chloride and citric acid.
  • the solids content of the first aqueous emulsion of polymer modified bitumen is not particularly restricted.
  • solids content refers to the portion of the composition, which when heated to a temperature of 105°C for one hour at one atmosphere pressure does not volatilize.
  • the first aqueous emulsion of polymer modified bitumen has a solids content of at least 30 wt.-%, more preferably at least 40 wt.-%, based on the total weight of the first aqueous emulsion of polymer modified bitumen.
  • the first aqueous emulsion of polymer modified bitumen has a solids content of 30 - 80 wt.-%, more preferably 40 - 70 wt.-%, most preferably 45 - 65 wt.-%, based on the total weight of the first aqueous emulsion of polymer modified bitumen.
  • the polymer may be present in the first aqueous emulsion of polymer modified bitumen, for example, in form of a polymer dispersion and/or an emulsion.
  • the amount of the polymer in the first aqueous emulsion of polymer modified bitumen is not particularly restricted. Increasing the amount of the polymer component has been found out to result in pre-formed waterproofing membranes having improved mechanical properties, in particular improved tensile and tear strength as well as improved UV-resistance. However, increasing the amount of polymer also increases the production costs of the pre-formed waterproofing membrane.
  • the weight ratio of the amount of bitumen to the amount of polymer in the first aqueous emulsion of polymer modified bitumen is in the range of from 1 :1 to 20:1 , more preferably from 2:1 to 15:1 , even more preferably from 2:1 to 10:1 , most preferably from 3:1 to 5:1.
  • the first aqueous emulsion of polymer modified bitumen comprises 1 - 35 wt.-%, more preferably 1.5 - 30 wt.-%, even more preferably 2.5 - 25.0 wt.-%, most preferably 5.0 - 20 wt.-%, of the polymer, based on the total weight of the first aqueous emulsion.
  • The“amount of the polymer” in the context of an aqueous emulsion of polymer modified bitumen in understood to mean the total weight of all polymer components present in the aqueous emulsion that are not part of the bitumen component.
  • the first aqueous polymer modified bitumen emulsion is preferably obtained by mixing an aqueous bitumen emulsion with at least one aqueous polymer dispersion. The mixing can be conducted using any conventional mixing technique known to a person skilled in the art, preferably using a high shear mixing
  • composition designates in the present document a physical state of matter that includes at least two distinct phases, wherein a first phase is
  • aqueous polymer dispersion refers to a dispersion containing a first phase of polymer particles distributed in an aqueous second phase that is predominately water and may contain minor amounts of water soluble or water miscible liquids, such as lower alkyl alcohols, ketones, or glycols.
  • Suitable aqueous bitumen emulsions are made from bitumen having a penetration value in of 5 - 400 dmm (tenths of millimeters), preferably 10 - 200 dmm.
  • the penetration value of can be measured at a temperature of 25°C measured according to AASHTO T 49 and ASTM D 5.
  • the aqueous bitumen emulsion has a solid content of 25 - 75 wt.-%, more preferably 35 - 75 wt.-%, most preferably 40 - 70 wt.-%, based on the total weigh of the aqueous bitumen emulsion and/or a softening point of the bitumen in the range of 45 - 90°C, more preferably 50 - 85°C, most preferably 50 - 80°C.
  • Suitable bitumen emulsions can be prepared by simultaneously passing solution of melted bitumen and an aqueous solution of emulsifying agent heated a temperature in the range of 40 - 80°C through an emulsifying apparatus, such as a colloid mill or a barrel homogenizer.
  • emulsifying agents for bitumen are known to a person skilled in the art. These include, for example, soaps, resin soaps, and organic emulsifiers.
  • the type of the at least one aqueous polymer dispersion is not particularly restricted as long as it provides fast coagulation with the bitumen emulsion when mixed with the aqueous coagulant composition as well as good mechanical properties of the cured layer, in particular high elongation at break.
  • Suitable aqueous polymer dispersions include, for example, aqueous dispersions of acrylic polymers, polyurethanes, polyurethane-urea polymers, styrene-butadiene copolymers, halogenated styrene-butadiene copolymers, ethylene vinyl acetate copolymers, polyvinyl alcohol, and polyvinyl acetate.
  • aqueous polymer dispersions include aqueous dispersions of rubbers, for example aqueous dispersions of styrene-butadiene rubber, natural rubber, styrene isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, butyl rubber, halogenated butyl rubber, chlorinated polyethylene, chlorosulfonated polyethylene, ethylene propylene rubber, and butadiene acrylonitrile copolymers.
  • rubbers for example aqueous dispersions of styrene-butadiene rubber, natural rubber, styrene isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, butyl rubber, halogenated butyl rubber, chlorinated polyethylene, chlorosulfonated polyethylene, ethylene propylene rubber, and butadiene acrylonitrile copolymers.
  • acrylic polymer refers in the present disclosure to homopolymers, copolymers and higher inter-polymers of an acrylic monomer with one or more further acrylic monomers and/or with one or more other ethylenically unsaturated monomers.
  • acrylic monomer refers in the present document to
  • (meth)acrylates (meth)acrylic acid, and to derivatives thereof, for example, amides of (meth)acrylic acid or nitriles of (meth)acrylic acid.
  • Preferred acrylic polymers contain at least 30 wt.-%, more preferably at least 40 wt.-%, most preferably at least 50 wt.-% of acrylic monomers.
  • the term“acrylic dispersion” refers in the present document to dispersions of acrylic polymers.
  • the at least one aqueous polymer dispersion is selected from the group consisting of aqueous polyurethane dispersions, acrylic dispersions, polyurethane-acrylic dispersions, styrene- butadiene copolymer dispersions, styrene-butadiene rubber dispersions, and styrene isoprene rubber dispersions.
  • Suitable acrylic polymers for the aqueous dispersion consist for the most part of (meth)acrylates of alcohols containing from 1 to 24 carbon atoms.
  • Preferred acrylic polymers contain, as polymerized units, at least 25 wt.-%, more preferably at least 35 wt.-%, most preferably at least 50 wt.-% of these acrylic monomers.
  • Suitable ethylenically unsaturated monomers that can be used as comonomers with the acrylic monomers include, for example, vinyl esters and allyl esters of carboxylic acids containing from 1 to 20 carbon atoms, vinyl ethers of alcohols containing from 1 to 8 carbon atoms, vinyl aromatic compounds, in particular styrene, vinyl halides, non-aromatic hydrocarbons containing from 2 to 8 carbon atoms and at least one olefinic double bond, a and b-unsaturated mono- or di-carboxylic acids containing from 3 to 6 carbon atoms, and derivatives thereof (especially amides, esters and salts).
  • acrylic polymers examples include poly(meth)acrylates, copolymers of (meth)acrylates and styrene, copolymers of (meth)acrylates and vinyl esters of tertiary carboxylic acids, copolymers and terpolymers of
  • (meth)acrylates vinyl esters of tertiary carboxylic acids and vinyl acetate, and copolymers of vinyl acetate and (meth)acrylates.
  • the at least one aqueous polymer dispersion is selected from the group consisting of polyurethane-acrylic dispersion, styrene-butadiene copolymer dispersion, and (meth)acrylate-styrene copolymer dispersion.
  • Polyurethane-acrylic dispersions can be prepared by using physical or chemical methods. In the first case, aqueous polyurethane and acrylic dispersions
  • emulsions are independently prepared first and then both dispersions are mixed together under mechanical mixing.
  • the polyurethane dispersion can be prepared first, and then acrylic monomers can be polymerized in the polyurethane dispersion.
  • acrylic monomers can be polymerized in the polyurethane dispersion.
  • a core-shell emulsion polymerization is used.
  • polyurethane particles are used as seed particles and the acrylates are polymerized within the polyurethane particles due to high hydrophobicity of the acrylates.
  • Polyurethane-acrylic dispersions obtained with chemical methods are also known as polyurethane-acrylic hybrid dispersions.
  • polyurethane-acrylic hybrid dispersions are known to a person skilled in the art and disclosed, for example, in US 7,534,830 B2.
  • the at least one aqueous polymer dispersion is an aqueous polyurethane-acrylic hybrid dispersion.
  • Suitable polyurethane-acrylic hybrid dispersions are commercially available, for example, under the trade name of Hybridur® from Air Products and Chemicals Inc., under the trade name of APU® from Alberdingk Boley, under the trade name of Joncryl® HYB from BASF, such as Joncryl® HYB 6336 and Joncryl® HYB 6340, and under the trade name of Acriten® from Sygla Columbiana, such as Acriten® PU 230.
  • the method for producing a pre-formed waterproofing membrane further comprises simultaneously spraying a second aqueous coagulant composition and a second aqueous emulsion of polymer modified bitumen to a second surface of a support sheet to effect coagulation of the second aqueous emulsion and formation of a solid layer of the sprayed material on the second surface of the support sheet.
  • the second surface of the support sheet is the surface on the side opposite to the first surface of the support sheet.
  • the temperature of the second aqueous emulsion of polymer modified bitumen and/or the second aqueous coagulant composition during the spraying step is not more than 80°C, more preferably not more than 60°C, most preferably not more than 40°C.
  • the first and second aqueous coagulant compositions sprayed to the first and second surfaces of the support sheet, respectively, may have same or different composition.
  • the first and second aqueous coagulant compositions have identical compositions.
  • the first aqueous emulsion of polymer modified bitumen and the second aqueous emulsion of polymer modified bitumen sprayed to the first and second surfaces of the support sheet, respectively may have same or different composition.
  • the first and second aqueous emulsions of polymer modified bitumen have identical compositions.
  • the method for producing a pre-formed waterproofing membrane comprises steps of: i) Feeding the first aqueous coagulant composition to a first spraying unit, ii) Feeding the first aqueous emulsion of polymer modified bitumen to a second spraying unit, iii) Spraying the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen by using said spraying units to provide at least two streams having intersecting spray paths such that the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to or at the moment of being contacted with the first surface of the support sheet.
  • the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to being contacted with the surface of the support sheet.
  • the distance between the spraying units and the point at which the two streams are intersect, i.e. the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are contacted is at least 10 cm, preferably at least 25 cm, more preferably at least 30 cm.
  • the first and second spraying units may contain one or more nozzles through which the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are sprayed.
  • the streams are preferably generated by using liquid pressure (airless).
  • the liquid streams can be pressurized by using gear pumps, centrifugal pumps or other means well known in the art. Other spraying techniques, such as gas atomization, are also possible.
  • the method comprises a further step of: iv) Subjecting the wet membrane obtained from step iii) to a drying step to remove at least part of the water separated from the first aqueous emulsion of polymer modified bitumen.
  • step iv) comprises subjecting the wet membrane obtained from step iii) to a squeezing step to press out the water separated from the aqueous emulsion of polymer modified bitumen.
  • the squeezing can be conducted, for example, by drawing the wet membrane through a pair of calender rolls.
  • step iv) comprises subjecting the wet membrane obtained from step iii) and/or membrane obtained from the squeezing step to a final drying step.
  • the final drying step can be conducted, for example, by heating in an oven, heating by air stream, or heating with infrared (IR)-radiation.
  • the method for producing a pre-formed waterproofing membrane is preferably conducted as a continuous process using a calender roll machine.
  • the method comprises further steps of: i') Feeding the second aqueous coagulant composition to a third spraying unit ii’) Feeding the second aqueous emulsion of polymer modified bitumen to a fourth spraying unit, iii’) Spraying the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen by using said spraying units to provide at least two streams having intersecting spray paths such that the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to or at the moment of being contacted with the second surface of the support sheet.
  • the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to being contacted with the second surface of the support sheet.
  • the distance between the spraying units and the point at which the two streams are intersect, i.e. the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen are contacted is at least 10 cm, preferably at least 25 cm, more preferably at least 30 cm.
  • the third and fourth spraying units may contain one or more nozzles through which the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen are sprayed.
  • the streams are preferably generated by using liquid pressure (airless).
  • the liquid streams can be pressurized by using gear pumps, centrifugal pumps or other means well known in the art. Other spraying techniques, such as gas atomization, are also possible.
  • steps i' - iii’) of the method may be conducted after the completion of steps i)
  • the steps i' - iii’) of the method are conducted after the completion of steps i) - iii), in particular after the completion of steps i) - iv) of the method.
  • the same spraying units can be used in steps i' - iii’) as in steps i) - iii), i.e. the third and fourth spraying unit correspond to the first and second spraying units.
  • the method comprises a further step of:
  • step iii’ Subjecting the wet membrane obtained from step iii’) to a drying step to remove at least part of the water separated from the second aqueous emulsion of polymer modified bitumen.
  • step iv’) comprises subjecting the wet membrane obtained from step iii’) to a squeezing step to press out the water separated from the aqueous emulsion of polymer modified bitumen.
  • step iv’) comprises subjecting the wet membrane obtained from step iii’) and/or membrane obtained from the squeezing step to a final drying step.
  • the final drying step can be conducted, for example, by heating in an oven, heating by air stream, or heating with infrared (IR)-radiation.
  • the dried waterproofing membrane obtained from step iv) or iv’) can further be subjected to one or more further post-treatment and/or finishing steps, for example, to cutting, up winding, rolling, and packaging steps.
  • the dried waterproofing membrane obtained from step iv) or iv’) can be subjected to further processing steps, in which one or more additional layers of material are applied on at least one of the outer surfaces of the waterproofing membrane.
  • suitable additional layers include, for example, particle-based layers of mineral particles, in particular composed of or comprising sand, talcum, gravel, or slates; singly-layer and multi-layer polymeric foils, in particular polymeric foils composed of or comprising polyethylene, in particular crosslaminated HDPE, polypropylene, PVC, polyethylene terephthalate (PET); single-layer metal foils, in particular aluminum foils; multi-layer composite foils comprising one or more polymeric foils and one or more metal foils; layers of adhesive compositions, in particular layer of pressure sensitive adhesive (PSA) or hot-melt (HM) adhesive, including pressure sensitive hot-melt adhesives (HM-PSA); and layers of fiber material, in particular layers of non-woven fabric.
  • PSA pressure sensitive adhesive
  • HM hot-mel
  • the one or more additional layers can be applied on the surface of the dried waterproofing membrane by using any conventional techniques.
  • the details of the application step depend on the type of the applied additional layer(s).
  • adhesive layers can be directly applied on the surface of the dried waterproofing membrane by via flat-die extrusion or calendering steps or by using adhesive transfer films. It may be preferable to cover the adhesive layer, if present, with a release liner, in particular if the applied adhesive is a pressure sensitive adhesive (PSA).
  • PSA pressure sensitive adhesive
  • Suitable materials for the release liner include Kraft paper, polyethylene coated paper, silicone coated paper as well as polymeric films, for example, polyethylene, polypropylene, and polyester films optionally coated with polymeric release agents, for example, selected from silicone, silicone urea, urethanes, waxes, and long chain alkyl acrylate release agents.
  • the additional polymeric, metal, and polymer-metal composite foils can be fixed onto the surface of the dried waterproofing membrane obtained from step iv) or iv’) by using conventional lamination techniques or by adhesive bonding.
  • Another subject of the present invention is a pre-formed waterproofing membrane comprising a waterproofing layer comprising a polymer modified bitumen composition and a support sheet, which is at least partially embedded, preferably fully embedded into the waterproofing layer.
  • a waterproofing layer comprising a polymer modified bitumen composition
  • a support sheet which is at least partially embedded, preferably fully embedded into the waterproofing layer.
  • the waterproofing layer is preferably sheet-like element having first and second surfaces, i.e. top and bottom surfaces, defined by peripheral edges and defining a thickness of the element there between.
  • sheet-like element refers in the present document to elements having a length and width at least 25 times, preferably at least 50 times, more preferably at least 100 times, greater than the thickness of the element.
  • the polymer modified bitumen composition comprises bitumen and at least one polymer.
  • the waterproofing layer is composed of a continuous layer of the polymer modified bitumen composition.
  • continuous layer is preferably composed of a continuous layer of the polymer modified bitumen composition.
  • a“discontinuous layer” is considered to consist of more than one areas of the respective material, which areas are not connected with each other to form a single continuous layer of the material.
  • the support sheet comprises at least one layer of fiber material.
  • the fiber material of the at least one layer of fiber material is preferably selected from the group consisting of non-woven fabrics, woven fabrics, and non-woven scrims.
  • the support sheet comprises at least one non-woven fabric layer composed of inorganic fibers, preferably having a mass per unit weight in the range of 5 - 300 g/m 2 , preferably 15 - 200 g/m 2 , more preferably 25 - 150 g/m 2 , even more preferably 25 - 125 g/m 2 , most preferably 25 - 100 g/m 2 .
  • the inorganic fibers are selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers.
  • the support sheet comprises at least one non-woven fabric layer composed of synthetic organic fibers, preferably having a mass per unit weight in the range of 5 - 250 g/m 2 , preferably 15 - 150 g/m 2 , more preferably 25 - 125 g/m 2 , even more preferably 25 - 100 g/m 2 , most preferably 25 - 75 g/m 2 .
  • the synthetic organic fibers are selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers.
  • the support sheet comprises at least one non-woven scrim composed of multifilament yarns of polyester, polypropylene, polyethylene, polyethylene terephthalate (PET), or glass fibers.
  • the support sheet comprises at least one non-woven fabric layer composed of inorganic or synthetic organic fibers and at least one non-woven scrim composed of multifilament yarns of polyester, polypropylene, polyethylene, polyethylene terephthalate (PET), or glass fibers.
  • the support sheet is a non-woven fabric layer composed of inorganic fibers, wherein the non-woven fabric preferably has a mass per unit weight in the range of 5 - 300 g/m 2 , preferably 15 - 200 g/m 2 , more preferably 25 - 150 g/m 2 , even more preferably 25 - 125 g/m 2 , most preferably 25 - 100 g/m 2 , wherein the inorganic fibers are preferably selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers.
  • the support sheet is a non-woven fabric layer composed of synthetic organic fibers, wherein the non-woven fabric preferably has a mass per unit weight in the range of 5 - 250 g/m 2 , preferably 15 - 150 g/m 2 , more preferably 25 - 125 g/m 2 , even more preferably 25 - 100 g/m 2 , most preferably 25 - 75 g/m 2 , wherein the synthetic organic fibers are preferably selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers.
  • the at least one polymer contained in the polymer modified bitumen composition is preferably selected from the group consisting of acrylic polymers, polyurethane polymers, polyurethane-urea polymers, styrene-butadiene copolymers,
  • halogenated styrene-butadiene copolymers ethylene vinyl acetate copolymers, styrene-butadiene rubber, natural rubber, styrene isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, butyl rubber, halogenated butyl rubber, chlorinated polyethylene, chlorosulfonated polyethylene, ethylene propylene rubber, and butadiene acrylonitrile copolymers.
  • the at least one polymer contained in the polymer modified bitumen composition is selected from the group consisting of acrylic polymers, polyurethane polymers, polyurethane-acrylic hybrid polymers, styrene-butadiene copolymers, styrene-butadiene rubber, and styrene isoprene rubber, preferably from the group consisting of polyurethane-acrylic hybrid polymers, styrene-butadiene copolymers, and (meth)acrylate-styrene copolymers.
  • the at least one polymer is a polyurethane-acrylic hybrid polymer.
  • the weight ratio of the amount of bitumen to the amount of the at least one polymer in the polymer modified bitumen composition is in the range of from 1 :1 to 20:1 , more preferably from 2:1 to 15:1 , even more preferably from 2:1 to 10:1 , most preferably from 3:1 to 5:1. Furthermore, it may be
  • the polymer modified bitumen composition comprises 5 - 70 wt.-%, more preferably 10 - 50 wt.-%, even more preferably 15 - 40 wt.-%, most preferably 20 - 35 wt.-%, of the at least one polymer, based on the total weight of the polymer modified bitumen composition.
  • the polymer modified bitumen composition comprises 5 - 70 wt.-%, more preferably 10 - 50 wt.-%, even more preferably 15 - 40 wt.-%, most preferably 20 - 35 wt.-%, of the at least one polymer, based on the total weight of the polymer modified bitumen composition.
  • the polymer modified bitumen comprises 5 - 70 wt.-%, more preferably 10 - 50 wt.-%, even more preferably 15 - 40 wt.-%, most preferably 20 - 35 wt.-%, of the at least one polymer, based on the total weight
  • composition is a cured composition of an aqueous emulsion of polymer modified bitumen, i.e. the waterproofing layer comprises a cured composition of an aqueous emulsion of polymer modified bitumen.
  • the expression“cured composition” refers in the context of an aqueous emulsion of polymer modified bitumen to a de- emulsified composition, from which the water has been separated resulting in at least partial coagulation of the polymer and bitumen parts, preferably resulting in substantially complete coagulation of the polymer and bitumen parts.
  • substantially complete coagulation is understood to mean that at least 90 wt.-%, preferably at least 95 wt.-%, most preferably at least 97.5 wt.-% of the total weight of the polymer and bitumen parts of the aqueous emulsion of polymer modified bitumen have been coagulated. It may be preferred that the weight ratio of the amount of bitumen to the amount of polymer in the aqueous emulsion of polymer modified bitumen is in the range of from 1 :1 to 20:1 , more preferably from 2:1 to 15:1 , even more preferably from 2:1 to 10:1 , most preferably from 3:1 to 5:1.
  • the aqueous emulsion of polymer modified bitumen comprises 1 - 35 wt.-%, more preferably 1.5 - 30 wt.-%, even more preferably 2.5 - 25.0 wt.-%, most preferably 5.0 - 20 wt.-%, of the polymer, based on the total weight of the aqueous emulsion of polymer modified bitumen.
  • the aqueous emulsion of polymer modified bitumen is obtained by mixing an aqueous bitumen emulsion with at least one aqueous polymer dispersion. The mixing can be conducted using any conventional mixing techniques known to a person skilled in the art, preferably using a high shear mixing equipment.
  • Suitable aqueous bitumen emulsions include the ones discussed above related to the method for producing a waterproofing membrane.
  • the at least one aqueous polymer dispersion is preferably selected from the group consisting of aqueous dispersions of acrylic polymers, polyurethanes,
  • polyurethane-urea polymers styrene-butadiene copolymers, halogenated styrene- butadiene copolymers, ethylene vinyl acetate copolymers, styrene-butadiene rubber, natural rubber, styrene isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, butyl rubber, halogenated butyl rubber, chlorinated
  • polyethylene chlorosulfonated polyethylene, ethylene propylene rubber, and butadiene acrylonitrile copolymers.
  • the at least one aqueous polymer dispersion is selected from the group consisting of acrylic dispersions,
  • polyurethane dispersions polyurethane-acrylic dispersions, styrene-butadiene copolymer dispersions, styrene-butadiene rubber dispersions, and styrene isoprene rubber dispersions, preferably from the group consisting of polyurethane- acrylic dispersions, styrene-butadiene copolymer dispersions, and (meth)acrylate- styrene copolymer dispersions.
  • the at least one polymer dispersion is a polyurethane-acrylic dispersion, preferably a polyurethane-acrylic dispersion hybrid dispersion.
  • the pre-formed waterproofing membrane is obtained by using the method for producing a pre-formed waterproofing membrane of the present invention.
  • the thickness of the waterproofing layer is not particularly restricted. It may be preferable that the waterproofing layer has a thickness, determined by using the measurement method as defined in DIN EN 1849-1 standard, in the range of 0.5 - 15.0 mm, preferably 0.5 - 10.0 mm, even more preferably 1.0 - 7.5 mm, most preferably 1.5 - 5.0 mm.
  • the pre-formed waterproofing membrane has an elongation at break, measured by using the method as defined in ISO 527-2 standard at a temperature of 23°C using a cross head speed of 100 mm/min, of at least 10%, more preferably at least 35%, most preferably at least 50 % and/or a tensile strength at break, measured using the method as defined in ISO 527-2 standard at a temperature of 23°C using a cross head speed of 100 mm/min, of at least 0.1 N/mm 2 , more preferably at least 0.5 N/mm 2 , most preferably at least 1.5 N/mm 2 .
  • the pre-formed waterproofing membrane further comprises at least one additional layer of material.
  • additional layers include, for example, particle-based layers of mineral particles, in particular composed of or comprising sand, talcum, gravel, or slates; single-layer and multi- layer polymeric foils, in particular polymeric foils composed of or comprising polyethylene, in particular crosslaminated HDPE, polypropylene, PVC,
  • PET polyethylene terephthalate
  • PSA pressure sensitive adhesive
  • HM hot-melt adhesive
  • HM-PSA pressure sensitive hot-melt adhesives
  • the additional layers may be fully embedded into the waterproofing layer or they may be directly or indirectly connected to at least part of the outer surfaces of the waterproofing membrane, i.e. top and/or bottom surfaces of the waterproofing layer.
  • the expression“directly connected” is understood to mean in the context of the present invention that no further layer or substance is present between the layers, and that the opposing surfaces of the two layers are directly bonded to each other or adhere to each other. At the transition area between the two layers, the materials forming the layers can also be present mixed with each other.
  • the pre-formed waterproofing membrane may comprise, for example, a protective film or a release liner, which is directly or indirectly connected to at least part of the top and/or bottom surfaces of the waterproofing layer.
  • the protective film may be used to protect the surface of the waterproofing layer from moisture, fouling, and other environmental factors.
  • the release liner enables ease of unwind without sticking of the adjacent surfaces of the membrane.
  • the protective film may be selected from the group consisting of particle-based layers of mineral particles, in particular composed of or comprising sand, talcum, gravel, or slates; singly-layer and multi-layer polymeric foils; single-layer metal foils, in particular aluminum foils; and multi-layer composite foils comprising one or more polymeric foils and one or more metal foils.
  • Suitable release liners include, for example, polymer coated paper films, such as Kraft paper, polyethylene coated paper, and silicone coated paper as well as polymeric films coated with a polymeric release agent, for example with silicone, silicone urea, urethane, wax, and or chain alkyl acrylate release agent.
  • the pre-formed waterproofing membrane comprises a protective film or a release liner covering at least part of, preferably substantially the entire the top surface of the waterproofing layer and/or a protective film or a release liner covering at least part of, preferably substantially the entire the bottom surface of the waterproofing layer.
  • the pre-formed waterproofing membrane comprises a first protective film, in particular a polymeric film, preferably a polyethylene, in particular crosslaminated HDPE, polypropylene, or polyester film, or a metal film, preferably an aluminum film, which first protective film covers the substantially the entire the top surface of the waterproofing layer and/or a second protective film, in particular a polymeric film, preferably a polyethylene,
  • the pre-formed waterproofing membrane may be a single-ply waterproofing membrane comprising one single waterproofing layer or a multi-ply waterproofing membrane comprising two or more waterproofing layers having same or different compositions.
  • the pre-formed waterproofing membrane further comprises a second waterproofing layer, wherein the waterproofing layer and the second waterproofing layer are directly or indirectly connected, preferably directly connected over at least part of their opposing surfaces.
  • the second waterproofing layer comprises a second polymer modified bitumen composition.
  • the second polymer modified bitumen composition is a cured composition of a second aqueous emulsion of polymer modified bitumen, i.e. the second waterproofing layer comprises a cured composition of a second aqueous emulsion of polymer modified bitumen.
  • the second aqueous emulsion of polymer modified bitumen may have same or different composition than the aqueous emulsion of polymer modified bitumen. According to one or more embodiments, the second aqueous emulsion of polymer modified bitumen has identical composition with the aqueous emulsion of polymer modified bitumen.
  • the second waterproofing layer is a thermoplastic waterproofing layer, preferably comprising at least 70 wt.-%, preferably at least 80 wt.-% of at least one thermoplastic polymer selected from the group consisting of ethylene - vinyl acetate copolymer (EVA), ethylene - acrylic ester copolymers, ethylene - a-olefin co-polymers, ethylene - propylene co-polymers, propylene - ethylene co-polymers, propylene - a-olefin co-polymers, polypropylene (PP), polyethylene (PE), polyvinylchloride (PVC), polyethylene terephthalate (PET), polystyrene (PS), polyamides (PA), chlorosulfonated polyethylene (CSPE), ethylene propylene diene rubber (EPDM), and
  • EVA ethylene - vinyl acetate copolymer
  • PVC polyvinylchloride
  • PET polyethylene tere
  • PIB polyisobutylene
  • the pre-formed waterproofing membrane is typically provided in a form of a roll, which is delivered to the construction site and unwound from rolls to provide sheets having a width of 1 - 5 m and length of several times the width.
  • the pre-formed waterproofing membrane can also be used in the form of strips having a width of typically 1 - 20 cm, for example so as to seal joints between two adjacent waterproofing membranes.
  • the pre-formed waterproofing membrane can also be provided in the form of planar bodies, which are used for repairing damaged locations in existing waterproofing or roofing systems.
  • Another subject of the present invention is a method for waterproofing a surface of a substrate comprising steps of: i) Applying pre-formed waterproofing membranes on surface of the substrate to be waterproofed, ii) Overlapping the adjacent edges of said membranes, iii) Bonding the opposing surfaces of the adjacent edges in the overlapping areas to each other by heat-welding or by using an adhesive.
  • the substrate to be waterproofed can be part of a structure, in particular, part of an above-ground or underground structure, for example a building, garage, tunnel, landfill, water retention, pond, or dike.
  • the material of the substrate can be, for example, concrete, metal, or wood.
  • the opposing surfaces of the adjacent edges of said pre-formed membranes are bonded to each other by heat-welding.
  • the heating of the adjacent edges of the pre-formed waterproofing membranes can be conducted manually, for example by an open-flame torch or using an automatic welding device, such as a hot-air seam welding device, for example the Leister BITUMAT® B2 hot-air welder.
  • the temperature to which the adjacent edges of the membranes are heated depends on the embodiment of the pre- formed waterproofing membrane. Examples
  • waterproofing membrane according to the example Ex-1 contained polypropylene fabric layer (SikaFelt 30 g/m 2 , from Sika Columbia).
  • An aqueous emulsion of polymer modified bitumen was obtained by mixing the aqueous bitumen emulsion with the aqueous polymer dispersion using a blade impeller mixer using a mixer speed of 800 rpm.
  • the waterproofing membranes were then produced in a continuous process using a calender roll machine equipped with a conveyor belt section and pair of calender rolls.
  • the component A (polymer modified bitumen) and component B (catalyst) comprising the constituents as shown in Table 2, were simultaneously sprayed to a surface of the conveyor belt section.
  • the spraying was conducted using two separate spraying units equipped with nozzles, which generated to intersecting streams of component A and B such that the streams were mixed with each other before contacting the surface of the calender roll machine.
  • component A was fed into a first spraying unit using a progressive pump at a mass flow 10 kg/min and component B was fed into a second spraying unit using a gear pump at a mass flow of 1 kg/min.
  • Ex-1 the streams of components A and B were mixed at a distance of 50 cm from the nozzles, in Ex-2 at a distance of 40 cm from the nozzles, and in Ex-3 at a distance of 50 cm from the nozzles.
  • the sprayed material was then drawn between pair of calender rolls to remove water and to obtain a membrane with a smooth surface structure.
  • the components A and B were simultaneously sprayed on surface of a reinforcement layer, which was fed into the calender roll machine from a feed roll.
  • the produced wet membranes were dried in a drying section with air stream having a temperature of 30 °C and relative humidity of 55 %. The dried
  • the tensile strength at break and the elongation at break were measured using the methods as defined in ISO 527-2 standard at a temperature of 23 °C using a cross head speed of 100 mm/min.
  • the values presented in Table 2 have been obtained with test specimens, which were cut from the produced waterproofing membranes in lengthwise direction (machine direction).

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Road Paving Structures (AREA)
  • Road Paving Machines (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

The invention is directed to a method for producing a pre-formed waterproofing membrane comprising a step of simultaneously spraying an aqueous coagulant composition and an aqueous emulsion of polymer modified bitumen to a surface of a support sheet. The invention is also directed to a pre-formed waterproofing membrane comprising a waterproofing layer and a support sheet, and to a method for waterproofing a surface of a substrate using the pre-formed waterproofing membranes.

Description

A method for producing a pre-formed bituminous waterproofing membrane
Technical field
The invention relates to pre-formed bitumen-based waterproofing membranes, which can be used for waterproofing of underground and above ground
constructions, in particular for waterproofing of roofing structures.
Background of the invention
In the field of construction, polymeric and bituminous sheets, which are often referred to as membranes or panels, are commonly used for sealing of
underground and above ground constructions against penetration of water. Pre- formed waterproofing membranes used for waterproofing of roof structures are typically provided as single-ply roofing membranes composed of one single waterproofing (barrier) layer or as multi-ply roofing membranes composed of multiple waterproofing (barrier) layers of same or different materials. Pre-formed waterproofing membranes used of waterproofing of underground structures are typically single-ply systems.
Commonly used materials for pre-formed waterproofing membranes include thermoplastics such as plasticized polyvinylchloride (PVC-p), thermoplastic olefins (TPE-O, TPO), elastomers such as ethylene-propylene diene monomer (EPDM), as well as bitumen/asphalt compositions. Pre-formed waterproofing membranes are typically delivered to a construction site in rolls, transferred to the place of installation, unrolled, and adhered to the substrate to be waterproofed by using mechanical, and/or adhesive, and/or thermal bonding means. The substrate on which the membrane is adhered may be comprised of variety of materials depending on the installation site. The roof substrate may be, for example, a concrete, metal, or wood deck, or it may include an insulation board or recover board and/or an existing membrane. Bituminous materials are also commonly used in waterproofing applications since they provide good resistance against environmental factors combined with relatively low costs compared to thermoplastic polymer materials. Bitumen compositions used for producing waterproofing membranes are typically modified with synthetic polymers to increase UV-resistance, toughness, and flexibility at low temperatures. These modified bitumen compositions are commonly known as polymer modified bitumen (PMB). Typical polymers mixed with the bitumen for producing waterproofing membranes include atactic polypropylenes (APP), amorphous poly-alpha-olefins (APAO), styrene block copolymers, in particular SBS and SEBS, as well as elastomers, in particular EPDM. In production of bitumen membranes, the synthetic polymers have to be mixed with bitumen in a molten state. This increases the production costs of bitumen membranes since the preferred polymers typically have high melting temperatures, such as above 180°C.
Coagulum-forming liquid compositions of bitumen emulsions and polymer dispersions, in particular rubber lattices, have also been used for in situ
waterproofing of below and above ground structures. Such compositions are applied in liquid form on a surface of a substrate to be waterproofed by brushing, rolling, or troweling followed by curing (coagulation) of the composition by air- drying at ambient temperature or by application of heat. The coagulum-forming liquid compositions can also be chemically cured by using a coagulating agent, which is able to break the emulsion resulting in coagulation of the bitumen and polymer parts and separation of water. In these applications, the coagulating agent and the polymer modified bitumen composition are simultaneously applied on a surface of a substrate, for example by spraying. The coagulating agent and the composition can be contacted and mixed with each other on the surface of the substrate or during the spraying step. The water separated from the de-emulsified composition is eventually removed, for example by drying. Waterproofing layers and coatings obtained by application of liquid compositions on a surface to be waterproofed are also known as“liquid-applied waterproofing membranes (LAM)”. These are fundamentally different from the pre-formed waterproofing membranes discussed above since the waterproofing layer is formed in situ, i.e. on the surface to be waterproofed, whereas pre-formed waterproofing membranes have been formed before being applied on the surface to be waterproofed. The disadvantages of the State-of-th e-Art bitumen-based pre-formed
waterproofing membranes include, for example, the relatively high production costs resulting from high amount of heat energy required for preparing the polymer-bitumen blends. The water-based emulsions of polymer modified bitumen can be produced without melting of the polymers but the liquid-applied
waterproofing coatings typically have low mechanical performance compared to waterproofing membranes based on polymer modified bitumen. Furthermore, the water-based bitumen emulsions have to be applied to a surface of a substrate to be waterproofed at the construction site, which means that the formed
waterproofing coating is immediately exposed to environmental conditions
Furthermore, due to the high water content, the applicability of these types of liquid-applied waterproofing coatings is restricted to temperatures significantly above the 0°C.
There is thus a need for a new bitumen-based pre-formed waterproofing membrane, which can be produced at lower costs than the State-of-th e-Art bitumen-based pre-formed waterproofing membranes.
Summary of the invention
The object of the present invention is to provide a method, which can be used for producing pre-formed bitumen-based waterproofing membranes with lower costs compared to State-of-th e-Art production methods. Another object of the present invention is to provide a bitumen-based pre-formed waterproofing membrane having good mechanical properties, in particular high tensile and tear strengths. The subject of the present invention is a method for producing a pre-formed waterproofing membrane as defined in claim 1.
It was surprisingly found out that aqueous bitumen emulsions modified with a specific synthetic polymer composition can be used for producing pre-formed bitumen-based waterproofing membranes having excellent waterproofing and mechanical properties.
One of the advantages of the production method of the present invention is that bitumen-based pre-formed waterproofing membranes can be produced with significantly lower costs compared to the State-of-th e-Art production methods based on the use of polymer modified bitumen.
Another advantage is that since the aqueous bitumen emulsions are used for producing pre-formed waterproofing membranes instead of in-situ formed waterproofing coatings, the inherent limitations of water-based systems related to the application temperatures no longer apply.
Other aspects of the present invention are presented in other independent claims. Preferred aspects of the invention are presented in the dependent claims.
Detailed description of the invention The subject of the present invention is a method for producing a pre-formed waterproofing membrane comprising simultaneously spraying a first aqueous coagulant composition and first aqueous emulsion of polymer modified bitumen to a first surface of a support sheet to effect coagulation of the first aqueous emulsion and formation of a solid layer of the sprayed material on the first surface of the support sheet.
Substance names beginning with "poly" designate substances which formally contain, per molecule, two or more of the functional groups occurring in their names. For instance, a polyol refers to a compound having at least two hydroxyl groups. A polyether refers to a compound having at least two ether groups.
The term“polymer” designates a collective of chemically uniform macromolecules produced by a polyreaction (polymerization, polyaddition, polycondensation) where the macromolecules differ with respect to their degree of polymerization, molecular weight and chain length. The term also comprises derivatives of said collective of macromolecules resulting from polyreactions, that is, compounds which are obtained by reactions such as, for example, additions or substitutions, of functional groups in predetermined macromolecules and which may be chemically uniform or chemically non-uniform.
The term“(meth)acrylic” designates both methacrylic or acrylic. Accordingly, the term“(meth)acrylate designates both acrylates and methacrylates.
The term“molecular weight” refers to the molar mass (g/mol) of a molecule or a part of a molecule, also referred to as“moiety”. The term“average molecular weight” refers to number average molecular weight (Mn) of an oligomeric or polymeric mixture of molecules or moieties. The molecular weight may be determined by gel permeation chromatography.
The term "bitumen" designates blends of heavy hydrocarbons, having a solid consistency at room temperature, which are normally obtained as vacuum residue from refinery processes, which can be distillation (topping or vacuum) and conversion (thermal cracking and visbreaking) processes of suitable crude oils. Furthermore, the term“bitumen” also designates natural and synthetic bitumen as well as bituminous materials obtained from the extraction of tars and bituminous sands. The term“emulsion” designates stable mixtures of two immiscible liquids, in which the other one is dispersed as fine droplets in the other. Typically an emulsifier, such as soap, is required to obtain a stable emulsion in which the liquid phases do not separate. The“amount or content of at least one component X” in a composition, for example“the amount of the at least one polyol” refers to the sum of the individual amounts of all polyols contained in the composition. For example, in case the composition comprises 20 wt.-% of at least one polyol, the sum of the amounts of all polyols contained in the composition equals 20 wt.-%.
The term“room temperature” designates a temperature of 23°C. The method for producing a pre-formed waterproofing membrane comprises a first step of simultaneously spraying a first aqueous coagulant composition and a first aqueous emulsion of polymer modified bitumen to a first surface of a support sheet. During the spraying step, the coagulant composition is contacted and mixed with the polymer modified bitumen emulsion, which results in coagulation
(breaking) of the emulsion and formation of a solid layer of the sprayed material on the surface of the support sheet. After mixing of the coagulant composition with the aqueous emulsion, the polymer and bitumen components, which were originally present as dispersed particles in a continuous aqueous phase, start to aggregate and the aqueous phase is simultaneously separated from the emulsion. The pre-formed membranes produced by using the method of the present invention have been found out to have a nearly homogeneous structure without weak spots consisting essentially of bitumen or areas of entrapped water.
The term“pre-formed waterproofing membrane” refers in the present disclosure to sheet-like solid articles, which have been formed before being applied on a surface of a substrate to be waterproofed. In particular the term“pre-formed waterproofing membrane” refers to sheet-like articles, which have not been formed in situ, i.e. not been formed on the surface of the substrate to be waterproofed. Such pre-formed waterproofing membranes are fabricated at a location that is typically remote from the construction site, brought to the site, for example, in the form of a roll and laid on a surface of a substrate to be waterproofed. In particular, the term“pre-formed waterproofing membrane” does not encompass layers of coatings, sealants, and the like that are formed in situ by applying a liquid composition on a surface of a substrate to be waterproofed and allowing the composition to harden and/or cure. The term“liquid” is understood to mean a material that flows at normal room temperature and has a pour point of less than 20°C.
Preferably, the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are simultaneously sprayed on the first surface of the support sheet in a manner that the solid layer of the sprayed material formed on the first surface of the support sheet has a thickness of at least 0.1 mm, preferably at least 0.25 mm, more preferably at least 0.35 mm, even more preferably at least 0.5 mm. According to one or more embodiments, the solid layer of the sprayed material formed on the first surface of the support sheet has a thickness in the range of 0.15 - 15 mm, preferably 0.25 - 10 mm, more preferably 0.35 - 5 mm.
According to one or more embodiments, the method for producing a pre-formed waterproofing membrane comprises a second step of subjecting the wet waterproofing membrane containing the support sheet obtained from the first step to a drying step to remove at least part of the water separated from the first aqueous emulsion of polymer modified bitumen. The drying step is preferably conducted by drawing the wet waterproofing membrane through a pair of calender rolls and/or by heating in an oven, heating by air stream, or heating with infrared (IR)-radiation. According to one or more embodiments, the method for producing a pre-formed waterproofing membrane comprises a third step of subjecting the dried
waterproofing membrane obtained from the second step to one or more post- treatment steps, preferably selected from the group consisting of rolling up the dried membrane into a roll, preferably with an inert divider layer, such as a release liner, cutting the dried waterproofing membrane into desired lengths, and applying one or more additional layers of material on at least one of the outer surfaces of the dried waterproofing membrane. Preferably, the 1st, 2nd, and 3rd steps of the method for producing a pre-formed waterproofing membrane are performed in their given numerical order.
The support sheet is preferably a sheet-like element having first and second surfaces, i.e. top and bottom surfaces, defined by peripheral edges and defining a thickness of the element there between. The term“sheet-like element” refers in the present document to elements having a length and width at least 25 times, preferably at least 50 times, more preferably at least 100 times greater than the thickness of the element.
The type of the support sheet is not particularly restricted. For example, the reinforcing layers commonly used for improving the dimensional stability of waterproofing and roofing membranes can be used as the support sheet.
Preferably, the support sheet comprises at least one layer of fiber material.
The term“fiber material” designates in the present disclosure materials composed of fibers. Suitable fibers to be used in the support sheet can comprise or consist of organic, inorganic or synthetic organic materials or any combination thereof.
Suitable organic fibers include, for example, cellulose fibers, cotton fibers, and protein fibers. Suitable synthetic organic fibers include, for example, fibers composed of polyester, homopolymers and copolymers of ethylene and/or propylene, viscose, nylon, and polyamides. Fiber materials composed of inorganic fibers are also suitable, in particular, those composed of mineral fibers, such as glass fibers, aramid fibers, wollastonite fibers, and carbon fibers. Inorganic fibers, which have been surface treated, for example, with silanes, may also be used.
The fiber material can comprise short fibers, long fibers, spun fibers (yarns), or filaments. The fibers can moreover be aligned or drawn fibers. It may also be advantageous to use a combination of different types of fibers, both in terms of geometry and composition.
Preferably, the at least one layer of fiber material has a mass per unit weight of not more than 500 g/m2, more preferably not more than 350 g/m2, even more preferably not more than 250 g/m2, still more preferably not more than 150 g/m2, most preferably not more than 100 g/m2. According to one or more embodiments, the at least one layer of fiber material has a mass per unit weight in the range of 5 - 350 g/m2, preferably 15 - 250 g/m2, more preferably 25 - 150 g/m2, even more preferably 25 - 100 g/m2, most preferably 25 - 75 g/m2.
The fiber material of the at least one layer of fiber material is preferably selected from the group consisting of non-woven fabrics, woven fabrics, and non-woven scrims. The term“non-woven fabric” designates in the present disclosure materials composed of fibers, which are bonded together by using chemical, mechanical, or thermal bonding means, and which are neither woven nor knitted. Non-woven fabrics can be produced, for example, by using a carding or needle punching process, in which the fibers are mechanically entangled to obtain the nonwoven fabric. In chemical bonding, chemical binders such as adhesive materials are used to hold the fibers together in a non-woven fabric.
The term“non-woven scrim” designates in the present disclosure web-like non- woven products composed of yarns, which lay on top of each other and are chemically bonded to each other. Typical materials for non-woven scrims include metals, fiberglass, and plastics, in particular polyester, polypropylene,
polyethylene, and polyethylene terephthalate (PET).
According to one or more embodiments, the support sheet comprises at least one non-woven fabric layer composed of inorganic fibers, preferably having a mass per unit weight in the range of 5 - 300 g/m2, preferably 15 - 200 g/m2, more preferably 25 - 150 g/m2, even more preferably 25 - 125 g/m2, most preferably 25 - 100 g/m2. The expression“composed of inorganic fibers” is understood to mean in the context of the present invention that the fiber base of the non-woven fabric layer is composed of inorganic fibers, wherein the fabric layer itself may contain further components, such as the chemical binders that hold the fibers together in the non- woven fabric layer. Preferably the inorganic fibers are selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers.
According to one or more embodiments, the support sheet comprises at least one non-woven fabric layer composed of synthetic organic fibers, preferably having a mass per unit weight in the range of 5 - 250 g/m2, preferably 15 - 150 g/m2, more preferably 25 - 125 g/m2, even more preferably 25 - 100 g/m2, most preferably 25 - 75 g/m2. The expression“composed of synthetic organic fibers” is understood to mean in the context of the present invention that the fiber base of the non-woven fabric layer is composed of synthetic organic fibers, wherein the fabric layer itself may contain further components, such as the chemical binders that hold the fibers together in the non-woven fabric layer. Preferably the synthetic organic fibers are selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers.
According to one or more embodiments, the support sheet comprises at least one non-woven scrim composed of multifilament yarns of polyester, polypropylene, polyethylene, polyethylene terephthalate (PET), or glass fibers. According to one or more embodiments, the support sheet comprises at least one non-woven fabric layer composed of inorganic or synthetic organic fibers and at least one non-woven scrim composed of multifilament yarns of polyester, polypropylene, polyethylene, polyethylene terephthalate (PET), or glass fibers. According to one or more further embodiments, the support sheet is a non-woven fabric layer composed of inorganic fibers, wherein the non-woven fabric preferably has a mass per unit weight in the range of 5 - 300 g/m2, preferably 15 - 200 g/m2, more preferably 25 - 150 g/m2, even more preferably 25 - 125 g/m2, most preferably 25 - 100 g/m2, wherein the inorganic fibers are preferably selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers. According to one or more embodiments, the support sheet is a non-woven fabric layer composed of synthetic organic fibers, wherein the non-woven fabric preferably has a mass per unit weight in the range of 5 - 250 g/m2, preferably 15 - 150 g/m2, more preferably 25 - 125 g/m2, even more preferably 25 - 100 g/m2, most preferably 25 - 75 g/m2, wherein the synthetic organic fibers are preferably selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers.
The temperature of the first aqueous emulsion of polymer modified bitumen and/or the first aqueous coagulant composition during the spraying step is not particularly restricted. It may be preferable that the temperature of the first aqueous emulsion of polymer modified bitumen and/or the first aqueous coagulant composition during the spraying step is not more than 80°C, more preferably not more than 60°C, most preferably not more than 40°C.
The weight ratio of the amount of the first aqueous emulsion of polymer modified bitumen to the amount of the first aqueous coagulant composition simultaneously sprayed to the first surface of the support sheet is not particularly restricted.
Preferably, the weight ratio of the amount of the first aqueous emulsion of polymer modified bitumen to the amount of the first aqueous coagulant composition is in the range of from 20:1 to 2:1 , preferably from 15:1 to 3:1 , more preferably from 15:1 to 5:1 , most preferably from 10:1 to 5:1.
According to one or more embodiments, the first aqueous coagulant composition comprises at least one coagulating agent selected from the group consisting of salts of alkali and earth alkali metals, organic acids, inorganic acids, metal sulfates, and polyamines. The term“aqueous composition” refers in the present disclosure to a composition in which water is the primary dissolving medium or solvent. Preferably, the“aqueous composition” refers to a composition, in which water is the only dissolving medium or solvent. It may be preferable that the coagulating agent is selected from the group consisting of calcium chloride and citric acid. The solids content of the first aqueous emulsion of polymer modified bitumen is not particularly restricted. However, increasing the solids content above a certain limit has been found the increase the viscosity of the emulsion to a level, which complicates the spraying step. Since the water separated from the emulsion as result of coagulation has to be removed, for example, by drying, relatively high solids content is typically preferred. The term“solids content” refers to the portion of the composition, which when heated to a temperature of 105°C for one hour at one atmosphere pressure does not volatilize. It may be preferable that the first aqueous emulsion of polymer modified bitumen has a solids content of at least 30 wt.-%, more preferably at least 40 wt.-%, based on the total weight of the first aqueous emulsion of polymer modified bitumen. In particular, it may be preferable that the first aqueous emulsion of polymer modified bitumen has a solids content of 30 - 80 wt.-%, more preferably 40 - 70 wt.-%, most preferably 45 - 65 wt.-%, based on the total weight of the first aqueous emulsion of polymer modified bitumen.
The polymer may be present in the first aqueous emulsion of polymer modified bitumen, for example, in form of a polymer dispersion and/or an emulsion. The amount of the polymer in the first aqueous emulsion of polymer modified bitumen is not particularly restricted. Increasing the amount of the polymer component has been found out to result in pre-formed waterproofing membranes having improved mechanical properties, in particular improved tensile and tear strength as well as improved UV-resistance. However, increasing the amount of polymer also increases the production costs of the pre-formed waterproofing membrane.
It may be preferred that the weight ratio of the amount of bitumen to the amount of polymer in the first aqueous emulsion of polymer modified bitumen is in the range of from 1 :1 to 20:1 , more preferably from 2:1 to 15:1 , even more preferably from 2:1 to 10:1 , most preferably from 3:1 to 5:1. Furthermore, it may be preferable that the first aqueous emulsion of polymer modified bitumen comprises 1 - 35 wt.-%, more preferably 1.5 - 30 wt.-%, even more preferably 2.5 - 25.0 wt.-%, most preferably 5.0 - 20 wt.-%, of the polymer, based on the total weight of the first aqueous emulsion. The“amount of the polymer” in the context of an aqueous emulsion of polymer modified bitumen in understood to mean the total weight of all polymer components present in the aqueous emulsion that are not part of the bitumen component. The first aqueous polymer modified bitumen emulsion is preferably obtained by mixing an aqueous bitumen emulsion with at least one aqueous polymer dispersion. The mixing can be conducted using any conventional mixing technique known to a person skilled in the art, preferably using a high shear mixing
equipment.
The term "dispersion" designates in the present document a physical state of matter that includes at least two distinct phases, wherein a first phase is
distributed in a second phase, with the second phase being a continuous medium. In particular, the dispersion comprises a solid phase which is dispersed as solid particles in a continuous liquid phase. The term“aqueous polymer dispersion” refers to a dispersion containing a first phase of polymer particles distributed in an aqueous second phase that is predominately water and may contain minor amounts of water soluble or water miscible liquids, such as lower alkyl alcohols, ketones, or glycols.
Suitable aqueous bitumen emulsions are made from bitumen having a penetration value in of 5 - 400 dmm (tenths of millimeters), preferably 10 - 200 dmm. The penetration value of can be measured at a temperature of 25°C measured according to AASHTO T 49 and ASTM D 5.
It may be preferable that the aqueous bitumen emulsion has a solid content of 25 - 75 wt.-%, more preferably 35 - 75 wt.-%, most preferably 40 - 70 wt.-%, based on the total weigh of the aqueous bitumen emulsion and/or a softening point of the bitumen in the range of 45 - 90°C, more preferably 50 - 85°C, most preferably 50 - 80°C. Suitable bitumen emulsions can be prepared by simultaneously passing solution of melted bitumen and an aqueous solution of emulsifying agent heated a temperature in the range of 40 - 80°C through an emulsifying apparatus, such as a colloid mill or a barrel homogenizer. Suitable emulsifying agents for bitumen are known to a person skilled in the art. These include, for example, soaps, resin soaps, and organic emulsifiers.
The type of the at least one aqueous polymer dispersion is not particularly restricted as long as it provides fast coagulation with the bitumen emulsion when mixed with the aqueous coagulant composition as well as good mechanical properties of the cured layer, in particular high elongation at break.
Suitable aqueous polymer dispersions include, for example, aqueous dispersions of acrylic polymers, polyurethanes, polyurethane-urea polymers, styrene- butadiene copolymers, halogenated styrene-butadiene copolymers, ethylene vinyl acetate copolymers, polyvinyl alcohol, and polyvinyl acetate. Further suitable aqueous polymer dispersions include aqueous dispersions of rubbers, for example aqueous dispersions of styrene-butadiene rubber, natural rubber, styrene isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, butyl rubber, halogenated butyl rubber, chlorinated polyethylene, chlorosulfonated polyethylene, ethylene propylene rubber, and butadiene acrylonitrile copolymers.
The term“acrylic polymer” refers in the present disclosure to homopolymers, copolymers and higher inter-polymers of an acrylic monomer with one or more further acrylic monomers and/or with one or more other ethylenically unsaturated monomers. The term“acrylic monomer” refers in the present document to
(meth)acrylates, (meth)acrylic acid, and to derivatives thereof, for example, amides of (meth)acrylic acid or nitriles of (meth)acrylic acid. Preferred acrylic polymers contain at least 30 wt.-%, more preferably at least 40 wt.-%, most preferably at least 50 wt.-% of acrylic monomers. The term“acrylic dispersion” refers in the present document to dispersions of acrylic polymers.
According to one or more embodiments, the at least one aqueous polymer dispersion is selected from the group consisting of aqueous polyurethane dispersions, acrylic dispersions, polyurethane-acrylic dispersions, styrene- butadiene copolymer dispersions, styrene-butadiene rubber dispersions, and styrene isoprene rubber dispersions. Suitable acrylic polymers for the aqueous dispersion consist for the most part of (meth)acrylates of alcohols containing from 1 to 24 carbon atoms. Preferred acrylic polymers contain, as polymerized units, at least 25 wt.-%, more preferably at least 35 wt.-%, most preferably at least 50 wt.-% of these acrylic monomers. Suitable ethylenically unsaturated monomers that can be used as comonomers with the acrylic monomers include, for example, vinyl esters and allyl esters of carboxylic acids containing from 1 to 20 carbon atoms, vinyl ethers of alcohols containing from 1 to 8 carbon atoms, vinyl aromatic compounds, in particular styrene, vinyl halides, non-aromatic hydrocarbons containing from 2 to 8 carbon atoms and at least one olefinic double bond, a and b-unsaturated mono- or di-carboxylic acids containing from 3 to 6 carbon atoms, and derivatives thereof (especially amides, esters and salts). Examples of particularly suitable acrylic polymers include poly(meth)acrylates, copolymers of (meth)acrylates and styrene, copolymers of (meth)acrylates and vinyl esters of tertiary carboxylic acids, copolymers and terpolymers of
(meth)acrylates, vinyl esters of tertiary carboxylic acids and vinyl acetate, and copolymers of vinyl acetate and (meth)acrylates.
According to one or more embodiments, the at least one aqueous polymer dispersion is selected from the group consisting of polyurethane-acrylic dispersion, styrene-butadiene copolymer dispersion, and (meth)acrylate-styrene copolymer dispersion.
Polyurethane-acrylic dispersions can be prepared by using physical or chemical methods. In the first case, aqueous polyurethane and acrylic dispersions
(emulsions) are independently prepared first and then both dispersions are mixed together under mechanical mixing. In the latter case, the polyurethane dispersion can be prepared first, and then acrylic monomers can be polymerized in the polyurethane dispersion. Typically, a core-shell emulsion polymerization is used.
In core-shell emulsion polymerization, polyurethane particles are used as seed particles and the acrylates are polymerized within the polyurethane particles due to high hydrophobicity of the acrylates. Other types of morphologies than core- shell, such as embedded sphere morphologies, can also be obtained by using different techniques. Polyurethane-acrylic dispersions obtained with chemical methods are also known as polyurethane-acrylic hybrid dispersions. Methods for production of
polyurethane-acrylic hybrid dispersions are known to a person skilled in the art and disclosed, for example, in US 7,534,830 B2. According to one or more preferred embodiments, the at least one aqueous polymer dispersion is an aqueous polyurethane-acrylic hybrid dispersion.
Suitable polyurethane-acrylic hybrid dispersions are commercially available, for example, under the trade name of Hybridur® from Air Products and Chemicals Inc., under the trade name of APU® from Alberdingk Boley, under the trade name of Joncryl® HYB from BASF, such as Joncryl® HYB 6336 and Joncryl® HYB 6340, and under the trade name of Acriten® from Sygla Columbiana, such as Acriten® PU 230. According to one or more embodiments, the method for producing a pre-formed waterproofing membrane further comprises simultaneously spraying a second aqueous coagulant composition and a second aqueous emulsion of polymer modified bitumen to a second surface of a support sheet to effect coagulation of the second aqueous emulsion and formation of a solid layer of the sprayed material on the second surface of the support sheet. The second surface of the support sheet is the surface on the side opposite to the first surface of the support sheet.
It may also be preferable that that the temperature of the second aqueous emulsion of polymer modified bitumen and/or the second aqueous coagulant composition during the spraying step is not more than 80°C, more preferably not more than 60°C, most preferably not more than 40°C. The first and second aqueous coagulant compositions sprayed to the first and second surfaces of the support sheet, respectively, may have same or different composition. According to one or more embodiments, the first and second aqueous coagulant compositions have identical compositions. Furthermore, the first aqueous emulsion of polymer modified bitumen and the second aqueous emulsion of polymer modified bitumen sprayed to the first and second surfaces of the support sheet, respectively, may have same or different composition.
According to one or more embodiments, the first and second aqueous emulsions of polymer modified bitumen have identical compositions.
According to one or more embodiments, the method for producing a pre-formed waterproofing membrane comprises steps of: i) Feeding the first aqueous coagulant composition to a first spraying unit, ii) Feeding the first aqueous emulsion of polymer modified bitumen to a second spraying unit, iii) Spraying the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen by using said spraying units to provide at least two streams having intersecting spray paths such that the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to or at the moment of being contacted with the first surface of the support sheet.
It may be preferable that the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to being contacted with the surface of the support sheet. According to one or more embodiments, the distance between the spraying units and the point at which the two streams are intersect, i.e. the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are contacted, is at least 10 cm, preferably at least 25 cm, more preferably at least 30 cm.
The first and second spraying units may contain one or more nozzles through which the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are sprayed. The streams are preferably generated by using liquid pressure (airless). The liquid streams can be pressurized by using gear pumps, centrifugal pumps or other means well known in the art. Other spraying techniques, such as gas atomization, are also possible.
According to one or more embodiments, the method comprises a further step of: iv) Subjecting the wet membrane obtained from step iii) to a drying step to remove at least part of the water separated from the first aqueous emulsion of polymer modified bitumen.
According to one or more embodiments, step iv) comprises subjecting the wet membrane obtained from step iii) to a squeezing step to press out the water separated from the aqueous emulsion of polymer modified bitumen. The squeezing can be conducted, for example, by drawing the wet membrane through a pair of calender rolls. According to one or more embodiments, step iv) comprises subjecting the wet membrane obtained from step iii) and/or membrane obtained from the squeezing step to a final drying step. The final drying step can be conducted, for example, by heating in an oven, heating by air stream, or heating with infrared (IR)-radiation.
The method for producing a pre-formed waterproofing membrane is preferably conducted as a continuous process using a calender roll machine. According to one or more embodiments, the method comprises further steps of: i') Feeding the second aqueous coagulant composition to a third spraying unit ii’) Feeding the second aqueous emulsion of polymer modified bitumen to a fourth spraying unit, iii’) Spraying the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen by using said spraying units to provide at least two streams having intersecting spray paths such that the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to or at the moment of being contacted with the second surface of the support sheet.
It may be preferable that the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to being contacted with the second surface of the support sheet. According to one or more embodiments, the distance between the spraying units and the point at which the two streams are intersect, i.e. the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen are contacted, is at least 10 cm, preferably at least 25 cm, more preferably at least 30 cm.
The third and fourth spraying units may contain one or more nozzles through which the second aqueous coagulant composition and the second aqueous emulsion of polymer modified bitumen are sprayed. The streams are preferably generated by using liquid pressure (airless). The liquid streams can be pressurized by using gear pumps, centrifugal pumps or other means well known in the art. Other spraying techniques, such as gas atomization, are also possible.
The steps i' - iii’) of the method may be conducted after the completion of steps i)
- iii) or simultaneously with the steps i) - iii). It may be preferable that the steps i' - iii’) of the method are conducted after the completion of steps i) - iii), in particular after the completion of steps i) - iv) of the method. In case the steps i' - iii’) of the method are conducted after the completion of steps i) - iii), more preferably after the completion of steps i) - iv) of the method, the same spraying units can be used in steps i' - iii’) as in steps i) - iii), i.e. the third and fourth spraying unit correspond to the first and second spraying units.
According to one or more embodiments, the method comprises a further step of:
Iv’) Subjecting the wet membrane obtained from step iii’) to a drying step to remove at least part of the water separated from the second aqueous emulsion of polymer modified bitumen.
According to one or more embodiments, step iv’) comprises subjecting the wet membrane obtained from step iii’) to a squeezing step to press out the water separated from the aqueous emulsion of polymer modified bitumen. The
squeezing can be conducted, for example, by drawing the wet membrane through a pair of calender rolls. According to one or more embodiments, step iv’) comprises subjecting the wet membrane obtained from step iii’) and/or membrane obtained from the squeezing step to a final drying step. The final drying step can be conducted, for example, by heating in an oven, heating by air stream, or heating with infrared (IR)-radiation.
The dried waterproofing membrane obtained from step iv) or iv’) can further be subjected to one or more further post-treatment and/or finishing steps, for example, to cutting, up winding, rolling, and packaging steps.
Furthermore, the dried waterproofing membrane obtained from step iv) or iv’) can be subjected to further processing steps, in which one or more additional layers of material are applied on at least one of the outer surfaces of the waterproofing membrane. Suitable additional layers include, for example, particle-based layers of mineral particles, in particular composed of or comprising sand, talcum, gravel, or slates; singly-layer and multi-layer polymeric foils, in particular polymeric foils composed of or comprising polyethylene, in particular crosslaminated HDPE, polypropylene, PVC, polyethylene terephthalate (PET); single-layer metal foils, in particular aluminum foils; multi-layer composite foils comprising one or more polymeric foils and one or more metal foils; layers of adhesive compositions, in particular layer of pressure sensitive adhesive (PSA) or hot-melt (HM) adhesive, including pressure sensitive hot-melt adhesives (HM-PSA); and layers of fiber material, in particular layers of non-woven fabric.
The one or more additional layers can be applied on the surface of the dried waterproofing membrane by using any conventional techniques. The details of the application step depend on the type of the applied additional layer(s). For example, adhesive layers can be directly applied on the surface of the dried waterproofing membrane by via flat-die extrusion or calendering steps or by using adhesive transfer films. It may be preferable to cover the adhesive layer, if present, with a release liner, in particular if the applied adhesive is a pressure sensitive adhesive (PSA). Suitable materials for the release liner include Kraft paper, polyethylene coated paper, silicone coated paper as well as polymeric films, for example, polyethylene, polypropylene, and polyester films optionally coated with polymeric release agents, for example, selected from silicone, silicone urea, urethanes, waxes, and long chain alkyl acrylate release agents. The additional polymeric, metal, and polymer-metal composite foils can be fixed onto the surface of the dried waterproofing membrane obtained from step iv) or iv’) by using conventional lamination techniques or by adhesive bonding.
Another subject of the present invention is a pre-formed waterproofing membrane comprising a waterproofing layer comprising a polymer modified bitumen composition and a support sheet, which is at least partially embedded, preferably fully embedded into the waterproofing layer. By the expression“fully embedded” is understood to mean that the support sheet is substantially fully covered by the matrix of the waterproofing layer.
The waterproofing layer is preferably sheet-like element having first and second surfaces, i.e. top and bottom surfaces, defined by peripheral edges and defining a thickness of the element there between. The term“sheet-like element” refers in the present document to elements having a length and width at least 25 times, preferably at least 50 times, more preferably at least 100 times, greater than the thickness of the element. The polymer modified bitumen composition comprises bitumen and at least one polymer. Preferably, the waterproofing layer is composed of a continuous layer of the polymer modified bitumen composition. The term“continuous layer”
designates in the present document layers consisting of one single area of the respective material. In contrast, a“discontinuous layer” is considered to consist of more than one areas of the respective material, which areas are not connected with each other to form a single continuous layer of the material.
Preferably, the support sheet comprises at least one layer of fiber material. The fiber material of the at least one layer of fiber material is preferably selected from the group consisting of non-woven fabrics, woven fabrics, and non-woven scrims.
According to one or more embodiments, the support sheet comprises at least one non-woven fabric layer composed of inorganic fibers, preferably having a mass per unit weight in the range of 5 - 300 g/m2, preferably 15 - 200 g/m2, more preferably 25 - 150 g/m2, even more preferably 25 - 125 g/m2, most preferably 25 - 100 g/m2. Preferably the inorganic fibers are selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers. According to one or more embodiments, the support sheet comprises at least one non-woven fabric layer composed of synthetic organic fibers, preferably having a mass per unit weight in the range of 5 - 250 g/m2, preferably 15 - 150 g/m2, more preferably 25 - 125 g/m2, even more preferably 25 - 100 g/m2, most preferably 25 - 75 g/m2. Preferably the synthetic organic fibers are selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers. According to one or more embodiments, the support sheet comprises at least one non-woven scrim composed of multifilament yarns of polyester, polypropylene, polyethylene, polyethylene terephthalate (PET), or glass fibers. According to one or more embodiments, the support sheet comprises at least one non-woven fabric layer composed of inorganic or synthetic organic fibers and at least one non-woven scrim composed of multifilament yarns of polyester, polypropylene, polyethylene, polyethylene terephthalate (PET), or glass fibers. According to one or more further embodiments, the support sheet is a non-woven fabric layer composed of inorganic fibers, wherein the non-woven fabric preferably has a mass per unit weight in the range of 5 - 300 g/m2, preferably 15 - 200 g/m2, more preferably 25 - 150 g/m2, even more preferably 25 - 125 g/m2, most preferably 25 - 100 g/m2, wherein the inorganic fibers are preferably selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers.
According to one or more embodiments, the support sheet is a non-woven fabric layer composed of synthetic organic fibers, wherein the non-woven fabric preferably has a mass per unit weight in the range of 5 - 250 g/m2, preferably 15 - 150 g/m2, more preferably 25 - 125 g/m2, even more preferably 25 - 100 g/m2, most preferably 25 - 75 g/m2, wherein the synthetic organic fibers are preferably selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers.
The at least one polymer contained in the polymer modified bitumen composition is preferably selected from the group consisting of acrylic polymers, polyurethane polymers, polyurethane-urea polymers, styrene-butadiene copolymers,
halogenated styrene-butadiene copolymers, ethylene vinyl acetate copolymers, styrene-butadiene rubber, natural rubber, styrene isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, butyl rubber, halogenated butyl rubber, chlorinated polyethylene, chlorosulfonated polyethylene, ethylene propylene rubber, and butadiene acrylonitrile copolymers. According to one or more embodiments, the at least one polymer contained in the polymer modified bitumen composition is selected from the group consisting of acrylic polymers, polyurethane polymers, polyurethane-acrylic hybrid polymers, styrene-butadiene copolymers, styrene-butadiene rubber, and styrene isoprene rubber, preferably from the group consisting of polyurethane-acrylic hybrid polymers, styrene-butadiene copolymers, and (meth)acrylate-styrene copolymers. According to one or more further embodiments, the at least one polymer is a polyurethane-acrylic hybrid polymer.
It may be preferred that the weight ratio of the amount of bitumen to the amount of the at least one polymer in the polymer modified bitumen composition is in the range of from 1 :1 to 20:1 , more preferably from 2:1 to 15:1 , even more preferably from 2:1 to 10:1 , most preferably from 3:1 to 5:1. Furthermore, it may be
preferable that the polymer modified bitumen composition comprises 5 - 70 wt.-%, more preferably 10 - 50 wt.-%, even more preferably 15 - 40 wt.-%, most preferably 20 - 35 wt.-%, of the at least one polymer, based on the total weight of the polymer modified bitumen composition. According to one or more embodiments, the polymer modified bitumen
composition is a cured composition of an aqueous emulsion of polymer modified bitumen, i.e. the waterproofing layer comprises a cured composition of an aqueous emulsion of polymer modified bitumen. The expression“cured composition” refers in the context of an aqueous emulsion of polymer modified bitumen to a de- emulsified composition, from which the water has been separated resulting in at least partial coagulation of the polymer and bitumen parts, preferably resulting in substantially complete coagulation of the polymer and bitumen parts. The term “substantially complete coagulation” is understood to mean that at least 90 wt.-%, preferably at least 95 wt.-%, most preferably at least 97.5 wt.-% of the total weight of the polymer and bitumen parts of the aqueous emulsion of polymer modified bitumen have been coagulated. It may be preferred that the weight ratio of the amount of bitumen to the amount of polymer in the aqueous emulsion of polymer modified bitumen is in the range of from 1 :1 to 20:1 , more preferably from 2:1 to 15:1 , even more preferably from 2:1 to 10:1 , most preferably from 3:1 to 5:1. Furthermore, it may be preferable that the aqueous emulsion of polymer modified bitumen comprises 1 - 35 wt.-%, more preferably 1.5 - 30 wt.-%, even more preferably 2.5 - 25.0 wt.-%, most preferably 5.0 - 20 wt.-%, of the polymer, based on the total weight of the aqueous emulsion of polymer modified bitumen. According to one or more embodiments, the aqueous emulsion of polymer modified bitumen is obtained by mixing an aqueous bitumen emulsion with at least one aqueous polymer dispersion. The mixing can be conducted using any conventional mixing techniques known to a person skilled in the art, preferably using a high shear mixing equipment.
Suitable aqueous bitumen emulsions include the ones discussed above related to the method for producing a waterproofing membrane.
The at least one aqueous polymer dispersion is preferably selected from the group consisting of aqueous dispersions of acrylic polymers, polyurethanes,
polyurethane-urea polymers, styrene-butadiene copolymers, halogenated styrene- butadiene copolymers, ethylene vinyl acetate copolymers, styrene-butadiene rubber, natural rubber, styrene isoprene rubber, polyisoprene, polybutadiene, polychloroprenes, butyl rubber, halogenated butyl rubber, chlorinated
polyethylene, chlorosulfonated polyethylene, ethylene propylene rubber, and butadiene acrylonitrile copolymers.
According to one or more embodiments, the at least one aqueous polymer dispersion is selected from the group consisting of acrylic dispersions,
polyurethane dispersions, polyurethane-acrylic dispersions, styrene-butadiene copolymer dispersions, styrene-butadiene rubber dispersions, and styrene isoprene rubber dispersions, preferably from the group consisting of polyurethane- acrylic dispersions, styrene-butadiene copolymer dispersions, and (meth)acrylate- styrene copolymer dispersions.
According to one or more embodiments, the at least one polymer dispersion is a polyurethane-acrylic dispersion, preferably a polyurethane-acrylic dispersion hybrid dispersion.
According to one or more embodiments, the pre-formed waterproofing membrane is obtained by using the method for producing a pre-formed waterproofing membrane of the present invention.
The thickness of the waterproofing layer is not particularly restricted. It may be preferable that the waterproofing layer has a thickness, determined by using the measurement method as defined in DIN EN 1849-1 standard, in the range of 0.5 - 15.0 mm, preferably 0.5 - 10.0 mm, even more preferably 1.0 - 7.5 mm, most preferably 1.5 - 5.0 mm.
It may be preferable that the pre-formed waterproofing membrane has an elongation at break, measured by using the method as defined in ISO 527-2 standard at a temperature of 23°C using a cross head speed of 100 mm/min, of at least 10%, more preferably at least 35%, most preferably at least 50 % and/or a tensile strength at break, measured using the method as defined in ISO 527-2 standard at a temperature of 23°C using a cross head speed of 100 mm/min, of at least 0.1 N/mm2, more preferably at least 0.5 N/mm2, most preferably at least 1.5 N/mm2.
It can be advantageous that the pre-formed waterproofing membrane further comprises at least one additional layer of material. Suitable additional layers include, for example, particle-based layers of mineral particles, in particular composed of or comprising sand, talcum, gravel, or slates; single-layer and multi- layer polymeric foils, in particular polymeric foils composed of or comprising polyethylene, in particular crosslaminated HDPE, polypropylene, PVC,
polyethylene terephthalate (PET); single-layer metal foils, in particular aluminum foils; multi-layer composite foils comprising one or more polymeric foils and one or more metal foils; layers of adhesive compositions, in particular layers of pressure sensitive adhesive (PSA) or hot-melt (HM) adhesive, including pressure sensitive hot-melt adhesives (HM-PSA); and layers of fiber material, in particular layers of non-woven fabric.
The additional layers may be fully embedded into the waterproofing layer or they may be directly or indirectly connected to at least part of the outer surfaces of the waterproofing membrane, i.e. top and/or bottom surfaces of the waterproofing layer. The expression“directly connected” is understood to mean in the context of the present invention that no further layer or substance is present between the layers, and that the opposing surfaces of the two layers are directly bonded to each other or adhere to each other. At the transition area between the two layers, the materials forming the layers can also be present mixed with each other.
The pre-formed waterproofing membrane may comprise, for example, a protective film or a release liner, which is directly or indirectly connected to at least part of the top and/or bottom surfaces of the waterproofing layer. The protective film may be used to protect the surface of the waterproofing layer from moisture, fouling, and other environmental factors. Furthermore, in case the pre-formed waterproofing membrane is provided in form of rolls, the release liner enables ease of unwind without sticking of the adjacent surfaces of the membrane.
The protective film may be selected from the group consisting of particle-based layers of mineral particles, in particular composed of or comprising sand, talcum, gravel, or slates; singly-layer and multi-layer polymeric foils; single-layer metal foils, in particular aluminum foils; and multi-layer composite foils comprising one or more polymeric foils and one or more metal foils. Suitable release liners include, for example, polymer coated paper films, such as Kraft paper, polyethylene coated paper, and silicone coated paper as well as polymeric films coated with a polymeric release agent, for example with silicone, silicone urea, urethane, wax, and or chain alkyl acrylate release agent. According to one or more embodiments, the pre-formed waterproofing membrane comprises a protective film or a release liner covering at least part of, preferably substantially the entire the top surface of the waterproofing layer and/or a protective film or a release liner covering at least part of, preferably substantially the entire the bottom surface of the waterproofing layer. The expression
“substantially entire surface” is understood to mean that at least 90%, preferably at least 95%, most preferably at least 97.5% of the corresponding surface is covered with the respective protective film or the release liner. According to one or more embodiments, the pre-formed waterproofing membrane comprises a first protective film, in particular a polymeric film, preferably a polyethylene, in particular crosslaminated HDPE, polypropylene, or polyester film, or a metal film, preferably an aluminum film, which first protective film covers the substantially the entire the top surface of the waterproofing layer and/or a second protective film, in particular a polymeric film, preferably a polyethylene,
crosslaminated HDPE, polypropylene, or polyester film, or a metal film, preferably an aluminum film, which second protective film covers the substantially the entire the bottom surface of the waterproofing layer. Furthermore, the pre-formed waterproofing membrane may be a single-ply waterproofing membrane comprising one single waterproofing layer or a multi-ply waterproofing membrane comprising two or more waterproofing layers having same or different compositions. According to one or more embodiments, the pre-formed waterproofing membrane further comprises a second waterproofing layer, wherein the waterproofing layer and the second waterproofing layer are directly or indirectly connected, preferably directly connected over at least part of their opposing surfaces. According to one or more embodiments, the second waterproofing layer comprises a second polymer modified bitumen composition. According to one or more embodiments, the second polymer modified bitumen composition is a cured composition of a second aqueous emulsion of polymer modified bitumen, i.e. the second waterproofing layer comprises a cured composition of a second aqueous emulsion of polymer modified bitumen.
The second aqueous emulsion of polymer modified bitumen may have same or different composition than the aqueous emulsion of polymer modified bitumen. According to one or more embodiments, the second aqueous emulsion of polymer modified bitumen has identical composition with the aqueous emulsion of polymer modified bitumen. According to one or more further embodiments, the second waterproofing layer is a thermoplastic waterproofing layer, preferably comprising at least 70 wt.-%, preferably at least 80 wt.-% of at least one thermoplastic polymer selected from the group consisting of ethylene - vinyl acetate copolymer (EVA), ethylene - acrylic ester copolymers, ethylene - a-olefin co-polymers, ethylene - propylene co-polymers, propylene - ethylene co-polymers, propylene - a-olefin co-polymers, polypropylene (PP), polyethylene (PE), polyvinylchloride (PVC), polyethylene terephthalate (PET), polystyrene (PS), polyamides (PA), chlorosulfonated polyethylene (CSPE), ethylene propylene diene rubber (EPDM), and
polyisobutylene (PIB).
The pre-formed waterproofing membrane is typically provided in a form of a roll, which is delivered to the construction site and unwound from rolls to provide sheets having a width of 1 - 5 m and length of several times the width. However, the pre-formed waterproofing membrane can also be used in the form of strips having a width of typically 1 - 20 cm, for example so as to seal joints between two adjacent waterproofing membranes. Moreover, the pre-formed waterproofing membrane can also be provided in the form of planar bodies, which are used for repairing damaged locations in existing waterproofing or roofing systems. Another subject of the present invention is a method for waterproofing a surface of a substrate comprising steps of: i) Applying pre-formed waterproofing membranes on surface of the substrate to be waterproofed, ii) Overlapping the adjacent edges of said membranes, iii) Bonding the opposing surfaces of the adjacent edges in the overlapping areas to each other by heat-welding or by using an adhesive.
The substrate to be waterproofed can be part of a structure, in particular, part of an above-ground or underground structure, for example a building, garage, tunnel, landfill, water retention, pond, or dike. The material of the substrate can be, for example, concrete, metal, or wood.
According to one or more embodiments, the opposing surfaces of the adjacent edges of said pre-formed membranes are bonded to each other by heat-welding.
In this embodiment, the adjacent edges of the pre-formed waterproofing
membranes in the overlapping areas are heat slightly above the melting
temperature of the waterproofing layer and the overlapped areas are seamed under sufficient pressure to provide acceptable seam strength without use of adhesive.
The heating of the adjacent edges of the pre-formed waterproofing membranes can be conducted manually, for example by an open-flame torch or using an automatic welding device, such as a hot-air seam welding device, for example the Leister BITUMAT® B2 hot-air welder. The temperature to which the adjacent edges of the membranes are heated depends on the embodiment of the pre- formed waterproofing membrane. Examples
The followings compounds and products shown in Table 1 were used in the examples:
Table 1
Figure imgf000032_0001
Preparation of ore-formed waterproofing membranes
The waterproofing membranes according to the reference examples Ref-1 and Ref-2 were produced without a support layer whereas the exemplary
waterproofing membrane according to the example Ex-1 contained polypropylene fabric layer (SikaFelt 30 g/m2, from Sika Columbia).
An aqueous emulsion of polymer modified bitumen was obtained by mixing the aqueous bitumen emulsion with the aqueous polymer dispersion using a blade impeller mixer using a mixer speed of 800 rpm. The waterproofing membranes were then produced in a continuous process using a calender roll machine equipped with a conveyor belt section and pair of calender rolls. In the production process, the component A (polymer modified bitumen) and component B (catalyst), comprising the constituents as shown in Table 2, were simultaneously sprayed to a surface of the conveyor belt section. The spraying was conducted using two separate spraying units equipped with nozzles, which generated to intersecting streams of component A and B such that the streams were mixed with each other before contacting the surface of the calender roll machine. In all examples, component A was fed into a first spraying unit using a progressive pump at a mass flow 10 kg/min and component B was fed into a second spraying unit using a gear pump at a mass flow of 1 kg/min. In Ex-1 the streams of components A and B were mixed at a distance of 50 cm from the nozzles, in Ex-2 at a distance of 40 cm from the nozzles, and in Ex-3 at a distance of 50 cm from the nozzles. The sprayed material was then drawn between pair of calender rolls to remove water and to obtain a membrane with a smooth surface structure. In Ex-3 the components A and B were simultaneously sprayed on surface of a reinforcement layer, which was fed into the calender roll machine from a feed roll. The produced wet membranes were dried in a drying section with air stream having a temperature of 30 °C and relative humidity of 55 %. The dried
membranes were stored in form of rolls. The compositions of components A and B and the properties of produced membranes are presented in Table 2. Mechanical properties
The tensile strength at break and the elongation at break were measured using the methods as defined in ISO 527-2 standard at a temperature of 23 °C using a cross head speed of 100 mm/min. The values presented in Table 2 have been obtained with test specimens, which were cut from the produced waterproofing membranes in lengthwise direction (machine direction).
Table 2
Figure imgf000034_0001

Claims

Claims
1 . A method for producing a pre-formed waterproofing membrane
comprising simultaneously spraying a first aqueous coagulant composition and first aqueous emulsion of polymer modified bitumen to a first surface of a support sheet to effect coagulation of the first aqueous emulsion and formation of a solid layer of the sprayed material on the first surface of the support sheet.
2. The method for producing a pre-formed waterproofing membrane
according to claim 1 , wherein the support sheet comprises at least one layer of fiber material.
3. The method for producing a pre-formed waterproofing membrane
according to claim 1 or 2, wherein the temperature of the first aqueous emulsion of polymer modified bitumen during the spraying step is not more than 80°C, more preferably not more than 60°C, most preferably not more than 40°C.
4. The method for producing a pre-formed waterproofing membrane
according to any of previous claims, wherein the first aqueous coagulant compositions comprises at least one coagulating agent selected from the group consisting of salts of alkali and earth alkali metals, organic acids, inorganic acids, metal sulfates, and polyamines and/or wherein the first aqueous emulsion of polymer modified bitumen has a solids content of 30 - 80 wt.-%, preferably 40 - 70 wt.-%, based on the total weight of the aqueous emulsion of polymer modified bitumen.
5. The method for producing a pre-formed waterproofing membrane
according to any of previous claims, wherein the weight ratio of the amount of bitumen to the amount of polymer in the first aqueous emulsion of polymer modified bitumen is in the range of 1 :1 to 20:1 , preferably from 2:1 to 15:1.
6. The method for producing a pre-formed waterproofing membrane according to any of previous claims, wherein the first aqueous polymer modified bitumen emulsion is obtained by mixing an aqueous bitumen emulsion with at least one aqueous polymer dispersion, preferably with at least one aqueous polymer dispersion selected from the group consisting of polyurethane dispersions, acrylic dispersions,
polyurethane-acrylic dispersions, styrene-butadiene copolymer dispersions, styrene-butadiene rubber dispersions, and styrene isoprene rubber dispersions.
7. The method for producing a pre-formed waterproofing membrane
according to claim 6, wherein the at least one polymer dispersion is a polyurethane-acrylic hybrid dispersion.
8. The method for producing a pre-formed waterproofing membrane
according to any of previous claims, wherein the method further comprises simultaneously spraying a second aqueous coagulant composition and a second aqueous emulsion of polymer modified bitumen to a second surface of the support sheet to effect coagulation of the second aqueous emulsion and formation of a solid layer of the sprayed material on the second surface of the support sheet, wherein the second surface of the support sheet is the surface on the side opposite to the first surface of the support sheet.
9. The method for producing a pre-formed waterproofing membrane
according to any of previous claims comprising steps of: i) Feeding the first aqueous coagulant composition to a first spraying unit,
ii) Feeding the first aqueous emulsion of polymer modified bitumen to a second spraying unit,
iii) Spraying the first aqueous coagulant composition and the first
aqueous emulsion of polymer modified bitumen by using said spraying units to provide at least two streams having intersecting spray paths such that the first aqueous coagulant composition and the first aqueous emulsion of polymer modified bitumen are contacted and mixed with each other external to said spraying units and prior to or at the moment of being contacted with the first surface of the support sheet, and
iv) Optionally subjecting the wet waterproofing membrane obtained from step iii) to a drying step to remove at least part of the water separated from the first aqueous emulsion of polymer modified bitumen.
10. A pre-formed waterproofing membrane comprising a waterproofing layer comprising a polymer modified bitumen composition and a support sheet, which is at least partially embedded into the waterproofing layer.
11. The pre-formed waterproofing membrane according to claim 10,
wherein the support sheet comprises at least one layer of fiber material.
12. The pre-formed waterproofing membrane according to claim 10 or 11 , wherein the support sheet comprises at least one non-woven fabric layer composed of synthetic organic fibers, the non-woven fabric layer preferably having a mass per unit weight in the range of 5 - 250 g/m2, preferably 15 - 150 g/m2.
13. The pre-formed waterproofing membrane according to any of claims I Q- 12, wherein the polymer modified bitumen composition is a cured composition of an aqueous emulsion of polymer modified bitumen.
14. The pre-formed waterproofing membrane according to claim 13,
wherein the weight ratio of the amount of bitumen to the amount of polymer in the aqueous emulsion of polymer modified bitumen is in the range of from 1 :1 to 20:1 , preferably from 2:1 to 15:1.
15. The pre-formed waterproofing membrane according to claim 13 or 14, wherein the aqueous emulsion of polymer modified bitumen is obtained by mixing an aqueous bitumen emulsion with at least one aqueous polymer dispersion, preferably with at least one aqueous polymer dispersion is selected from the group consisting of polyurethane dispersions, acrylic dispersions, polyurethane-acrylic dispersions, styrene-butadiene copolymer dispersions, styrene-butadiene rubber dispersions, and styrene isoprene rubber dispersions.
16. The pre-formed waterproofing membrane according to claim 15,
wherein the at least one aqueous polymer dispersion is an aqueous polyurethane-acrylic hybrid dispersion.
17. A pre-formed waterproofing membrane obtained by using the method as defined in any of claims 1 -9.
18. A method for waterproofing a surface of a substrate comprising steps of: a) Applying pre-formed waterproofing membranes according to any of claims 10-17 on surface of the substrate to be waterproofed, b) Overlapping adjacent edges of said membranes and,
c) Bonding the opposing surfaces of the adjacent edges in the
overlapping areas to each other by heat-welding or by using an adhesive, preferably by heat-welding.
PCT/EP2019/057190 2018-03-29 2019-03-22 A method for producing a pre-formed bituminous waterproofing membrane WO2019185459A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
BR112020015689-2A BR112020015689A2 (en) 2018-03-29 2019-03-22 METHOD TO PRODUCE A PRE-FORMED BETUMINOUS WATERPROOFING MEMBRANE
MX2020009995A MX2020009995A (en) 2018-03-29 2019-03-22 A method for producing a pre-formed bituminous waterproofing membrane.

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP18164846.0 2018-03-29
EP18164846 2018-03-29

Publications (1)

Publication Number Publication Date
WO2019185459A1 true WO2019185459A1 (en) 2019-10-03

Family

ID=61906619

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2019/057190 WO2019185459A1 (en) 2018-03-29 2019-03-22 A method for producing a pre-formed bituminous waterproofing membrane

Country Status (3)

Country Link
BR (1) BR112020015689A2 (en)
MX (1) MX2020009995A (en)
WO (1) WO2019185459A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111101658A (en) * 2019-12-27 2020-05-05 唐山东方雨虹防水技术有限责任公司 Modified asphalt waterproof coiled material and preparation method thereof
CN113738153A (en) * 2021-09-13 2021-12-03 通号工程局集团有限公司 Construction method for waterproof renovation of railway metal roof
WO2022182492A1 (en) * 2021-02-25 2022-09-01 Milliken & Company Liquid applied roofing composite

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3843574A1 (en) * 1988-09-01 1990-03-15 Roland Werke Dachbaustoffe U B Process and apparatus for producing a waterproof membrane with preferably two supporting liners
WO2001088040A1 (en) * 2000-05-17 2001-11-22 Antonino Ancione S.P.A. Aqueous catalyst and sprayable bituminous emulsion for cold impermeabilization
GB2392399A (en) * 2002-08-28 2004-03-03 Antonino Ancione S P A Process for the application of a bituminous coating
US20080028978A1 (en) * 2006-01-23 2008-02-07 Blak Tuf-Stuf, Inc. Water-based asphalt emulsion-based coatings, compositions, manufacture and applications for use
FR2912427A1 (en) * 2007-02-14 2008-08-15 Soprema Soc Par Actions Simpli Making non-woven fabric for reinforcing sealing membranes for use e.g. in buildings, involves forming the fabric from natural fibres and then needling, chemical- or thermal-bonding and waterproofing
US7534830B2 (en) 2002-12-17 2009-05-19 Imperial Chemical Industries Aqueous dispersions of polyurethane-addition polymer hybrid particles especially for use in coating compositions
WO2016001606A1 (en) * 2014-07-04 2016-01-07 Saint-Gobain Adfors Mineral fibre mat and bitumen products incorporating said mat
US20170291384A1 (en) * 2016-04-11 2017-10-12 Gardner-Gibson, Inc. Silicone-Containing Roof Assemblies and Methods for Production and Use

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3843574A1 (en) * 1988-09-01 1990-03-15 Roland Werke Dachbaustoffe U B Process and apparatus for producing a waterproof membrane with preferably two supporting liners
WO2001088040A1 (en) * 2000-05-17 2001-11-22 Antonino Ancione S.P.A. Aqueous catalyst and sprayable bituminous emulsion for cold impermeabilization
GB2392399A (en) * 2002-08-28 2004-03-03 Antonino Ancione S P A Process for the application of a bituminous coating
US7534830B2 (en) 2002-12-17 2009-05-19 Imperial Chemical Industries Aqueous dispersions of polyurethane-addition polymer hybrid particles especially for use in coating compositions
US20080028978A1 (en) * 2006-01-23 2008-02-07 Blak Tuf-Stuf, Inc. Water-based asphalt emulsion-based coatings, compositions, manufacture and applications for use
FR2912427A1 (en) * 2007-02-14 2008-08-15 Soprema Soc Par Actions Simpli Making non-woven fabric for reinforcing sealing membranes for use e.g. in buildings, involves forming the fabric from natural fibres and then needling, chemical- or thermal-bonding and waterproofing
WO2016001606A1 (en) * 2014-07-04 2016-01-07 Saint-Gobain Adfors Mineral fibre mat and bitumen products incorporating said mat
US20170291384A1 (en) * 2016-04-11 2017-10-12 Gardner-Gibson, Inc. Silicone-Containing Roof Assemblies and Methods for Production and Use

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111101658A (en) * 2019-12-27 2020-05-05 唐山东方雨虹防水技术有限责任公司 Modified asphalt waterproof coiled material and preparation method thereof
CN111101658B (en) * 2019-12-27 2021-10-12 唐山东方雨虹防水技术有限责任公司 Modified asphalt waterproof coiled material and preparation method thereof
WO2022182492A1 (en) * 2021-02-25 2022-09-01 Milliken & Company Liquid applied roofing composite
CN113738153A (en) * 2021-09-13 2021-12-03 通号工程局集团有限公司 Construction method for waterproof renovation of railway metal roof

Also Published As

Publication number Publication date
MX2020009995A (en) 2020-10-14
BR112020015689A2 (en) 2020-12-08

Similar Documents

Publication Publication Date Title
JP7463300B2 (en) Self-adhesive sealing device having an adhesive sealant layer
US6696125B2 (en) Self-adhered modified bitumen roofing material
US6764733B1 (en) Hot bitumen compatible EPDM roofing sheet
WO2019185459A1 (en) A method for producing a pre-formed bituminous waterproofing membrane
US9708513B2 (en) Sealing device with improved adhesion
CA2885144A1 (en) Peel and stick waterproofing material
CN101675197B (en) Fluorinated polymer system
US10968376B2 (en) Oil-enhanced polymer modified asphalt adhesive compositions and methods of making
US20220339913A1 (en) Self-healing sealing device
CN112368141B (en) Self-adhesive sealing device with adhesive layer arrangement
CN102211895A (en) Gelatinized asphalt film / felt sheet composite waterproof material for external waterproof of concrete structure
CN108454193A (en) A kind of novel exposed composite of water-proof coiled material
US8604160B2 (en) Composite roofing overlay containing recycled paint waste and recycled crushed glass
EP3368270B1 (en) Self-adhering underlayment sheets to form waterproofing joints, related building assemblies and uses
US10988933B2 (en) Flashing assemblies prepared with liquid flashing compositions
KR101408630B1 (en) Aqueous complex sheet waterproof construction method
KR101179227B1 (en) Solventless asphalt coating material and the thermoplastic polyolefin sheet to use the method
US8663792B2 (en) Composite roofing overlay containing paint waste
JPS6389768A (en) Composite waterproof construction method
GB2560576A (en) Waterproof membrane
US20210131107A1 (en) Construction material with improved lap integrity
JP3197459B2 (en) Composite waterproof sheet and method of manufacturing the same
JP2007210286A (en) Air-permeable buffering sheet for coating film waterproofing construction
DE2240860A1 (en) Fibre-reinforced bitumen or bitumen/polyolefine sheets - contg thermo-plastic, esp polyamide or polyolefine fibres, with no coating or bonding agent
CN117693566A (en) Method for bonding a sealing element to a substrate using a cement-based adhesive

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 19711923

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

REG Reference to national code

Ref country code: BR

Ref legal event code: B01A

Ref document number: 112020015689

Country of ref document: BR

ENP Entry into the national phase

Ref document number: 112020015689

Country of ref document: BR

Kind code of ref document: A2

Effective date: 20200731

122 Ep: pct application non-entry in european phase

Ref document number: 19711923

Country of ref document: EP

Kind code of ref document: A1