Title of Invention	A PROCESS FOR MANUFACTURING MEMBRANE FOR SURFACE COATING
Abstract	The present invention relates to a process for manufacturing membrane for surface coating which involves manufacturing of a component A by means of bitumen emulsion, surfactant, dispersing agent and alcohol ethoxylate ; a component B by means of acrylic or styrene or acrylic polypropylene, cross linking agent, hydrocellulose, aliphatic or aromatic amine, organic additive and organizing agent and a component C by means of acrylic or strylene , acrylic emulsion, inorganic fillers, metal silicates, titanium dioxide, fiber, dispersing agent, distilled water and biocides and obtaining a final product by a permutartion of components A, B and C and adding amines, alcohol, wax emulsion, closing agent and a product thereof.

Title of Invention

A PROCESS FOR MANUFACTURING MEMBRANE FOR SURFACE COATING

Abstract

The present invention relates to a process for manufacturing membrane for surface coating which involves manufacturing of a component A by means of bitumen emulsion, surfactant, dispersing agent and alcohol ethoxylate ; a component B by means of acrylic or styrene or acrylic polypropylene, cross linking agent, hydrocellulose, aliphatic or aromatic amine, organic additive and organizing agent and a component C by means of acrylic or strylene , acrylic emulsion, inorganic fillers, metal silicates, titanium dioxide, fiber, dispersing agent, distilled water and biocides and obtaining a final product by a permutartion of components A, B and C and adding amines, alcohol, wax emulsion, closing agent and a product thereof.

Full Text	The present invention relates to a Membrane for Surface Coating Membranes of polymer modified bitumen have become a trend in the industry. What are membrane types? With the advent of membrane technology, Built Up Roofing (BUR) has been made a class by itself. It is still the single biggest type of roofing installed. The new materials introduced as alternatives to Built Up Roofing are products of different chemical formulations. Although no panacea, they do provide a wide range of options that meet required performance characteristics. The first generation of these materials suffered some setbacks due to lack of design and performance criteria and also lack of experience. Membrane Technology on roofs and other substrate of the building are quite well known. Materials used as masonry coating are Bitumen products, Asphalts, Acrylates, Polyurethanes, epoxies or Polyesters dissolved in suitable solvents. Actually, we can divide the membranes into liquid membranes or sheet membranes. The advantage of a liquid applied system are that material is sprayed over the entire roof as a liquid and dries to form a monolithic surface - no seams. While the sheet membranes like Asphalt and various grades of bitumen felts are quite commonly used and the advantages are that the preparation of the substrate is not as critical since membrane is usually separated from deck by a separation course, The other advantage is that roof contamination and roof cracking is not as crucial. The terms sheet and membrane tend to be interchangeable. By definition, a membrane refers to the finished built-up waterproofing layer comprising one or more prefabricated sheets. As such, a sheet becomes a membrane in a single-ply application and a modified bituminous membrane may have two sheets, base and cap. Most of these membranes are composed of mastic which is the waterproofing component, and reinforcing fabrics which give the membranes the desired physical properties. Some important disadvantages with coatings Blister formation due to out gassing of the slab or the presence of moisture. This is generally found with the single coat liquid applied membrane systems where the membrane thickness is less than 2 mm. Poor resistance to chemical attack. Asphalt shifting occurs under wheel loading. This is generally a function of the asphalt stability and thickness of the membrane, Debonding of membrane where vapour pressures exceed bond strength. This is a particular problem with sheet applied adhesive membranes where vapour gets trapped. Due to the thickness of the system, concrete delaminations on the surface of the slab are not evident at an early date. Mastic type wearing surfaces are not suited to exterior applications. On exterior applications black surface increases temperature of slab, increasing slab thermal movement and cracking. Additional load to the structure Use of bitumen is known since last 5000 years and even now consumption of bitumen has grown to 75 million tones a year with road construction grabbing the lion's share (80%). In addition to Built Up Roofing, there are many different types of new membranes that are mostly prefabricated sheets or liquid applied materials that cure to form waterproof sheets or closed cell foams. They are made from a wide variety of synthetic organic materials (polymers) with various chemical compositions and additives. In some cases natural materials such as bitumen, organic fibres, etc. are compounded with them. In surface coating, the pores and capillaries are blocked and the natural breathing of the building is hampered. Consequently these impermeable surface coating may allow water to build up behind the surface coating with the risk of disruption to the coating and possibility of damage. Infact trapped water would be moving behind surface coating and wherever it finds weaker segments, it would come out resulting in cracks and blisters in the surface. Moreover the aging process begins with exposure of the roof surface to the elements of area and ultra violet light. This photo-oxidation sometimes causes the top layer to become brittle. As the weathering continues and the fluctuation in temperature causes expansion and contraction, the membrane becomes even more brittle and less able to accommodate the normal expansion and contraction of the roof. Surface cracks appear, become deeper at the time passes and gradually exposes the unprotected layer to weather resulting in the deterioration of the membrane and causing seepage. THE MAIN DISADVANTAGE OF THE THICK TOPPINGS IN GENERAL ARE AS FOLLOWS: 1. Blister formation 2. Poor resistance to chemical attack. 3. Asphalt shifting 4. Debonding of membrane 5. Concrete delaminations on the surface of the slab are not evident at an early date. 6. Mastic type wearing surfaces are not suited to exterior applications. 7. On exterior applications black surface increases temperature of slab, increasing slab thermal movement and cracking. 8. Additional load to the structure. 9. Need to consider impact on headroom. These disadvantages are more pronounced in bitumen The asphalt is applied to the roof as a base layer. If left unprotected, however, the asphalt degrades under ultraviolet light radiation, resulting in delamination and cracking. Blister formation is very common because of expansion and contraction on account of variable temperature. For example: - If white surface absorbs 40%, Black surface would absorb 90%. This results in photo oxidation and disintegration. Bitumen material under sunlight starts this photo-oxidation. It produces water soluble and volatile products by photo-oxidation, which is caused by ultra violet rays in the presence of oxygen. It has, therefore, long been recognized that it is necessary to protect base asphaltic roofing layers from ultraviolet light and temperature variation. In addition to problems related with durability of these membranes or coatings, we should also look into the possible harmful effects on our environment or on the health of the people who are handling these products. Let us understand that by and large only two bitumens are used in the roofing industry: Coal tar pitch and Asphalt. Coal tar pitch is a byproduct of the production of coke from coal; roofing asphalt is the oxidized residue of the distillation of crude oil. The basic chemical components of crude petroleum oil include paraffinic, naphthenic and aromatic hydrocarbons as well as heterocyclic molecules containing sulfur, oxygen and nitrogen. The composition of the Asphalt will vary based on the origin of crude oil. Saturated felts consist primarily of organic or inorganic fibres (asbestos) which are interlocked to form a continuous sheet, then saturated with asphalt or coal tar pitch (organic felts only) and perforated for use in roofing. The coal tar is known to contain chemicals, which can be classified as polycyclic aromatic hydrocarbons, a class of chemical with harmful properties. Polycyclic aromatic hydrocarbons in high concentrations are harmful not only to wild life, but to humans as well, It is a well-known thing that the general exposure to asphalt fumes is by inhalation or they may also be absorbed through the skin, causing harm to concerned people. Most of the studies of genotoxicity and carcinogenicity in animals have shown that the samples tested exerted mutagenic activity. However the mutagenic responses of the asphalt fume condensates were approximately 100 fold less than the coal tar pitch samples and weak to moderate in potency. Besides these carcinogenicity effects and skin problems reported in animals, it has been found that the workers engaged in these activities handling these products reported symptoms of abnormal fatigue, reduced appetite, eye irritation and laryngeal/pharyngeal irritation. Polymer Modified Asphalt and methods for preparing Polymer Modified Asphalt composition are well-known. There are several polymers which have been used including diene elastomers such as EPDM, EPR, butyl rubber, polybutadiene, polyisoprene, terpolymers, styrene conjugated diene copolymers and thermoplastic elastomers such as styrene-butadiene and styrene-isoprene block copolymers, are commonly combined with asphalt to improve the performance of the asphalt. In many concrete structural engineering buildings or other building materials including road asphalt are generally coated using different techniques to avoid penetration of water. This asphalt used as a construction body which is rigid and are generally vulnerable to the creation of cracks. Such cracks promote the penetration of water. There are several examples in the literature where bitumen sheets, self-adhesive bitumen or polymer modified bitumen sheets are used. However this needs lot of surface preparation like application of primer using scaffolding handling of open flames etc., Apart from it being very complex heat spraying technology these kinds of techniques need warm weather and dry surfaces. The use of asphalt is very common in USA, However when asphalt is used as roofing material it need torch heating and heating method of asphalt has several drawbacks for example when asphalt is melted, smoke and odour are heavily generated which does not only effect the environment but toxic gases which are carcinogenic in nature affect the workers. To avoid this problems cold construction method has been used and for this they use blown asphalt, which is brittle and tends to crack at low temperature, (the material is hard) different products have been used like rubber modifier, natural rubber, Styrene butadiene, however these modifiers are poorly compatible with asphalt. Recently there are patents on Curable composition but they have the same problems, In addition to BUR there are many different types of new membranes that are mostly prefabricated sheets or liquid applied materials that cure to form waterproof sheets or closed cell foams. They are made from a wide variety of synthetic organic materials (Polymers) with various chemical compositions and additives. In some cases natural materials such as bitumen, organic fibers, etc., are compounded with them. Need to consider impact on headroom. Names of some of them are as follows. Classification Membrane Conventional roofing Bituminous built-up roofing (BUR) Prefabricated sheets Thermoplastic sheets • PVC and blends • EIP (ethylene interpolymer) • CAP (copolymer alloys) Elastomeric (synthetic rubber) sheets • Vulcanized: EPDM (ethylene-propylene-diene monomer) • Non-vulcanized: CSPE (chlorosulfonated polyethylene) CPE (chlorinated polyethylene) PIB(polyisobutylene) NBP (butadiene-acrylonitrile) Modified bituminious sheet • Polymer modifiers SBS (Styrene-butadiene-styrene) APP (atactic polypropylene) IPP (isotactic polyproylene) Cast in sit Hot applied rubberized asphalt Cold applied liquid compounds • Various polymeric and bituminous materials Polyurethane foam roof with protective coating Generally unstable on steep sloped applications. Specially in temperate climate of India some of the roofs are exposed to the sun's rays from sunrise to sunset and much of the sunlight strikes the roof surfaces at a steep angle. A dark roof coated by bitumen can attain a very high surface temperature and in addition the reflected radiation from adjacent surface can raise the surface temperature much above that attained by direct radiation. We all know that colour has a great role to play in the absorption of solar irradiation by surface for example: - If white surface absorbs 40%, black surface would absorb 90%. This results in photo oxidation and disintegration caused by ultra violet rays in the presence of oxygen and the bitumen material produces water soluble and volatile products, mostly polyaromatic, which adversely affect the environment since most of these compounds are carcinogenic. The Indian climate has summer, winter and monsoon seasons and each season has a different range of temperatures. This fluctuation can contribute to the breakdown of bitumen and in addition it can lead to large thermal movements of the total membrane. The seasonal variation is not the only cause but in towns like Bangalore short time variation in temperature also affects the durability of bitumen. If there is a fire in a structure, roof structures and materials reduce the risk of fire from the neighbouring buildings from spreading. However the resistance of bitumen materials is generally poor, making it an additional problem with bitumen surfaces. Roof Membrane can be damaged by pollutants from the environment and local pollution. These pollutants deposited on the roof surface may form acids that can damage the exposed bitumen membrane. This process of damage continues until rain washes the waste into the drain. While laying bitumen / tarfelt membrane, basic flaws and defects in structural membrane are not taken into consideration, since it is just a covering over the surface. Tarfelt or any bituminous products are prone to oxidation, thereby slowly becoming brittle and developing cracks. Since these types of treatments are physical barriers, the trapped moisture tends to come out in the hot weather cycle and form blisters which subsequently burst and create openings for water entry. Cracks which occur due to aging also contribute to water entry and once water enters below the tarfelt layer, it tends to come out through the slab or any weak points in the structure, thus damaging the reinforcement. Earlier bitumen was used but because of its inherent disadvantages and toxicity it was necessary to modify this bitumen and change its properties. Initially bitumen was modified by using styrene butadiene rubber (SBR) or rubber emulsion. However, in the recent past several membranes that are of polymer-modified bitumen have entered in the market. Unfortunately all these membranes are to be torched on the surface at high temperatures. At those very high temperatures polyaromatic compounds get oxidized and toxic gases like benzpyrene are emitted and photo-oxidation under UV light is very normal consequence. PRIOR ART US 7402619 relates to a bituminous composition comprising a bituminous component, an elastomeric polymer component, and a specific cross-linking composition component comprising elemental sulfur, a sulfur-containing derivative, a sulfur activator, a fatty acid or fatty acid derivative and a polymeric carrier. Compositions according to the invention are particularly useful in preparing polymer-modified asphalt ("PMA") for road applications. US 2004/0249024 teaches a dispersing agent that facilitates the delivery of a cross-linking agent to polymer modified asphalt. It further includes a composition comprising a liquid hydrocarbon, the dispersant and cross-linking agent, and methods of preparing the composition and of preparing cross-linked polymer modified asphalt composition. US 6767939 discloses a method for preparing an asphalt and thermoplastic elastomer composition. The process comprises heating an asphalt cut in a stirred tank to a temperature sufficient to allow the stirring of the asphalt in the tank. A thermoplastic elastomer or rubber is added to the asphalt while continuing to stir the asphalt. The mixture is stirred at a speed and for a period of time sufficient to increase the distribution of the elastomer into the asphalt. The stirring speed is reduced and the temperature is increased to add crosslinking agents to the tank. Stirring is continued for a period of time sufficient to improve the distribution of the crosslinking agent dispersion in the asphalt. Crosslinking agents include compositions of mercaptobenzothiazole, zinc oxide and elemental sulfur; compositions of mercaptobenzothiazole, zinc oxide, and mixed polythiomorpholine; and compositions of zinc 2-mercaptobenzothiazole and dithiodimorpholine, US 6569925 relates to an accelerator-gel additive used to deliver an accelerator such as sulfur, into a system for the production of polymer modified asphalt, vulcanized rubber or similar system. Unlike conventional methods of delivering accelerator into the system, the accelerator-gel additive suspends the accelerator in a gel system thereby preventing the sedimentation of the accelerator during processing. As a result, the polymer and asphalt are processed at lower temperature reducing the production of toxic and flammable gases such as hydrogen sulfide. US 7439286 teaches a modified asphalt composition comprising at least one plastomer, at least one elastomer, and asphalt. More specifically, a modified asphalt composition is provided comprising an oxidized polyethylene, a styrene-butadiene-styrene block copolymer, and asphalt. A hot mix asphalt composition is also provided comprising the modified asphalt composition and aggregate. Processes for producing the modified asphalt composition and the hot mix asphalt composition is also provided as well as articles produced from these inventive compositions. MX 2007004739 teaches that asphalt and polymer mixtures treated with an inorganic acid and cross-linked with sulfur and/or other crosslinkers or accelerators gives a polymer modified asphalt with improved high temperature properties. The acid should be added to the asphalt before the crosslinker. CN 101125957 discloses a method for preparing polymer modified asphalt and is divided into the following steps. First melted substrate asphalt is mixed with polymer modifying agent to form evenly melted polymer modified asphalt system and then added to a double-screw extruder and an extruding reaction takes place in the double-screw extruder and the polymer modified asphalt is obtained, wherein, the temperature in the first area of the double-screw extruder ranges from 90-190 DEG C, in the second area of the double-screw extruder ranges from 100-250 DEG C, in the third area of the double-screw extruder ranges from 120-220 DEG C and in the fourth area of the double-screw extruder ranges from 120-220 DEG C. The invention has simple manufacturing process, short manufacturing time with the manufacturing cycle of 0.5-1 h and reduces control process and can realize continuous industrial production. The performance of membranes: A brief generic list of roofing membranes is given in the following Table. In each type there is a long and growing list of products. No two products are identical even if they consist of the same predominant polymer. A manufacturer may have a number of different products: unreinforced, or reinforced with different fabrics, for protected or exposed application, with different seaming techniques and different attachment methods, availability in different colours, etc. (O. Dutt, Properties and Performance of Membranes, Building Science Insight). Table The following summarizes some of the requirements for a good membrane, which are in line with Elastomeric coatings. Tensile strength Temperature flexibility Elongation Weatherability Crack bridging Temperature and pollutant aging Fatigue resistance Thermal Shock Dimensional stability Tear resistance Granule embedment Abrasion resistance Interply adhesion (bonding) Lap joint integrity Membrane attachment Static puncture Mateirals compatibility Impact resistance Wind uplift resistance The Applicant has been able to develop self-adhesive non-toxic membranes with the above properties. The applicant decided to work on modern catalyst and polymers to produce polymer modified bitumen which can be used in cold without torching in thickness of 1 to 2 mm. Thus these membranes developed by the applicant have no problems of heating or the disadvantages mentioned above. Unlike other membranes available in the market the applicant developed membranes can be applied directly on the concrete in cold without torching and thus it is not only more durable and bonded but also because of non-torching it is environmentally friendly. This is a major breakthrough in this development. Statement of Invention: According to the invention, a process for manufacturing membrane for surface coating comprises as follows- a), taking 45 to 65% of water based bitumen emulsion in a stainless steel open vessel fitted with a homogenizer, b), adding 20 to 40% of DM water, stirring the said composition for 5 minutes at a speed 2800 rpm. c). Adding 4 to 14% of non-ionic surfactant and 2 to 12%, of closing agent, d). stirring the solution with a dispersing agent e). adding 2 to 8% of alcohol ethoxylate for at least two hours stirring the solution to obtain water based emulsion hereinafter called "Elastofelt" (component A). According to another embodiment of the invention, a process for manufacturing membrane for surface coating comprises the following steps: a) taking 10 to 15 kg of distilled water in the 200 ltr stainless steel reactor fitted with a homogenizer. b) adding 20 to 30 kg of acrylic or strylene c) adding 15 to 20 kg of acrylic emulsion, d) stirring the said composition for 10 minutes at 2800 rpm, e) taking another vessel and making a mixture of 20 to 25 kg of inorganic fillers, 2 to 4 kg of metal silicate and 0.4 to 0.6 kg. of titanium dioxide, f) adding slowly half of this powder into the reactor, g) adding 0,2 kg-0.4 kg of fiber and 0.8 to 0.1 kg of dispersing agent and stirring the composition for 15 minutes, h) adding the remaining powder and continue stirring, i) adding 10 to 20 kg of distilled water and stirring for 5 minutes j) adding 0.20-0.25 kg of biocides and stirring for 5 minutes k) adding 0.2 to 0.4 kg. of fiber and stirring for 15 minutes, to obtain the product herein after called "Flexphalt" (component C) According to another embodiment of the invention, a process for manufacturing membrane for surface coating wherein comprises the following steps: (A) taking a 200 liter fitted with a homonizer (B) adding 30 to 80 % of component A obtained from claim 1 (C) adding 30 to 80% of component C obtained from claim 5 (D) adding 2 - 20% of DM water (E) stirring the said composition for 5 minutes at 2800 rpm (F) adding 2 to 9 % of Pid-Amine (G) adding 2 to 18 % alcohol ethoxylate (H) adding 3 to 12 % of wax emulsion (I) stirring the said composition for 15 minutes at 2800 rpm (J) adding 2-8 % of closing agent (K) adding 10 to 24 % of bisphinol (L) stirring the said composition for 30 minutes to obtain the homogenous a thick paste a membrane hereinafter called as "Plasofelt" According to another embodiment of the invention, a process for manufacturing membrane for surface coating wherein comprises the following steps: (A) taking a 200 ltr stainless steel reactor fitted with a homogenizer. (B) adding 30 to 80 % of component A obtained from claim 1. (C) adding 40 to 80 % of component B obtained to claim 3. (D) adding 2 to 20 % of DM water (E) stirring the said solution for 5 minutes at speed of 2800 rpm (F) adding alcohol ethoxylate 2 to 18 % (G) adding wax emulsion 3-12 % (H) stirring the said solution for 15 minutes at 2800 rpm (I) adding 2 to 8 % of closing agent (J) optionally adding 10 to 14% of bisphinol (K) stirring the said composition for 30 min at 2800 rpm allowing the said composition is settle down for 30 mm to obtain a thick paste hereinafter called "Plastoflex" The first component A produced for such membrane is Elastofelt. Elastofelt was prepared without the use of any styrene-butadiene or rubber polymer. The objective was to provide polymer modified bitumen which is aqueous emulsion and can be used while cold. The other component is known as Flexphalt. Properties of Protekta Flexphalt • Excellent water vapour permeability, but totally waterproof at the same • Resistant to weathering • Does not block pores and capillaries and allows normal breathing of the building • Most effective and useful product in protecting and repairs of roofs and other substrates where contraction and expansion possess problems • Very effective in repairing cracks using technique where a very special gauge is sandwiched between the 2 layers of Flexphalt • The membrane blocks U.V. light and it is U.V. resistant • It can withstand positive and negative hydrostatic pressure Properties of Protekta Plastofelt • Protekta Plastofelt forms a highly elastic waterproofing and water resistance membrane. • Does not require preheating like normal bitumen based coatings. This eliminates fire or health hazards. • Sealing of balconies, terraces, parking garages, asbestos and concrete roofs and decks against surface water. • Sealing of industrial wash rooms, shower and bathrooms • Sealing of water reservoirs and swimming pools, • Sealing of foundations, cellar walls, retaining walls, bridges in contact with soils. How to use Sandwiched with very special gauge -brush coating • The surface to be treated should be clean and free from oil and grease. • Loose particles should be removed and damaged sports repaired first • Cracks should be filled up. • Apply Protekta Plastofelt Primer • Apply Protekta Plastofelt (1 mm thick) • Wet the special Non oven fabric (80gsm) by Plastofelt Primer • And laid on the top of Protekta Plastofelt and then give a coat of Plastofelt (1.5mm thick) Properties of Protekta Flex joint • It can be used on any surface where expansion and contraction is the major factor and where strong bonding with the old surface is required. • It does not block pores and allows normal breathing of the building. • Can be used as a durable and flexible coating for different parts of the building including roof • Is an extremely useful product for closing the joints of the blocks in the basement • Elongation % -500% • Tensile Strength -1.2 N/mm2 • No water permeation through the block. Properties of Protekta Plastoflex • Protekta Plastoflex forms a highly elastic waterproofing and water resistance membrane. • Excellent water vapour permeability, but totally waterproof at the same. • Resistant to weathering • Does not block pores and capillaries and allows normal breathing of the building. • Most effective and useful product in protecting and repairs of roofs and other substrates where contraction and expansion possess problems. • Very effective in repairing cracks. • The membrane blocks U.V. light and it is U.V. resistant It can withstand positive and negative hydrostatic pressure. PROCESS [PLASTOFELT] : COMPONENT -A( Elastofelt) Take a clean and dry 200 Itr stainless steel open vessel fitted with a homogenizer with 2800 rpm. Take 45 to 65 % of water based bitumen emulsion into the above vessel and add 20 to 40% of DM water and stir for 5 minutes with 2800 rpm. Add 4 to 14% of non-ionic surfactant and 2 to 10% of colosing agent and stir with material known as dispersion agent like polyacrylate and 2 to 8% of alcohol ethoxylate. After 2 hours of stirring a water-based emulsion was produced. This final product is known as Protekta Blastofelt. COMPONENT - B ( Flexjoint) Take a clean and dry 200 ltr stainless steel reactor fitted with a homogeniser with 2800 rpm. Take 10 kg of distilled water in the reactor, by stirring add 10 to 50 kg of acrylic or styrene or acrylic polypropylene, add 0.1 to 0.5 kg of cross linking agent stir for 5 min, add 0.1 to 0,4 kg of hydro cellulose stir for 5 min, add 0.2 to 0.6 of any aliphatic or aromatic amine stir for 5min, add minor amount of organic additive and oxidizing agent like persulphate or peroxide. After 30 minutes you will get a thick pasty material Protekta Flex joint. COMPONENT - C ( Flexphalt) Take a clean and dry 200 ltr stainless steel reactor fitted with a homogeniser with 2800 rpm. Take 10 to 15 kg of distilled water in the reactor, add 20 to 30 kg of acrylic or styrene, add 15 to 20 kg of acrylic emulsion and stir for 10 minutes. In a powder mixer make the mixture of 20 to 25 kg of inorganic fillers like metal carbonate and metal oxides, 2 to 4 kg of metal silicates and 0,4 to 0.6 kg of titanium dioxide, add this powder into the reaction vessel slowly. After adding half of the powder slowly add 0.2 kg to 0.4 kg fiber and 0.8 to 0.10 kg dispersing agent and stir for 15 minutes. Add remaining powder and continue stirring. Add 10 to 20 kg of distilled water and stir for 5 minutes, Add 0.20 to 0.25 kg of biocides and stir for 5 minutes. By stirring slowly add 0.2 to 0.4 kg of fiber and stir for 15 minutes. Obtained product called as Protekta Flexphalt. The invention is described with reference to the examples, which are provided by way of illustration only, and these examples should not be construed to limit the scope of the present invention: PROCESS (PLASTOFLEX) EXAMPLE -1 Take a clean and dry 200 ltr stainless steel reactor fitted with a homogeniser with 2800 rpm. Take 40 to 80% of component A and 40 to 80% of component B and add 8 to 16 % of DM water stir for 5 minutes, add 3 to 9 % of Pid Amine, and alcohol ethoxylate 6 to 18% , 6 to 12 % wax emulsion and stir for 15 minutes. Add 2 to 8% of colosing agent (polyacrylate) and stir for 30 minutes. After 30 minutes you will get a thick paste as the final product known as Protekta Plastoflex and hereinafter known as Product "A". EXAMPLE - 2 Take a clean and dry 200 ltr stainless steel reactor fitted with a homogeniser with 2800 rpm. Take 30 to 60% of component A and 30 to 60% of component B and add 2 to 20 % of DM water stir for 5 minutes, and alcohol ethoxylate 2 to 8%, 3 to 12 % wax emulsion and stir for 15 minutes. Add 4 to 8% of colosing agent (polyacrylate) and add 10 to 14 % of bisphinol and stir for 30 minutes. After 30 minutes you will get a thick paste as the final product known as Protekta Plastoflex and hereinafter known as Product "A". DESCRIPTION Protekta Plastoflex is a highly elastic paste applied waterproofing system based on a specially modified emulsion system using bitumen and flexible Properties of Protekta Plastoflex • Protekta Plastoflex forms a highly elastic waterproofing and water resistance membrane. • Excellent water vapour permeability, but totally waterproof at the same. • Resistant to weathering • Does not block pores and capillaries and allows normal breathing of the building, • Most effective and useful product in protecting and repairs of roofs and other substrates where contraction and expansion possess problems. • Very effective in repairing cracks. • The membrane blocks U.V. light and it is U.V, resistant • It can withstand positive and negative hydrostatic pressure. TECHNICAL DATA Appearance: Dark brown thick liquid Specific gravity: 1.02 to 1,06 pH : 8.20 to 8.70 APPLICATION Sandwiched with very special gauge -brush coating • The surfaces to be treated should be clean and free from oil and grease. • Loose particles should be removed and damaged spots repaired first. Cracks should be filled up. • Priming is recommended as this improves the adherence. • Apply Protekta Plastoflex Primer • Apply Protekta Plastoflex (1 mm thick) • Wet the special Non oven fabric (80gsm) by Plastoflex Primer • And laid on the top of Protekta Plastoflex and then give a coat of Plastoflex (1.5mm thick) • Recommended consumption of product should be followed. • For multiple coats allow sufficient drying between coats. • Wherever possible apply coats cross-wise to achieve even thickness of coating. Result: Toxicity Test Result : 800cm2 area coated with Protekta Plastoflex dried for 24 hrs and exposed in 5 litre of aerated water, 100% survival of fishes for 96 hrs. Remarks: The sample is free from acute lethal toxicity II. Chloride ion depth penetration in mm : Control : 12 mm Protekta Plastofelt: 2.2mm II. Carbon dioxide penetration test for Concrete blocks. pH of the solution Surface Inner core Control 1136 11,85 Protekta Plastoflex 12.2 12.5 Control (without exposure 12.3 12.8 To carbon dioxide) We claim:- 1. A process for manufacturing membrane for surface coating comprising the following steps: a) taking 45 to 65% of water based bitumen emulsion in a stainless steel open vessel fitted with a homogenizer, b) adding 20 to 40% of DM water, stirring the said composition for 5 minutes at a speed 2800 rpm. c) Adding 4 to 14% of non-ionic surfactant and 2 to 12%, of closing agent, d) stirring the solution with a dispersing agent e) adding 2 to 8% of alcohol ethoxylate for at least two hours stirring the solution to obtain water based emulsion hereinafter called "Elastofelt" (component A), 2. A process for manufacturing membrane for surface coating as claimed in claim 1 wherein, the dispersing agent is Polyacrylate. 3. A process for manufacturing membrane for surface coating comprising the following steps: a) taking 10 kg of distilled water in a stainless steel reactor; b) adding 10 to 50 kg of acrylic or styrene or acrylic polypropylene, c) stirring the solution and adding 0.1 to 0.5 kg of cross linking agent for 5 minutes. d) adding 0.1 to 0.4 kg of hydrocellulose, stirring the solution for 5minuts at 2800 rpm. e) adding 0.2 to 0.6 of any aliphatic or aromatic amine stirring for 5 minutes. f) adding a very small % of organic additive and organizing agent g) stirring the solution at 2800 rpm for 30 minutes to obtain a thick paste material hereinafter called "Flex joint" (component B). 4. A process for manufacturing membrane for surface coating as claimed in claim 3, wherein the oxidizing agent is flexphalt peroxide. 5. A process for manufacturing membrane for surface coating comprising the following steps: a) taking 10 to 15 kg of distilled water in the 200 ltr stainless steel reactor fitted with a homogenizes b) adding 20 to 30 kg of acrylic or strylene c) adding 15 to 20 kg of acrylic emulsion, d) stirring the said composition for 10 minutes at 2800 rpm, f) taking another vessel and making a mixture of 20 to 25 kg of inorganic fillers, 2 to 4 kg of metal silicate and 0.4 to 0.6 kg. of titanium dioxide, g) adding slowly half of this powder into the reactor, h) adding 0.2 kg - 0,4 kg of fiber and 0.8 to 0,1 kg of dispersing agent and stirring the composition for 15 minutes, i) adding the remaining powder and continue stirring, j) adding 10 to 20 kg of distilled water and stirring for 5 minutes k) adding 0.20-0.25 kg of biocides and stirring for 5 minutes l) adding 0.2 to 0.4 kg. of fiber and stirring for 15 minutes, to obtain the product herein after called "Flexphalt" (component C). 6. A process for manufacturing membrane for surface coating wherein comprising the following steps: a) taking a 200 liter fitted with a homonizer b) adding 30 to 80 % of component A obtained from claim 1 c) adding 30 to 80% of component C obtained from claim 5 d) adding 2 - 20% of DM water e) stirring the said composition for 5 minutes at 2800 rpm f) adding 2 to 9 % of Pid-Amine g) adding 2 to 18 % alcohol ethoxylate h) adding 3 to 12 % of wax emulsion i) stirring the said composition for 15 minutes at 2800 rpm j) adding 2-8 % of closing agent k) adding 10 to 24 % of bisphinol l) stirring the said composition for 30 minutes to obtain the homogenous a thick paste a membrane hereinafter called as "Plasofelt" 7. A process for manufacturing membrane for surface coating wherein comprising the following steps: a) taking a 200 ltr stainless steel reactor fitted with a homogenizes b) adding 30 to 80 % of component A obtained from claim 1. c) adding 40 to 80 % of component B obtained to claim 3. d) adding 2 to 20 % of DM water e) stirring the said solution for 5 minutes at speed of 2800 rpm f) adding alcohol ethoxylate 2 to 18 % g) adding wax emulsion 3-12 % h) stirring the said solution for 15 minutes at 2800 rpm i) adding 2 to 8 % of closing agent j) optionally adding 10 to 14% of bisphinol k) stirring the said composition for 30 min at 2800 rpm l) allowing the said composition is settle down for 30 min to obtain a thick paste hereinafter called "Plastoflex" 8. A process for manufacturing membrane for surface coating wherein the closing agent is Polyacrylate. 9. A process for manufacturing membrane for surface coating substantially as hereinbefore described with reference to the accompanying examples.

Full Text

The present invention relates to a Membrane for Surface Coating

Membranes of polymer modified bitumen have become a trend in the industry.

What are membrane types?

With the advent of membrane technology, Built Up Roofing (BUR) has been made a class by itself. It is still the single biggest type of roofing installed. The new materials introduced as alternatives to Built Up Roofing are products of different chemical formulations. Although no panacea, they do provide a wide range of options that meet required performance characteristics. The first generation of these materials suffered some setbacks due to lack of design and performance criteria and also lack of experience.

Membrane Technology on roofs and other substrate of the building are quite well known. Materials used as masonry coating are Bitumen products, Asphalts, Acrylates, Polyurethanes, epoxies or Polyesters dissolved in suitable solvents. Actually, we can divide the membranes into liquid membranes or sheet membranes. The advantage of a liquid applied system are that material is sprayed over the entire roof as a liquid and dries to form a monolithic surface - no seams. While the sheet membranes like Asphalt and various grades of bitumen felts are quite commonly used and the advantages are that the preparation of the substrate is not as critical since membrane is usually separated from deck by a separation course, The other advantage is that roof contamination and roof cracking is not as crucial.

The terms sheet and membrane tend to be interchangeable. By definition, a membrane refers to the finished built-up waterproofing layer comprising one or more prefabricated sheets. As such, a sheet becomes a membrane in a single-ply application and a modified bituminous membrane may have two sheets, base and cap.

Most of these membranes are composed of mastic which is the waterproofing component, and reinforcing fabrics which give the membranes the desired physical properties.

Some important disadvantages with coatings

Blister formation due to out gassing of the slab or the presence of moisture. This is generally found with the single coat liquid applied membrane systems where the membrane thickness is less than 2 mm.

Poor resistance to chemical attack.

Asphalt shifting occurs under wheel loading. This is generally a function of the asphalt stability and thickness of the membrane,

Debonding of membrane where vapour pressures exceed bond strength. This is a particular problem with sheet applied adhesive membranes where vapour gets trapped.
Due to the thickness of the system, concrete delaminations on the surface of the slab are not evident at an early date.

Mastic type wearing surfaces are not suited to exterior applications.

On exterior applications black surface increases temperature of slab, increasing slab thermal movement and cracking.

Additional load to the structure

Use of bitumen is known since last 5000 years and even now consumption of bitumen has grown to 75 million tones a year with road construction grabbing the lion's share (80%).

In addition to Built Up Roofing, there are many different types of new membranes that are mostly prefabricated sheets or liquid applied materials that cure to form waterproof sheets or closed cell foams. They are made from a wide variety of synthetic organic materials (polymers) with various chemical compositions and additives. In some cases natural materials such as bitumen, organic fibres, etc. are compounded with them.

In surface coating, the pores and capillaries are blocked and the natural breathing of the building is hampered. Consequently these impermeable surface coating may allow water to build up behind the surface coating with the risk of disruption to the coating and possibility of damage. Infact trapped water would be moving behind surface coating and wherever it finds weaker segments, it would come out resulting in cracks and blisters in the surface. Moreover the aging process begins with exposure of the roof surface to the elements of area and ultra violet light. This photo-oxidation sometimes causes the top layer to become brittle. As the weathering continues and the fluctuation in temperature causes expansion and contraction, the membrane becomes even more brittle and less able to accommodate the normal expansion and contraction of the roof. Surface cracks appear, become deeper at the time passes and gradually exposes the unprotected layer to weather resulting in the deterioration of the membrane and causing seepage.

THE MAIN DISADVANTAGE OF THE THICK TOPPINGS IN GENERAL ARE AS FOLLOWS:

1. Blister formation

2. Poor resistance to chemical attack.

3. Asphalt shifting

4. Debonding of membrane

5. Concrete delaminations on the surface of the slab are not evident at an early date.

6. Mastic type wearing surfaces are not suited to exterior applications.

7. On exterior applications black surface increases temperature of slab, increasing slab thermal movement and cracking.

8. Additional load to the structure.

9. Need to consider impact on headroom.

These disadvantages are more pronounced in bitumen

The asphalt is applied to the roof as a base layer. If left unprotected, however, the asphalt degrades under ultraviolet light radiation, resulting in delamination and cracking. Blister formation is very common because of expansion and contraction on account of variable temperature. For example: - If white surface absorbs 40%, Black surface would absorb 90%. This results in photo oxidation and disintegration. Bitumen material under sunlight starts this photo-oxidation. It produces water soluble and volatile products by photo-oxidation, which is caused by ultra violet rays in the presence of oxygen. It has, therefore, long been recognized that it is necessary to protect base asphaltic roofing layers from ultraviolet light and temperature variation.

In addition to problems related with durability of these membranes or coatings, we should also look into the possible harmful effects on our environment or on the health of the people who are handling these products. Let us understand that by and large only two bitumens are used in the roofing industry: Coal tar pitch and Asphalt. Coal tar pitch is a byproduct of the production of coke from coal; roofing asphalt is the oxidized residue of the distillation of crude oil.

The basic chemical components of crude petroleum oil include paraffinic, naphthenic and aromatic hydrocarbons as well as heterocyclic molecules containing sulfur, oxygen and nitrogen. The composition of the Asphalt will vary based on the origin of crude oil. Saturated felts consist primarily of organic or inorganic fibres (asbestos) which are interlocked to form a continuous sheet, then saturated with asphalt or coal tar pitch (organic felts only) and perforated for use in roofing. The coal tar is known to contain chemicals, which can be classified as polycyclic aromatic hydrocarbons, a class of chemical with harmful properties. Polycyclic aromatic hydrocarbons in high concentrations are harmful not only to wild life, but to humans as well,

It is a well-known thing that the general exposure to asphalt fumes is by inhalation or they may also be absorbed through the skin, causing harm to concerned people. Most of the studies of genotoxicity and carcinogenicity in animals have shown that the samples tested exerted mutagenic activity. However the mutagenic responses of the asphalt fume condensates were approximately 100 fold less than the coal tar pitch samples and weak to moderate in potency. Besides these carcinogenicity effects and skin problems reported in animals, it has been found that the workers engaged in these activities handling these products reported symptoms of abnormal fatigue, reduced appetite, eye irritation and laryngeal/pharyngeal irritation.

Polymer Modified Asphalt and methods for preparing Polymer Modified Asphalt composition are well-known. There are several polymers which have been used including diene elastomers such as EPDM, EPR, butyl rubber, polybutadiene, polyisoprene, terpolymers, styrene conjugated diene copolymers and thermoplastic elastomers such as styrene-butadiene and styrene-isoprene block copolymers, are commonly combined with asphalt to improve the performance of the asphalt.

In many concrete structural engineering buildings or other building materials including road asphalt are generally coated using different techniques to avoid penetration of water. This asphalt used as a construction body which is rigid and are generally vulnerable to the creation of cracks. Such cracks promote the penetration of water.

There are several examples in the literature where bitumen sheets, self-adhesive bitumen or polymer modified bitumen sheets are used. However this needs lot of surface preparation like application of primer using scaffolding handling of open flames etc., Apart from it being very complex heat spraying technology these kinds of techniques need warm weather and dry surfaces.

The use of asphalt is very common in USA, However when asphalt is used as roofing material it need torch heating and heating method of asphalt has several drawbacks for example when asphalt is melted, smoke and odour are heavily generated which does not only effect the environment but toxic gases which are carcinogenic in nature affect the workers. To avoid this problems cold construction method has been used and for this they use blown asphalt, which is brittle and tends to crack at low temperature, (the material is hard) different products have been used like rubber modifier, natural rubber, Styrene butadiene, however these modifiers are poorly compatible with asphalt. Recently there are patents on Curable composition but they have the same problems,

In addition to BUR there are many different types of new membranes that are mostly prefabricated sheets or liquid applied materials that cure to form waterproof sheets or closed cell foams. They are made from a wide variety of synthetic organic materials (Polymers) with various chemical compositions and additives. In some cases natural materials such as bitumen, organic fibers, etc., are compounded with them.

Need to consider impact on headroom.

Names of some of them are as follows.

Classification Membrane

Conventional roofing Bituminous built-up roofing (BUR)
Prefabricated sheets Thermoplastic sheets
• PVC and blends
• EIP (ethylene interpolymer)
• CAP (copolymer alloys) Elastomeric (synthetic rubber) sheets
• Vulcanized:
EPDM (ethylene-propylene-diene monomer)
• Non-vulcanized:
CSPE (chlorosulfonated polyethylene) CPE (chlorinated polyethylene)

PIB(polyisobutylene) NBP (butadiene-acrylonitrile) Modified bituminious sheet
• Polymer modifiers
SBS (Styrene-butadiene-styrene)
APP (atactic polypropylene)
IPP (isotactic polyproylene)
Cast in sit Hot applied rubberized asphalt
Cold applied liquid compounds
• Various polymeric and bituminous materials
Polyurethane foam roof with protective coating

Generally unstable on steep sloped applications.

Specially in temperate climate of India some of the roofs are exposed to the sun's rays from sunrise to sunset and much of the sunlight strikes the roof surfaces at a steep angle. A dark roof coated by bitumen can attain a very high surface temperature and in addition the reflected radiation from adjacent surface can raise the surface temperature much above that attained by direct radiation. We all know that colour has a great role to play in the absorption of solar irradiation by surface for example: - If white surface absorbs 40%, black surface would absorb 90%. This results in photo oxidation and disintegration caused by ultra violet rays in the presence of oxygen and the bitumen material produces water soluble and volatile products, mostly polyaromatic, which adversely affect the environment since most of these compounds are carcinogenic.

The Indian climate has summer, winter and monsoon seasons and each season has a different range of temperatures. This fluctuation can contribute to the breakdown of bitumen and in addition it can lead to large thermal movements of the total membrane. The seasonal variation is not the only cause but in towns like Bangalore short time variation in temperature also affects the durability of bitumen.

If there is a fire in a structure, roof structures and materials reduce the risk of fire from the neighbouring buildings from spreading. However the resistance of bitumen materials is generally poor, making it an additional problem with bitumen surfaces.

Roof Membrane can be damaged by pollutants from the environment and local pollution. These pollutants deposited on the roof surface may form acids that can damage the exposed bitumen membrane. This process of damage continues until rain washes the waste into the drain.

While laying bitumen / tarfelt membrane, basic flaws and defects in structural membrane are not taken into consideration, since it is just a covering over the surface.
Tarfelt or any bituminous products are prone to oxidation, thereby slowly becoming brittle and developing cracks. Since these types of treatments are physical barriers, the trapped moisture tends to come out in the hot weather cycle and form blisters which subsequently burst and create openings for water entry. Cracks which occur due to aging also contribute to water entry and once water enters below the tarfelt layer, it tends to come out through the slab or any weak points in the structure, thus damaging the reinforcement.

Earlier bitumen was used but because of its inherent disadvantages and toxicity it was necessary to modify this bitumen and change its properties. Initially bitumen was modified by using styrene butadiene rubber (SBR) or rubber emulsion. However, in the recent past several membranes that are of polymer-modified bitumen have entered in the market. Unfortunately all these membranes are to be torched on the surface at high temperatures. At those very high temperatures polyaromatic compounds get oxidized and toxic gases like benzpyrene are emitted and photo-oxidation under UV light is very normal consequence.

PRIOR ART

US 7402619 relates to a bituminous composition comprising a bituminous component, an elastomeric polymer component, and a specific cross-linking composition component comprising elemental sulfur, a sulfur-containing derivative, a sulfur activator, a fatty acid or fatty acid derivative and a polymeric carrier. Compositions according to the invention are particularly useful in preparing polymer-modified asphalt ("PMA") for road applications.

US 2004/0249024 teaches a dispersing agent that facilitates the delivery of a cross-linking agent to polymer modified asphalt. It further includes a composition comprising a liquid hydrocarbon, the dispersant and cross-linking agent, and methods of preparing the composition and of preparing cross-linked polymer modified asphalt composition.

US 6767939 discloses a method for preparing an asphalt and thermoplastic elastomer composition. The process comprises heating an asphalt cut in a stirred tank to a temperature sufficient to allow the stirring of the asphalt in the tank. A thermoplastic elastomer or rubber is added to the asphalt while continuing to stir the asphalt. The mixture is stirred at a speed and for a period of time sufficient to increase the distribution of the elastomer into the asphalt. The stirring speed is reduced and the temperature is increased to add crosslinking agents to the tank. Stirring is continued for a period of time sufficient to improve the distribution of the crosslinking agent dispersion in the asphalt. Crosslinking agents include compositions of mercaptobenzothiazole, zinc oxide and elemental sulfur; compositions of mercaptobenzothiazole, zinc oxide, and mixed polythiomorpholine; and compositions of zinc 2-mercaptobenzothiazole and dithiodimorpholine,

US 6569925 relates to an accelerator-gel additive used to deliver an accelerator such as sulfur, into a system for the production of polymer modified asphalt, vulcanized rubber or similar system. Unlike conventional methods of delivering accelerator into the system, the accelerator-gel additive suspends the accelerator in a gel system thereby preventing the sedimentation of the accelerator during processing. As a result, the polymer and asphalt are processed at lower temperature reducing the production of toxic and flammable gases such as hydrogen sulfide.

US 7439286 teaches a modified asphalt composition comprising at least one plastomer, at least one elastomer, and asphalt. More specifically, a modified asphalt composition is provided comprising an oxidized polyethylene, a styrene-butadiene-styrene block copolymer, and asphalt. A hot mix asphalt composition is also provided comprising the modified asphalt composition and aggregate. Processes for producing the modified asphalt composition and the hot mix asphalt composition is also provided as well as articles produced from these inventive compositions.

MX 2007004739 teaches that asphalt and polymer mixtures treated with an inorganic acid and cross-linked with sulfur and/or other crosslinkers or accelerators gives a polymer modified asphalt with improved high temperature properties. The acid should be added to the asphalt before the crosslinker.

CN 101125957 discloses a method for preparing polymer modified asphalt and is divided into the following steps. First melted substrate asphalt is mixed with polymer modifying agent to form evenly melted polymer modified asphalt system and then added to a double-screw extruder and an extruding reaction takes place in the double-screw extruder and the polymer modified asphalt is obtained, wherein, the temperature in the first area of the double-screw extruder ranges from 90-190 DEG C, in the second area of the double-screw extruder ranges from 100-250 DEG C, in the third area of the double-screw extruder ranges from 120-220 DEG C and in the fourth area of the double-screw extruder ranges from 120-220 DEG C. The invention has simple manufacturing process, short manufacturing time with the manufacturing cycle of 0.5-1 h and reduces control process and can realize continuous industrial production.

The performance of membranes: A brief generic list of roofing membranes is given in the following Table. In each type there is a long and growing list of products. No two products are identical even if they consist of the same predominant polymer. A manufacturer may have a number of different products: unreinforced, or reinforced with different fabrics, for protected or exposed application, with different seaming techniques and different attachment methods, availability in different colours, etc. (O. Dutt,
Properties and Performance of Membranes, Building Science Insight).

Table
The following summarizes some of the requirements for a good membrane, which are in line with Elastomeric coatings.

Tensile strength Temperature flexibility
Elongation Weatherability
Crack bridging Temperature and pollutant aging
Fatigue resistance
Thermal Shock Dimensional stability
Tear resistance Granule embedment
Abrasion resistance Interply adhesion (bonding)
Lap joint integrity Membrane attachment
Static puncture Mateirals compatibility
Impact resistance Wind uplift resistance

The Applicant has been able to develop self-adhesive non-toxic membranes with the above properties.

The applicant decided to work on modern catalyst and polymers to produce polymer modified bitumen which can be used in cold without torching in thickness of 1 to 2 mm. Thus these membranes developed by the applicant have no problems of heating or the disadvantages mentioned above. Unlike other membranes available in the market the applicant developed membranes can be applied directly on the concrete in cold without torching and thus it is not only more durable and bonded but also because of non-torching it is environmentally friendly. This is a major breakthrough in this development.

Statement of Invention:

According to the invention, a process for manufacturing membrane for surface coating comprises as follows-

a), taking 45 to 65% of water based bitumen emulsion in a stainless steel open vessel fitted with a homogenizer,

b), adding 20 to 40% of DM water, stirring the said composition for 5 minutes at a speed 2800 rpm.

c). Adding 4 to 14% of non-ionic surfactant and 2 to 12%, of closing agent, d). stirring the solution with a dispersing agent

e). adding 2 to 8% of alcohol ethoxylate for at least two hours stirring the solution to obtain water based emulsion hereinafter called "Elastofelt" (component A).

According to another embodiment of the invention, a process for manufacturing membrane for surface coating comprises the following steps:

a) taking 10 to 15 kg of distilled water in the 200 ltr stainless steel reactor fitted with a homogenizer.

b) adding 20 to 30 kg of acrylic or strylene

c) adding 15 to 20 kg of acrylic emulsion,

d) stirring the said composition for 10 minutes at 2800 rpm,

e) taking another vessel and making a mixture of 20 to 25 kg of inorganic fillers, 2 to 4 kg of metal silicate and 0.4 to 0.6 kg. of titanium dioxide,

f) adding slowly half of this powder into the reactor,

g) adding 0,2 kg-0.4 kg of fiber and 0.8 to 0.1 kg of dispersing agent and stirring the composition for 15 minutes,

h) adding the remaining powder and continue stirring, i) adding 10 to 20 kg of distilled water and stirring for 5 minutes j) adding 0.20-0.25 kg of biocides and stirring for 5 minutes k) adding 0.2 to 0.4 kg. of fiber and stirring for 15 minutes, to obtain the product herein after called "Flexphalt" (component C)

According to another embodiment of the invention, a process for manufacturing membrane for surface coating wherein comprises the following steps:

(A) taking a 200 liter fitted with a homonizer

(B) adding 30 to 80 % of component A obtained from claim 1

(C) adding 30 to 80% of component C obtained from claim 5

(D) adding 2 - 20% of DM water

(E) stirring the said composition for 5 minutes at 2800 rpm

(F) adding 2 to 9 % of Pid-Amine

(G) adding 2 to 18 % alcohol ethoxylate

(H) adding 3 to 12 % of wax emulsion

(I) stirring the said composition for 15 minutes at 2800 rpm (J) adding 2-8 % of closing agent

(K) adding 10 to 24 % of bisphinol

(L) stirring the said composition for 30 minutes to obtain the homogenous a thick paste a membrane hereinafter called as "Plasofelt"

According to another embodiment of the invention, a process for manufacturing membrane for surface coating wherein comprises the following steps:

(A) taking a 200 ltr stainless steel reactor fitted with a homogenizer.

(B) adding 30 to 80 % of component A obtained from claim 1.

(C) adding 40 to 80 % of component B obtained to claim 3.

(D) adding 2 to 20 % of DM water

(E) stirring the said solution for 5 minutes at speed of 2800 rpm

(F) adding alcohol ethoxylate 2 to 18 %

(G) adding wax emulsion 3-12 %

(H) stirring the said solution for 15 minutes at 2800 rpm

(I) adding 2 to 8 % of closing agent

(J) optionally adding 10 to 14% of bisphinol

(K) stirring the said composition for 30 min at 2800 rpm allowing the said composition is settle down for 30 mm to obtain a thick paste hereinafter called "Plastoflex"

The first component A produced for such membrane is Elastofelt. Elastofelt was prepared without the use of any styrene-butadiene or rubber polymer. The objective was to provide polymer modified bitumen which is aqueous emulsion and can be used while cold. The other component is known as Flexphalt. Properties of Protekta Flexphalt

• Excellent water vapour permeability, but totally waterproof at the same

• Resistant to weathering

• Does not block pores and capillaries and allows normal breathing of the building

• Most effective and useful product in protecting and repairs of roofs and other substrates where contraction and expansion possess problems

• Very effective in repairing cracks using technique where a very special gauge is sandwiched between the 2 layers of Flexphalt
• The membrane blocks U.V. light and it is U.V. resistant

• It can withstand positive and negative hydrostatic pressure
Properties of Protekta Plastofelt

• Protekta Plastofelt forms a highly elastic waterproofing and water resistance membrane.

• Does not require preheating like normal bitumen based coatings. This eliminates fire or health hazards.

• Sealing of balconies, terraces, parking garages, asbestos and concrete roofs and decks against surface water.

• Sealing of industrial wash rooms, shower and bathrooms

• Sealing of water reservoirs and swimming pools,

• Sealing of foundations, cellar walls, retaining walls, bridges in contact with soils.

How to use

Sandwiched with very special gauge -brush coating

• The surface to be treated should be clean and free from oil and grease.

• Loose particles should be removed and damaged sports repaired first

• Cracks should be filled up.

• Apply Protekta Plastofelt Primer

• Apply Protekta Plastofelt (1 mm thick)

• Wet the special Non oven fabric (80gsm) by Plastofelt Primer

• And laid on the top of Protekta Plastofelt and then give a coat of Plastofelt (1.5mm thick)

Properties of Protekta Flex joint

• It can be used on any surface where expansion and contraction is the major factor and where strong bonding with the old surface is required.

• It does not block pores and allows normal breathing of the building.

• Can be used as a durable and flexible coating for different parts of the building including roof

• Is an extremely useful product for closing the joints of the blocks in the basement

• Elongation % -500%

• Tensile Strength -1.2 N/mm2

• No water permeation through the block.

Properties of Protekta Plastoflex

• Protekta Plastoflex forms a highly elastic waterproofing and water resistance membrane.

• Excellent water vapour permeability, but totally waterproof at the same.

• Resistant to weathering

• Does not block pores and capillaries and allows normal breathing of the building.

• Most effective and useful product in protecting and repairs of roofs and other substrates where contraction and expansion possess problems.

• Very effective in repairing cracks.

• The membrane blocks U.V. light and it is U.V. resistant

It can withstand positive and negative hydrostatic pressure.

PROCESS [PLASTOFELT] :

COMPONENT -A( Elastofelt)

Take a clean and dry 200 Itr stainless steel open vessel fitted with a homogenizer with 2800 rpm. Take 45 to 65 % of water based bitumen emulsion into the above vessel and add 20 to 40% of DM water and stir for 5 minutes with 2800 rpm. Add 4 to 14% of non-ionic surfactant and 2 to 10% of colosing agent and stir with material known as dispersion agent like polyacrylate and 2 to 8% of alcohol ethoxylate. After 2 hours of stirring a water-based emulsion was produced. This final product is known as Protekta Blastofelt.

COMPONENT - B ( Flexjoint)

Take a clean and dry 200 ltr stainless steel reactor fitted with a homogeniser with 2800 rpm. Take 10 kg of distilled water in the reactor, by stirring add 10 to 50 kg of acrylic or styrene or acrylic polypropylene, add 0.1 to 0.5 kg of cross linking agent stir for 5 min, add 0.1 to 0,4 kg of hydro cellulose stir for 5 min, add 0.2 to 0.6 of any aliphatic or aromatic amine stir for 5min, add minor amount of organic additive and oxidizing agent like persulphate or peroxide. After 30 minutes you will get a thick pasty material Protekta Flex joint.

COMPONENT - C ( Flexphalt)

Take a clean and dry 200 ltr stainless steel reactor fitted with a homogeniser with 2800 rpm. Take 10 to 15 kg of distilled water in the reactor, add 20 to 30 kg of acrylic or styrene, add 15 to 20 kg of acrylic emulsion and stir for 10 minutes. In a powder mixer make the mixture of 20 to 25 kg of inorganic fillers like metal carbonate and metal oxides, 2 to 4 kg of metal silicates and 0,4 to 0.6 kg of titanium dioxide, add this powder into the reaction vessel slowly. After adding half of the powder slowly add 0.2 kg to 0.4 kg fiber and 0.8 to 0.10 kg dispersing agent and stir for 15 minutes. Add remaining powder and continue stirring. Add 10 to 20 kg of distilled water and stir for 5 minutes, Add 0.20 to 0.25 kg of biocides and stir for 5 minutes. By stirring slowly add 0.2 to 0.4 kg of fiber and stir for 15 minutes. Obtained product called as Protekta Flexphalt.
The invention is described with reference to the examples, which are provided by way of illustration only, and these examples should not be construed to limit the scope of the present invention:

PROCESS (PLASTOFLEX)

EXAMPLE -1

Take a clean and dry 200 ltr stainless steel reactor fitted with a homogeniser with 2800 rpm. Take 40 to 80% of component A and 40 to 80% of component B and add 8 to 16 % of DM water stir for 5 minutes, add 3 to 9 % of Pid Amine, and alcohol ethoxylate 6 to 18% , 6 to 12 % wax emulsion and stir for 15 minutes. Add 2 to 8% of colosing agent (polyacrylate) and stir for 30 minutes. After 30 minutes you will get a thick paste as the final product known as Protekta Plastoflex and hereinafter known as Product "A".

EXAMPLE - 2

Take a clean and dry 200 ltr stainless steel reactor fitted with a homogeniser with 2800 rpm. Take 30 to 60% of component A and 30 to 60% of component B and add 2 to 20 % of DM water stir for 5 minutes, and alcohol ethoxylate 2 to 8%, 3 to 12 % wax emulsion and stir for 15 minutes. Add 4 to 8% of colosing agent (polyacrylate) and add 10 to 14 % of bisphinol and stir for 30 minutes. After 30 minutes you will get a thick paste as the final product known as Protekta Plastoflex and hereinafter known as Product "A".

DESCRIPTION

Protekta Plastoflex is a highly elastic paste applied waterproofing system based on a specially modified emulsion system using bitumen and flexible

Properties of Protekta Plastoflex

• Protekta Plastoflex forms a highly elastic waterproofing and water resistance membrane.

• Excellent water vapour permeability, but totally waterproof at the same.

• Resistant to weathering

• Does not block pores and capillaries and allows normal breathing of the building,

• Most effective and useful product in protecting and repairs of roofs and other substrates where contraction and expansion possess problems.

• Very effective in repairing cracks.

• The membrane blocks U.V. light and it is U.V, resistant

• It can withstand positive and negative hydrostatic pressure.

TECHNICAL DATA

Appearance: Dark brown thick liquid
Specific gravity: 1.02 to 1,06
pH : 8.20 to 8.70

APPLICATION

Sandwiched with very special gauge -brush coating

• The surfaces to be treated should be clean and free from oil and grease.

• Loose particles should be removed and damaged spots repaired first. Cracks should be filled up.

• Priming is recommended as this improves the adherence.

• Apply Protekta Plastoflex Primer

• Apply Protekta Plastoflex (1 mm thick)

• Wet the special Non oven fabric (80gsm) by Plastoflex Primer

• And laid on the top of Protekta Plastoflex and then give a coat of Plastoflex (1.5mm thick)

• Recommended consumption of product should be followed.

• For multiple coats allow sufficient drying between coats.

• Wherever possible apply coats cross-wise to achieve even thickness of coating.

Result:

Toxicity Test

Result : 800cm2 area coated with Protekta Plastoflex dried for 24 hrs and exposed in 5 litre of aerated water, 100% survival of fishes for 96 hrs.

Remarks: The sample is free from acute lethal toxicity

II. Chloride ion depth penetration in mm :

Control : 12 mm
Protekta Plastofelt: 2.2mm

II. Carbon dioxide penetration test for Concrete blocks.

pH of the solution Surface Inner core
Control 1136 11,85
Protekta Plastoflex 12.2 12.5
Control (without exposure 12.3 12.8
To carbon dioxide)

We claim:-

1. A process for manufacturing membrane for surface coating comprising the following steps:

a) taking 45 to 65% of water based bitumen emulsion in a stainless steel open vessel fitted with a homogenizer,

b) adding 20 to 40% of DM water, stirring the said composition for 5 minutes at a speed 2800 rpm.

c) Adding 4 to 14% of non-ionic surfactant and 2 to 12%, of closing agent,

d) stirring the solution with a dispersing agent

e) adding 2 to 8% of alcohol ethoxylate for at least two hours stirring the solution to obtain water based emulsion hereinafter called "Elastofelt" (component A),

2. A process for manufacturing membrane for surface coating as claimed in claim 1 wherein, the dispersing agent is Polyacrylate.

3. A process for manufacturing membrane for surface coating comprising the following steps:

a) taking 10 kg of distilled water in a stainless steel reactor;

b) adding 10 to 50 kg of acrylic or styrene or acrylic polypropylene,

c) stirring the solution and adding 0.1 to 0.5 kg of cross linking agent for 5 minutes.

d) adding 0.1 to 0.4 kg of hydrocellulose, stirring the solution for 5minuts at 2800 rpm.

e) adding 0.2 to 0.6 of any aliphatic or aromatic amine stirring for 5 minutes.

f) adding a very small % of organic additive and organizing agent

g) stirring the solution at 2800 rpm for 30 minutes to obtain a thick paste material hereinafter called "Flex joint" (component B).

4. A process for manufacturing membrane for surface coating as claimed in claim 3, wherein the oxidizing agent is flexphalt peroxide.

5. A process for manufacturing membrane for surface coating comprising the following steps:

a) taking 10 to 15 kg of distilled water in the 200 ltr stainless steel reactor fitted with a homogenizes

b) adding 20 to 30 kg of acrylic or strylene

c) adding 15 to 20 kg of acrylic emulsion,

d) stirring the said composition for 10 minutes at 2800 rpm,

f) taking another vessel and making a mixture of 20 to 25 kg of inorganic fillers, 2 to 4 kg of metal silicate and 0.4 to 0.6 kg. of titanium dioxide,

g) adding slowly half of this powder into the reactor,

h) adding 0.2 kg - 0,4 kg of fiber and 0.8 to 0,1 kg of dispersing agent and
stirring the composition for 15 minutes,

i) adding the remaining powder and continue stirring,

j) adding 10 to 20 kg of distilled water and stirring for 5 minutes

k) adding 0.20-0.25 kg of biocides and stirring for 5 minutes

l) adding 0.2 to 0.4 kg. of fiber and stirring for 15 minutes, to obtain the product herein after called "Flexphalt" (component C).

6. A process for manufacturing membrane for surface coating wherein comprising the following steps:

a) taking a 200 liter fitted with a homonizer

b) adding 30 to 80 % of component A obtained from claim 1

c) adding 30 to 80% of component C obtained from claim 5

d) adding 2 - 20% of DM water

e) stirring the said composition for 5 minutes at 2800 rpm

f) adding 2 to 9 % of Pid-Amine

g) adding 2 to 18 % alcohol ethoxylate h) adding 3 to 12 % of wax emulsion

i) stirring the said composition for 15 minutes at 2800 rpm

j) adding 2-8 % of closing agent

k) adding 10 to 24 % of bisphinol

l) stirring the said composition for 30 minutes to obtain the homogenous a thick paste a membrane hereinafter called as "Plasofelt"

7. A process for manufacturing membrane for surface coating wherein comprising the following steps:

a) taking a 200 ltr stainless steel reactor fitted with a homogenizes

b) adding 30 to 80 % of component A obtained from claim 1.

c) adding 40 to 80 % of component B obtained to claim 3.

d) adding 2 to 20 % of DM water

e) stirring the said solution for 5 minutes at speed of 2800 rpm

f) adding alcohol ethoxylate 2 to 18 %

g) adding wax emulsion 3-12 %

h) stirring the said solution for 15 minutes at 2800 rpm

i) adding 2 to 8 % of closing agent

j) optionally adding 10 to 14% of bisphinol

k) stirring the said composition for 30 min at 2800 rpm

l) allowing the said composition is settle down for 30 min to obtain a thick paste hereinafter called "Plastoflex"

8. A process for manufacturing membrane for surface coating wherein the closing agent is Polyacrylate.

9. A process for manufacturing membrane for surface coating substantially as hereinbefore described with reference to the accompanying examples.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=hXluXkxdm63lwZQxvQ+9Gw==&loc=egcICQiyoj82NGgGrC5ChA==

« Previous Patent

Next Patent »

Patent Number

270160

Indian Patent Application Number

483/CHE/2009

PG Journal Number

49/2015

Publication Date

04-Dec-2015

Grant Date

30-Nov-2015

Date of Filing

04-Mar-2009

Name of Patentee

TECH-DRY (INDIA) PVT. LTD

Applicant Address

769, GROUND FLOOR, 1ST STAGE, 1ST CROSS, INDRA NAGAR, BANGALORE - 560 038

Inventors:

#	Inventor's Name	Inventor's Address
1	SURENDRA P. BHATNAGAR	205, 2ND FLOOR, KRISHNA JEE, 3RD MAIN DEFENCE COLONY, INDRA NAGAR, BANGALORE - 560 038

PCT International Classification Number

C09D

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA