Preapplied waterproofing bonding coating and systems and methods involving the same and methods involving the same

Patent metadata

Field	Value
Publication number	US-2025171642-A1
Application number	US-202218843687-A
Country	US
Kind code	A1
Filing date	Mar 4, 2022
Priority date	Mar 4, 2022
Publication date	May 29, 2025
Grant date	—

Abstract

Waterproofing bonding coating compositions comprise synthetic film-forming polymer having very small average particle size within emulsion systems that enable the coating to be used on various substrates, including formwork, conventional as well as pre-applied waterproofing membranes, and even on other coatings, to provide an excellent waterproofing bond with post-cast concrete. Waterproofing bonding coating compositions can be applied in liquid form upon various substrates and building surfaces. They can be used in the manner of a bonding coating layer, or additional bonding coating layer, when applied upon membranes installed at the building site, or, alternatively, when incorporated onto the membrane as an outermost layer at the membrane manufacturing plant. The waterproofing bonding coating can be used to enhance water- and weather-resistance in both conventional and pre-applied waterproofing membranes.

First claim

What is claimed is:

1 . A method for establishing a waterproofing bond with post-cast concrete, comprising:
(A) providing a substrate chosen from formwork, a waterproofing membrane established by application of a previous coating composition or a rollable/unrollable sheet-form membrane having a carrier layer, a building surface, a civil engineering surface, or any combination of the foregoing substrates; and (B) applying onto the substrate, to establish a waterproofing bond for concrete that is subsequently cast against the substrate, a waterproofing bonding coating composition which is an aqueous synthetic polymer emulsion system comprising: (i) at least one film-forming synthetic polymer present in the amount of 5% to 100%, preferably in the amount of 50% to 100%, more preferably in the amount of 80% to 100%, based total dry weight of the aqueous synthetic polymer emulsion system, wherein the average particle size of the at least one film-forming synthetic polymer is in the range of 5 to 150 nanometers; and, optionally, (ii) a surfactant in the amount of zero to no greater than 1%, and preferably zero to no greater than 0.5%, all percentages of polymer above being based on total dry weight of the aqueous synthetic polymer emulsion system.

2 . The method of claim 1 wherein, in applying the waterproofing bonding coating composition onto the substrate in step (B), the waterproofing bonding coating composition comprises at least one film-forming synthetic polymer, having average particle size of the at least one film-forming synthetic polymer in the range of 5 to 150 nanometers, is present in the amount of 50% to 100%.

3 . The method of claim 1 wherein, in applying the waterproofing bonding coating composition onto the substrate in step (B), the waterproofing bonding coating composition comprises at least one film-forming synthetic polymer, having average particle size of the at least one film-forming synthetic polymer in the range of 5 to 150 nanometers, is present in the amount of 80% to 100%.

4 . The method of claim 1 wherein, in applying the waterproofing bonding coating composition onto the substrate in step (B), the waterproofing bonding coating composition comprises at least one film-forming synthetic polymer, having average particle size of the at least one film-forming synthetic polymer in the range of 5 to 100 nanometers, is present in the amount of 5% to 100%.

5 . The method of claim 1 wherein, in applying onto the substrate in step (B), the waterproofing bonding coating composition is applied at a coverage rate of 10-2500 grams per square meter (gsm), more preferably in the range of 20-200 gsm, and most preferably in the range of 30-100 gsm, based on total dry weight of the aqueous synthetic polymer emulsion system.

6 . The method of claim 1 wherein, in applying the waterproofing bonding coating composition onto the substrate in step (B), the waterproofing bonding coating composition has glass transition temperature no less than −20° C. and no greater than 100° C., more preferably no greater than 85° C., and most preferably no greater than 65° C.

7 . The method of claim 1 , in applying the waterproofing bonding coating composition onto the substrate in step (B), the waterproofing bonding coating composition has glass transition temperature below 0° C.

8 . The method of claim 1 wherein, in applying the waterproofing bonding coating composition onto the substrate in step (B), the waterproofing bonding coating composition further comprises a polymer emulsion chosen from fluoroacrylate or fluorinated polymers, copolymer with carboxyl and siloxane functionality that can react or form strong interactions with cement, or a mixture thereof.

9 . The method of claim 1 wherein, in applying the waterproofing bonding coating composition onto the substrate in step (B), the waterproofing bonding coating composition comprises at least one white pigment, and preferably wherein the white pigment is chosen from titanium dioxide, antimony oxide, zinc sulfide, zinc oxide, white cement, organic hollow sphere pigment, or a mixture thereof.

10 . The method of claim 1 wherein, after applying the waterproofing bonding coating composition onto the substrate in step (B), the method further comprises casting concrete against the applied waterproofing bonding coating composition (hereinafter “post-cast concrete”), and allowing the post-cast concrete to harden against the waterproofing bonding coating composition.

11 . The method of claim 10 wherein the post-cast concrete is allowed to cure and harden against, and to form a waterproofing bond with, the post-cast concrete, and further wherein the waterproofing bond between the coating composition and the post-cast concrete is greater than 0.53 Newton per millimeter or three pounds per linear inch, when tested in accordance with modified ASTM D903-98 (2017), wherein the testing procedure is modified by casting concrete against a waterproofing membrane to form the bond between the coating and concrete and using a peel rate of 100 mm (4 inches) per minute, whereby the waterproofing membrane is peeled away from the concrete after the concrete is allowed to harden.

12 . A waterproofed substrate made according to the method of claim 1 .

13 . A coating composition comprising: an aqueous synthetic polymer emulsion system comprising: at least one film-forming synthetic polymer present in the amount of 5% to 100%, more preferably in the amount of 50% to 100%, and most preferably in the amount of 80% to 100%, based total weight of the aqueous synthetic polymer emulsion system, wherein the average particle size of the at least one film-forming synthetic polymer is in the range of 5 to 150 nanometers; and, optionally, a surfactant in the amount of zero to no greater than 1%, and preferably zero to no greater than 0.5%, and most preferably zero to no greater than 0.1% based on total weight of the aqueous synthetic polymer emulsion system.

14 . A waterproofing membrane, comprising: (A) a carrier layer; (B) a pressure-sensitive adhesive layer; (C) optionally a protective coating layer comprising particles, elastomeric coating, or mixture thereof; and (D) a waterproofing bonding coating composition comprising: an aqueous synthetic polymer emulsion system comprising: at least one film-forming synthetic polymer present in the amount of 5% to 100%, more preferably in the amount of 50% to 100%, and most preferably in the amount of 80% to 100%, based total weight of the aqueous synthetic polymer emulsion system, wherein the average particle size of the at least one film-forming synthetic polymer is in the range of 5 to 150 nanometers; and, optionally, a surfactant in the amount of zero to no greater than 1%, and preferably zero to no greater than 0.5%, and most preferably zero to no greater than 0.1% based on total weight of the aqueous synthetic polymer emulsion system.

15 . The coating composition of claim 13 further wherein the at least one film-forming synthetic polymer has an average particle size in the range of 5 to 150 nanometers, and is present in the amount of 50% to 100%.

16 . The coating composition of claim 13 further wherein the at least one film-forming synthetic polymer has an average particle size in the range of 5 to 150 nanometers, and is present in the amount of 80% to 100%.

17 . The coating composition of claim 13 further wherein the at least one film-forming synthetic polymer has an average particle size in the range of 5 to 100 nanometers, and is present in the amount of 5% to 100%.

18 . The waterproofing

Assignees

• Gcp Applied Tech Inc

Inventors

• Wang Qian
• Chen Huhe
• Cao Xia

Classifications

• E04B1/665

  Sheets or foils impervious to water and water vapor · CPC title

• E04B1/644

  Damp-proof courses (in combination with lintels E04C3/02) · CPC title

• C09D5/16

  Antifouling paints; Underwater paints · CPC title

• C09J7/38

  Pressure-sensitive adhesives [PSA] · CPC title

• C09D7/61

  inorganic · CPC title