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WO2024209058A1 - Kit et procédé d'application d'un revêtement d'imperméabilisation - Google Patents

Kit et procédé d'application d'un revêtement d'imperméabilisation Download PDF

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Publication number
WO2024209058A1
WO2024209058A1 PCT/EP2024/059343 EP2024059343W WO2024209058A1 WO 2024209058 A1 WO2024209058 A1 WO 2024209058A1 EP 2024059343 W EP2024059343 W EP 2024059343W WO 2024209058 A1 WO2024209058 A1 WO 2024209058A1
Authority
WO
WIPO (PCT)
Prior art keywords
coating
calcium
suspension
substrate
waterproofing
Prior art date
Legal status (The legal status 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 status listed.)
Pending
Application number
PCT/EP2024/059343
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English (en)
Inventor
Wolfgang Seidl
Tatiana MITKINA
Simon Huber
Wolfgang ALDRIAN
Damir JOKIC
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Construction Research and Technology GmbH
Original Assignee
Construction Research and Technology GmbH
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 Construction Research and Technology GmbH filed Critical Construction Research and Technology GmbH
Priority to AU2024253112A priority Critical patent/AU2024253112A1/en
Publication of WO2024209058A1 publication Critical patent/WO2024209058A1/fr
Priority to MX2025011939A priority patent/MX2025011939A/es
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/0028—Aspects relating to the mixing step of the mortar preparation
    • C04B40/0039—Premixtures of ingredients
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/06—Aluminous cements
    • C04B28/065—Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • C04B28/141—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements containing dihydrated gypsum before the final hardening step, e.g. forming a dihydrated gypsum product followed by a de- and rehydration step
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/06—Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
    • C04B40/0641—Mechanical separation of ingredients, e.g. accelerator in breakable microcapsules
    • C04B40/065—Two or more component mortars
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00034—Physico-chemical characteristics of the mixtures
    • C04B2111/00146—Sprayable or pumpable mixtures
    • C04B2111/00155—Sprayable, i.e. concrete-like, materials able to be shaped by spraying instead of by casting, e.g. gunite
    • C04B2111/00172—Sprayable, i.e. concrete-like, materials able to be shaped by spraying instead of by casting, e.g. gunite by the wet process
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C04B2111/00508—Cement paints
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C04B2111/00517—Coating or impregnation materials for masonry
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C04B2111/00568—Multiple coating with same or similar material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials

Definitions

  • the invention relates to a waterproofing coating comprising a calcium aluminium sulfate mineral embedded in a polymer matrix.
  • waterproofing coatings can be applied on walls of tunnels or mines to prevent water ingress and deterioration of the concrete.
  • the coatings shall prevent passage of liquid water, but not water vapor.
  • large surfaces are coated, which are often not easily accessible and of irregular shape.
  • the coating compositions can be applied onto the substrate by spraying.
  • the coating composition must have a consistency such that it can be processed, pumped and sprayed conveniently.
  • the sprayed composition must adhere properly to the substrate, even if it has inclined and/or overhanging surfaces, without significant dripping and creeping.
  • the coating composition can be dried and consolidated within a short time span after application.
  • the waterproofing coating should be uniform and have good mechanical properties.
  • such waterproofing coatings for construction applications are often prepared from mixtures of cementitious powders and organic polymers.
  • the coating compositions in the art are prepared by adding water or a liquid component to a cementitious powder mixture, thereby obtaining the liquid coating composition, which is sprayed onto the substrate immediately after mixing.
  • WO 01/28955 A1 discloses cementitious compositions and methods for applying coatings to rock surfaces. At first, a powder component is provided from the cementitious constituents, such as calcium aluminate, lime and calcium sulfate. The cement powder is mixed with a polymer emulsion, fed into a mixer and applied to the substrate.
  • a powder component is provided from the cementitious constituents, such as calcium aluminate, lime and calcium sulfate.
  • the cement powder is mixed with a polymer emulsion, fed into a mixer and applied to the substrate.
  • WO 98/58886 A2 discloses a coating composition for construction applications, which is prepared from a dry mixture of the cementitious components and a liquid component comprising an emulsion polymer binder. The components are mixed in a hopper and can be sprayed onto a substrate.
  • WO 2005/070849 A1 relates to cementitious coating compositions comprising polymers. The inventors note that the methods of WO 01/28955 A1 and WO 98/58886 would require a relatively high time span for drying and curing.
  • a modified composition is proposed which comprises calcium oxide as a water binding component.
  • the coating composition is prepared from a powder mixture of the cementitious components, which is mixed with a polymer emulsion.
  • WO 00/05487 A1 discloses a waterproofing coating composition, which is especially suitable for overhanging substrates, such as tunnel walls.
  • the composition comprises the cementitious components and emulsion polymer, and is sprayable onto the substrate wall.
  • WO 2022/247993 A1 discloses the use of a reactive liquid applied material for producing a roofing membrane, wherein the reactive liquid applied material has a liquid component and a powder component, wherein the powder component comprises a mineral binder system consisting of a plurality of binders capable of forming an ettringite phase when combined.
  • the liquid component comprises one or more polymer dispersions.
  • the powder component comprises cements, such as calcium aluminate cement, Ordinary Portland Cement (OPC), calcium sulfoaluminate cement and a calcium sulfate source.
  • WO 2021/003519 A1 describes a composition for waterproofing building substrates, the composition comprising a cementitious mixture, which includes calcium sulfoaluminate cement and at least one other cementitious material. Further comprised in the composition is latex in a ratio with the cementitious mixture of at least 1.2 :1. Also disclosed is a method of forming a waterproofing membrane on a building substrate and methods of application of the composition onto a surface.
  • a commercial product for preparing waterproofing coatings for tunneling is available under the trademark MasterRoc MSL 345TM (Master Builders Solutions, DE).
  • the product is a cementitious powder mixture comprising mineral particles and ethylene vinyl acetate copolymer.
  • a liquid coating composition is prepared by mixing the dry powder with water, for example in a static mixer.
  • the coating composition is sprayed onto a concrete surface and dried, thereby obtaining a waterproofing membrane.
  • the cementitious components can react with water to form ettringite.
  • the membrane is overlaid with a second layer of sprayed concrete, thereby yielding a compositional shell lining.
  • the composite is characterized by high stability and effective water barrier properties.
  • Lumps and sticky pieces can form and accumulate, which can clog the spraying nozzle, mixer or tubes of the processing devices. This can lead to various problems, such as non-optimal spraying, poor adhesion to the substrate, low uniformity or cracks of the waterproofing coating. Overall, the preparation and application of the coating composition is difficult to control, the processing must be carried out within a short time-span, and non-homogeneous coatings can be obtained.
  • cementitious powder mixtures which comprise very fine particles
  • causes severe dust formation This is inconvenient for the user and can lead to safety problems.
  • cementitious components and additives such as calcium oxide
  • Polymer dispersion powders can form explosive dusts and aerosols. Dust formation can especially lead to problems in interior applications, for example tunnels or mines.
  • the problem underlying the present invention is to provide waterproofing coatings, methods for coating substrates, and coated substrates which overcome the problems as outlined above. It is a specific problem to provide coating compositions for preparing waterproofing coatings, which can be produced, handled and applied conveniently by the user. At the same time, the waterproofing coating should have good performance, especially regarding mechanical properties. The coating shall be uniform and provide efficient water protection to the substrate.
  • kits for preparing a waterproofing coating comprising a calcium aluminium sulfate mineral embedded in a polymer matrix
  • the kit comprises a first container containing an aqueous suspension (A) comprising
  • suspension (A) has a pH of 5 - 9, and a second container containing an aqueous suspension (B) comprising
  • a “kit” (kit of parts) is a combination of functionally interacting individual components.
  • the components comprise the first container with aqueous suspension (A) and the second container with aqueous suspension (B).
  • the kit is used for preparing a coating composition by mixing suspension (A) with suspension (B).
  • the coating composition is coated onto a substrate for preparing the waterproofing coating.
  • the kit may comprise further components, such as an instruction manual, tools or devices for preparing and applying the coating composition and/or waterproofing coating, or further containers or compositions.
  • the first container and second container are in spatial proximity, for example in a combined packaging, or as components of a system with connections to transfer the suspensions to a device for further application, such as mixing and/or spraying.
  • the coating composition and/or suspension (A) and (B) may comprise further components and can be modified before coating onto a substrate.
  • a container is a receptacle for storing and handling suspensions (A) or (B).
  • the container can be closed, such that leakage of the suspension is prevented.
  • the container has an opening for filling and removing the suspension.
  • the container can have a standard form, such as a barrel or canister, made from a suitable material, such as plastic.
  • the suspensions (A) and (B) are in liquid form, wherein solid particles are suspended in the aqueous phase. However, components of the suspension can be fully or partially dissolved.
  • the coating composition which is obtained by mixing suspensions (A) and (B), is also an aqueous suspension.
  • the coating composition is applied onto the substrate by spraying.
  • the waterproofing coating is obtained when the coating composition on the substrate consolidated. During consolidation, the coating composition is dried.
  • the waterproofing coating blocks the passage of water in liquid form but is permeable for water vapor. The coating can prevent the passage of liquid water from the environment into the substrate, and from the substrate into the environment.
  • the solid waterproofing coating is obtained when the coated composition is consolidated.
  • the waterproofing coating is also referred to as a “membrane” because it is typically relatively thin.
  • the waterproofing coating comprises a calcium aluminium sulfate mineral.
  • a mineral is an inorganic material having a crystalline structure.
  • the calcium aluminium sulfate mineral is not yet a component of suspension (A) or (B). Instead, it is formed after mixing suspensions (A) and (B) by chemical reaction of the precursor components. Accordingly, the mineral is formed during and after application of the coating composition and becomes dispersed in the waterproofing coating.
  • the suspensions (A) and (B) comprise compounds which are capable of forming the calcium aluminium sulfate mineral after mixing.
  • suspension (A) comprises the aluminium (III) source and suspension (B) comprises the calcium (II) source and the sulfate source.
  • source refers to a compound, which provides a constituent of the calcium aluminium sulfate mineral in a form which can participate in the crystallization reaction after mixing the suspensions.
  • the waterproofing coating comprises the calcium aluminium sulfate mineral in a polymer matrix, preferably the calcium aluminium sulfate mineral is embedded in the polymer matrix.
  • the organic polymer which forms the polymer matrix is a component of suspension (A).
  • the polymer matrix is a continuous phase of the waterproofing coating.
  • the mineral can be dispersed throughout the matrix in the form of small particles or a continuous phase, depending on the amount of the mineral and processing conditions.
  • the calcium aluminium sulfate mineral is formed simply after mixing suspensions (A) and (B). It is not required to initiate or support the reaction by additional means, such as further additives, for example catalysts, or specific reaction conditions, such as high temperature or radiation.
  • additional means such as further additives, for example catalysts, or specific reaction conditions, such as high temperature or radiation.
  • a coating composition which is obtained simply by mixing suspensions (A) and (B) with the components and pH values as outlined above, can form a waterproofing coating providing all required characteristics.
  • Suspension (A) comprises an aluminium (III) source.
  • the aluminium (III) source is an aluminium compound, which is capable of forming the calcium aluminium sulfate mineral when suspension (A) is combined with suspension (B).
  • the aluminium (III) source can be an aluminium (III) salt, hydroxide or complex.
  • the invention is a kit for preparing a waterproofing coating comprising a calcium aluminium sulfate mineral embedded in a polymer matrix, the preferably consolidated waterproofing coating comprising
  • kits comprises a first container containing an aqueous suspension (A) comprising
  • suspension (A) has a pH of 5 - 9, and a second container containing an aqueous suspension (B) comprising
  • the aluminium (III) source comprises aluminium (III) hydroxide.
  • the aluminium (III) source is aluminium (III) hydroxide.
  • the aluminium (III) hydroxide is amorphous. It was found that aluminium (III) hydroxide, especially in amorphous form, can provide a homogeneous and stable suspension with organic polymers. Moreover, it was found that in the coating from suspensions (A) and (B), the aluminium (III) hydroxide, especially when amorphous, can yield calcium aluminium sulfate mineral in homogeneous distribution in a polymer matrix.
  • the pH of suspension (A) is in the range of 5 to 9, preferably between 5.5 to 8.5, more preferably between 6 and 8, and most preferably of about 7.
  • the aluminium (III) source especially aluminium (III) hydroxide
  • the pH of suspension (B) is > 9, preferably > 10; preferably between 9 and 13, and more preferably between 11 and 13. It was found that the suspension (B) can be stable and uniform at such pH.
  • the aluminium (III) source especially aluminium (III) hydroxide
  • the pH of the coating composition is preferably > 8 or > 9, for example between 11 and 12.5.
  • suspensions (A) and (B) and the coating composition attain the respective pH values simply when being prepared from their components, such that no adaptation of the pH by adding additional acid or base is required.
  • the acid for the pH adjustment can be preferably chosen from the group of mineral acids and the base for the pH adjustment can be preferably chosen from the group of (earth) alkaline hydroxides.
  • the pH of the aqueous suspensions (A) and (B) is preferably measured at a temperature of 20°C using the pH-meter SevenGo, equipped with pH-Sensor InLab® 413/1 P67.
  • the following buffer solutions were used for the calibration of the pH-meter: InLab® NIST/DIN Buffer Solution pH 1 ,679 (METTLER TOLEDO) InLab® NIST/DIN Buffer Solution pH 4,006 (METTLER TOLEDO) InLab® Technical Buffer Solution pH 7,00 (METTLER TOLEDO) InLab® NIST/DIN Buffer Solution pH 10,012 (METTLER TOLEDO).
  • other aluminium (III) sources can be used, such as aluminium sulfate or sodium aluminate.
  • Suspension (B) comprises a calcium (II) source and a sulfate source, which provide the calcium (II) and sulfate into the coating composition for formation of the calcium aluminium sulfate mineral.
  • the calcium (II) source and sulfate source are different compounds, at least in part.
  • suspension (B) does not only comprise calcium (II) sulfate as the only calcium (II) and sulfate source. This is particularly for obtaining a molar excess of calcium to sulfate in the suspension (B).
  • the molar ratio of Ca (II) to sulfate is from 1.5 / 1 to 5 / 1 , more preferably from 1.5 / 1 to 4: 1 , most preferably from 2 / 1 to 4 / 1.
  • the calcium source is preferably an inorganic calcium salt or compound, such as calcium hydroxide, oxide, carbonate, chloride or nitrate.
  • the calcium source is dissolved in the suspension at least in part.
  • the calcium (II) source comprises calcium hydroxide and/or calcium oxide, more preferably the calcium (II) source is calcium hydroxide and/or calcium oxide. It was found that an efficient and homogeneous formation of the calcium aluminium sulfate mineral can be achieved when the calcium (II) source is selected accordingly.
  • calcium oxide or hydroxide can provide a relatively high pH for activating the aluminium (III) source, especially aluminium hydroxide, for mineral formation.
  • Calcium hydroxide is especially preferred, because it can be handled and dispersed conveniently in powder form or in water when preparing suspension (B).
  • the sulfate source comprises a calcium sulfate, preferably calcium sulfate hydrate, preferably calcium sulfate dihydrate. More preferably the sulfate source is calcium sulfate, preferably calcium sulfate hydrate, preferably calcium sulfate dihydrate.
  • the sulfate source is calcium sulfate, preferably calcium sulfate hydrate, preferably calcium sulfate dihydrate.
  • Calcium sulfate hydrate, and especially calcium sulfate dihydrate can be especially advantageous, because the reaction towards the calcium aluminium sulfate mineral can be especially efficient.
  • the most efficient sulfate source was found to be calcium sulfate dihydrate (gypsum).
  • gypsum calcium sulfate dihydrate
  • an additional source of calcium is used in the suspension (B) together with the calcium sulfate in order to increase the molar ratio of calcium to sulfate.
  • the additional source of calcium is calcium hydroxide and/or calcium oxide.
  • suspensions (A) and (B) By mixing suspensions (A) and (B), the reaction to the calcium aluminium sulfate mineral is initiated.
  • various types of calcium aluminium sulfate minerals can be formed in the coating.
  • the mineral may comprise additional cations and/or anions, which are different from calcium, aluminium and sulfate.
  • the major portion of the total mineral in the waterproofing coating is calcium aluminium sulfate mineral, for example more than 50%, more than 80% or more than 95% by weight.
  • the waterproofing coating When the waterproofing coating is consolidated, it cannot be excluded that a certain portion of other minerals is also formed. For example, limited amounts of gypsum and/or portlandite and/or calcium carbonate can also be present in the waterproofing coating. Practically, it is difficult to avoid completely the formation of other minerals, which could result for example from an excess of reagents or concurring side reactions. However, for an efficient waterproofing coating, it is not required that all the mineral in the coating is calcium aluminium sulfate mineral.
  • the calcium aluminium sulfate mineral is or comprises ettringite.
  • ettringite is a hydrous mineral having the formula Ca6Al2(SO4)3(OH)i2'26H2O.
  • the waterproofing coating can have especially favorable properties when the mineral is ettringite.
  • the reaction can be efficient and provide a stable and uniform coating.
  • ettringite is an often occurring hydration phase, which can be formed from different chemical compositions containing soluble calcium, aluminum, sulfate, and water at alkaline conditions when the pH is about or >10.
  • the amount of calcium, aluminium and sulfate in suspensions (A) and (B) and in the coating composition is adjusted approximately to the stoichiometry for ettringite formation.
  • Various reaction pathways are known in the art for ettringite formation. Under sub-optimal conditions, either a lower amount of ettringite is formed, or other crystalline phases can be generated.
  • the reaction products can be ettringite, Ca6Ah(SO4)3(OH)i2-26H2O, or Ca4Al2Oe(SO4)- 14H2O, or the calcium aluminum oxide hydrate, Ca4Al2Oy 19H2O.
  • Ettringite can especially be formed if sufficient CaSO4'2H2O is present.
  • Ettringite can be converted to monosulfate, if all CaSO4'2H2O is consumed in the synthesis of ettringite.
  • Ca-aluminate hydrates can form in case of an insufficient sulfate amount present.
  • suspensions (A) and (B) a liquid composition can be obtained which provides efficient ettringite formation.
  • ettringite formation it is especially preferred to use amorphous aluminum hydroxide in suspension (A) and calcium hydroxide and calcium sulfate dihydrate in suspension (B). It was found that an efficient formation of ettringite is especially favored by a combination of these source materials.
  • suspensions (A) and (B) do not comprise compounds, and especially calcium, aluminium and sulfate sources, which can be hydrated under standard conditions in the presence of water. Instead, it is preferred that the components of suspensions (A) and (B), and especially the calcium, aluminium and sulfate sources, are fully hydrated.
  • water consuming components such as cements, e.g. ordinary Portland cement, calcium aluminate cement, calcium sulfoaluminate cement and any blended versions, but also compounds such as calcium oxide, calcium sulfate anhydrite or calcium sulfate hemihydrate, could be problematic for the formation of the waterproofing coating. If non-hydrated components of suspension (A) or (B) would become hydrated over time, the viscosity could change. This could have the effect that handling and processing become difficult or impossible, for example when the coating composition is mixed and sprayed onto the substrate.
  • Suspension (A) comprises an organic polymer which forms the polymer matrix of the waterproofing coating.
  • the organic polymer is a synthetic polymer.
  • the organic polymer can be a polymer latex or soluble polymer.
  • the polymer is in the form of a polymer latex. It was found that a stable coating, in which the mineral particles are distributed, can be prepared from polymer latex.
  • the latex can be provided into suspension (A) in the form of a dispersion or powder.
  • suspension (A) comprises additives for maintaining the latex particles uniformly distributed, such as colloids or emulsifiers.
  • the polymer must be capable of forming a polymer matrix in the coating, in which the mineral particles are dispersed. After application of the coating composition, the polymer matrix is formed upon drying.
  • the organic polymer forms a film upon drying. Film formation of an organic polymer depends on its film forming temperature.
  • the coating is preferably consolidated at ambient temperature.
  • the organic polymer should be capable of film formation at 22°C, and/or at 10°C, and/or at 0°C; which are typical ambient temperatures in construction applications.
  • the glass transition temperature of the polymer is low, for example ⁇ 0°C, preferably ⁇ -10°. Such a relatively low T g can be advantageous for stability of the waterproof coating, because the coating is flexible at ambient temperature and can provide a stable assembly with adjacent layers.
  • the polymer is selected from ethylene-vinyl acetate copolymers, acrylic polymers, styrene-butadiene (SBR), polyurethane, or copolymers of these polymers.
  • SBR styrene-butadiene
  • the organic polymer is ethylene-vinyl acetate copolymer (EVA).
  • Ethylene-vinyl acetate copolymers (EVA) are copolymers from ethylene and vinyl acetate, which may optionally comprise additional monomer units. It is especially preferred that the polymer is an ethylene-vinyl acetate copolymer dispersion, more preferably a latex dispersion. According to the invention, it was found that ethylene-vinyl acetate copolymer can confer advantageous properties to the waterproofing coating, such as high uniformity, low liquid water permeability and high bond strength to the substrate.
  • ethylenevinyl acetate copolymers can have low film forming temperature and glass-transition temperature, and have good water vapor permeability. Moreover, ethylene-vinyl acetate copolymers can stabilize aluminium hydroxide in suspension (A).
  • ethylene-vinyl acetate copolymer is advantageous, because it can promote rapid gelling of the coating composition after mixing suspensions (A) and (B). By gelling, the viscosity of the coating composition can be increased significantly within a short time, for example within a few seconds. This is desirable for attaching the coating composition to the substrate in the spraying process, but also for accelerated consolidation and formation of a stable and uniform membrane.
  • the ethylene vinyl acetate copolymer is based on at least 90%, more preferably at least 95%, ethylene and vinyl acetate monomeric units, based on the total number of monomeric units.
  • the EVA is based solely on ethylene and vinyl acetate monomers.
  • the EVA comprises additional other monomeric units, typically in small amounts of less than 10% or less than 5%, for modifying the properties, such as solubility or elasticity.
  • the ethylene-vinyl acetate copolymer comprises acrylic monomeric units, such as acrylate (acrylic ester), for example methyl methacrylate or vinyl versatate. Suitable ethylene-vinyl acetate copolymers are commercially available, for example under the trademarks Vinnapas or Etonis from Wacker, DE.
  • the organic polymer is provided in the form of a powder dispersion.
  • the powder dispersion comprises additives, for example protective colloids, commonly polyvinyl alcohol, or anti-caking agent, which can be advantageous for processing the coating composition or in the coating itself.
  • the organic polymer is an acrylic polymer, preferably in the form of a latex.
  • acrylic polymers are commercially available, for example under the trademark Acronal (BASF, DE).
  • suspension (A) comprises at least one additive selected from the group consisting of a biocide, filler, emulsifier, plasticizer, protective colloid and colorant.
  • suspension (B) comprises at least one additive selected from the group consisting of a gelling agent, stabilizer, plasticizer, filler and colorant.
  • Biocides can be added, especially to suspension (A), to prevent deterioration by microorganisms. Liquid polymer dispersions are often provided with suitable biocides from the manufacturer.
  • Plasticizers can be added for modifying the physical properties of the suspensions and coating composition.
  • the plasticizer can adjust the viscosity, thereby improving processing of the suspension and coating composition.
  • the plasticizer can also maintain the suspension stable upon storage over long time periods.
  • the plasticizer, especially for suspension (B) is selected from polycarboxylate ether, acrylic polymer, copolymers thereof, or a polycondensate selected from ketone-formaldehyde condensate, melamine sulfonate-formaldehyde condensate, polyarylether or lignin sulfonate.
  • the amount of plasticizer is less than 2 wt.%, or less than 1 wt. %, of the suspension.
  • a colorant can be added for visually controlling the preparation and application of the coating composition and uniformity of the coating.
  • a uniform color can indicate homogeneous application of the coating composition on the substrate, whilst regions with insufficient coating have deviating coloration.
  • the user can also monitor visually if the coating composition is provided uniformly from suspensions (A) and (B).
  • Conventional colorants can be used which are stable at alkaline pH, such as red iron oxide, carbon black, black iron oxide, green chromium (III) oxide or fluorescein.
  • the inventive use of a colored suspension is advantageous compared to conventional coating systems based on a dry powder mixture, because it is often problematic to dissolve and homogenize solid colorants within the short time span for mixing with water and application.
  • Emulsifiers or protective colloids can be included in suspension (A) to stabilize the organic polymer, especially in latex dispersions.
  • Emulsifiers for stabilizing polymer particles, typically surfactants, or protective colloids, are often provided by the manufacturer together with the polymer dispersion or spray-dried powder.
  • a stabilizer is added to suspension (B) for preventing segregation effects.
  • Stabilizers are typically high molecular weight organic polymers, like gums, cellulose or starch ethers, acrylamide copolymers or derivatives thereof.
  • the stabilizer is cellulose ether. It was found that such a stabilizer can improve stability of suspension (B) and facilitate processing.
  • the amount of stabilizer is less than 2 wt.%, or less than 1 wt. %, of the suspension.
  • suspension (A) and/or (B) may comprise a filler for modifying the properties of the waterproofing coating, for example a particulate filler, such as sand, dolomite or limestone, or fibers, such as microfibers.
  • a filler can be included for cost reasons, but also for modifying the properties.
  • fibers can be added for reinforcing and stabilizing the coating.
  • suspension (B) comprises a gelling agent.
  • the gelling agent is a borate compound, such as boric acid, or a borate salt, such as calcium, sodium or potassium borate.
  • the borate compound is boric acid.
  • a gelling agent can be advantageous, because it can initiate and/or support gelling of the organic polymer after mixing suspensions (A) and (B). Accordingly, the viscosity of the composition can be increased rapidly after mixing suspensions (A) and (B), typically over a time span from a few seconds to 1 to 2 minutes. Thereby, adhesion of the coating composition to the substrate can be improved, and undesirable effects such as sagging are prevented. Further, the gelling can lead to more effective consolidation.
  • suspension (A) comprises a film-forming organic polymer, more preferably EVA, especially as a polymer dispersion. It was found that gelling of the coating composition was especially fast and pronounced when such polymers were combined with a gelling agent, especially borate compound.
  • boric acid as a gelling agent can be especially advantageous in combination with an alkaline calcium salt in suspension (B), especially calcium hydroxide. Accordingly, it was found that a finely dispersed calcium borate (hexahydroborite) can be precipitated in suspension (B), which can provide an effective gelling effect upon contact with the polymer when mixing suspensions (A) and (B). It is also possible to add a calcium borate mineral (colemanite) to suspension (B), but this can incur further crystal growth in suspension, which can lead to an undesirable change of properties during storage. However, such a mineral borate source may be applicable, if suspension (B) is not stored for a long time period.
  • the amount of water in suspension (A) and (B) is adjusted such that the components can be suspended homogeneously, and such that the viscosities are appropriate for mixing and further processing.
  • the water content of each suspension is between 20% and 80 wt.%, more preferably between 35% and 60 wt.%.
  • the amount of water is adjusted such that the suspensions and the coating composition can be poured and pumped conveniently with the mixing and spraying device.
  • the amount of water should be maintained as low as possible, such that the coating solution can adhere to the substrate and can dry rapidly after coating.
  • suspensions (A) and (B) have similar viscosities. Similar viscosities can be advantageous for efficient mixing and processing of the suspensions in a mixing and spraying device.
  • the difference between the dynamic viscosities of suspensions (A) and (B) is less than 20%, as determined with a Brookfield viscosimeter or rheometer at rotation speed 100 rpm (for example, as recorded after 1 min spindle rotation in the sample or until viscosity gets constant; prior to viscosity measurement the sample is sufficiently agitated).
  • viscosities can be determined according to DIN EN ISO 2884-2, part 2.
  • suspensions (A) and (B) can be stable over long time periods.
  • they can be stored at ambient temperature (22°C) for at least 7 days, more preferably at least 30 days.
  • the suspension is considered stable during storage, if the viscosity does not change by more than 20%, more preferably by not more than 10%, and/or if no phase separation or phase change occurs (like sedimentation, solidification or growth of large crystals), and/or if no chemical reaction occurs in the suspension.
  • Subject of the invention is also a method for producing a coated substrate with the inventive kit, comprising the steps of
  • step (b) coating the substrate with the coating composition obtained in step (a), and
  • step (c) consolidating the coating obtained according to step (b).
  • suspensions (A) and (B) are mixed to obtain the coating composition.
  • the coating is prepared directly from the mixture without intermediate modification.
  • the suspensions (A) and (B) and the coating composition can be flowable or paste-like. However, for better handling and processing, it is preferred that they are flowable.
  • step (a) the suspensions are mixed either in a continuous or a batch process; preferably a continuous process.
  • step (b) the substrate is also coated in a continuous process.
  • the mixing is continuous, if the suspensions are fed continuously into the mixing device, preferably at constant flow rate.
  • solutions (A) and (B) are pumped into the mixing device (for example, static mixer) directly from the containers of the kit.
  • a constant flow of the suspensions is adjusted, such that the so formed coating composition can be applied continuously onto the substrate.
  • the coating is applied over a defined region of the substrate, for example by moving the spraying nozzle over the substrate, such that approximately the same amount of coating composition is adhered over the entire region.
  • the continuous process is terminated when the desired amount of coating composition has been prepared and/or applied onto the substrate.
  • continuous mixing and coating preferably by spraying, are carried out with the same device.
  • the mixing ratio of suspension (A) and (B) is adjusted as required, such that the coating composition can be mixed and coated conveniently. Moreover, the mixing ratio is adjusted such that the components are present in the coating composition in amounts for effective mineral and matrix formation.
  • suspension (A) is used in an excess over suspension (B) which is at least two- or three-fold (by volume).
  • the mixing ratio of suspension (A) to suspension (B) is in the range of 3:1 to 10:1 (by volume).
  • Suspension (B) even in lower amount, can confer a relatively high pH to the coating composition, which can be advantageous for formation of the calcium aluminium sulfate mineral, especially ettringite.
  • the molar ratio of Ca (II) from suspension (B) to Al (III) from suspension (A) is from 1 :1 to 5:1 , more preferably from 1.5:1 to 3:1.
  • the suspensions are mixed until the homogenous coating composition is obtained.
  • the coating composition should be coated onto the substrate before a significant amount of gelling occurs.
  • the substrate is coated with the coating composition.
  • the coating composition can be applied to any substrate, for which a waterproofing coating is desired.
  • the inventive coating is especially advantageous when applied onto inorganic substrates, especially cementitious surfaces.
  • the waterproofing coating is preferably for a construction application, such as a wall, for example of a tunnel or mine; or building, bridge, harbor, or the like.
  • the substrate is inclined or vertical, or preferably even overhanging. Because the coating composition can adhere strongly, it was found that even overhanging substrates can be coated uniformly and conveniently with the inventive coating composition, without undesirable effects such as sagging. This is especially advantageous, if the substrate is not easily or conveniently accessible, such as the upper wall or ceiling of a tunnel. Because of its adhesiveness, the coating composition can be sprayed conveniently from a certain distance, such that the use of elevating platforms or ladders may be reduced or even avoided.
  • the substrate can be coated by methods known in the art.
  • the coating composition can be applied onto the substrate by spraying, extrusion, or with appropriate hand tools, such as a trowel, brush or spatula.
  • the coating composition is applied such that a continuous and uniform layer is obtained.
  • a single device is used for mixing in step (a) and coating the composition in step (b).
  • step (b) the substrate is coated by spraying.
  • the coating composition can adhere to a substrate even shortly after mixing suspensions (A) and (B), without undesirable flowing or dripping. Accordingly, a uniform waterproofing membrane can be obtained even on overhanging or irregular substrates.
  • spraying is advantageous if substrates are not easily accessible. In this regard, the distance between spraying nozzle and substrate can be several meters. The user does not need direct access to the substrate, which renders the coating process more efficient in tunnels or the like. Nonetheless, it can be advantageous to apply the coating with a tool, for example to regions of the substrate of irregular shape such as edges or cavities, or when coating only small substrates, for example during restoration.
  • step (c) the coating is consolidated.
  • consolidation is the change of the coating from the liquid to the solid state, in which the coated composition becomes the waterproofing coating.
  • the consolidation of the coating can be active or passive. It is preferred that the coating is passively consolidated. Accordingly, the coated substrate is simply left as it is after the coating has been applied. Passive consolidation can be advantageous for efficiency and cost reasons, especially for large-scale construction applications, such as tunnel walls. It was found that the waterproofing coating can attain good mechanical properties already within a few days after coating.
  • the consolidation can be actively supported, for example by applying heat or ventilation. This can be advantageous if rapid consolidation is required.
  • the coating composition is dried and the coating compositions undergoes physical and/or chemical changes.
  • the organic polymer forms the polymer matrix, which can be especially stable when a film is formed from a film-forming polymer, and when the composition is subjected to gelling.
  • the calcium aluminium sulfate mineral is formed in a crystallization reaction. Since these reactions and changes proceed in parallel, a uniform layer can be formed in which the components are in intimate contact with each other.
  • step (a) the mixing in step (a) and coating in step (b) are carried out with a device comprising
  • (v.) optionally means for adjusting the temperature of the suspensions and/or the mixture.
  • the device is capable of mixing suspensions (A) and (B) and spraying the thus obtained coating composition onto the substrate after mixing.
  • the device comprises pumps for feeding the suspensions into the static mixer and/or from the static mixer into the nozzle.
  • the device comprises means for regulating the temperature of the static mixer and/or spraying means, especially for heating the coating composition during processing.
  • suspensions (A) and (B) can be heated to a desired temperature before feeding into the static mixture, for example by heating the containers of the kit. It can be advantageous to heat suspensions (A) and (B) and/or the coating composition during mixing and spraying. By heating, the viscosity of suspensions (A) and (B) can be lowered. This renders the handling and processing more convenient, and can accelerate gelling.
  • spraying through the nozzle is airless.
  • a further water supply line or water container can be present, for diluting the mixture and adjusting the viscosity and/or for immediate flushing the mixer and the pipelines after the coating process is stopped.
  • the nozzle is at the outlet of connection means to the mixer, such as a hose or tube. With a flexible hose, the user can conveniently distribute the composition onto the surface.
  • Respective devices for mixing and spraying are commercially available, for example from Sulzer, DE, or Graco, DE.
  • the substrate is selected from the group consisting of an inorganic material, organic material, and inorganic/organic composite material.
  • the substrate is concrete, mortar, glass, stone or rocks, metal or plastic (for example PVC).
  • the substrate is an inorganic material, preferably a cementitious material.
  • the cementitious material is concrete.
  • a cementitious material is a cement or a material obtained from or based on cement.
  • a cement is a binder, a chemical substance used for construction that sets, hardens, and adheres to other materials to bind them together.
  • cement comprises fillers, such as sand or gravel. Cement mixed with fine aggregate produces mortar for masonry, or with sand and gravel, produces concrete.
  • the concrete is shotcrete (sprayed concrete).
  • the combination of the inventive waterproofing coating with shotcrete is especially advantageous, because shotcrete and the inventive coating composition can be sprayed successively in an aligned workflow.
  • the bonding strength of the waterproofing coating to shotcrete was found to be especially high.
  • the coating composition is highly suitable for providing a stable waterproofing coating on inorganic substrates, especially concrete. Without being bound to theory, bonding might be supported by the growth of the calcium aluminium sulfate mineral crystals on crystal nuclei on the concrete substrate, and/or by physical entanglement between emerging aluminium sulfate mineral crystals of the coating and surface crystals of mineral substrate.
  • the final bond strength of the inventive coating to a substrate was surprisingly high both on rough substrate surfaces, for example shotcrete with up to 12 mm aggregate size, and smooth surfaces, for example, precast concrete elements.
  • the structure of the waterproofing coating on the concrete substrate is different from comparable coatings in the art, which are obtained from cementitious powders.
  • Such conventional coatings can have lower bond strength, because attachment of the coating to the substrate is weaker.
  • a further (second) layer is applied onto the surface of the waterproofing coating of the invention.
  • the further layer is preferably a further coating, which is provided in liquid or paste form, and which is consolidated after application onto the waterproofing coating.
  • the further coating is applied onto the solid waterproofing coating, after it has been consolidated.
  • the further coating is selected from the group consisting of an inorganic, organic, and inorganic/organic composite materials.
  • the further coating is a cementitious material, especially cement, and more preferably shotcrete. According to the invention, it was found that a highly stable composite can be obtained when an additional cementitious coating is provided onto the inventive waterproofing coating.
  • the so-called “double-bond strength" can be especially high between the substrate, especially a cementitious substrate, the waterproofing coating, especially when comprising ettringite, and a further cementitious coating.
  • the cement in the further layer during consolidation, can establish a strong bond to the calcium aluminium sulfate mineral and/or to functional groups of the polymer of the inventive coating.
  • the waterproofing coating can be especially advantageous, when used as an internal waterproofing layer between two cementitious layers, especially in building applications.
  • a further (second) waterproofing coating of the invention is applied onto the surface of a composite from the substrate and first waterproofing coating.
  • first coating is not yet sufficiently uniform or has defects, for example because the substrate has an irregular surface, or in order to improve the strength and stability.
  • inventive coatings can be applied onto a substrate, on top of each other.
  • the first waterproofing coating and the at least one further (second) waterproofing coating are structurally distinct.
  • the first coating and at least second coating have different colors. This can be advantageous for visually monitoring the coating process and uniformity of the waterproofing membrane. Generally, it is important that the waterproofing coating is uniform. Otherwise, water can leak through in regions which are not adequately coated.
  • the coating composition may be applied non-uniformly to surface which is irregular or not easily accessible. In this case, a second inventive coating can be applied to correct the defects.
  • the coating compositions have distinct colors, such as white and red, or red and blue, it can be conveniently monitored, if the first coating is covered uniformly with the second coating.
  • a second white coating is provided onto a first red coating, it can be examined if there are regions where the second coating has not been applied uniformly, and which are thus still more or less red.
  • the user can conveniently monitor the coating performance and uniformity, and overall achieve an efficient and uniform waterproofing coating.
  • such colored coating compositions can only be prepared and applied conveniently with the inventive kit, because it is based on liquid suspensions.
  • Subject of the invention is also a coated substrate, which is obtainable by the inventive method.
  • the substrate is covered by the waterproofing coating, which comprises a calcium aluminium sulfate mineral embedded in a polymer matrix.
  • the coated substrate of the invention can have a unique structure and properties. Without being bound to theory, it is assumed that in situ generation of calcium aluminium sulfate mineral crystals in an emerging polymer matrix, which is obtained from liquid polymer dispersion, confers a unique structure to the composite. It was surprisingly found that the mechanical properties of the coated substrate can be superior compared to a comparative coating, which comprises ettringite particles from a cementitious power mixture.
  • the crystals can grow directly on the substrate, which can lead to high bonding strength, especially on a cementitious substrate. Moreover, the in situ growth of the mineral crystals can provide an intimate dispersion in the polymer matrix. Overall, the coated substrate can be structurally distinct and advantageous compared to conventional composites from the prior art.
  • the substrate is only coated with the waterproofing coating, which thus forms the outer surface of the composite.
  • the consolidated waterproofing coating comprises
  • organic polymer preferably ethylene vinyl acetate copolymer
  • the moist or even dried coating may comprise water, for example up to 10% by weight, or even up to 20% by weight, based on 100% of the total weight of the coating.
  • the water content of the consolidated coating depends not only on initial composition of suspensions (A) and (B), but also on humidity of the environment.
  • the coating may absorb water and become moist, but even the dried coating may comprise water which is internally bound.
  • the waterproofing coating is a thin layer.
  • the thickness and/or average thickness is in the range of 0.5 to 20 mm, preferably 1 to 10 mm, more preferably 2 to 6 mm. It was found that such a thin coating can have high mechanical strength and provide good waterproofing performance. A thin layer is advantageous for cost reasons, especially for large scale applications.
  • the thickness of the coating is determined by the roughness of the substrate surface. The rougher the substrate is, the thicker should be the coating. Application of the coating on very rough substrate surfaces (>5-6mm roughness) is possible, but would lead to heavily increased consumption of the inventive coating composition. In such cases, it can be advantageous from an economical perspective to apply an additional smoothening cementitious layer onto the substrate, followed by the application of a relatively thin coating composition on the hardened smoothening layer.
  • Subject of the invention is also a structure, comprising the coated substrate of the invention and at least one further (second) layer, which is applied onto the surface of the coated substrate.
  • the term "structure" refers to the composite which comprises the at least two layers on the substrate.
  • the structure can be formed by providing the inventive coating onto a substrate, thereby obtaining the waterproofing coating, followed by providing an additional layer onto the surface of the coated substrate.
  • the additional layer is applied onto the consolidated waterproofing coating.
  • the additional layer can be at least one further inventive coating, or can be a different layer, such as a cementitious layer.
  • the inventive structure is especially advantageous with cementitious layer, because the bonding strength can be very high.
  • the structure may consist of the coated substrate and the additional layer, or may comprise two or more additional layers.
  • the structure is or comprises an inventive waterproofing layer between a cementitious substrate and cementitious upper layer.
  • the structure comprises two or more inventive waterproofing layers over each other, on the same substrate.
  • the structure comprises the substrate, two or more inventive waterproofing layers on the substrate, and a further different layer on top, such as a cementitious layer. Accordingly, a specific composite with tailored properties can be provided, in view of the specific conditions and requirements regarding substrate material, stability, waterproofing and the like.
  • Subject of the invention is also a coating composition, which is obtainable by mixing suspension (A) and suspension (B) of the inventive kit. After mixing and during processing, the coating composition is liquid and can be coated onto the substrate. Preferably, it is a flowable liquid or paste.
  • the calcium aluminium mineral has not yet been formed in significant amounts, for example less than 20% or less than 10%, based on the amount of mineral formed after coating and consolidation.
  • a waterproofing coating is applied to the substrate as outlined above.
  • the coating can render the substrate waterproof.
  • the coating can be used for covering the substrate, for example for shielding it against the environment and/or mechanical stress.
  • the coating can be used for stabilizing the substrate, for example by protecting it from deterioration and degradation.
  • the coating can also be used for covering another waterproofing coating, which had previously been applied, especially onto a cementitious substrate.
  • the underlying waterproofing coating, onto which the inventive coating is applied can be an inventive coating, but can also be a different, conventional coating, such as a waterproofing membrane or plastic sheet.
  • the inventive coating can be coated onto another waterproofing coating for repairing, sealing, stabilizing or strengthening it.
  • waterproofing coatings in construction applications have a limited life span. They can deteriorate, can be damaged and have defects.
  • the inventive waterproofing coating can be used for improving the properties of an underlying waterproofing layer.
  • the inventive coated substrate, or structure is especially for use in construction applications and/or for covering walls, especially for a tunnel, mine or building.
  • the invention also relates to a liquid suspension (A), comprising
  • suspension has a pH of 5 - 9, wherein all amounts are wt.%, based on the total weight of suspension (A).
  • the invention also relates to a liquid suspension (B), comprising
  • suspension 0 to 20% further additives, and water making up for the remainder, wherein the suspension has a pH > 9, wherein all amounts are wt.%, based on the total weight of suspension (B).
  • a waterproofing coating is provided, which can be handled and applied conveniently by the user, if desired in a continuous process. At the same time, the waterproofing coating has excellent performance, especially regarding mechanical properties. It can be applied uniformly onto a substrate by spraying.
  • the kit and suspensions can be stored and transported without impairing the use and performance.
  • the coating composition can be prepared rapidly without significant dust formation during processing and application. By coloring suspensions (A) and/or (B), a visual quality control of the coating procedure can be incorporated.
  • the coating composition can be mixed and sprayed conveniently with conventional 2K devices and systems.
  • Shore A hardness of the membranes was measured according to DIN 53505, ISO 868. As specimens the “dog bones” S2 membrane samples were used, which were cut out from the membrane sheets, after applying it on PET foil (HostaphanTM, Mitsubishi Chemicals, DE), and consolidation at required conditions for required duration (usually with 3-6 mm fresh membrane layer thickness). The measurements were performed using the Shore A Durometer 3100 (Zwick, DE) and manual Shore A durometer PCE-DX-A (PCE Group, DE).
  • Double bond strength of the membranes to concrete was measured for “sandwich” specimens, prepared by coating the fully cured precast concrete slabs with smooth flat surface of 40 x 40 cm 2 , with a membrane layer, consolidating the membrane under defined conditions for defined time, followed by casting the second concrete layer on the membrane layer and consolidating the whole sandwich element further at defined conditions for defined time.
  • Either the prismatic “sandwich” specimens with square cross-section 60x60 mm or cylindric sandwich specimens (cores) with round cross-section of 50 mm diameter were cut/drilled out, the stamps glued on each concrete side and the strength measurement was done by pull-off method like in the case of single bond measurement.
  • Suspensions (A) and (B) were prepared and used for producing coatings on substrates.
  • the compositions are summarized in table 1 below.
  • the procedure for preparing the suspensions is outlined in the following.
  • Amorphous aluminum hydroxide is added to water and mixed with mechanical stirrer until the suspension gets homogeneous.
  • the polymer dispersion powder is portion-wise added to the suspension of aluminum hydroxide and homogenized.
  • aluminum hydroxide can be added directly to the liquid dispersion.
  • biocide is added at the end to the mixture.
  • a white, viscous, but well flowable, pumpable suspension is obtained, which has a pH of about 7 to 8.
  • boric acid is added, crystalline boric acid is dissolved in water using a mechanical stirrer, or if available boric acid solution is used as it is instead.
  • the stabilizer is optionally added and mixed until homogeneous.
  • calcium hydroxide, optionally calcium carbonate, and calcium sulfate dihydrate are added and stirred, until the mixture is fully homogeneous and lump-free.
  • Further additives such as a defoamer, plasticizer and/or pigment can be added and mixed until homogeneous.
  • a viscous, but well flowable and pumpable, optionally colored, suspension is obtained., which has a pH of about 12 to 13.
  • Table 1 Compositions A to J for suspensions (A) and (B)
  • EVA1 vinyl acetate-ethylene copolymer
  • Example 2 Methods for preparing the coating compositions
  • Coating compositions were prepared in batch methods and continuous methods from suspensions (A) and (B) according to example 1. Conventional devices were used which can be fed with a single component (1 K systems) or two components (2K systems, with mixing means). a) Batch method
  • suspension (B) is added to suspension (A) in a suitable container (beaker, bucket, drum) and homogenized with a mechanical stirrer. As soon as a homogeneous mixture is obtained, mixed material is applied. b) Continuous method
  • a two-component setup with a static mixer can be used, which consists of two separate A and B supplying units.
  • the device can be 2K pumps with appropriate feeding volume ratio A:B or a 2K extrusion/spraying gun with a 2K cartridge system at suitable volume A:B ratio, like 2K MixCoatTM spray cartridge gun (Sulzer, DE), and a static mixer, wherein A & B are mixed continuously during pumping.
  • a continuous method is generally advantageous for large- scale application, and for rapid coating of compositions having a short gelling time.
  • Substrates were coated by various methods with the coating compositions prepared according to example 1. In all cases, the coatings were applied to the substrate and left standing under standard conditions for defined time spans, as indicated in the following examples. No additional means for drying or consolidation were applied, such as heating or radiation. a) Manual coating
  • the desired substrate surface can be coated either by pouring the coating composition onto a substrate, or by brushing, painting or sweeping the coating composition with suitable tools (trowel, brush etc.) before the coating composition gels.
  • the coating composition prepared in a batch can be pumped by a suitable 1 K pump for liguids and extruded or sprayed onto a substrate surface using an appropriate nozzle.
  • Coating compositions were prepared from suspensions (A) and (B) according to formulations A to F of example 1 (table 1).
  • the coating composition was prepared by batch method a) of example 2.
  • the substrate was coated by manual coating method a) of example 3.
  • the substrate surfaces were placed horizontally, so that even if gelling was not fast enough, the freshly applied coating composition could not flow down under gravity from the surface.
  • the surfaces coated were PET foil for preparation of “dog bone” specimens and precast concrete slabs with smooth flat surface 40 x 40 cm. Thickness of fresh membrane layer was in all cases 3 mm.
  • the membrane specimens were stored after preparation at +20°C and 65% relative humidity for 28 days, and mechanical testing of membrane specimens was performed after 1 , 3, 7, 14 and 28 days according to the testing procedures. The average from three specimen was determined, with the exception of two specimen for Shore A hardness. The results are listed in table 2 below.
  • compositions E, F With polymer dispersion EVA2, much less elastic (significantly lower failure strain values), and harder (higher Shore A hardness values) membranes could be obtained (compositions E, F) compared to the membranes with polymer EVA1 (compositions A to D).
  • the results for coating compositions C and D show, that even without boric acid preparation of membranes with sufficient final mechanical properties is possible (in comparison to compositions A and B which contain borate).
  • application of the coating compositions C and D onto vertical surfaces would be difficult, because gelling of the coating composition is slow, so that such compositions would flow down from the vertically placed substrate before proper consolidation.
  • Coating compositions were prepared from suspensions (A) and (B) according to formulations G and H of example 1 (table 1).
  • the coating composition was prepared by continuous method b) of example 2.
  • the substrate was coated with a 2K spraying device according to method c) of example 3.
  • Continuous mixing of suspensions (A) and (B) at a volume ratio of 4:1 and surface coating were performed with the 2K MixCoatTM Spray cartridge gun with static mixer (Sulzer, DE).
  • the surfaces coated were PET foil for preparation of “dog bone” specimens and precast concrete slabs with smooth flat surface 40x40 cm.
  • the thickness of freshly applied membrane layer was about 3 mm.
  • Suspensions (B) of formulations G and H contain stabilizer for improving long term storage stability of the suspensions against sedimentation.
  • the coating compositions G and H contain more boric acid than coating compositions A to F. Therefore, they have significantly shorter gelling time.
  • the membrane specimens obtained were stored at 20°C and 65% relative humidity for 28 days, and mechanical testing of membrane layers was performed after 1 , 3, 7, 14 and 28 days according to the testing procedures. The results are listed in table 3. The results demonstrate that membranes G and H have very good mechanical properties.
  • a coating composition was prepared from suspensions (A) and (B) according to formulation J of example 1 (table 1).
  • the coating composition was prepared by continuous method b) of example 2.
  • the substrate was coated with a 2K spraying device according to method c) of example 3.
  • Suspensions (A) and (B) were mixed at a volume ratio 4:1 and sprayed with the 2K MixCoat Spray cartridge gun with static mixer (Sulzer, DE) onto a PET foil for preparation for dog bone specimens and concrete plates with smooth even surface for preparation of specimens for single bond and double bond measurements, with fresh membrane layer thickness of about 3 mm.
  • a membrane was prepared from a commercial powder product for waterproofing coatings for tunnel concrete surfaces (MasterRoc MSL 345TM, Master Builders Solutions, DE).
  • the comparative membrane is based on ettringite and ethylene vinyl acetate copolymer.
  • the coating composition for the comparative membrane is prepared by suspending the MasterRoc MSL 345TM powder comprising mineral and polymer particles in water.
  • the coating composition was prepared according to the manufacturer's instructions by mixing the dry powder with a stirrer at a water/powder ratio of 0.5.
  • the coating composition was manually applied onto the same surfaces with the same layer thickness of about 3 mm.
  • Bond strength concrete (65% RH): 1.2+/- 0.2 MPa (3-6mm wet layer thickness)
  • the new 2K membrane is superior to the comparative membrane regarding elasticity (failure strain), single bond strength to concrete, and especially double bond strength. Shore A hardness values for both membranes are similar. Although failure stress of the inventive membrane is lower, the target value > 1,5 MPa is already reached after 3 days, and thus the performance is very good.
  • the results suggest that the inventive membrane has a unique structure which confers advantageous properties to the product. The novel structure could result from the combined effect of in situ formation of ettringite crystals in the polymer dispersion and intimate adherence of the composition and polymer to the substrate.
  • Example 7 Influence of ambient humidity on double bond strength of inventive membrane and comparative membrane
  • An inventive membrane from an inventive composition was prepared and sprayed by 2K Sulzer MixCoatTM Spray cartridge gun with static mixer and volume ratio A:B 4:1 onto PET foil and concrete plates with smooth even surface (3 mm fresh membrane layer thickness).
  • a membrane was prepared from the commercial product MasterRoc MSL 345TM (water/powder w/w ratio 0.5) with a stirrer and manually applied onto the same surfaces with the same fresh membrane layer thickness of 3 mm.
  • a second concrete layer of 5 cm thickness was casted onto both membrane layers.
  • the sandwich elements concrete I membrane I concrete were stored for further 35 and 56 days under various conditions. Second concrete layer cores were drilled and double bond measurement was performed. In each case, the average of 5 specimens was determined. The results are summarized in table 5:
  • an inventive membrane was prepared by mixing and spraying the inventive coating composition with a XP50 2K airless spraying machine (Graco, DE) equipped with the nozzle XHD549 at ca. 35-40°C of both suspensions (preheated in the spraying machine) onto PET foils, for preparation of “dog bone” specimens for Shore A, failure strain and failure stress measurements of membrane itself, as well as onto concrete slabs with smooth even surface 40 x 40 cm.
  • the “sandwich” specimens for double bond strength measurements were prepared by casting the second layer of concrete onto a membrane layer at membrane’s age of 7 days, subsequently consolidating the sandwich element for 7 days, and then cutting the “sandwich” prisms with square cross-section of 60x60 mm.
  • the ambient conditions during spraying and storage of specimens were 20°C/65% relative humidity.
  • the target values for Shore A hardness of at least about 80 were already met after 14 days.
  • the target values regarding failure stress (single bond strength) of at least 1.5 N/mm 2 were already met at 3 days.
  • the target values for failure strain to break >100% were exceeded at all time points, including at day 1.
  • the inventive kit can be used with standard 2K devices in the technical field.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Analytical Chemistry (AREA)
  • Paints Or Removers (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

L'invention concerne un kit de préparation d'un revêtement d'imperméabilisation comprenant un minéral de sulfate d'aluminium calcique noyé dans une matrice polymère, le kit comprenant un premier récipient contenant une suspension aqueuse (A) comprenant • - une source d'aluminium (III) et • - un polymère organique, la suspension (A) ayant un pH de 5 à 9, et un second récipient contenant une suspension aqueuse (B) comprenant • - une source de calcium (II) et • - une source de sulfate, à condition qu'il existe un excédent molaire de calcium (II) par rapport au sulfate dans la suspension (B), la suspension (B) ayant un pH > 9. L'invention concerne également un procédé de production d'un substrat revêtu avec un tel kit et l'utilisation du kit pour le revêtement, le recouvrement, l'étanchéité, l'imperméabilisation, la stabilisation et/ou la réparation d'un substrat.
PCT/EP2024/059343 2023-04-06 2024-04-05 Kit et procédé d'application d'un revêtement d'imperméabilisation Pending WO2024209058A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU2024253112A AU2024253112A1 (en) 2023-04-06 2024-04-05 Kit and method for applying waterproofing coating
MX2025011939A MX2025011939A (es) 2023-04-06 2025-10-06 Kit y metodo para aplicar un recubrimiento impermeabilizante

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP23167053 2023-04-06
EP23167053.0 2023-04-06

Publications (1)

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WO2024209058A1 true WO2024209058A1 (fr) 2024-10-10

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AU (1) AU2024253112A1 (fr)
MX (1) MX2025011939A (fr)
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WO1998058886A2 (fr) 1997-06-20 1998-12-30 Evermine Limited Matiere de recouvrement de surface
WO2000005487A1 (fr) 1998-07-20 2000-02-03 Mbt Holding Ag Revetement impermeable
WO2001028955A1 (fr) 1999-10-19 2001-04-26 Fosroc International Limited Compositions cimentaires et procede de leur utilisation
WO2005070849A1 (fr) 2004-01-26 2005-08-04 Construction Research & Technology Gmbh Melange durcissable contenant de la chaux, une composition cimenteuse et un polymere
WO2012127066A1 (fr) * 2011-03-24 2012-09-27 Parexlanko Composition cimentaire seche pour la preparation d'une formulation humide d'enduit, de mortier ou de beton sans efflorescence
CN104291740A (zh) * 2013-07-20 2015-01-21 吕孟龙 碱激发无机聚合物防水涂料
WO2017076807A1 (fr) * 2015-11-02 2017-05-11 Basf Se Matière de revêtement à deux composants à séchage rapide et son procédé de production
US20180050963A1 (en) * 2015-03-09 2018-02-22 Basf Se Flexible cementitious waterproofing slurry
CN111320440A (zh) * 2020-03-06 2020-06-23 科顺防水科技股份有限公司 一种防腐快干型水泥基防水涂料及其制备方法
WO2021003519A1 (fr) 2019-07-09 2021-01-14 Canasia Australia Pty Ltd Compositions et procédés d'imperméabilisation
CN113929408A (zh) * 2021-10-29 2022-01-14 科顺民用建材有限公司 刚性防水浆料组合物、刚性防水浆料及其制备方法和应用
WO2022247993A1 (fr) 2021-05-25 2022-12-01 Remmers Gmbh Utilisation d'un produit d'imperméabilisation de toit appliqué liquide réactif pour la production d'une membrane de toiture

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Publication number Priority date Publication date Assignee Title
WO1998058886A2 (fr) 1997-06-20 1998-12-30 Evermine Limited Matiere de recouvrement de surface
WO2000005487A1 (fr) 1998-07-20 2000-02-03 Mbt Holding Ag Revetement impermeable
WO2001028955A1 (fr) 1999-10-19 2001-04-26 Fosroc International Limited Compositions cimentaires et procede de leur utilisation
US20020161071A1 (en) * 1999-10-19 2002-10-31 Mills Peter Shelly Cementitious compositions and a method of their use
WO2005070849A1 (fr) 2004-01-26 2005-08-04 Construction Research & Technology Gmbh Melange durcissable contenant de la chaux, une composition cimenteuse et un polymere
US20070298249A1 (en) * 2004-01-26 2007-12-27 Thomas Kothe Settable Mixture Containing Lime, a Cementitious Composition and a Polymer
WO2012127066A1 (fr) * 2011-03-24 2012-09-27 Parexlanko Composition cimentaire seche pour la preparation d'une formulation humide d'enduit, de mortier ou de beton sans efflorescence
CN104291740A (zh) * 2013-07-20 2015-01-21 吕孟龙 碱激发无机聚合物防水涂料
US20180050963A1 (en) * 2015-03-09 2018-02-22 Basf Se Flexible cementitious waterproofing slurry
WO2017076807A1 (fr) * 2015-11-02 2017-05-11 Basf Se Matière de revêtement à deux composants à séchage rapide et son procédé de production
WO2021003519A1 (fr) 2019-07-09 2021-01-14 Canasia Australia Pty Ltd Compositions et procédés d'imperméabilisation
CN111320440A (zh) * 2020-03-06 2020-06-23 科顺防水科技股份有限公司 一种防腐快干型水泥基防水涂料及其制备方法
WO2022247993A1 (fr) 2021-05-25 2022-12-01 Remmers Gmbh Utilisation d'un produit d'imperméabilisation de toit appliqué liquide réactif pour la production d'une membrane de toiture
CN113929408A (zh) * 2021-10-29 2022-01-14 科顺民用建材有限公司 刚性防水浆料组合物、刚性防水浆料及其制备方法和应用

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CHRISTENSEN ET AL., J. SOLID STATE CHEM., vol. 177, no. 6, 2004, pages 1944 - 1951

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