Composite waterproof membrane

Abstract

A composite waterproof membrane for waterproofing concrete slabs and foundation walls is disclosed. The waterproof membrane includes: a rubberized asphalt layer; a polymeric adhesive layer having one face bonded to one surface of the rubberized asphalt layer and having an opposite face with surface voids; and a vapor barrier layer bonded to an opposite surface of the rubberized asphalt layer. The surface voids of the adhesive layer allow concrete poured on the adhesive layer to be filled in the voids and anchor the concrete to the adhesive layer, thereby ensuring water tightness between the composite waterproof membrane and the concrete. Methods and systems for waterproofing blind-side building foundations using the waterproofing membranes are also disclosed.

Description

Technical Field

[0001] This technology generally relates to composite waterproof membranes for preventing the migration of water or moisture through concrete slabs and foundation walls. In particular, this technology relates to composite waterproof membranes with improved adhesion to concrete, which can minimize or prevent lateral water migration, especially in blind-side waterproofing applications. Background Technology

[0002] Waterproof membranes are commonly used in the construction industry to keep water and moisture away from concrete slabs and foundation walls. Commercially available moisture and vapor barriers are typically multi-layer systems, including polymer-based barrier layers to limit the migration of moisture and water vapor. The polymers used in the barrier layers include thermoplastic polyolefins and elastomers. Additional layers in multi-layer systems may include rubberized bitumen or asphalt layers, which can be modified with elastomers or polymers.

[0003] Blind-side waterproofing is a method of waterproofing the concrete surface of underground structures under continuous or intermittent hydrostatic pressure, where a tight boundary line prevents access to the foundation wall for conventional post-installation self-adhesive waterproofing. Conventional blind-side waterproofing systems are pre-applied to the structural retaining wall or concrete formwork before pouring the underground concrete foundation or retaining wall. The newly poured concrete contacts the waterproofing membrane and bonds to it as the concrete hardens. The acceptance of the membrane by the outward-facing surface of the new concrete placement is a crucial aspect of blind-side waterproofing systems, as this surface (the membrane or similar) must be integrally bonded to the new concrete pour to ensure watertightness.

[0004] One challenge with waterproof membranes is maintaining watertightness when the membrane's integrity is compromised. This compromise can be caused by punctures or damage during construction, such as steel reinforcement or gravel penetration, tensile or shear forces acting on the membrane, or failure of the integrity of the bonded surface to concrete. If watertightness is lost, water can flow laterally beneath or behind the membrane, thus penetrating the building structure.

[0005] Extensive research has focused on developing vapor barriers and waterproof membranes with improved adhesive layers that provide sufficient bond strength between the membrane and concrete to reduce or eliminate water vapor and moisture permeability, as well as lateral water migration. Adhesive layers already used to promote adhesion between the membrane and concrete include pile fabric materials and geotextile layers. Ideally, blind-side waterproof membranes will meet the modified ASTM D5385 standard for testing lateral water migration, which specifies that they remain without water leakage for one hour or more under a pressure of at least 100 PSI or higher.

[0006] The aim is to provide a composite waterproof membrane that provides improved adhesion to freshly poured concrete, thereby minimizing the possibility of lateral water migration due to compromise of membrane integrity. Summary of the Invention

[0007] This technology relates to a composite waterproof membrane, particularly suitable for blind-side waterproofing applications. The membrane comprises a unique polymer adhesive layer with an irregular surface having depressions or cavities. These depressions or cavities allow concrete poured onto the adhesive layer to fill the cavities and anchor the concrete to the adhesive layer. The cavityd surface structure advantageously reduces the likelihood of lateral water migration because the cavities allow the cured concrete to anchor within the polymer adhesive layer, thereby ensuring a watertight seal that does not provide a path for water migration.

[0008] One aspect of this technology is a composite waterproof membrane comprising: (a) a polymer adhesive layer having a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (b) a rubberized bitumen layer having a first side and an opposite second side, the first side of the rubberized bitumen layer being directly bonded to the second side of the polymer adhesive layer; and (c) a metal barrier sheet adhered to the second side of the rubberized bitumen layer.

[0009] Another aspect of the present invention is a composite waterproof membrane comprising: (a) a polymer adhesive layer having a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (b) a rubberized bitumen layer having a first side and an opposite second side, the first side of the rubberized bitumen layer being directly bonded to the second side of the polymer adhesive layer; and (c) a multilayer vapor barrier being adhered to the second side of the rubberized bitumen layer.

[0010] In some embodiments, the composite waterproof membrane mitigates lateral water movement under pressures of at least 100 PSI as determined by a modified ASTM D5385 standard for testing lateral water migration.

[0011] Another aspect of this technology is a method for waterproofing a blind-side building foundation, the method comprising: (a) forming a retaining wall; (b) applying a composite waterproof membrane to the retaining wall, wherein the composite waterproof membrane comprises: (i) a polymer adhesive layer having a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (ii) a rubberized bitumen layer having a first side and an opposite second side, the first side of the rubberized bitumen layer being directly bonded to the second side of the polymer adhesive layer; and (iii) a metal barrier sheet or multilayer vapor barrier adhering to the second side of the rubberized bitumen layer; and wherein the metal barrier sheet or multilayer vapor barrier of the composite waterproof membrane is adjacent to the retaining wall, and the polymer adhesive layer faces the area where concrete will be poured; (c) pouring concrete onto the polymer adhesive layer such that the concrete flows into the surface cavities of the polymer adhesive layer to bond the composite waterproof membrane to the concrete; and (d) allowing the concrete to harden.

[0012] Another aspect of the present invention is a system for waterproofing a blind-side building foundation, the system comprising: (a) a retaining wall; (b) a composite waterproof membrane adhered to the retaining wall, the composite waterproof membrane comprising: (i) a polymer adhesive layer having a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (ii) a rubberized bitumen layer having a first side and an opposite second side, the first side of the rubberized bitumen layer being directly adhered to the second side of the polymer adhesive layer; and (iii) a metal barrier sheet having a first side and a second side or a multilayer vapor barrier having a first side and a second side, wherein the first side of the metal barrier sheet or the multilayer vapor barrier is adhered to the second side of the rubberized bitumen layer, and the second side of the metal barrier sheet or the multilayer vapor barrier is adhered to the retaining wall; and (c) a concrete substrate embedded in the surface cavities of the polymer adhesive layer.

[0013] Another aspect of the invention is a kit for waterproofing blind-side building foundations, wherein the kit comprises: (a) a composite waterproof membrane comprising: (i) a polymer adhesive layer having a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (ii) a rubberized bitumen layer having a first side and an opposite second side, the first side of the rubberized bitumen layer being directly bonded to the second side of the polymer adhesive layer; and (iii) a metal barrier sheet or multilayer vapor barrier adhered to the second side of the rubberized bitumen layer; and (b) instructions for installing the composite waterproof membrane to waterproof blind-side building foundations. The kit may include additional items, including measuring tools, cutting tools, and other components known in the art for installing the waterproof membrane. Attached Figure Description

[0014] Figure 1 This is an enlarged cross-section of one embodiment of the composite membrane of this technology.

[0015] Figure 2 This is a photograph showing the porous surface of the adhesive layer of the composite membrane.

[0016] Figure 3 This is an enlarged cross-section of an alternative implementation of the composite layer of this technology.

[0017] Figure 4 This is a perspective view of the blind-side mounting of the composite film of this technology, showing the release strips used to form overlapping edges. Detailed Implementation

[0018] Although the technology described herein is presented in conjunction with one or more preferred embodiments, those skilled in the art will understand that the technology is not limited to those specific embodiments. Rather, the technology described herein includes all alternatives, modifications, and equivalents that may be included within the spirit and scope of the appended claims.

[0019] The term "about" means + / - 10% of the reference value. In some implementations, about means + / - 5% of the reference value, or + / - 4% of the reference value, or + / - 3% of the reference value, or + / - 3% of the reference value, or + / - 2% of the reference value, or + / - 1% of the reference value.

[0020] The composite waterproof membrane of this technology comprises three main layers: a rubberized bitumen layer; a polymer adhesive layer adhered to one side of the rubberized bitumen layer; and a vapor barrier adhered to the opposite side of the rubberized bitumen layer. The vapor barrier can be a single sheet of metal with a permeability of less than 0.1 perm, or it can be a multi-layered vapor barrier with a permeability of less than 0.1 perm. Perm is defined as the ability to allow one square foot of water vapor to pass through one square foot of flat material in one hour at one inch of mercury. The multi-layered vapor barrier can have at least two layers, alternatively at least three, four, five, six, seven, or more layers, depending at least in part on the end application of the composite waterproof membrane.

[0021] Figure 1An embodiment of the composite waterproof membrane of the present technology is illustrated, depicting a cross-section of the membrane. The composite waterproof membrane 10 includes a rubberized bitumen layer 12 sandwiched between a polymer adhesive layer 20 on one side and a multilayer vapor barrier 30 on the opposite side. The rubberized bitumen layer 12 has a first side 14 bonded to a second side 24 of the polymer adhesive layer 20 and a second side 16 bonded to the multilayer vapor barrier 30. Each of these layers will be described in further detail. Rubberized asphalt layer

[0022] The rubberized asphalt layer 12 of the waterproof membrane 10 comprises an asphaltene material modified with a polymeric material to provide elastic properties. The asphaltene material comprises a mixture of hydrocarbons that can be obtained naturally or as residues of petroleum distillation. Preferably, the asphaltene material is a homogeneous, high-softening-point asphaltene material based on petroleum and has a penetration of 0 dmm to 400 dmm as determined by ASTM D5. The polymeric material may include atactic polypropylene, isotactic polypropylene, butyl rubber, ethylene propylene diene monomer (EPDM) rubber, block copolymers, isocyanates, polyphosphates, sulfur, or combinations thereof. Examples of block copolymers that can be used to modify the asphaltene material include, but are not limited to, styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-ethylene-butene-styrene, styrene-butadiene, and atactic polypropylene. The polymer in the block copolymer can be radial, linear, or a combination thereof, depending on the desired properties of the rubberized asphalt layer. Recycled tire rubber can also be used as a source of the elastomeric polymeric material. Based on the weight of the rubberized asphalt layer, the polymeric material in the rubberized asphalt layer can range from about 1% to about 20% by weight, or alternatively from about 2% to about 20% by weight. The rubberized asphalt may also include plasticizing oils, such as aliphatic or aromatic oils, and inorganic fillers, such as silica, calcium carbonate, talc, or clay. The thickness of the rubberized asphalt layer can range from about 125 micrometers to about 12,500 micrometers. polymer adhesive layer

[0023] Reference Figure 1 and Figure 2 The polymer adhesive layer 20 of the waterproof membrane 10 is a sheet membrane having a first side 22 and an opposite second side 24. The first side 22 has surface cavities 26, and the second side 24 is bonded to the first side 14 of the rubberized asphalt layer 12. The polymer adhesive layer and the rubberized asphalt layer can be bonded together using heat and / or pressure. The surface cavities 26 allow the polymer adhesive layer 20 to form an integral bond between the adhesive layer of the waterproof membrane 10 and the concrete poured on the adhesive layer. Figure 2As best observed, surface cavities 26 are highly irregular surface defects, taking the form of open, discrete pits or cavities, which can have various diameters or opening sizes ranging from about 1 mm to about 6 mm and depths up to about 175 micrometers. Cavities can be formed by applying a warm, foamed (large bubble) polymer material to the surface of a smooth polymer sheet. The laminated polymer material is then passed through a set of pressure rollers, during which the foam bubbles burst, leaving surface cavities. Unbound by theory, it is thought that the cavities in the first surface 22 of the polymer adhesive layer 20 allow wet concrete to fill the pits and anchor the concrete to the adhesive layer, thereby mechanically adhering the polymer adhesive layer to the concrete as it dries. The surface structure with cavities also advantageously reduces the possibility of lateral water migration because the cavities allow the cured concrete to anchor within the polymer adhesive layer, thus ensuring a watertight seal that does not provide a path for water migration.

[0024] The polymer adhesive layer 20 is preferably formed of one or more thermoplastic or thermosetting materials or combinations thereof. Polymer films with surface cavities suitable for use herein are commercially available. Exemplary materials for the polymer adhesive layer include polyolefin materials such as polypropylene or polyethylene, nylon, polyethylene terephthalate (PET), ethylene vinyl acetate, or Kevlar. In one embodiment, the polymer adhesive layer comprises polypropylene. The polymer adhesive layer may also be a multilayer laminated film having at least a polymer base layer laminated or fused together to form the polymer adhesive layer and one or more additional polymer layers. The polymer layers may be formed of the same polymer or different polymers. In some embodiments, the base layer may be formed of a linear polyethylene polymer, and a second layer laminated to the base layer may be formed of a linear polypropylene polymer. In some embodiments, the polymer adhesive layer 20 may include one or more polymer nonwoven porous meshes, which are melted, fused, or otherwise adhered to the cavitated side of the polymer adhesive layer 20. One or more nonwoven webs may be formed of polyethylene, polypropylene, copolyester, copolyimide, polyurethane, ethylene vinyl acetate, polyolefin, or combinations thereof. The polymer adhesive layer 20 may also include up to about 10% by weight, or alternatively up to about 5% by weight, of inert mineral filler. Inert mineral filler may include, for example, calcium carbonate, crystalline silica, clay, and talc.

[0025] The polymer adhesive layer 20 may have a total thickness in the range of about 25 micrometers to about 225 micrometers, alternatively about 25 micrometers to about 200 micrometers, alternatively about 25 micrometers to about 150 micrometers, and alternatively about 25 micrometers to about 100 micrometers. Steam barrier

[0026] The multilayer vapor barrier 30 of the waterproof membrane 10 includes a metal sheet 32 ​​laminated between two composite outer layers 34 and 36. The metal sheet 32 ​​forms the core of the multilayer vapor barrier and can be any metal that restricts water vapor permeability. Metals that can be used for the metal sheet include aluminum, copper, tin, zinc, lead, or combinations thereof. The metal sheet 32 ​​has barrier properties that restrict water vapor permeability and reduce the permeability of harmful gases such as radon, methane, ethane, and propane. The metal sheet 32 ​​can be an aluminum vapor-deposited film made by forming a vapor-deposited layer with a film thickness of 5 nm or greater on the surface of a base material membrane. Such films typically have a base film thickness in the range of 40 nm to 125 nm and an oxide vapor-deposited film thickness in the range of 10 nm to 25 nm. Alternatively, the metal sheet 32 ​​can be an aluminum film or aluminum foil with a thickness of about 2 micrometers or greater, or 7 micrometers or greater.

[0027] Each composite outer layer 34 and 36 comprises polyolefin film layers 34a and 36a, thermoplastic film layers 34c and 36c, and primer layers 34b and 36b, respectively. Primer layers 34b and 36b are each sandwiched between the respective polyolefin film layer and the thermoplastic film layer in each composite outer layer, and bond each respective polyolefin film layer to the respective thermoplastic film layer. Composite outer layers 34 and 36 provide mechanical stability and puncture resistance, and protect the metal sheet from corrosion. Preferably, the composite outer layers are formed of a vapor-impermeable polymer material to enhance the barrier properties of the metal sheet.

[0028] The polyolefin film layer 34a of the composite outer layer 34 adheres to one side of the metal sheet 32, and the polyolefin film layer 36a of the composite outer layer 36 adheres to the opposite side of the metal sheet. The polyolefin layers 34a and 36a are preferably formed of a polyolefin resin, such as polyethylene, low-density polyethylene, or a blend of polyethylene and low-density polyethylene. Preferably, the polyolefin films 34a and 36a have adhesive properties that enable them to adhere firmly to the metal sheet 32.

[0029] Primer layers 34b and 36b firmly bond the corresponding thermoplastic film layers 34c and 36c to the corresponding polyolefin film layers 34a and 36a to form composite outer layers 34 and 36. Primer layers 34b and 36b can be formed of any material that promotes adhesion between the polyolefin film layers and the thermoplastic film layers.

[0030] Thermoplastic film layers 34c and 36c are the outermost layers of composite outer layers 34 and 36, respectively, and are formed of thermoplastic polymer resins, such as polyethylene terephthalate (PET). Thermoplastic film layer 34c is adhered to the second surface 16 of the rubberized asphalt layer 12 to bond the multilayer vapor barrier 30 to the rubberized asphalt layer. Adhesion between the thermoplastic film layer 34c and the rubberized asphalt layer can be achieved by laminating the multilayer vapor barrier and the rubberized asphalt layer together under heat and pressure. The thermoplastic film layer can also undergo physical surface treatment to promote adhesion between the multilayer vapor barrier 30 and the rubberized asphalt layer 12. For example, physical surface treatment can be performed by means of flame treatment or corona treatment in which a high-frequency voltage is applied to the surface of the thermoplastic film. Corona treatment causes a change in surface chemistry, thereby enhancing adhesion to the rubberized asphalt layer. Flame treatment or plasma surface treatment can also be used to change the chemical properties of the thermoplastic film surface to impart improved adhesion properties. Adhesion to the rubberized asphalt layer can also be promoted by applying a chemical adhesion promoter to the surface of the thermoplastic film layer 34c. For example, the adhesion promoter can be an acrylic coating, preferably selected from the group consisting of crosslinked copolymers of methacrylates and glycidyl acrylates, or methacrylates, or copolymers of acrylonitrile and styrene. The multilayer vapor barrier can have a total thickness ranging from about 25 micrometers to about 1300 micrometers.

[0031] Multilayer vapor barriers provide a water and vapor barrier that substantially prevents moisture penetration, having a permeability of less than 0.1 perm, preferably less than 0.01 perm, and most preferably less than 0.002 perm. Multilayer vapor barriers also exhibit excellent tensile strength and puncture resistance, and reduce the permeability of radon and methane.

[0032] Reference Figure 3 An alternative embodiment of the waterproof membrane of this technology is shown, wherein the multilayer barrier layer is replaced by a metal barrier sheet 50. In this embodiment, the waterproof membrane 11 includes a rubberized bitumen layer 12 and a polymer adhesive layer 20 as described above, and a metal barrier sheet 50 bonded to a second surface 16 of the rubberized bitumen layer 12. The bonding between the metal barrier sheet 50 and the rubberized bitumen layer can be achieved by laminating the metal barrier sheet and the rubberized bitumen layer together under heat and pressure.

[0033] Metal barrier sheets are films or foils that can be formed from any metal that restricts water vapor permeability. Preferably, the metal barrier sheet has a water vapor migration of less than 0.01 perm as determined by ASTM E96 Method A and / or Method B. Metals that can be used for metal barrier sheets include aluminum, copper, tin, zinc, lead, or combinations thereof. In some embodiments, the metal barrier sheet may be an aluminum vapor-deposited film, aluminum foil, or aluminum film as described above for metal sheet 32. In some embodiments, the metal barrier sheet may have a thickness ranging from about 2 micrometers to about 130 micrometers.

[0034] The composite waterproof membrane of this technology has a total thickness ranging from about 500 micrometers to about 12,700 micrometers. When properly installed, the waterproof membrane offers several improvements and advantages over prior art waterproof membranes. Unbound by theory, it is assumed that because the cavities in the adhesive layer are discrete and non-interconnected, if the composite waterproof membrane breaks, there is no path for lateral water migration. Therefore, the composite waterproof membrane of this technology can mitigate lateral water movement under pressures of at least 100 PSI as determined by a modified ASTM D5385 for lateral water migration. The composite waterproof membrane also resists hydrostatic pressures of at least 100 PSI as determined by ASTM D5385, has puncture resistance ranging from 40 psi to about 300 psi as determined by ASTM E154, and water vapor migration of less than 0.01 perm as determined by ASTM E96 Method A and / or Method B. In some embodiments, the waterproof membrane has water vapor migration between 0.001 perm and 0.01 perm.

[0035] Another advantage of waterproof membranes is that, because the bond between the polymer adhesive layer and the poured concrete is mechanical, membrane installation is not limited by temperature, precipitation (rain), humidity, atmospheric dew point, or surface cleanliness. In contrast, the adhesive strength between a waterproof membrane and a concrete substrate can be affected by temperature, humidity, dew point, or surface cleanliness, thus limiting the conditions under which adhesively bonded waterproof membranes can be installed. The porous polymer adhesive layer of this technology also has advantages over pile fabrics, geotextiles, and other fiber adhesive layers because the cavities in the polymer adhesive layer do not possess the fiber properties that could flatten or become water-saturated when interacting with groundwater conditions during the product's lifespan. How to use

[0036] Another aspect of this technology is a method for waterproofing concrete structures. The concrete structure can be any hardened concrete structure or substrate requiring moisture protection and / or waterproof sealing. The structure can be above or below ground level and can be horizontal or vertical. The waterproofing membrane of this technology is particularly suitable for waterproofing underground foundations and structures, such as blind-side building foundations, although it is also suitable for other applications, such as waterproofing cured concrete structures.

[0037] Methods for waterproofing concrete structures include applying a composite waterproof membrane of this technology to a building substrate or concrete formwork, wherein the polymer adhesive layer of the membrane faces the area where concrete will be poured. Any of the embodiments of the waterproof membrane described herein can be used to waterproof concrete structures. New concrete is then poured into the cavities on the surface of the polymer adhesive layer. The new concrete flows into the cavities and is allowed to harden. As the concrete hardens, a strong mechanical bond forms between the concrete and the polymer adhesive layer, thereby securing the waterproof membrane to the concrete structure.

[0038] Another aspect of this technology is a method for waterproofing blind-side building foundations. This method involves forming a retaining wall and applying any embodiment of the composite waterproofing membrane of this technology to the retaining wall, wherein the polymer adhesive layer faces the area where concrete will be poured. Concrete is then poured onto the polymer adhesive layer, allowing the concrete to flow into the surface cavities of the adhesive layer. The concrete is allowed to harden, thereby bonding the waterproofing membrane to the concrete. Typically, the retaining wall is installed vertically alongside the soil and is formed by multiple piles and multiple retaining plates positioned between and spanning adjacent piles. The composite waterproofing membrane can be secured to the retaining wall using mechanical fasteners, etc., wherein the polymer adhesive layer faces away from the retaining wall. In some embodiments, the composite waterproofing membrane can be installed vertically by attaching the membrane to the retaining wall using fasteners applied at approximately 12-inch intervals on top, allowing the waterproofing membrane 10 to hang downwards along the wall while awaiting concrete pouring. It should be understood that the waterproofing membrane can be installed in blind-side applications using substrates other than retaining walls. Other common substrates include corrugated steel piles, auger-drilled caissons, rock, and shotcrete, etc.

[0039] Reference Figure 4 The waterproof membrane 10 is typically installed with overlapping side seams. The overlap can be approximately 4 inches, alternatively approximately 6 inches, or alternatively approximately 8 inches. Desiredly, the waterproof membrane includes removable release strips 40 along its side edges. The release strip is removed to expose the rubberized bitumen layer of the membrane. Subsequent sheets of the waterproof membrane can then be positioned such that they overlap the exposed rubberized bitumen, and roller pressure is applied to the overlapping side seams to ensure good adhesion.

[0040] In some implementations, the composite waterproofing membrane can be installed horizontally. For horizontal slab installations, the waterproofing membrane is applied to a compacted substrate or soil base, with the vapor barrier against the substrate and the polymer adhesive layer facing upwards or away from the substrate. Subsequent membrane sheets are typically installed with overlapping side seams and rolled to ensure good adhesion. For horizontal base wall installations, membrane sheets are applied in rows from bottom to top, such that each consecutive sheet overlaps the adjacent lower membrane for better drainage. Once the membrane sheets are installed, concrete is poured onto the polymer adhesive layer, allowing the concrete to flow into the surface cavities of the adhesive layer. The concrete is allowed to harden, thereby bonding the waterproofing membrane to the concrete.

[0041] In another embodiment, the composite waterproof membrane may be part of a waterproofing system for waterproofing the foundation of a building on a blind side. The waterproofing system includes a retaining wall, a composite waterproof membrane adhered to the retaining wall, and a concrete substrate embedded in surface cavities of a polymer adhesive layer of the composite waterproof membrane, wherein the composite waterproof membrane may be any of the composite waterproof membranes described above.

[0042] In another embodiment, the composite waterproof membrane can be sold as part of a kit that includes the composite waterproof membrane and instructions for installing the membrane to waterproof the blind side of a building foundation. The kit may also include additional items such as cutting tools, measuring tools, and other components known in the art for installing the composite waterproof membrane.

[0043] The presently described technology and its advantages will be better understood by referring to the following examples. These examples are provided to illustrate specific implementations of the technology. The provision of these specific examples is not intended to limit the scope and spirit of the technology. It will be understood by those skilled in the art that the full scope of the presently described technology covers the subject matter defined by the appended claims and any variations, modifications, or equivalents of those claims.

[0044] The following test methods are used to determine the performance of the composite waterproof membrane of this technology.

[0045] Water vapor transmission rate was measured according to ASTM E96 Method A and Method B.

[0046] The puncture resistance of the membrane was measured according to ASTM E154.

[0047] Membrane hydrostatic pressure resistance was measured according to ASTM D5385.

[0048] A modified ASTM D5385 standard for testing lateral water migration is used to determine the lateral water migration of composite waterproofing membranes subjected to a maximum pressure of up to 100 PSI applied between the adhesive layer and concrete. For the modified ASTM D5385 test, a 1-inch square hole is cut from the center of the waterproofing membrane to create a defect, i.e., a direct, unobstructed path for pressurized water to apply hydrostatic pressure between the porous surface of the waterproofing membrane and the concrete. The waterproofing membrane is placed in a concrete formwork with the porous surface facing upwards. At each opposite end of the concrete formwork, a half-inch diameter conduit is positioned perpendicular to the waterproofing membrane, with one open end of the conduit abutting the porous surface of the waterproofing membrane and the other open end extending out of the concrete formwork before concrete pouring. The conduit forms a path for any water that may migrate laterally during the test. Concrete is then poured into the formwork, allowed to harden, and then cured for at least 28 days. The cured concrete is removed from the formwork and the membrane is mounted on a hydrostatic testing apparatus for testing. The test is conducted at an incremental pressure of up to 100 psi and maintained at 100 psi for at least one hour. This test is a pass / fail test, and a test is considered pass if no water leakage is recorded from the insertion pipe against the membrane surface after at least one hour at 100 psi. Example Example 1: Preparation of an example membrane

[0049] A waterproof membrane according to this technology is prepared using the following layers. The polymer adhesive layer is a porous polymer membrane having a polyethylene substrate and a polypropylene top layer. The top layer has the following characteristics: Figure 2 The surface cavities are depicted. The total thickness of the polymer adhesive layer is approximately 100 micrometers. The rubberized bitumen layer comprises bitumen, styrene-butadiene-styrene rubber, recycled tire rubber, process oil, and inorganic filler, and has a thickness of approximately 1676 micrometers. The vapor barrier is a 7-layer composite sheet comprising the following layers: PET / primer / PE-LDPE / aluminum foil / PE-LDPE / primer / PET, and has a thickness of approximately 76 micrometers. The total thickness of the waterproof membrane is approximately 1854 micrometers. The waterproof membrane exhibits water vapor migration of less than 0.10 perm as determined by ASTM E96 Methods A and B, and has a puncture resistance of at least 210 psi as determined by ASTM E154. Example 2: Lateral water migration test

[0050] Lateral water migration was tested on the waterproof membrane of Example 1 using the modified ASTM D5385 method described above for testing lateral water migration. No pipe leakage was observed after 1 hour at a pressure of 100 psi. Example 3: Hydrostatic Pressure Resistance Test

[0051] The hydrostatic pressure resistance test of the waterproof membrane in Example 1 was performed according to ASTM D5385. In this test, test specimens of the waterproof membrane with overlapping seams were prepared. No leakage occurred in the test specimens after 1 hour at pressures between 0 psi and 100 psi. Example 4: Water vapor transmission rate

[0052] Water vapor migration of the waterproof membrane in Example 1 was evaluated according to ASTM E96 Methods A and B. For each test method, three 3-inch diameter samples were cut from a single waterproof membrane sheet. The average water vapor transmission rate of the waterproof membrane according to Method A was 0.001 perm (grains per hour-square feet-inch-mercury), and the average water vapor transmission rate according to Method B was 0.003 perm (grains per hour-square feet-inch-mercury). Example 5: Puncture resistance

[0053] The puncture resistance of the waterproof membrane in Example 1 was evaluated according to ASTM E154 Part 10. The waterproof membrane has a puncture resistance of 210 psi. Example 6: Alternative Implementation

[0054] An alternative embodiment for preparing a waterproof membrane using an alternative embodiment of a polymer adhesive layer. The rubberized bitumen layer and the vapor barrier layer are the same as those in the waterproof membrane of Example 1. In this alternative embodiment, a nonwoven porous polymer web is applied to the porous surface of a porous polypropylene membrane. The non-porous side of the porous polypropylene membrane is heated to a temperature higher than the melting temperature of the polymer web, and the polymer web is pressed into and melted into the porous side of the porous polypropylene membrane. The porous polypropylene membrane is allowed to cool, and a second nonwoven porous polymer web is applied to the porous surface in a manner that prevents the second polymer web from completely melting.

[0055] This technology is now described in such complete, clear, and concise terminology to enable those skilled in the art to practice it. It should be understood that the foregoing describes preferred embodiments of the technology, and modifications can be made thereto without departing from the spirit or scope of the technology as set forth in the appended claims. Furthermore, the examples provided are not exhaustive but rather illustrative of several embodiments falling within the scope of the claims.

Claims

1. A composite waterproof membrane, comprising: (a) A polymer adhesive layer comprising a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (b) A rubberized asphalt layer having a first side and an opposite second side, wherein the first side of the rubberized asphalt layer is directly bonded to the second side of the polymer adhesive layer; as well as (c) A metal barrier sheet, said metal barrier sheet being adhered to the second side of the rubberized asphalt layer.

2. A composite waterproof membrane, comprising: (a) A polymer adhesive layer comprising a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (b) a rubberized asphalt layer having a first side and an opposite second side, the first side of the rubberized asphalt layer being directly bonded to the second side of the polymer adhesive layer; and (c) A multi-layer vapor barrier, wherein the multi-layer vapor barrier is adhered to the second surface of the rubberized asphalt layer.

3. The membrane according to claim 1 or 2, wherein, The polymer adhesive layer comprises polypropylene, polyethylene, nylon, polyethylene terephthalate, ethylene vinyl acetate, Kevlar, or a combination thereof.

4. The membrane according to any one of claims 1 to 3, wherein, The polymer adhesive layer has a thickness in the range of 25 micrometers to 225 micrometers, or 50 micrometers to 200 micrometers, or 50 micrometers to 175 micrometers.

5. The membrane according to any one of claims 1 to 4, wherein, The polymer adhesive layer contains up to 10% by weight of inert mineral filler.

6. The membrane according to any one of claims 1 to 5, wherein, The polymer adhesive layer is a multilayer film.

7. The membrane according to claim 6, wherein, The multilayer film includes at least one polymer web.

8. The membrane according to any one of claims 1 to 7, wherein, The rubberized asphalt layer comprises an elastomer material, which includes one or more of the following: atactic polypropylene, isotactic polypropylene, butyl rubber, ethylene propylene diene monomer (EPDM) rubber, block copolymer, isocyanate, polyphosphate, sulfur, or combinations thereof.

9. The membrane according to claim 8, wherein, The block copolymer is selected from the group consisting of styrene-butadiene-styrene, styrene-isoprene-styrene, styrene-ethylene-butene-styrene, styrene-butadiene rubber, random polypropylene, and combinations thereof.

10. The membrane according to claim 8 or 9, wherein, The elastomeric material comprises about 1% to about 20% by weight of the rubberized asphalt layer.

11. The membrane according to any one of claims 1 to 10, wherein, The metal barrier sheet includes aluminum, copper, lead, tin, zinc, or a combination thereof.

12. The membrane according to any one of claims 1 to 11, wherein, The metal barrier sheet has a thickness ranging from about 2 micrometers to about 130 micrometers.

13. The membrane according to any one of claims 1 to 12, wherein, The membrane is resistant to hydrostatic pressure of at least 100 PSI as determined by ASTM D5385.

14. The membrane according to any one of claims 1 to 13, wherein, The membrane mitigates lateral water movement at a pressure of at least 100 PSI, as determined by a modified ASTM D5385 standard for testing lateral water migration.

15. The membrane according to any one of claims 1 to 14, wherein, The membrane has a water vapor transmission rate of less than 0.10 perm, preferably less than 0.05 perm, as determined by ASTM E96 Method A and / or Method B.

16. The membrane according to any one of claims 1 to 15, wherein, The membrane has a puncture resistance of up to 300 pounds as determined by ASTM E154.

17. The membrane according to any one of claims 2 to 16, wherein, The multilayer vapor barrier comprises a metal sheet laminated between two composite outer layers.

18. The membrane according to claim 17, wherein, Each composite outer layer includes a primer layer sandwiched between a polyethylene layer and a thermoplastic film layer, wherein the polyethylene layer of each composite outer layer is adhered to the side of the metal sheet.

19. The membrane according to any one of claims 17 to 18, wherein, The metal sheet is an aluminum foil sheet.

20. The membrane according to any one of claims 2 to 19, wherein, The multi-layered vapor barrier has a thickness of approximately 25 micrometers to approximately 1300 micrometers.

21. A method for waterproofing concrete structures, comprising: (a) applying the composite waterproof membrane according to any one of claims 1 to 20 to a building substrate or concrete formwork, wherein the polymer adhesive layer of the composite waterproof membrane faces the area to which concrete will be poured; and (b) pouring the concrete into the surface cavities of the polymer adhesive layer to bond the composite waterproof membrane to the concrete.

22. A method for waterproofing the foundation of a building on a blind side, the method comprising: (a) Formation of a protective wall; (b) Applying a composite waterproof membrane to the retaining wall, wherein the composite waterproof membrane comprises: (i) a polymer adhesive layer having a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (ii) a rubberized bitumen layer having a first side and an opposite second side, the first side of the rubberized bitumen layer being directly bonded to the second side of the polymer adhesive layer; and (iii) a metal barrier sheet or a multilayer vapor barrier, the metal barrier sheet or the multilayer vapor barrier being adhered to the second side of the rubberized bitumen layer; and wherein the metal barrier sheet or the multilayer vapor barrier of the composite waterproof membrane is adjacent to the retaining wall, and the polymer adhesive layer faces the area where concrete will be poured; (c) Pouring the concrete onto the polymer adhesive layer, causing the concrete to flow into the surface cavities of the polymer adhesive layer to bond the composite waterproof membrane to the concrete; and (d) Allow the concrete to harden.

23. A system for waterproofing the foundation of a building on the blind side, comprising: (a) Wall protection; (b) A composite waterproof membrane adhered to the retaining wall, the composite waterproof membrane comprising: (i) a polymer adhesive layer having a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (ii) a rubberized bitumen layer having a first side and an opposite second side, the first side of the rubberized bitumen layer being directly adhered to the second side of the polymer adhesive layer; and (iii) a metal barrier sheet having a first side and a second side or a multilayer vapor barrier having a first side and a second side, wherein the first side of the metal barrier sheet or the first side of the multilayer vapor barrier is adhered to the second side of the rubberized bitumen layer, and the second side of the metal barrier sheet or the second side of the multilayer vapor barrier is adhered to the retaining wall; and (c) A concrete substrate, wherein the concrete substrate is embedded in the surface cavity of the polymer adhesive layer.

24. A kit for waterproofing blind-side building foundations, comprising: (a) A composite waterproof membrane, comprising: (i) a polymer adhesive layer having a first side and an opposite second side, the first side of the polymer adhesive layer having surface cavities; (ii) a rubberized bitumen layer having a first side and an opposite second side, the first side of the rubberized bitumen layer being directly bonded to the second side of the polymer adhesive layer; and (iii) a metal barrier sheet or a multilayer vapor barrier, the metal barrier sheet or the multilayer vapor barrier being adhered to the second side of the rubberized bitumen layer; and (b) Instructions for installing the composite waterproof membrane to waterproof the blind side building foundation.

25. The kit of claim 24, further comprising at least one measuring tool, or at least one cutting tool, or a combination thereof.

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