Textured coating formulation with low water absorption and high efflorescence resistance.

Abstract

ABSTRACT Title: Textured coating formulation with low water absorption and high efflorescence resistance. A texture coating formulation is provided preferably suitable for trowel application based on a select binder and including sand / extender formulation of select dimensions that are key to the thickness and the final attributes of the coating, said coatings being trowel able coatings have advantageous features of low water absorption, exterior durability and efflorescence resistance also extendable to interior application. Fig. 1

Description

FIELD OF INVENTIONThe present invention relates to a texture coating formulation preferably suitablefor trowel application based on a select binder and including sand / extenderformulation of select dimensions that are key to the thickness and the finalattributes of the coating, said coatings being trowel able coatings haveadvantageous features of low water absorption, exterior durability andefflorescence resistance also extendable to interior application.BACKGROUND ARTTexture coatings are known to have PVC 75-85% which aids in the formation ofthe scratch design during trowel application. These coating is found to have ahigh-water absorption in the range of 40-50% after 7 days of immersion inwater. Water absorption of a coating determines the overall durability and theanti-microbial performance of the coatings. The coatings also have high porositywhich helps in the transportation of the dissolve salts and hence the resistance toefflorescence is low.On this reference is invited to Materials (Basel). 2021 Dec; 14(24): 7558 thatteaches results of research on the influence of polymer modifiers: styrene-acryliccopolymer, vinyl acetate / ethylene (EVA), vinyl acetate / acrylic copolymer (VAAc),and VA / VeoVa / acrylic terpolymer on the water permeability and adhesion ofcement-containing waterproofing mortars in concrete. The content of thepolymers in the composition of the mortars was 15, 20 and 26% (m / m) inrelation to the weight of the dry ingredients. Using microscopic methods, anattempt was made to analyse the relationship between the microstructure of themortars and the properties of these polymers. The EVA and the vinylacetate / acrylic copolymer, which were used in the form of dry powders, had themost favourable effect on water permeability and adhesion to the concretesubstrate. They may prove to be useful for the production of one-componentcement-containing waterproofing mortars. On the other hand, theVA / VeoVa / acrylic terpolymer modifier had the least favourable effect on thetested properties. For mortars with this modifier, the desired water-permeabilityparameters were not achieved. Depending on the amount of polymer modifier,the mortars were characterized by differences in water tightness, as establishedon the basis of changes in porosity and differences in the adhesion of thecement-polymer paste to the surface of aggregate grains. It was determined thatthe type of polymer and its dispergation properties influence the waterpermeability of mortars, as well as their adhesion to concrete substrates.US20090264585A1 teaches copolymers of hydrophobic higher branched vinylesters, and a polymerization process for polymerization of hydrophobicmonomers in the presence of surfactants having low critical micelleconcentration.Mingguang Hu et al. in Advances in Engineering Research, volume 125, Pg 271-274 teaches that in order to get good weather resistance, water repellency, andthermal stability of emulsion lattices, this prior art aimed to prepare QuaternaryCo-polymer Emulsion, therefore, a conventional seeded emulsion polymerizationis prepared by (NH4)2S2O8-initiation and by core / shell technique of fourmonomers namely MMA, BA, MAA, and VeoVa-10. As a result, stable Tertiaryacrylic emulsion with improved physico-mechanical properties were obtained. Theeffect of the VeoVa-10 and emulsifier content on the properties of the resultingemulsion lattices and their corresponding films were investigated and achievedenhanced and excellent properties. Characterization of the prepared emulsionswas performed using e.g. IR, TEM, SEM, thermal analysis. The VeoVa-10 andemulsifier amount had a great influence on the properties of the resulting latticesand their corresponding films.Aspects of Water Sensitivity of PVAc Latex Films by Chen, Zhijin 2011 teachesacetoacetoxy ether methacrylate (AAEM)-Vinyl acetate-VeoVa10 terpolymer latexemployed as wood adhesive with enhanced water resistance when crosslinkedwith diamines.Inspite of the above binders and formulation known in the art there was need tofurther explore for coating formulations that would have overall enhanceddurability in terms of reduced water adsorption and would have reduced porosityto not much facilitate transportation of the dissolve salts to cause higherresistance to efflorescence.OBJECTS OF THE INVENTIONThe primary object of the present invention is to provide for texture coatingformulation preferably suitable for trowel application based on a select binderincluding a sand / particle / extender formulation that would have advantageousfeatures of low water absorption, exterior durability and efflorescence resistancealso extendable to interior application.It is another object of the present invention to provide for said texture coatingformulation and a process thereof including the preparation of said bindertogether with the preparation of sand / extender formulation based oninvolvement of extenders of select dimensions key to the thickness and the finalattributes of the coating formulation including necessary attributes of reducedwater adsorption and anti-efflorescence.SUMMARY OF THE INVENTIONThus according to the basic aspect of the present invention there is providedtexture paint / coating formulation comprising synergistic co-acting combination ofselect (i) silane modified Veova-acrylic tetramer binder emulsion formulation and(ii) sand formulation based on coarser dolomite, dolomite sand and marblepowder as filler / extender.Said texture coating formulation provided is suitable for trowel applicationwherein said silane modified Veova-acrylic tetramer binder emulsion formulation(i) comprises silane modified tetramer of monomers styrene - butyl acrylate -Veova-10 - methacrylic acid with Veova-10 content between 1-10 wt. %, totalmonomers between 38-50 wt.% and silane content between 0.2-3 wt. % of thetotal binder emulsion formulation also having polymerizable surfactant in thelevels of 0.05-0.5 wt.%.Preferably said texture coating formulation is provided wherein Veova-10 contentonly between 1-5 wt.%, silane content only between 0.6-1.0 wt.% andmethacrylic acid content between 0.5-2 wt.% of the total binder emulsionformulation with particle size of the binder emulsion in the range of 80-130 nmare key to water absorption and anti-efflorescence performance of the resultingtexture coating formulation due to efficient packing together with conventional / select sand formulation where water absorption is reduced by 50% with 2 timesimprovement in efflorescence of the resulting coating observed as compared toconventionally known texture paint samples.According to another preferred aspect of the present invention there is providedsaid texture coating formulation wherein said binder emulsion formulation ispresent in the levels of 4-40 wt. % depending on scratch designs to be formed onsubstrate upon trowel application and is preferably present in the levels of 8-14wt.% also adapted to reduce water absorption of conventional texture paintswhen added to it.Preferably said texture coating formulation is provided wherein said sandformulation (ii) comprises coarser dolomite, dolomite sand and marble powder asfiller / extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10-50 wt.%Dolomite Sand 30 / 80 mesh, 5-20 wt.% Dolomite Sand 16 / 30 mesh, 1-10 wt.%Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6 / 8 / 12 mesh, and 5-40 wt.%marble powder 18 / 240Mesh of the total sand formulation.According to another aspect a sand formulation adapted to reduce waterabsorption in texture coating formulations is provided comprising coarserdolomite, dolomite sand and marble powder as filler / extender in select levels of5-30 wt.% Dolomite 240 mesh, 10-50 wt.% Dolomite Sand 30 / 80 mesh, 5-20wt.% Dolomite Sand 16 / 30mesh, 1-10 wt.% Dolomite Sand 3 MM, 1-10 wt.%Dolomite Sand 6 / 8 / 12 mesh, and 5-40 wt.% marble powder 18 / 240Mesh of thetotal sand formulation optionally including china clay in amounts of 0-10 wt.%,said sand formulation when incorporated in conventional texture paints could alsoenable reduction in water absorption.According to another aspect of the present invention there is provided a processfor manufacture of texture coating formulation comprising the steps of providing(i) silane modified Veova-acrylic tetramer binder emulsion formulation and (ii)sand formulation based on coarser dolomite, dolomite sand and marble powderas filler / extender in the levels of 4-40 wt. % depending on scratch designs to beformed on substrate and blending the same to attain said texture coatingformulation.Preferably said process is provided for manufacture of texture coatingformulation wherein said step (i) of providing silane modified Veova-acrylictetramer binder emulsion is based on the following sub-steps based on seededemulsion polymerization(a) Pre-heating demineralized water in a reactor at 78-82 degree C followed byadding anionic surfactant alkyldiphenyloxide Disulfonate for emulsion processing;(b) dissolving the Initiator Potassium persulfate (PPS) in demineralized water;(c) dissolving buffer agent Sodium Bicarbonate(SBC) in demineralized water;(d) preparing a pre-emulsion separately containing anionic surfactant likepolymerizable surfactant and non-ionic surfactant like Alcohol ethoxylate (30M),adding Potassium persulfate dissolved in demineralized water followed by addingmonomers-Styrene, Butyl acrylate, Veova-10, Methacrylic acid, Vinyl TrimethoxySilane one by one into the pre-emulsion;(e) adding 5% pre-emulsion seed into the reactor followed by adding dissolvedPPS solution and dissolved SBC solution (b) and (c) into the reactor and post 15mins rest of pre-emulsion addition is done for 240-260 mins for seeded emulsionpolymerization to proceed due to which free monomers are consumed by additionof digestion catalyst, Tertiary butyl hydroperoxide (TBHP) and Sodiumformaldehyde sulfoxylate(SFS) by 90 min of continuous addition;(f) cooling the emulsion down to 40-45 degree C;(e) adding additives of in-can biocide Nipacide CFF MV, defoamers TegofoamexK3, followed by adding neutralizer Liquor Ammonia that is followed by filtrationgiving said binder emulsion formulation of particle size of 80-130 nm preferably90-105 nm with glass transition temperature of 19-21 degree C and enabling anemulsion film that is bits free, non-tacky and clear with Bluish white appearance.Preferably in said process for manufacture of texture coating formulation whereinsaid step (ii) of providing sand formulation comprises adding coarser dolomite,dolomite sand and marble powder as filler / extender in select levels of 5-30 wt.%Dolomite 240 mesh, 10-50 wt.% Dolomite Sand 30 / 80 mesh, 5-20 wt.%Dolomite Sand 16 / 30 mesh, 1-10 wt.% Dolomite Sand 3 MM, 1-10 wt.%Dolomite Sand 6 / 8 / 12 mesh, and 5-40 wt.% marble powder 18 / 240Mesh of toobtain select sand formulation.According to another preferred aspect of the process for manufacture of texturecoating formulation wherein said texture coating formulation by incorporatingsaid binder emulsion and said sand formulation is based on the followingsequence of blending steps comprising:(a) adding Water, defoamer, non-ionic surfactant, dispersing additive and biocidein a blender followed by slow addition of Bentonite organo clay and mixed for 10mins to form a uniform jelly;(b) adding neutralizer and then carrying out mixing for 10 mins, addingdispersing agent, non-ionic surfactant and open time enhancer sequentiallyfollowed by binder emulsion formulation addition and mixing again for 10 mins,again followed by intermittently adding sand formulation / extenders includingDolomite, Marble powder and optionally China clay followed by adding selectlevels of binder emulsion formulation to maintain consistency and thereafteradding PU (polyurethane) thickener, coalescent, and demineralized water toobtain therefrom said texture coating formulation of consistency desired of saidformulation.BRIEF DESCRIPTION OF FIGURESFigure 1: illustrates efflorescence test results for (a) Texture paint 1 with Latex Aas per the present invention and (b) commercial sample that shows completewetting, tested as per Test method C.DETAILED DESCRIPTION OF THE INVENTIONAs discussed hereinbefore, the present invention provides for texture coating formulation preferably suitable for trowel application comprising a select Veovaacrylic binder in select dosage levels, and includes sand formulation having wide sized sandy fillers / extenders of select particle sizes leading to efficient packing when applied as a coating film enabling significantly low water absorption by the film.The select latex binder of the present invention involved in the coating formulation has a Tg between 5-15 °C and MFFT between 10-15 °C, including a silane modified tetramer of styrene-butyl acrylate-Veova-10-methacrylic acid with Veova-10 content only between 1-5% of the total formulation with the total active monomers between 38-50 wt% and silane content between 0.6%-1.0%.The acid content of the copolymer tetramer utilized is between 0.5-2% of the total formulation. The particle size of the latex is between 80-130 nm. All the aspects in the design of the latexes are key for water absorption and antiefflorescence performance of the texture coating. Texture coating formulation of the present invention comprises fillers / extenders including Marble powder 18 / 240Mesh, Dolomite sand 30 / 80 mesh, Dolomite 240 mesh, Dolomite sand 16 / 30mesh, Dolomite 3MM, Dolomite 6 / 8 / 12 mesh, which fillers synergizes with select silane modified tetramer of styrene-butyl acrylateVeova-10-methacrylic acid in combination that is critical towards the attainment of most efficient packing of the resultant coating enabling significantly low water absorption by the coating film.The water absorption is reduced by 50% and 2 times improvement inefflorescence of the coating film is observed.Examples:-Attainment of Waterproofing textureSynthesis of Emulsion Latex AThe Veova-Styrene-Acrylic emulsion is synthesized by conventional seededemulsion polymerization. Pre-heated demineralized water (DMW) is taken intothe reactor for processing of emulsion. Anionic surfactant Dowfax 2A1 is addedinto the reactor. Buffer agent Sodium Bicarbonate (SBC) is dissolved indemineralized water. Initiator Potassium persulfate is dissolved in demineralizedwater. Pre-emulsion contains anionic surfactant like Adeka SR 2090 and non-ionicsurfactant like Atpol 5731. Potassium persulfate (PPS) is dissolved indemineralized water and added into the pre-emulsion vessel. Monomers -Styrene, Butyl acrylate, Veova-10, Methacrylic acid is added one by one into thepre-emulsion vessel.5% seed is added into the reactor in between 78-82 degree C. Dissolved PPSsolution and SBC solution is charged into the reactor. After 15 mins, preemulsion addition is done for 240-260 mins. Free monomers are consumed by addition of digestion catalyst, TBHP and SFS by 90 min continuous addition.Emulsion is cooled down to 40-45 degree C. Additives added are In-can biocideNipacide CFF MV, defoamers Tegofoamex K3, and neutralizer Liquor Ammonia.Properties were checked after filtration of the batch. Particle size was found to bewithin 80-130 nm preferably around 90-105 nm. Glass transition temperature istested in DSC instrument found to be 19-21 degree C. Emulsion film is found tobe bits free, non-tacky and clear with Bluish white appearance, which is desired,as any alteration of monomer constitution and wt.% range and process pathwayleads to particle size variation and presence of bits on film and tackiness of films.Table 1-Texture coating / Paint formulationA typical texture paint TP-01 with 2 mm thickness is made by mixing thecomponents given in Table 2 below in a blender as described in select sequenceto maintain consistency desired of a texture paint formulation. Water, defoamerand biocide are added in the blender followed by slow addition of organo clay.The mixture is mixed for 10 mins and a uniform jelly is prepared. Neutralizer isadded and then mixing is carried out for 10 mins, then dispersing agent, nonionic surfactant and open time enhancer are added sequentially. Mixing is carried out for 10 mins, and extenders (Dolomite, Marble powder and China clay) areadded sequentially followed by latex A. Sand is added as per the sequence withthe addition of Latex A to maintain the consistency. After addition of all the sandand Latex A, PU thickener is added. Finally coalescent is added and demineralizedwater is added.The formulation can be extended to 1mm-3mm.Table 2Test Method A: Procedure to determine Water Absorption of Texture Filmattained:1. Take glass plate of Specific shape and size.(Note: All glass plates should have uniform size and weight.2. Weigh all glass plates and Record the readings for reference.3. Apply uniformly texture sample as such on glass plate (in duplicate set)by Trowel without scratch to achieve uniform thickness of Texture asdesired (as per spreading capacity of texture).4. Allow the applied panels to air dry properly for 7 Days at RoomTemperature.5. After 7 days drying, record the weight of glass plates with texture asInitial weight and then dip all plates in container containing water (Fullyimmerse in water).6. Remove all panels from container after 3 days and soak the extra watergently from panel surface with Cotton / Muslin cloth.7. Record the weights of all panels as Final weight after 1 Hr, 2 Hrs, 4 Hrs,24 Hrs, 48 Hrs, 5 Days and 7 Days, and calculate the percentage ofwater absorption as mentioned below:Percentage of Water absorbed by Texture Film = (Final Weight of Texture Panel - Initial Weight of Texture Panel) / Initial Weight of texture panel X 100Test Method B: Procedure to Perform Rilem Test on Texture Film: WaterAbsorption Under Low Pressure (Pipe Method)1. Apply the texture system: Primer + Texture (With Topcoat or withouttopcoat) as per mentioned test method.2. Allow it to air dry for 7 days then start to perform the test by applicationof Rilem tube.3. Record the results after 4Hrs, 24 Hrs and 96 Hrs (4days) with drop inlevel of water in Rilem tube.4. Test to be conducted always in comparison with Control Sample.Test Method C: Procedure to check Efflorescence Resistance of Texture:Highly porous mortar method of application:1. Take highly porous concrete mortar bed having dimensions of 150 X 150X 20 mm.2. Apply texture system on Mortar bed (application as per covering capacity): Primer + Texture + Topcoat (2 coat) with Terracotta Shade / Blue Shade(Shades are only for better observations of efflorescence).3. Allow it to air dry for 7 days. After complete drying, place this mortar bedin 15 % NaCl Solution in water.4. Note down the observation for any defect like efflorescence, blisters,cracking etc periodically and record it for 15 days to 2 months incomparison with control sample.The generic binder synthesis was carried as per the procedure in Table 1. Thebinder prototypes were made, and paint was made as per the Table 2 above. Theindividual components of the binder are shown in Table 3 varied within the scopeof Table 1 ingredients for studying the impact on water resistance. Latex B andLatex C shows the importance of vinyl trimethoxy silane in the formulationespecially indicated by Latex C which leads to the desired decrease in waterabsorption. Comparative binder formulation Latex D and E shows the role ofpolymerizable surfactant through Latex D. As both the formulations are same,only the surfactant type is different, it can be inferred that the polymerizablesurfactant in combination is essential for achieving the low water absorption butis required to be involved at lower amounts due to cost considerations. Theintroduction of Veova-1 synergistically further decreases the water absorption asshown in Latex A.Table 3-Water absorption tested for the texture paint as per the methoddescribed in method 1 except 3 days curing and 96 hrs of immersion inwater. Batch no. describes the Latex formulation used in the paint.Emulsion dosage in the formulation is 12%To understand the impact of binder in the formulation, comparison is made ofcommercial texture paint and the commercial paint with Latex A (Table 4). Thewater absorption goes down significantly. The texture Paint with the commerciallatex shows poor water resistance as compared to the Texture paint 1 as definedby Table 1 involving Latex A.Table 4- Water absorption of texture paint with Latex A and Commerciallatex.The select binder content in the formulation is between 8%-14%. Increase in thebinder content will negatively impact the application properties, material lossduring application. The formulation also becomes economically unviable. For lowwater absorption, 12-14% binder emulsion formulation is required. In Table 5below, water absorption of the texture paint at dosage 10.75% and 12% ismeasured. At 12% dosage, significant improvement is seen. Rilem testing hasnot shown the difference as shown in Table 6.Table-5 Water absorption showing select dosage of the Latex A in thetexture paint formulation.Table-6 Rilem testing showing select dosage of Latex A in texture paintformulationThe sand / filler formulation used as per the formulation of Table 8 is unique andimpactful as can be seen in water absorption results of Table 9 below. Anychange of the formulation causes loss of impact. Table 9 further shows that thetexture paint 1 of the present invention involving the select binder A but with theconventional sand formulation as shown in Table 7 shows significantimprovement in water absorption decrease as compared to the standard sample(Commercial texture paint sample) that can be attributed to the present selectlatex binder A, however, after 48 hrs the film detached. Moreover, the presenttexture paint A with latex binder A together with unique sand formulation ofTable 8 shows further improvement in water absorption test, as compared totexture paint A of the present invention with sand formulation of Table 7. It canbe also inferred from the results of Table 9 that commercial sample with presentunique sand formulation significantly improves water absorption test bydecreasing water absorption.Table-7 Sand formulation of the commercial texture paintsTable-8 Unique Sand formulation of the Texture paint 1This sand formulation specified in select wt.% ranges is unique in being key towater absorption and anti-efflorescence performance of the resulting texturecoating formulation due to allowing efficient packing based on said select sandformulation where water absorption could be much reduced as exemplified. Anychanges in the type of material and wt.% ranges destroys such stated packing. Table-9 Water absorption table to demonstrate the sand compositionimpact on the formulationIt is thus possible by way of the present advancement to provide for texturecoating formulation preferably suitable for trowel application comprising a selectVeova-acrylic binder in select dosage levels, and includes sand formulationhaving wide sized sandy fillers / extenders of select particle sizes leading toefficient packing when applied as a coating film enabling significantly low waterabsorption by the film.

Claims

1. Texture paint / coating formulation comprising synergistic co-acting combination of select (i) silane modified Veova-acrylic tetramer binder emulsion formulation and (ii) sand formulation based on coarser dolomite, dolomite sand and marble powder as filler / extender.

2. The texture coating formulation as claimed in claim 1 suitable for trowel application wherein said silane modified Veova-acrylic tetramer binder emulsion formulation (i) comprises silane modified tetramer of monomers styrene - butyl acrylate - Veova-10 - methacrylic acid with Veova-10 content between 1-10 wt. %, total monomers between 38-50 wt.% and silane content between 0.2-3 wt. % of the total binder emulsion formulation also having polymerizable surfactant in the levels of 0.05-0.5 wt.%.

3. The texture coating formulation as claimed in claims 1 or 2 wherein Veova-10 content only between 1-5 wt.%, silane content only between 0.6-1.0 wt.% and methacrylic acid content between 0.5-2 wt.% of the total binder emulsion formulation with particle size of the binder emulsion in the range of 80-130 nm are key to water absorption and anti-efflorescence performance of the resulting texture coating formulation due to efficient packing together with conventional / select sand formulation where water absorption is reduced by 50% with 2 times improvement in efflorescence of the resulting coating observed as compared to conventionally known texture paint samples.

4. The texture coating formulation as claimed in claims 1-3 wherein said binder emulsion formulation is present in the levels of 4-40 wt. % depending on scratch designs to be formed on substrate upon trowel application and is preferably present in the levels of 8-14 wt.% also adapted to reduce water absorption of conventional texture paints when added to it.

5. The texture coating formulation as claimed in claims 1-4 wherein said sand formulation (ii) comprises coarser dolomite, dolomite sand and marble powder as filler / extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10-50 wt.% Dolomite Sand 30 / 80 mesh, 5-20 wt.% Dolomite Sand 16 / 30 mesh, 1-10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6 / 8 / 12 mesh, and 5-40 wt.% marble powder 18 / 240Mesh of the total sand formulation.

6. Sand formulation adapted to reduce water absorption in texture coating formulations comprising coarser dolomite, dolomite sand and marble powder as filler / extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10-50 wt.% Dolomite Sand 30 / 80 mesh, 5-20 wt.% Dolomite Sand 16 / 30mesh, 1-10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6 / 8 / 12 mesh, and 5-40 wt.% marble powder 18 / 240Mesh of the total sand formulation optionally including china clay in amounts of 0-10 wt.%, said sand formulation when incorporated in conventional texture paints could also enable reduction in water absorption.

7. A process for manufacture of texture coating formulation as claimed in claims 1-5 comprising the steps of providing (i) silane modified Veova-acrylic tetramer binder emulsion formulation and (ii) sand formulation based on coarser dolomite, dolomite sand and marble powder as filler / extender in the levels of 4-40 wt. % depending on scratch designs to be formed on substrate and blending the same to attain said texture coating formulation.

8. The process for manufacture of texture coating formulation as claimed in claim 7 wherein said step (i) of providing silane modified Veova-acrylic tetramer binder emulsion is based on the following sub-steps based on seeded emulsion polymerization (a) Pre-heating demineralized water in a reactor at 78-82 degree C followed by adding anionic surfactant alkyldiphenyloxide Disulfonate for emulsion processing; (b) dissolving the Initiator Potassium persulfate (PPS) in demineralized water; (c) dissolving buffer agent Sodium Bicarbonate(SBC) in demineralized water; (d) preparing a pre-emulsion separately containing anionic surfactant like polymerizable surfactant and non-ionic surfactant like Alcohol ethoxylate (30M), adding Potassium persulfate dissolved in demineralized water followed by adding monomers-Styrene, Butyl acrylate, Veova-10, Methacrylic acid, Vinyl Trimethoxy Silane one by one into the pre-emulsion; (e) adding 5% pre-emulsion seed into the reactor followed by adding dissolved PPS solution and dissolved SBC solution (b) and (c) into the reactor and post 15 mins rest of pre-emulsion addition is done for 240-260 mins for seeded emulsion polymerization to proceed due to which free monomers are consumed by addition of digestion catalyst, Tertiary butyl hydroperoxide (TBHP) and Sodium formaldehyde sulfoxylate(SFS) by 90 min of continuous addition; (f) cooling the emulsion down to 40-45 degree C; (e) adding additives of in-can biocide Nipacide CFF MV, defoamers Tegofoamex K3, followed by adding neutralizer Liquor Ammonia that is followed by filtration giving said binder emulsion formulation of particle size of 80-130 nm preferably 90-105 nm with glass transition temperature of 19-21 degree C and enabling an emulsion film that is bits free, non-tacky and clear with Bluish white appearance.

9. The process for manufacture of texture coating formulation as claimed in claim 7 or 8 wherein said step (ii) of providing sand formulation comprises adding coarser dolomite, dolomite sand and marble powder as filler / extender in select levels of 5-30 wt.% Dolomite 240 mesh, 10-50 wt.% Dolomite Sand 30 / 80 mesh, 5-20 wt.% Dolomite Sand 16 / 30 mesh, 1-10 wt.% Dolomite Sand 3 MM, 1-10 wt.% Dolomite Sand 6 / 8 / 12 mesh, and 5-40 wt.% marble powder 18 / 240Mesh of to obtain select sand formulation.

10. The process for manufacture of texture coating formulation as claimed in claims 7-9 wherein said texture coating formulation by incorporating said binder emulsion and said sand formulation based on the following sequence of blending steps comprising: (a) adding Water, defoamer, non-ionic surfactant, dispersing additive and biocide in a blender followed by slow addition of Bentonite oregano clay and mixed for 10 mins to form a uniform jelly; (b) adding neutralizer and then carrying out mixing for 10 mins, adding dispersing agent, non-ionic surfactant and open time enhancer sequentially followed by binder emulsion formulation addition and mixing again for 10 mins, again followed by intermittently adding sand formulation / extenders including Dolomite, Marble powder and optionally China clay followed by adding select levels of binder emulsion formulation to maintain consistency and thereafter adding PU (polyurethane) thickener, coalescent, and demineralized water to obtain therefrom said texture coating formulation of consistency desired of said formulation.