PRE-APPLIED WATERPROOF BONDING COATINGS AND SYSTEMS AND METHODS INCLUDING SAME - Patent application

Abstract

The waterproof bond coating composition includes a synthetic film-forming polymer with a very small average particle size in an emulsion system, which allows the coating to be used on a variety of substrates, including formwork, conventional and pre-applied waterproof membranes, and even on other coatings to provide an excellent waterproof bond with post-cast concrete. The waterproof bond coating composition can be applied in liquid form on a variety of substrates and building surfaces. They can be used in the manner of a bond coating layer or additional bond coating layers when applied on a membrane installed at the building site, or when incorporated on a membrane as the outermost layer at a membrane manufacturing plant. The waterproof bond coating can be used to improve water resistance and weather resistance in both conventional and pre-applied waterproof membranes.

Description

[Technical field]

[0001] The present invention relates to the field of waterproofing compositions, and more particularly to coating or layering compositions having film-forming properties such that they can be used as pre-applied waterproof bond coating compositions, which in exemplary embodiments can be applied as a liquid onto a substrate or building surface, or applied onto a pre-applied or post-applied waterproof membrane, or used as a pre-applied waterproof bond coating layer incorporated during the manufacture of a pre-applied waterproof membrane laminate, thereby imparting properties including UV and water resistance, in particular waterproof bonding capabilities to subsequently applied (post-cast) concrete to the coating composition, in these different applications. [Background technology]

[0002] "Pre-applied" membranes are known in the waterproofing art. Such waterproofing membranes are first installed on a substrate or building surface and then used to form a waterproof bond with "post-cast" concrete, or in other words, applied to and cured (i.e., hardened) and bonded to fresh concrete that is subsequently poured, sprayed (e.g., shotcrete), or otherwise installed.

[0003] For example, in U.S. Patent No. 4,994,328, Cogliano disclosed a waterproofing membrane that could be adhered to freshly poured concrete, an early example of "blind-side" or "pre-applied" waterproofing. The membrane included a bituminous adhesive layer coated with a mixture of water-insoluble polymers, such as polyvinyl alcohol, silica, and glycerin. The coating allegedly protected the adhesive layer while allowing the post-cast concrete to bond to the adhesive.

[0004] Bartlett, in US Pat. No. 5,316,848, discloses a preapplied waterproof membrane having a carrier layer, a pressure sensitive adhesive layer (PSA), and a styrene butyl acrylate protective coating that may be applied as a latex over the PSA.

[0005] In US Patent No. 5,496,615, Bartlett discloses a similar pre-applied membrane onto which a protective coating of sand, calcium carbonate, cement, and titanium dioxide particles are dispersed. The particulates range in size from 0.1 to 1000 um, preferably 0.2 to 100 um, and are dispersed onto the protective coating.

[0006] In WO2017058154, Chen et al. disclose a pre-applied membrane having a carrier sheet, a PSA layer, a layer of inorganic silica-containing particles partially embedded in the PSA layer, and a coating layer attached to the non-embedded portions of the inorganic particles, the coating layer intended to prevent complete embedding in the PSA layer when the membrane is rolled up.

[0007] In WO 2020 / 118515, Chen et al. disclosed a pre-applied membrane having a carrier sheet, a PSA layer, aluminum oxide trihydrate particles partially embedded in the PSA layer, and an outer polymeric protective coating layer attached to the particle layer. The top coating of Chen et al. provides resistance to dust, dirt, water ingress, high temperatures and other deleterious conditions while also providing excellent bond strength with post-cast concrete (see paragraphs

[0010] -

[0013] of WO 2020 / 118515).

[0008] The foregoing technical documents are owned or were owned by the common assignee of the present invention (and / or its predecessor company). These summaries are provided for illustrative purposes and should not be construed as an admission of material relevance to determining the patentability of the present invention. Summary of the Invention

[0009] In the present invention, the inventors seek to achieve superior performance of a waterproof bond coating composition that can be used as an outermost coating layer on a pre-applied waterproof membrane to achieve superior waterproof bond properties when used to accept concrete poured against the coating composition in layer form, and / or can also be used as a coating that is applied separately on-site (e.g., on an installed pre-applied membrane, for example).

[0010] The exemplary waterproof bonded coatings of the present invention may also be used to establish a monolithic waterproof bonded barrier even when using different components such as membranes and coatings and when they are installed on different surfaces (e.g., formwork, soil retention systems, slabs, membranes on building surfaces).

[0011] The waterproof bonded coating composition of the present invention can be used as a stand-alone (reverse tanking) waterproofing system by itself, or in other words, the coating composition can be applied directly onto a building or civil engineering substrate, or formwork surface to establish a pre-applied waterproofing membrane and bond to the concrete that is subsequently applied to the coating composition (post-cast).The coating composition of the present invention is believed to be effective for pre-applied applications even when applied by itself onto a variety of substrates, such as formwork, building surfaces (e.g., foundations, walls), or civil engineering surfaces (e.g., tunnel walls, wall cladding, etc.), or onto coatings or laminates that are not pre-applied.

[0012] The waterproof bond coating composition of the present invention is believed to offer greater versatility in that it may be used by itself, such as by one or more separate coating applications, or may be used directly on a substrate or architectural surface, and has excellent UV and water immersion resistance while achieving strong bonding with post-cast concrete (e.g., subsequently spray-applied or poured) directly onto the coating composition. The waterproof bond coating composition may be applied, for example, onto the PSA layer and / or waterproof bond coating layer of a rollable / non-rollable waterproof (laminate) membrane at the plant where such membrane is manufactured, or they may be applied at the construction site.

[0013] In a further exemplary embodiment, the waterproof bond coating composition may include additional pigments or white pigments to provide further protection for the waterproof bond coating layer and / or PSA layer and / or the waterproof bond coating layer of a pre-applied membrane installed at a construction site. In yet another exemplary embodiment, the waterproof bond coating composition of the present invention may be applied over conventional waterproof membranes not intended or designed for pre-applied applications, either at a factory or at a construction site, to convert them into pre-applied membranes that form a waterproof bond with post-cast concrete.

[0014] The waterproof bond coating composition of the present invention may also be spray applied onto cladding and / or waterproof drainage materials, and / or geotextiles, vapor barriers, foam materials such as those used in foundation wall or tunnel waterproofing applications, to bond with shotcrete or concrete which is sprayed or extruded or otherwise poured against the tunnel interior wall or membrane assembly to form a waterproof bond with such shotcrete or extruded or poured concrete.

[0015] The terms "bond," "waterproof bond," "waterproof bond," "bonding capacity," and the like, when used in reference to the contact between the coating composition of the present invention and post-cast concrete, are understood to be a fully adherent or waterproof bond capable of preventing lateral water migration. This means that after the composition is applied onto a substrate, form, membrane, or other surface, water from leaks through defects or joint openings in the membrane, perforations, or other openings in the membrane cannot migrate to cracks or openings (e.g., pipe conduits) in the space between the coating composition layer and the post-cast concrete layer where water can enter the concrete structure.

[0016] In an alternative exemplary embodiment, the waterproof bond coating composition may be applied to or used within a pre-applied waterproof membrane laminate to provide increased protection and / or improve bonding with the fresh concrete post-cast to the membrane. For example, the coating composition of the present invention, preferably containing a white pigment, filler, or mixtures thereof, may be coated onto the membrane at a factory or installation site to provide improved UV and water ingress protection while also allowing for excellent bonding capabilities with the fresh concrete that is post-cast to the coating.

[0017] A protective coating composition having a relatively large film-forming polymer particle size is shown in Figure 1, while Figure 2 shows a waterproof coating composition including relatively small synthetic polymer particles. The inventors believe that the use of small film-forming polymer particles has a greater tendency to reduce the likelihood of voids forming or occurring in the resulting formed film, and that in some exemplary embodiments of the invention, smaller particles can be advantageously used in combination with larger particles to provide benefits with respect to establishing a waterproof bond between the coating layer and the post-cast concrete, thus establishing a higher packing density that can benefit water resistance.

[0018] When used in the context of latex or latex emulsion, the term "polymer particles" is understood to refer to a stabilized polymer emulsion in which polymer particles are dispersed within the aqueous phase of the emulsion.Exemplary polymers can be selected from polyvinyl acetate, acrylates (e.g., polymethacrylates, polyacrylates), acrylates with reactive functional groups (e.g., hydroxyl groups, acid groups, silane groups), acrylate copolymers (e.g., acrylate / acetate copolymers, acrylate / styrene copolymers, acrylate / silicone copolymers, acrylate / polyurethane copolymers, acrylate / epoxy copolymers), and mixtures thereof.

[0019] When used in reference to a latex or latex emulsion, the term "polymer particle size" and the like can be measured by common light scattering techniques to determine the average particle size and distribution. The average particle size of the polymer particles in a latex emulsion can be expressed as the volume or weight average diameter Dv50, which is defined as the size in microns that divides the particle size distribution, where 50% of the weight or volume is above this diameter and 50% of the weight or volume is below this diameter.

[0020] Thus, in an exemplary embodiment, the present invention provides a method for establishing a waterproof bond with post-cast concrete, comprising:

[0021] (A) providing a substrate selected from a form (e.g., wood lagging, wooden form or mold, or a fabric, geotextile, drainage board, or mat disposed over a wooden form or mold, wood lagging, or other substrate), a waterproofing membrane established by application of a previous coating composition, or a rollable / non-rollable sheet membrane having a carrier layer, a building surface, a civil engineering surface, or any combination of the foregoing substrates;

[0022] (B) applying a waterproof bond coating composition onto a substrate to establish a waterproof bond to concrete subsequently poured to the substrate, the aqueous synthetic polymer emulsion system comprising (i) at least one film forming synthetic polymer present in an amount of 5% to 100%, preferably in an amount of 50% to 100%, more preferably in an amount of 80% to 100%, based on the total weight of the aqueous synthetic polymer emulsion system, wherein the at least one film forming synthetic polymer has an average particle size in the range of 5 to 150 nanometers, and optionally (ii) a surfactant in an amount of 0 to 1% or less, preferably 0 to 0.5% or less, more preferably 0 to 0.1% or less, based on the total weight of the aqueous synthetic polymer emulsion system.

[0023] In a further exemplary method, concrete is then poured against the waterproof bond coating composition side and allowed to set against the coating composition.

[0024] In another exemplary embodiment, the present invention provides a waterproof bond coating composition comprising an aqueous synthetic polymer emulsion system, the aqueous synthetic polymer emulsion system comprising at least one film-forming synthetic polymer present in an amount of 5% to 100%, preferably in an amount of 50% to 100%, more preferably in an amount of 80% to 100%, based on the total weight of the aqueous synthetic polymer emulsion system, wherein the at least one film-forming synthetic polymer has an average particle size in the range of 5 to 150 nanometers, and optionally a surfactant in an amount of 0 to 1% or less, preferably 0 to 0.5% or less, more preferably 0 to 0.1% or less, based on the total weight of the aqueous synthetic polymer emulsion system.

[0025] In another exemplary embodiment, the present invention provides a waterproof membrane having at least one carrier sheet, preferably at least one pressure-sensitive adhesive layer, an optional protective coating layer (e.g., a layer of particles, a layer of elastomeric coating, or a combination thereof), and the above-described waterproof bond-coating composition of the present invention made from an aqueous synthetic polymer emulsion system. The exemplary membrane can be provided as a rollable / unrollable sheet-like laminate that can be made using ingredients as previously known and used in the art of pre-applied membranes, or it can be a flexible carrier sheet with a pre-formed pressure-sensitive (PSA) layer attached adjacent thereto (e.g., rollable at a factory for transport in a box or bag to a construction site, where it is unwound for installation). This membrane with a PSA layer and optional protective coating (e.g., elastomeric coating, particles, or mixtures thereof) can be coated with the waterproof bond-coating composition of the present invention at the factory where the waterproof membrane is manufactured, or at the construction site after the membrane is attached to a formwork, building surface (e.g., substructure), or civil engineering surface (e.g., tunnel surface, membrane, and / or drainage device). The waterproofing membranes, whether pre-applied or of a conventional nature, may be supplied with or without a removable release sheet (with or without removable edge release strips along one or both longitudinal edges of the membrane to cover the edge adhesive portions intended to be bonded to an adjacent membrane or to a substrate such as a formwork or wall), depending on the design choice.

[0026] The invention accordingly comprises features of construction, combination of elements, and arrangement of parts that are further exemplified in the following detailed description. [Brief description of the drawings]

[0027] An understanding of the advantages and features of the exemplary embodiments disclosed herein may be more readily appreciated when the following written description of the exemplary embodiments is considered in conjunction with the drawings.

[0028] [Figure 1] FIG. 2 is a representative illustration of a large particle size synthetic polymer emulsion, shown as having a relatively large void volume between the synthetic polymer particles when the polymer emulsion is dried to form a film layer. [Diagram 2] A representative diagram of an exemplary smaller synthetic polymer particle size emulsion according to the present invention, placed to the right of the diagram in FIG. 1 for purposes of comparison of diagrams of the same size, shows that when the emulsion is dried to form a film layer, even when used with a larger particle size of larger synthetic polymer particles, relatively small voids are created between the smaller synthetic polymer particles because the smaller synthetic polymer particle size helps to fill the void volume (air space) between the synthetic polymer particles when the film is formed. [Diagram 3] Placed immediately below the diagram in FIG. 1 for purposes of comparison of same sized diagrams is a representative diagram of a synthetic polymer particle size emulsion having a substantial percentage of small particle size (e.g., the polymer is 5%-100% by volume of the emulsion, more preferably 80%-100% by volume, and has an average particle size in the range of 5-150 nanometers), which is believed to result in a higher degree of UV and water resistance when the emulsion is dried to form a film with better packing density of the small and large particles compared to films made from latexes with larger particle sizes. (For ease of comparison between FIGS. 1-3, FIG. 3 shows mostly small sized particles to suggest the advantage of close packing). [Figure 4] FIG. 2 is a cross-sectional view of an exemplary silane functional group on a small synthetic polymer particle in an exemplary waterproof bond coating composition of the present invention. [Diagram 5]FIG. 1 is a partial cross-sectional view, not to scale, of an exemplary waterproof membrane (10) of the present invention having at least one carrier sheet layer (shown at 12), preferably a pressure sensitive adhesive layer (shown at 14), optionally a protective coating layer (shown at 16), such as a particulate coating layer, an elastomeric coating layer, or mixtures thereof (shown generally at 16), and an exemplary waterproof bond coating (shown at 20) of the present invention used as an outermost (facing the top of the page of the drawing) layer to which post-cast concrete may be applied. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings which form a part hereof, and which show, by way of illustration, specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.

[0030] As used in this specification and the appended claims, the singular forms "a," "and," and "the" include plural referents unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term "or" is generally used in its sense including "and / or" unless the context clearly dictates otherwise.

[0031] As used herein, "about" means approximately or near, and in the context of a stated numerical value or range, means ±15% of the numerical value. In exemplary embodiments, the term "about" can include conventional rounding to significant digits of the numerical value. Additionally, the phrase "about 'x' to 'y'" includes "about 'x' to about 'y'".

[0032] The term "pre-applied" is typically used herein to refer to a coating or membrane that is first placed against a substrate, such as a form or wall, and that it is intended that the plastic concrete is subsequently poured against the coating or membrane (which may be referred to as "post-cast") and that it bonds to such techniques for "blind-side" or "reverse stanking" waterproofing.

[0033] It is intended that concrete post-cast against the pre-applied waterproof bond coating composition of the present invention will form a waterproof bond such that migration of moisture penetrating between the contacting surfaces of the concrete and the coating composition is minimized and prevented.

[0034] An exemplary waterproof bond coating composition of the present invention is established using a water-based synthetic polymer emulsion system, in which one or more film-forming synthetic polymers are used with particle sizes and size ranges carefully selected to establish a tight barrier to moisture when the polymers solidify / cure to form a film. As shown by the presence of smaller particle sizes (compare the smaller particles shown in FIG. 3 to the larger particles shown in FIG. 1), the inventors demonstrate the fact that void spaces (air gaps or potential leak paths through the polymer film) can be minimized or presented compared to using only the larger polymer particle sizes shown in FIG. 1. The use of smaller polymer particles helps fill the gaps between the larger particle sizes, as shown in FIG. 2.

[0035] More preferred by the inventors is the use of a film-forming synthetic polymer having an average particle size mainly in the smallest size range. For example, the film-forming synthetic polymer should have an average size in the range of 5 to 150 nanometers, and the particle polymer of this size should constitute 5% to 100%, preferably 50% to 100%, more preferably 80% to 100% of the total weight of the aqueous synthetic polymer emulsion system.

[0036] It is understood that the average particle size and particle size distribution of a polymer emulsion system can be determined by conventional techniques such as light scattering.

[0037] Exemplary synthetic polymers contemplated for use in the present invention can be selected from acrylates, acrylates with reactive functional groups, polyvinyl acetates, acrylate / vinyl acetate copolymers, acrylate / styrene copolymers, acrylate / silicone copolymers, acrylate / polyurethane copolymers, acrylate / epoxy copolymers, and mixtures thereof. Mixtures of acrylates and acrylate / silicone are preferred.

[0038] Also preferred are mixtures of any of the foregoing homopolymers or copolymers, preferably where one or both contain UV resistant functional groups.

[0039] Exemplary waterproof bond coating compositions of the present invention may also include one or more fillers selected from calcium carbonate, magnesium carbonate, alumina trihydrate, alumina oxide, dolomite, wollastonite, barium sulfate, crystalline or amorphous silica, clay, talc, bentonite, diatomaceous earth, barite, magnesium silicate, or mixtures thereof.

[0040] The exemplary waterproof bond coating composition of the present invention optionally, but preferably, includes one or more white pigments (which may include fillers as specified in the list above). Preferred white (or reflective) pigments contemplated for use in the present invention are selected from titanium dioxide, antimony oxide, zinc sulfide, zinc oxide, white cement, organic hollow sphere pigments, white cement, or mixtures thereof. Thus, in a further exemplary embodiment, one or more white pigments can be incorporated into the waterproof bond coating composition.

[0041] In another exemplary embodiment, the waterproof bond coating composition having an aqueous synthetic polymer emulsion comprises one or more white pigments, fillers, or both in the range of 10% to 80%, more preferably in the range of 30% to 40%, based on the total weight of the waterproof bond coating.

[0042] The preferred particle size of the white pigments and fillers is in the range of 20 nm to 50 um, more preferably in the range of 40 nm to 15 um, and are preferably used in the waterproof bond coating composition of the present invention in an amount of 10% to 80% filler by dry weight (e.g., based on a percentage of the dry coating film).

[0043] In other exemplary embodiments, thickeners may be used to stabilize the use of white pigments, fillers, or mixtures thereof. Exemplary thickeners are selected from hydroxyethyl cellulose (HEC), hydroxymethyl hydroxyethyl cellulose (HMHEC), and other aqueous-based thickeners, and mixtures thereof.

[0044] The inventors note that any range of numbers described in the specification or claims, e.g., expressing a particular set of properties, units of measurement, conditions, physical states, or percentages, is intended to expressly and literally incorporate herein by reference or otherwise any number falling within such range (including any subset of numbers within any range so described). For example, whenever a numerical range having a lower limit, RL, and an upper limit, RU, is disclosed, any number R falling within that range is specifically disclosed. In particular, the following numbers R within the range are specifically disclosed: R=RL+k(RU-RL), where k is a variable ranging from 1% to 100% in 1% increments, e.g., k is 1%, 2%, 3%, 4%, 5%, ... 50%, 51%, 52%, ... 95%, 96%, 97%, 98%, 99%, or 100%. Additionally, any numerical range represented by any two values ​​of R calculated above is also specifically disclosed.

[0045] Exemplary embodiments of the invention are described below along with various exemplary aspects of the embodiments. Exemplary methods for establishing a waterproof bond with post-cast concrete are described along with exemplary waterproof bonding coating compositions, as well as exemplary packaging systems in which liquid and / or sheet-like membranes may be supplied as part of a package or system along with the exemplary waterproof bonding compositions of the invention. It is understood that exemplary details or aspects of the various methods for establishing a waterproof bond with post-cast concrete apply to the exemplary waterproof bonding compositions and packages of the invention, and vice versa, in other words, exemplary aspects or details specified for the compositions or packages apply to the various embodiments of the methods of the invention.

[0046] In a first exemplary embodiment, the present invention provides a method for establishing a waterproof bond with post-cast concrete, comprising: (A) providing a substrate selected from a formwork, a waterproofing membrane established by application of a previous coating composition (e.g., SILCOR™ polyurethane liquid, DECSEAL™ acrylic liquid, INTEGRITANK™ and ELIMINATOR™ brand coatings), or a rollable / non-rollable sheet membrane having a carrier layer (e.g., PREPRUFE™ brand, BITUTHENE™ brand, or PV™ 100 brand rollable pre-applied membranes available from GCP Applied Technologies Inc., having offices in Alpharetta, Georgia and Wilmington, Massachusetts, USA), a building surface (e.g., foundation, floor, wall, corner, penetration), a civil engineering surface (e.g., soil retention, tunnel wall, or cladding), or any combination of the foregoing substrates; (B) applying a waterproof bond coating composition onto a substrate to establish a waterproof bond to concrete subsequently poured to the substrate, the aqueous synthetic polymer emulsion system comprising (i) at least one film forming synthetic polymer present in an amount ranging from 5% to 100%, preferably in an amount ranging from 50% to 100%, more preferably in an amount ranging from 80% to 100%, and most preferably in an amount ranging from 90% to 100% based on the total weight of the aqueous synthetic polymer emulsion system, wherein the at least one film forming synthetic polymer has an average particle size in the range of 5 to 150 nanometers, and optionally (ii) a surfactant in an amount of 0 to 1% or less, preferably 0 to 0.5% or less, more preferably 0 to 0.1% or less, based on the total weight of the aqueous synthetic polymer emulsion system.

[0047] Exemplary aspects within the first exemplary embodiment above include various applications or application methods: for example, (i) use of the waterproofing bond coating composition to form a single waterproofing bond coating all by itself on a formwork or building or civil engineering surface (e.g., referred to as a pre-applied application or otherwise as a river stanking application); (ii) additional protection from post-cast concrete when applied over a pre-applied (river stanking) form membrane (e.g., a laminate membrane that is rollable / non-rollable with the use of a flexible carrier sheet) that is already installed on a substrate at a construction site, or whereby the coating composition is applied over a sheet-like laminate waterproofing membrane at a factory where such membranes are made; and (iii) additional protection when applied over non-reverse stanking membranes to convert them to pre-applied (reverse stanking) waterproofing applications; (iv) additional protection when applied over liquid applied coating membranes that are not pre-applied (reverse stanking) type membrane forming liquid applied coating compositions to convert them to river stanking capabilities; (v) additional protection when applied over liquid applied coating membranes that are pre-applied (reverse stanking) type membrane forming liquid applied coating compositions for additional protection and bonding ability with post cast concrete; and (v) the ability to combine a variety of different types of waterproofing compositions and systems, as described in sections (i)-(iv) above, into a monolithic protective barrier.

[0048] In the exemplary aspect of the first exemplary embodiment, in the step of providing a substrate, a waterproof laminate membrane is provided as the substrate. Such membrane preferably has a flexible carrier layer for carrying a pressure-sensitive adhesive (PSA) layer, and optionally an outer protective coating layer having inorganic or organic particles embedded on or within the outer surface of the PSA and / or protective coating.

[0049] In another exemplary aspect of the first exemplary embodiment, the aqueous synthetic polymer emulsion of the waterproof bond coating composition is preferably substantially free of surfactants, whereby the inventors prefer that the amount of surfactant, if any, is 0-0.5% or less based on the total weight of the aqueous synthetic polymer emulsion system, and most preferably the aqueous synthetic polymer emulsion contains 0-0.1% or less.

[0050] In a second exemplary embodiment, which may be based on the first exemplary embodiment, the present invention provides a method, wherein in applying the waterproof bond coating composition onto the substrate in step (B), the waterproof bond coating composition comprises at least one film-forming synthetic polymer, having an average particle size of the at least one film-forming synthetic polymer in the range of 5 to 150 nanometers, and is present in an amount of 5 to 100%, more preferably 50% to 100%. In a first aspect of this second exemplary embodiment, the at least one film-forming synthetic polymer having an average particle size in the range of 5 to 150 nanometers is present in an amount of 5% to 100%.

[0051] In a third exemplary embodiment, which may be based on any of the first to second exemplary embodiments, the present invention provides a method, wherein, upon applying the waterproof bond coating composition onto a substrate in step (B), the waterproof bond coating composition comprises at least one film-forming synthetic polymer, has an average particle size of the at least one film-forming synthetic polymer in the range of 5 to 150 nanometers, and is present in an amount of 80% to 100%.

[0052] In a fourth exemplary embodiment, which may be based on any of the above first to third exemplary embodiments, the present invention provides a method, wherein, when applying the waterproof bond coating composition onto a substrate in step (B), the waterproof bond coating composition comprises at least one film-forming synthetic polymer, and has an average particle size of the at least one film-forming synthetic polymer in the range of 5 to 150 nanometers, more preferably in the range of 5 to 100 nanometers, and is present in an amount of 80% to 100%.

[0053] In a fifth exemplary embodiment, which may be based on any of the above first to fourth exemplary embodiments, the present invention provides a method, wherein when applied onto the substrate in step (B), the waterproof bond coating composition is applied at a coverage of 20 to 2500 grams per square meter (gsm), more preferably in the range of 30 to 200 gsm, and most preferably in the range of 30 to 100 gsm, based on the total dry weight of the aqueous synthetic polymer emulsion system.

[0054] In a sixth exemplary embodiment, which may be based on any of the above first to fifth exemplary embodiments, the present invention provides a method, wherein the waterproof bond coating composition, when applied onto a substrate in step (B), has at least one polymer composition in an emulsion having a glass transition temperature of (-)20° C. or more and 100° C. or less, more preferably 85° C. or less, and most preferably 65° C. or less. This exemplary glass transition temperature range is believed to enhance the transport capability of the coating composition.

[0055] In a seventh exemplary embodiment, which may be based on any of the above first to sixth exemplary embodiments, the present invention provides a method, wherein the waterproof bond coating composition, when applied onto the substrate in step (B), has at least one polymer composition in an emulsion having a glass transition temperature of less than 0°. Such glass transition temperature characteristics are believed to promote good film formation and low temperature flexibility during installation.

[0056] In an eighth exemplary embodiment, which may be based on any of the above first to seventh exemplary embodiments, the present invention provides a method, wherein the waterproof bond coating composition, when applied onto the substrate in step (B), further comprises a polymer emulsion selected from a fluoroacrylate or fluorinated polymer, a copolymer having carboxyl and siloxane functional groups that can react or form strong interactions with cement, or a mixture thereof.

[0057] In a ninth exemplary embodiment, which may be based on any of the first to eighth exemplary embodiments above, the present invention provides a method, wherein the waterproof bond coating composition comprises one or more white pigments when applied onto a substrate in step (B). The exemplary white pigments contemplated for use in the waterproof bond coating composition of the present invention should function to reduce the surface temperature of the coating composition when applied to a substrate exposed to sunlight, thereby reducing or slowing down the degradation to the coating composition caused by sunlight exposure, as well as reducing or slowing down the degradation of any underlying waterproof coating or membrane located below the waterproof bond coating composition of the present invention. For example, the white pigment can be selected from titanium dioxide, antimony oxide, zinc sulfide, zinc oxide, white cement, organic hollow sphere pigment, or mixtures thereof.

[0058] In a tenth exemplary embodiment, which may be based on any of the above first to ninth exemplary embodiments, the present invention provides a method, wherein after applying the waterproof bond-coating composition on the substrate in step (B), the method further includes pouring concrete against the applied waterproof bond-coating composition (hereinafter "post-cast concrete"), and curing the post-cast concrete against the waterproof bond-coating composition.

[0059] In an eleventh exemplary embodiment, which may be based on any of the above first through tenth exemplary embodiments, the method includes pouring concrete against the installed waterproof bond coating composition, wherein the post-cast concrete is allowed to set and harden against the post-cast concrete, whereby a waterproof bond with the post-cast concrete is formed, and the waterproof bond between the coating composition and the post-cast concrete has a waterproof bond strength of greater than 3 pounds per linear inch when tested according to a modified ASTM D903-98(2017) (the test procedure involves pouring concrete against a waterproof membrane to form a bond between the coating and the concrete, and using a peel rate of 100 mm (4 in.) / min, whereby the waterproof membrane is modified by peeling from the concrete after the concrete is cured).

[0060] In a twelfth exemplary embodiment, the present invention provides a waterproof substrate produced according to the method of any of the above exemplary embodiments 1-11.

[0061] In a thirteenth exemplary embodiment, the present invention provides a waterproof bond coating composition comprising an aqueous synthetic polymer emulsion system, the aqueous synthetic polymer emulsion system comprising at least one film-forming synthetic polymer present in an amount of 5%-100%, preferably in an amount of 50%-100%, more preferably in an amount of 80%-100%, based on the total weight of the aqueous synthetic polymer emulsion system, wherein the at least one film-forming synthetic polymer has an average particle size in the range of 5-150 nanometers, more preferably in the range of 5-100 nanometers, and optionally a surfactant in an amount of 0-1% or less, preferably 0-0.5% or less, most preferably 0-0.1% or less, based on the total weight of the aqueous synthetic polymer emulsion system.

[0062] In an exemplary aspect of this thirteenth exemplary embodiment, the average particle size of the at least one film-forming synthetic polymer is in the range of 5-150 nanometers and is present in an amount of 5%-100%, more preferably 50%-100%, and most preferably 80%-100%, based on the total weight of the aqueous synthetic polymer emulsion system. Further exemplary aspects of the coating composition may use at least one film-forming synthetic polymer having these size and amount ranges in addition to having another emulsion system having another size and amount range.

[0063] In another exemplary aspect of the thirteenth exemplary embodiment above, the aqueous synthetic polymer emulsion system includes at least two average particle size ranges, a first average particle size range being in the range of 5-150 nanometers, preferably in the range of 5-100 nanometers, and a second average particle size range being in the range of 150-400 nanometers. In some cases, the presence of the two average particle size ranges can be confirmed using a light diffraction test, in which the first and second average particle size ranges are detected by separately identifiable light intensity peaks.

[0064] In a fourteenth exemplary embodiment, the present invention provides a waterproof membrane, comprising: (A) a carrier layer; (B) a pressure sensitive adhesive layer; (C) optionally a protective coating layer comprising particles, an elastomeric coating, or a mixture thereof; and (D) a waterproof bond coating composition comprising an aqueous synthetic polymer emulsion system, the aqueous synthetic polymer emulsion system comprising at least one film-forming synthetic polymer present in an amount of 5%-100%, more preferably in an amount of 50%-100%, and most preferably in an amount of 80%-100%, based on the total weight of the aqueous synthetic polymer emulsion system, wherein the at least one film-forming synthetic polymer has an average particle size in the range of 5-150 nanometers, more preferably in the range of 5-100 nanometers; and optionally a surfactant in an amount of 0-1% or less, preferably 0-0.5% or less, based on the total weight of the aqueous synthetic polymer emulsion system. In an exemplary aspect of this fourteenth exemplary embodiment, the average particle size of the at least one film-forming synthetic polymer is in the range of 5 to 150 nanometers and is present in an amount of 5% to 100%, more preferably 50% to 100%, and most preferably 80% to 100%, based on the total weight of the aqueous synthetic polymer emulsion system.

[0065] In another aspect of the above fourteenth exemplary embodiment, the waterproofing membrane includes at least one carrier sheet (sufficiently flexible to allow the membrane to be rolled for transportation and unrolled for installation at the construction site), a pressure sensitive adhesive (PSA) layer, an optional protective coating layer (e.g., particles, elastomeric coating, or combinations thereof), and the novel and inventive waterproofing bond coating composition described in detail above as an outermost layer for direct contact with the post-cast concrete that is applied to the waterproofing membrane.

[0066] FIG. 5 is a cross-sectional view of an exemplary waterproof membrane (10) laminate of the present invention, including a carrier sheet (12), a PSA layer (14), an (optional) protective coating layer (16), and an exemplary waterproof bond coating composition of the present invention (20) as described above.

[0067] Examples of carrier sheets (12) include polymeric films or films (e.g., multi-layer, coextruded films), fabrics (e.g., extrusion coated woven fabrics, nonwoven fabrics), or combinations thereof. Exemplary polymeric films, sheets, and fabrics may include polypropylene, polyethylene, ethylene propylene copolymers, ethylene-olefin copolymers, ethylene-vinyl acetate copolymers, polyvinyl acetate, poly(ethyl acrylate), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), polyethylene terephthalate (PET), polyvinyl chloride (PVC), polyamide, and combinations thereof. Preferably, the carrier sheet has an average thickness of 0.05 to 2.0 mm.

[0068] Examples of pressure sensitive adhesive (PSA) layers (14) include rubber modified bituminous adhesives such as butyl rubber, polyisobutylene, styrene-isoprene-styrene (SIS), styrene ethylene-butylene-styrene (SEBS), styrene-butadiene-styrene (SBS), styrene butadiene rubber (SBR), amorphous polyolefin (APO), and synthetic polymer adhesives (non-bituminous) adhesives, or mixtures of any of the aforementioned adhesives. Conventional average PSA layer thicknesses can be used, and average thickness measurements are most conveniently made after application of the PSA layer (14) onto the carrier sheet (12) film or web using a simple measuring caliper or other convenient measuring device to ensure a relatively uniform coating (or more specifically adhesive coating), before applying any protective coating layer (16) onto the PSA (14) and before applying a waterproof tie coating onto the membrane (10).

[0069] Examples of the (optional) protective coating layer (16) or layers include inorganic particles or polymeric synthetic (organic) particulate materials, such as may be selected from cement (e.g., white cement), which may be partially or fully hydrated, calcium carbonate, silica sand, sand, amorphous silica, slag, alumina trihydrate, alumina oxide, bottom ash, slate flour, granite flour, acylate resins and other polymeric synthetic particles, or mixtures thereof. The particles should preferably have an average diameter of 50 to 450 microns.

[0070] Although the present invention is described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the invention described and claimed elsewhere herein. Modifications and variations from the described embodiments exist. More specifically, the following examples are given as specific illustrations of exemplary embodiments of the claimed invention, and it should be understood that the invention is not limited to the specific details described in the examples. All parts and percentages, as well as the remainder of the specification, are by weight of the total coating / layer composition unless otherwise specified.

[0071] Examples / Experiments This example relates to the use of a waterproof bond coating composition as described above as the outermost coating of a pre-applied membrane used in a river tanking operation (i.e., with the carrier layer side attached to a substrate). Conventional pre-applied membranes typically have a carrier layer, a pressure sensitive adhesive (PSA) layer, and optional protective coatings (such as particle and / or elastomeric coatings), which provide the outer surface onto which the post-cast concrete is poured.

[0072] The exemplary waterproof bond coating composition of the present invention may be used additionally as an outermost coating over any protective coating, or may even replace or substitute for the protective coating, while improving the performance of the membrane with respect to achieving a strong waterproof bond with post-cast concrete, as previously explained above.

[0073] Within the context of this disclosure, the bond characteristic to concrete (hereinafter, "BTC") refers to the strength of the waterproof bond between an exemplary waterproof bond coating (applied on a pre-applied membrane) and post-cast concrete. This bond strength can be measured using a peel test according to ASTM D903-98(2017) (modified). (As mentioned elsewhere herein, the modified version of this test involves peeling the waterproof membrane coated with the waterproof bond coating from the concrete after the concrete has set, at a peel rate of 100 mm (4 in) / min. The adhesion of the (pre-applied) membrane to concrete is tested by pouring concrete against the outermost surface of a 3.8 cm x 15 cm (1.5 in x 6 in) membrane sample, allowing the concrete to set for 7 days, and then measuring the peel adhesion using an Instron™ mechanical testing machine at a peel angle of 180° and a peel rate of 100 mm (4 in) / min. The bond strength to concrete is measured on samples that have not been exposed to UV radiation (pristine).

[0074] Within the context of this disclosure, the term "setting" or "curing" of concrete refers to the amount of time required for the concrete to reach the desired compressive strength (≧about 3 kpsi). The BTC peel adhesion of the membrane is measured only when the concrete has reached sufficient "setting". Waterproofing assemblies in which certain embodiments of the current waterproofing bonded coatings are typically used include membrane specimens that bond to concrete while the concrete is setting. It is contemplated herein that for embodiments of the current waterproofing bonded coatings where bonding to concrete is desired, the concrete mix design is held constant and the concrete reaches the desired compressive strength after about 7 days of setting at 23°C (75°F). For simulation of cold weather, low temperature BTC tests may be performed in which concrete accelerators are used in the concrete mix design to accelerate setting at 50°F or below. Additional details of low temperature concrete setting, acceptable accelerators, and cold weather definitions can be found in ACI 306R-88. Peel tests may be performed over a range of temperatures or after various exposure tests such as water immersion or temperature cycling. The waterproofing membrane may also be subjected to various environmental conditions, such as outdoor exposure at various angles, intensive UV exposure, high humidity, or a combination of conditions, either prior to bonding to concrete or after formation of the concrete bonding layer. BTC peel adhesion is typically measured in Newtons of force per millimeter (pounds / inch), or N / mm (lbs / in), of the bonded waterproofing membrane. Preferably, the waterproofing system having the waterproof bonding coating according to the present invention has a BTC peel adhesion between about 0.53 and about 8.76 N / mm (about 3 and about 50 lbs / in), more preferably about 0.70 and about 7.01 N / mm (about 4 and about 40 lbs / in), and even more preferably about 0.88 and about 5.25 N / mm (about 5 and about 30 lbs / in).

[0075] Within the context of this disclosure, the ability of the waterproofing membrane to maintain a waterproof bond when subjected to exposure to sunlight prior to placing post-cast concrete against the membrane is measured with the waterproofing membrane exposed to QUV radiation prior to pouring the concrete, using the same procedure outlined as "BTC" peel adhesion, where the UV exposure is at test conditions of UVA 340 nm, 0.68 w / m2 / nm radiation using a QUV accelerated weathering tester and chamber temperature set at 60±3°C.

[0076] Within the context of this disclosure, the ability of a waterproofing membrane to maintain a waterproof bond when subjected to water exposure after placing post-cast concrete against the membrane is measured by the same procedure outlined as "BTC" peel adhesion by pouring post-cast concrete against the waterproofing membrane and allowing it to set for 7 days, then the assembly is fully immersed in water for 28 days. Water may penetrate between any of the interfaces of the assembly including the concrete / waterproofing bond coating interface, the waterproofing bond coating / particle interface, or the particle / pressure sensitive adhesive interface.

[0077] Within the context of this disclosure, the ability of the waterproof membrane system to unwind when in roll form without the use of a removable release sheet is evaluated for blocking resistance. To test for blocking resistance, the carrier sheet of the waterproof membrane system is placed on the outermost surface of a 2.0 x 6.0 inch sample membrane and subjected to a pressure of about 20.7 kilopascals (3 pounds per square inch, psi) at 65°C for one week. After cooling to room temperature, each assembly is manually peeled away to evaluate the separation of the carrier sheet and the outermost waterproof bond coating. Easy peeling without coating damage after pressure and heat aging of the laminated membrane is considered sufficient blocking resistance to roll / unwind the membrane without the need to use a removable release sheet.

[0078] Testing of Exemplary Embodiment 1

[0079] In the following examples, several exemplary waterproof bond coating compositions are formulated using polymer emulsions with varying average polymer particle size. The inventors have surprisingly discovered that coatings formulated with small polymer particles or a mixture of small and large particles provide better waterproof bonding to post-cast concrete, especially after submersion, when compared to coatings having only large polymer particle sizes. These findings can be summarized as follows:

[0080] The bond performance of waterproof bond coatings formulated with various particle sizes is evaluated as a coating on a (pre-applied) waterproof membrane that is bonded to concrete and then peeled off to test the bond strength.

[0081] As summarized in Table 1 below, the twelve example waterproof bond coatings are identified in the leftmost column and by coating number (column "A"), polymer emulsion identification (column "B"), average particle size in nanometers (nm) for emulsion #1 (column "C"), average particle size in nanometers (nm) for emulsion #2 (column "D", applies to formulations only when two different polymer emulsions are used), BTC in Newtons per millimeter ("N / mm") (column "E"), and BTC after four weeks of submersion (column "F") The coatings are evaluated as waterproof bond coatings as the outermost layer on a waterproof membrane, and then concrete is poured over the coating layer.

[0082] [Table 1]

[0083] The above exemplary waterproof bond coating composition is coated onto a waterproof membrane to obtain a four-layer laminate membrane, with the waterproof bond coating layer facing outward (or upward) to receive fresh concrete. The four-layer waterproof membrane has the following layers: a 0.75 mm carrier layer, a 0.3 mm pressure sensitive adhesive (PSA) layer, a particle coating (average particle size between 70-100 um) layer with a coverage between 10-300 grams per square meter (gsm), and a sample waterproof bond coating layer made from the exemplary coating described above.

[0084] The waterproofing membrane is prepared by coating a carrier layer with a PSA to form an adhesive layer, then applying a particulate layer onto the PSA layer, and then coating the particulate layer with an exemplary waterproofing coating composition. The exemplary waterproofing membrane has a carrier sheet (12), a PSA layer (14), an (optional) protective coating layer (16), which may be particulate, and a waterproofing bond coating composition (20), as shown in Figure 5. Concrete is poured against the coating composition (20) and allowed to harden.

[0085] An exemplary waterproof bond coating composition (20) of the present invention as shown in Figure 5 is prepared as follows: First, the pigment grind, including water, dispersant, thickener, white pigment, and filler, are mixed together at high speed using a high speed mixer. Then, the polymer emulsion and additives are added and mixed at low speed. Of course, other mixing sequences and techniques may be used depending on the mixing technique, available equipment, and preference.

[0086] Thus, the waterproof bond coating composition is preferably applied as the final layer of the waterproof membrane shown in Figure 5. This coated membrane can then be tested and evaluated, such as for its ability to maintain a strong waterproof bond when concrete is poured against the coated (20) side and then allowed to cure. Once cured, the waterproof membrane coated with the waterproof bond coating composition (20) of the present invention and concrete poured against the coated side (20) of the membrane are subjected to water exposure.

[0087] When the waterproofing bond coating composition contains single particle emulsions with average particle size in the range of 350-450 nm (see coating C1) and 250-350 nm (see coatings C2, C3, C4), respectively, the initial BTC peel adhesion of all membrane samples to post-cast concrete is greater than 1.5 N / mm. However, the BTC peel adhesion after 4 weeks of water immersion drops to zero (0) or has no adhesion. The poor water resistance is believed to be caused by a large number of voids in the coating layer resulting from the use of large size emulsion particles that are layered during film formation. When the pre-applied waterproofing membrane is prepared with a waterproofing bond coating containing single emulsions with average particle size in the range of 100-150 nm (see coatings C5 and C6) and 5-50 nm (see coatings C7 and C8), respectively, the initial BTC peel adhesion values ​​of all membrane samples to post-cast concrete are close to 3.0 N / mm. The BTC peel adhesion after 4 weeks of water immersion ranges from 0.60 to 0.76 N / mm (see coatings C5 and C8) and 2.70 to 2.71 N / mm (see coatings C6 and C7). It is therefore believed that smaller particle size can result in better packing density, leading to denser film formation, which in turn can provide improved water resistance to the waterproof membrane system.

[0088] Two mixed emulsions with various particle sizes, e.g., a mixture of emulsions with particle sizes of 350-450 nm and 5-50 nm (see coating C9), or a mixture of emulsions with particle sizes of 100-150 nm and 5-50 nm (see coatings C10, C11 and C12), were used to make waterproof bonded coating composition samples, which were also tested as waterproof membranes (see, e.g., Figure 5). Compared to the membrane configuration with coating C1, which contains a single large particle size emulsion (350-450 nm) and has a bonded coating with no bond to concrete after 4 months of submersion, the addition of about 5% of the small size emulsion based on dry polymer in the waterproof bonded coating formulation was seen to increase the initial BTC from 1.7 N / mm to 3.0 N / mm and was also seen to achieve a waterproof bond of over 2 N / mm after 4 weeks of submersion.

[0089] Waterproof bonded coating composition samples were made using two emulsions with different sizes of small polymer particles and their bond to concrete was tested for bond strength test on membrane for BTC after water immersion and improved bond was observed. For example, waterproof membranes with coating formulation C5 with emulsion 5 (particle size 100-150 nm) and coating formulation C8 with emulsion 8 (particles 5-50 nm) had initial BTC of 3.0 N / mm and BTC after 4 weeks of water immersion ranged from 0.60 to 0.76 N / mm. Waterproof membranes with coating formulation C10 with emulsion 5 (particle size 100-150 nm) and emulsion 7 (particles 5-50 nm) showed improvement in terms of BTC after 4 weeks of water immersion at 3.58 N / mm compared to coatings with individual emulsions (0.76 N / mm for coating with emulsion 5 and 2.7 N / mm for coating with emulsion 7). Waterproofing membranes using coating formulation C12 with emulsion 6 (particle size 100-150 nm) and emulsion 8 (particles 5-50 nm) showed improvement in terms of BTC after 4 weeks of submersion at 3.1 N / mm compared to coatings with the individual emulsions (0.6 N / mm for coating with emulsion 8 and 2.71 N / mm for coating with emulsion 6). This series of evaluations shows improved BTC after submersion with coating formulations containing emulsions with small average particle size or emulsions with a blend of different particle sizes compared to emulsions with only large average particle size above 200 nm.

[0090] Experiments of Exemplary Embodiment 2

[0091] In the following examples, several exemplary waterproof bond coating compositions are formulated using polymer emulsions with varying average particle size of the polymer. The performance of the waterproof bond coatings formulated with various glass transition temperatures and particle sizes is evaluated in a pre-applied waterproof membrane configuration for their ability to maintain waterproof bond when the waterproof membrane is subjected to bending, temperature exposure and UV exposure before placing post-cast concrete against the membrane, and when the waterproof membrane is subjected to water exposure after placing post-cast concrete against the membrane. Table 2 summarizes the polymer particle size and glass transition temperature (Tg, in ° C) of the coating formulation, as well as the BTC performance when evaluated as a bond coating in a four-layer configuration of pre-applied waterproof membrane to post-cast concrete, and the specific details regarding the polymer particle emulsion in the bond coating formulation.

[0092] Coating formulations C6-C14 are identified (leftmost columns) as shown in Table 2. The emulsion or emulsion combination is shown in column A. The glass transition temperature (Tg, in °C) is shown in column B. The average polymer particle size (nm) for emulsion #1 is shown in column C. The average polymer particle size (nm) for emulsion #2 is shown in column D. The percentage of emulsions having an average particle size in the range of 5 nm to 50 nm as a percentage based on the dry weight of the polymer emulsion is shown in column E. The percentage of emulsions having an average particle size in the range of 5 nm to 150 nm as a percentage based on the dry weight of the polymer emulsion is shown in column F. The presence or absence of surface cracks is shown in column G. The BTC (N / mm) is shown in column H. The BTC (QUV per N / mm) after 120 hours of UV exposure is shown in column I, and the BTC (N / mm) after 4 weeks of water exposure is shown in column J.

[0093] Further specific details regarding the polymer particle emulsions in bond coatings and performance in waterproofing membranes are set forth in Table 2 below.

[0094] [Table 2]

[0095] The example waterproof coating composition formulations were laminated onto a waterproof membrane to provide a four-layer membrane. The exemplary waterproof membrane includes a carrier layer (0.75 mm), a PSA layer (0.3 mm), a particle coating layer having an average particle size of 50-200 μm and a coverage of 10-300 grams per square meter (gsm), and a sample waterproof bond coating composition layer (formulated above).

[0096] To prepare a waterproof membrane, a carrier layer is coated with a polymer-based pressure-sensitive adhesive, then laminated with a particulate layer on top of the adhesive, and then a waterproof bond coating is applied on top of the particulate layer to a desired coating weight. Following such a process, a four-layer membrane (10) is obtained, including a carrier sheet (12), a waterproof pressure-sensitive adhesive (14), a particulate protective coating layer (16), and a waterproof bond coating composition layer (20) as the outermost protective topcoat, which has the general laminate structure shown in Figure 5.

[0097] The waterproof bond coating composition may be prepared by first preparing a pigment grind (paste) containing the dispersant, thickener, white pigment and filler and mixing these together at high speed using a high speed mixer, then the polymer particle emulsion and other additives may be added and mixed at a lower mixing speed.

[0098] Sample membranes (e.g., having a structure similar to that shown in FIG. 5) are evaluated for waterproof bond coating layers (20) and their respective polymer particle characteristics. Coating examples using emulsions with small average particle size (less than 150 nm), as well as combinations of emulsions with small average particle size or combinations of emulsions with small and large average particle size (150 nm), demonstrated good bonding to concrete after water immersion and QUV aging. However, sample membranes with emulsions 7 and 8 (see coatings C7, C8), which have a glass transition temperature (Tg) of the polymer emulsion above 5° C., showed surface cracking. Other examples with emulsions or combinations of two polymer emulsions with Tg less than 0° C., as well as one polymer with a Tg less than 0° C., did not appear to show surface cracking and were therefore likely able to maintain a waterproof bond.

[0099] Testing of Exemplary Embodiment 3 In the following examples, the coverage of the waterproof bond coating is evaluated on a pre-applied waterproof membrane. Thus, a three-layer membrane was used that had a carrier sheet, a pressure-sensitive adhesive (PSA) layer, but no protective coating layer on the PSA, so that the waterproof bond coating layer was applied directly onto the PSA layer. Waterproof bond coating formulation C11 was used: we believe this provided some of the protection that would otherwise have been provided by a particle or elastomer-based protective coating layer (as shown at 16 in FIG. 5).

[0100] [Table 3]

[0101] At three different levels of coating coverage, the waterproof bond coating C11 contains two polymer particle emulsions, one with an average particle size between 100-150 nm and one with a polymer containing siloxane reactive functional groups and an average particle size less than 50 nm. The C11 coating formulation demonstrated good bonding to concrete, good retention of bond to concrete after 28 days of submersion in water, and good bonding to concrete after QUV exposure.

[0102] All the above examples have shown that the waterproof bonded coating formulation has excellent water and UV resistance when used as a protective top coating for pre-applied waterproof membrane applications that are post-poured onto the concrete installed membrane. The fine particle size emulsion and hydrophobic properties are believed to form a denser coating layer and provide good water resistance, while the white pigment and siloxane groups in the polymer latex formulation of coating C11 can improve weather resistance properties.

[0103] Blocking resistance (or the ability to prevent the adhesive side from sticking to the carrier side when the membrane is rolled up on itself for transport to the construction site) may depend on the coating weight of the outermost coating layer. A low coating weight of 34 gsm could not cover all the pressure sensitive adhesive to provide sufficient blocking properties. For membrane structures where the waterproof bond coating formulation is applied directly onto the PSA layer (without protective coatings and / or particles to prevent the pressure sensitive adhesive from sticking to the carrier sheet when wound into a roll form without a release sheet), an appropriate coverage of the bond coating should be used to obtain sufficient blocking resistance properties, and the minimum thickness of the outer coating layer may depend on many design factors (e.g., tenacity of the PSA layer, selection of ingredients in the waterproof bond coating composition). Coating at a coverage of 74 gsm or more (140 gsm in this exemplary embodiment) can provide good blocking resistance performance. Sufficient coverage is also related to the dispersion performance of the spraying equipment, so that it is believed that using the same top coating weight, better dispersion properties will result in smaller droplets for better coverage.

[0104] When particles are used as a protective coating layer between the PSA layer and the outermost coating layer, a membrane with a waterproof bond coating coverage of 42 gsm or more (140 gsm in this exemplary embodiment) could provide sufficient blocking properties. However, this also depends on other selected design factors. For example, the effective contact surface between the protective top coating / waterproof bond coating and the HDPE carrier layer is considered, but this consideration can be significantly influenced by the particle layer, particle size and distribution, coverage, depth of particle embedment in the PSA, and the nature of the particles to provide a non-uniform surface topography, effectively reducing surface contact.

[0105] The foregoing examples and embodiments have been presented for illustrative purposes only and are not intended to limit the scope of the present invention.

[0106] All features disclosed in the specification, including the claims, abstract, and drawings, and all steps in any disclosed method or process, may be combined in any combination, except combinations in which some of such features and / or steps are mutually exclusive. Each feature disclosed in this specification, including the claims, abstract, and drawings, may be replaced by an alternative feature serving the same, equivalent, or similar purpose, unless expressly stated otherwise.

[0107] The advantages set forth above and those which will become apparent from the preceding description are efficiently attained. Since certain changes may be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Claims

1. 1. A method for establishing a waterproof bond with post-cast concrete, comprising: (A) providing a substrate selected from a formwork, a waterproofing membrane established by application of a previous coating composition, or a rollable / non-rollable sheet membrane having a carrier layer, a building surface, a civil engineering surface, or any combination of the aforementioned substrates; (B) applying onto said substrate a waterproof bond coating composition, which is an aqueous synthetic polymer emulsion system, to establish a waterproof bond to concrete that is subsequently poured to said substrate, the aqueous synthetic polymer emulsion system comprising (i) at least one film forming synthetic polymer present in an amount of 5% to 100%, preferably in an amount of 50% to 100%, more preferably in an amount of 80% to 100%, based on the total dry weight of said aqueous synthetic polymer emulsion system, wherein the average particle size of said at least one film forming synthetic polymer is in the range of 5 to 150 nanometers, and optionally (ii) a surfactant in an amount of 0-1% or less, preferably 0-0.5% or less, all percentages of said polymers being based on the total dry weight of said aqueous synthetic polymer emulsion system.

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

3. 2. The method of claim 1, wherein upon applying said waterproof bond coating composition onto said substrate in step (B), said waterproof bond coating composition comprises at least one film-forming synthetic polymer, having an average particle size of said at least one film-forming synthetic polymer in the range of 5 to 150 nanometers, and being present in an amount of 80% to 100%.

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

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

6. 2. The method of claim 1, wherein when applying the waterproof bond coating composition onto the substrate in step (B), the waterproof bond coating composition has a glass transition temperature of -20°C or more and 100°C or less, more preferably 85°C or less, and most preferably 65°C or less.

7. 10. The method of claim 1, wherein when applying the waterproof bond coating composition onto the substrate in step (B), the waterproof bond coating composition has a glass transition temperature of less than 0°C.

8. 2. The method of claim 1, wherein when applying the waterproof bond coating composition onto the substrate in step (B), the waterproof bond coating composition further comprises a polymer emulsion selected from fluoroacrylate or fluorinated polymer, copolymers having carboxyl and siloxane functional groups that can react or form strong interactions with cement, or mixtures thereof.

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

10. 10. The method of claim 1, wherein after applying the waterproof bond coating composition on the substrate in step (B), the method further comprises pouring concrete against the applied waterproof bond coating composition (hereinafter "post-cast concrete"), and curing the post-cast concrete against the waterproof bond coating composition.

11. 11. The method of claim 10, wherein the post-cast concrete is allowed to set and harden against the post-cast concrete, a waterproof bond is formed with the post-cast concrete, and further wherein the waterproof bond between the coating composition and the post-cast concrete is greater than 0.53 Newtons / millimeter or 3 pounds / linear inch when tested according to a modified ASTM D903-98(2017), the test procedure using pouring concrete against a waterproof membrane to form a bond between the coating and the concrete and a peel rate of 100 mm (4 in) / min, whereby the waterproof membrane is modified by peeling it from the concrete after the concrete has hardened.

12. A waterproof substrate produced according to the method of claim 1.

13. 1. A coating composition comprising an aqueous synthetic polymer emulsion system comprising at least one film-forming synthetic polymer present in an amount of 5% to 100%, more preferably in an amount of 50% to 100%, and most preferably in an amount of 80% to 100%, based on the total weight of the aqueous synthetic polymer emulsion system, wherein the average particle size of the at least one film-forming synthetic polymer is in the range of 5 to 150 nanometers, and optionally a surfactant in an amount of 0-1% or less, preferably 0-0.5% or less, and most preferably 0-0.1% or less, based on the total weight of the aqueous synthetic polymer emulsion system.

14. 1. A waterproof membrane comprising: (A) a carrier layer; (B) a pressure sensitive adhesive layer; (C) optionally a protective coating layer comprising particles, an elastomeric coating, or a mixture thereof; and (D) a waterproof bond coating composition comprising an aqueous synthetic polymer emulsion system comprising at least one film-forming synthetic polymer present in an amount of 5% to 100%, more preferably in an amount of 50% to 100%, and most preferably in an amount of 80% to 100%, based on the total weight of the aqueous synthetic polymer emulsion system, wherein the at least one film-forming synthetic polymer has an average particle size in the range of 5 to 150 nanometers; and optionally a surfactant in an amount of 0-1% or less, preferably 0-0.5% or less, and most preferably 0-0.1% or less, based on the total weight of the aqueous synthetic polymer emulsion system.

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

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

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

18. 15. The waterproof membrane of claim 14, further comprising said at least one synthetic film-forming polymer having an average particle size in the range of 5 to 150 nanometers and present in an amount of 50% to 100%.

19. 15. The waterproof membrane of claim 14, further comprising said at least one synthetic film-forming polymer having an average particle size in the range of 5 to 150 nanometers and present in an amount of 80% to 100%.

20. 15. The waterproof membrane of claim 14, further comprising said at least one synthetic film-forming polymer having an average particle size in the range of 5 to 100 nanometers and present in an amount of 5% to 100%.

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