Waterproof extruded ballast protection

Abstract

1. A method of providing a ballast protective membrane on a waterproof membrane, the method comprising the steps of: a. providing at least one layer of the waterproof membrane on a surface to form a waterproof seal on the surface; and b. applying a liquid curable composition on the surface of the waterproof membrane to an average uncured thickness of 0.5 mm to 50 mm, the liquid curable composition comprising (i) at least one reactive acrylate-based monomer and (ii) a polymerization initiator added to activate polymerization of the reactive acrylate-based monomer, the liquid curable composition curing when applied to the surface of the waterproof membrane to form a resin film.

Description

[Technical field]

[0001] The present disclosure relates generally to the field of waterproofing and ballast protection for railway and bridge deck applications, and more particularly to a novel method and system in which protective members or units are extruded onto a waterproofing membrane to provide protection to ballast material that is placed on the membrane as is typically done in railway applications. [Background technology]

[0002] Track ballast, typically made of gravel and rock, is used in railroad construction to provide a stable substrate upon which railroad ties and track are placed. One example of a prior art system for waterproofing and supporting railroad ballast includes the use of a primer and waterproofing membrane, and a ballast mat to protect the waterproofing membrane from puncturing the overlying ballast material.

[0003] Conventional ballast mats can include fabrics such as fleece or geotextiles, bituminous protection boards, reactive composition membranes, and rubber particles contained between or within coatings. The fabric, by itself, offers little protection to the membrane against forces sufficient to displace or cause denting. A highly undesirable condition can result from water pooling on top of the waterproofing membrane, allowing water or corrosive chemicals to seep through the fabric.

[0004] For several decades, spray application of fast gelling waterproofing membranes has been used in railroad and highway bridge deck systems using resin compositions available under the ELIMINATOR® brand from Stirling Lloyd, a subsidiary of the present assignee. On top of the membrane, a ballast protection course was spray applied using successive spray coatings to build up a thick ballast protection coating, and ballast mats were also typically used.

[0005] Spray coating of wet film compositions requires multiple successive spray passes to provide a railroad ballast protective coating, and this technique has been described in the patent literature, see, for example, U.S. Patent Nos. 9,441,335, 9,869,065, 10,132,049, 10,415,197, 10,612,198, and Canadian Patent No. 2,832,030.

[0006] For example, U.S. Patent No. 9,441,335 to Haydu describes an exemplary method for providing a ballast protective coating, including spraying the coating successively "as a series of layers, such as resin, then filler, then resin, etc." (see, e.g., column 5, lines 42-47). The compounds and fillers can be rubber-based. As shown in FIG. 3 of Haydu and described in column 4, line 57 to column 5, line 10, it is explained that the ballast protective coating can be applied to irregular or non-uniform surfaces in various thicknesses to form flat or uniformly sloped surfaces, including "isosceles triangular cross-sectional profiles" (see column 6, lines 33-34). Haydu's rubber-containing coating system also used a ballast mat and a sealing layer (see Abstract).

[0007] In addition to being time consuming, prior art spray applied ballast protective coatings required additional steps to address other shortcomings. For example, protective boards had to be used for additional mechanical protection over the spray applied coating. Protective boards such as bitumen or asphalt sheets were sometimes used, but these were rigid and presented a tripping hazard for workers. Rubber particles and / or rubber fillers had to be used in the coating to provide compressibility, and the use of rubber particles between spray coatings was labor intensive and time consuming.

[0008] Therefore, there is a need in the art to overcome the problems associated with conventional ballast protective coating technologies, such as poor ballast indentation resistance, non-uniform surface finish, inefficient spray application challenges, poor skid resistance, and other deficiencies. Summary of the Invention

[0009] The present invention may address one or more of the problems and deficiencies of the prior art discussed above. However, it is believed that the present invention may prove useful in addressing other problems and deficiencies in many technical fields. Thus, although it is shown that the novel nature of the present invention can fairly easily solve many of these problems, the claimed invention should not necessarily be construed as being limited to addressing any of the specific problems or deficiencies discussed herein.

[0010] According to one aspect, disclosed is a method of providing a ballast protective membrane on a waterproof membrane comprising: a. providing at least one layer of the waterproof membrane on a surface to form a waterproof seal on the surface; and b. applying a liquid curable composition onto the surface of the waterproof membrane to an average uncured thickness of at least about 0.5 mm, the liquid curable composition comprising (i) at least one reactive acrylate based monomer and (ii) a polymerization initiator added to activate polymerization of the reactive acrylate based monomer, wherein the liquid curable composition cures when applied to the surface of the waterproof membrane to form a resin film.

[0011] According to another aspect of the present disclosure, a method for providing a ballast protective membrane on a waterproof membrane is disclosed, the method comprising the steps of: a. providing at least one layer of a waterproof membrane on a surface to form a waterproof seal on the surface; b. mixing together at least two components, one component comprising at least one reactive (meth)acrylate monomer and another component comprising at least one polymerization initiator, to activate polymerization of the reactive (meth)acrylate monomer to form a liquid curable composition; and c. depositing a liquid curable composition on the surface of the waterproof membrane. applying a curable composition to an average uncured thickness of at least about 0.5 mm, the liquid curable composition comprising: (i) about 1 to about 20 wt % of at least one reactive (meth)acrylate monomer; (ii) about 1.0 to about 10 wt % of a polymerization initiator added to activate polymerization of the reactive (meth)acrylate monomer, the liquid curable composition curing to form a resin film when applied to a surface of the waterproof membrane; and (iii) about 55 wt % to about 80 wt % of inorganic particles. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] Where a document, act, or item of knowledge is mentioned or discussed in this specification, this mention or discussion is not an admission that that document, act, or item of knowledge, or any combination thereof, existed at the priority date, was publicly available, was known to the public, was part of the common knowledge, or otherwise constituted prior art under applicable legal provisions with respect to the present invention, or was known to be relevant to any attempt to solve any problem to which this specification pertains.

[0013] Aspects of the present disclosure will now be described in detail with reference to the drawings, in which like reference numerals refer to like elements throughout, unless otherwise specified. In the following description, certain terms are used for convenience only and are not limiting. As used herein, the term "plurality" means more than one. The terms "portion" and "at least a portion" of a structure include the entire structure. Certain features of the present disclosure that are described herein in the context of separate embodiments may be provided in combination in a single embodiment. Conversely, various features of the present disclosure that are described in the context of a single embodiment may also be provided separately or in any subcombination.

[0014] 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.

[0015] 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. Furthermore, the phrase "about 'x' to 'y'" includes "about 'x' to about 'y'."

[0016] Furthermore, 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 with 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%. Furthermore, any numerical range represented by any two values ​​of R calculated above is also specifically disclosed.

[0017] The liquid curable compositions disclosed herein form slurries that have desirable slump characteristics during curing and desirable properties when applied and fully cured on a deck, with a rough, durable surface texture. These performance characteristics are ideal for coatings that need to withstand traffic and other stresses. Furthermore, the ballast protection membranes disclosed herein exhibit excellent shear and tensile adhesion to waterproofing membranes. The above viscosity of the compositions has been found to allow for easy and rapid application to large areas using large screed bars, mechanical pumps for extrusion or spray application. Once cured, the compositions provide sufficient surface texture and have excellent anti-slip properties. Depending on how the composition is applied during curing, the composition can form a flat or stepped shape. For example, the use of a flat screed bar results in a flat textured surface of the ballast protection membrane. Multiple longitudinal applications of flat applications at various thicknesses can also form a stepped pattern. Furthermore, in scenarios where the mold section is simply filled with slurry to the mold height without any screeding, it is not necessary to use a screed bar. A pin rake can be used to spread the resin onto the deck to the desired thickness, with or without a mold.

[0018] The present disclosure is a method of providing a ballast protective membrane on a waterproof membrane, the method comprising the steps of: a. providing at least one layer of waterproof membrane on a surface to form a waterproof seal on the surface; and b. applying a liquid curable composition onto the surface of the waterproof membrane to an average uncured thickness of 0.5 mm to 50 mm, the liquid curable composition comprising (i) at least one reactive acrylate-based monomer and (ii) a polymerization initiator added to activate polymerization of the reactive acrylate-based monomer, the liquid curable composition curing when applied to the surface of the waterproof membrane to form a resin film.

[0019] The first step of the method includes providing at least one layer of a waterproof membrane comprising a surface for forming a waterproof seal on a surface. The surface may be a substrate, which may include an additional layer onto which at least one layer of the waterproof membrane may be applied. Substrates include, for example, concrete, steel, wood, or plastic sole plates. The additional layer may include, for example, additional membrane and / or primer layers (e.g., methacrylate adhesive layers, epoxy layers) that may be spray coated or applied as a sheet of material. For the purposes of this step, the term "substrate" to which the waterproof membrane is applied includes the substrate and any additional layers or materials on the substrate to which the waterproof membrane is applied. The waterproof membrane is preferably elastic and may be made from commercially available sprayable resin types, such as those sold under the Eliminator® brand by Stirling Lloyd (UK). The membrane is preferably installed after application of a primer coating on the concrete deck or on the steel substrate.

[0020] The substrate or substrate system may include, for example, a support system and supporting ballast under a railroad track, such as, for example, a railroad bed, such as fill soil, concrete, asphalt, concrete and steel rail bridge structures, tunnels, and other structures. In other embodiments, the railroad system may include railroads, light rail, subway systems, and elevated rail structures. Typically, a railroad protection system is disposed between the railroad bed and the ballast. Thus, in some embodiments, the substrate is a railroad protection system that includes a waterproof membrane and an integrated ballast mat.

[0021] The waterproofing membrane can be applied along any length of the railroad bed. The waterproofing membrane can be applied evenly over irregular surfaces and can be applied horizontally, vertically, and elevated. The thickness of each layer of the waterproofing membrane can be 10-150 mils thick, and can be 60-120 mils thick. In one embodiment, the waterproofing membrane can be 80 mils thick. In some embodiments, one or more layers of the waterproofing membrane can be applied on top of each other. In one embodiment, a first layer of the waterproofing membrane is 40 mils thick and a second layer of the membrane is 40 mils thick. The waterproofing membrane can be applied to have a substantially uniform thickness. In some embodiments, the waterproofing membrane can be applied having a variety of thicknesses. The term "mils" (singular and plural) is a unit of measurement that refers to one thousandth of an inch. For example, 20 mils means 20 / 1000 of an inch.

[0022] The waterproof membrane can cover all or a portion of the railway bed. For example, on a bridge, the waterproof membrane can cover the entire surface of the bridge deck. In some instances, the waterproof membrane extends to a predetermined location or location, such as a drainage area. Preferably, the waterproof membrane defines a fluid-tight seal on the surface of the railway bed. Preferably, the waterproof membrane can cover the railway bed without seams, which can reduce weak points in the fluid-tight seal.

[0023] In some embodiments where an adhesive or primer layer is applied, the adhesive layer may be a primer application or may be applied prior to placement of the waterproofing membrane. The adhesive layer may be the same material as all or part of the waterproofing membrane. The adhesive layer may be applied by spraying or rolling the material while it is in a substantially fluid state. In some embodiments, the adhesive layer may be between 2 mils and 10 mils thick.

[0024] The second step of the method is to apply a liquid curable composition directly onto the surface of the waterproofing membrane with an average uncured thickness of at least about 0.5 mm, the liquid curable composition comprising (i) at least one reactive (meth)acrylate monomer and (ii) a polymerization initiator added to activate the polymerization of the reactive (meth)acrylate monomer, the liquid curable composition curing to form a resin film when applied to the surface of the waterproofing membrane. As described below, the liquid curable composition needs to be mixed before the application step, and therefore the method of the present invention includes the step of mixing at least a first component and a second component together, the liquid composition being activated to polymerize upon mixing of the components.

[0025] In a preferred embodiment, the liquid curable composition is applied as a single layer over the waterproofing membrane such that when cured, a single layer ballast protective membrane is formed.

[0026] The liquid curable composition includes at least one reactive (meth)acrylate monomer as one component. As used herein, the term "reactive (meth)acrylate monomer" includes both acrylate and methacrylate functional groups. As intended herein, "resin" refers to a polymerized, cured, or crosslinked composition. The reactive acrylate monomer may be an alkyl (meth)acrylate, and the alkyl (meth)acrylate may be an alkyl (meth)acrylate having an alkyl group with 1 to 20 carbon atoms. Specific examples include methyl (meth)acrylate, ethyl (meth)acrylate, n-propyl (meth)acrylate, isopropyl (meth)acrylate, n-butyl (meth)acrylate, isobutyl (meth)acrylate, tert-butyl (meth)acrylate, n-pentyl (meth)acrylate, n-hexyl (meth)acrylate, n-heptyl (meth)acrylate, n-octyl (meth)acrylate, isooctyl (meth)acrylate, 2-ethylhexyl (meth)acrylate, n-nonyl (meth)acrylate, isononyl (meth)acrylate, decyl (meth)acrylate, lauryl (meth)acrylate, stearyl (meth)acrylate, etc. These can be used alone or in combination of two or more.

[0027] In certain embodiments, the at least one reactive (meth)acrylate monomer is methyl methacrylate, n-butyl methacrylate, 2-ethylhexyl acrylate, and mixtures thereof.

[0028] The at least one reactive (meth)acrylate monomer, once mixed, may be present in the composition at about 5% to about 30% by weight, preferably about 10% to about 20% by weight, and more preferably about 12% to about 15% by weight.

[0029] The composition also includes a polymerization initiator that is added to activate the polymerization of the reactive acrylate monomer. In an embodiment, the polymerization initiator is an organic peroxide and functions to initiate the free radical polymerization of the (meth)acrylate monomer. Organic peroxides can be classified as diacyl peroxides, hydroperoxides, dialkyl peroxides, peroxyesters, peroxyketals, and peroxy(di)carbonates, all of which are well known to those skilled in the art. Examples of free radical polymerization initiators include, for example, dicumyl peroxide, tert-butyl peroxybenzoate, dibenzoyl peroxide (BPO), 2,5-dimethyl-2,5-di(tert-butylperoxy)-3-hexyne (25B), bis(tert-butylperoxyisopropyl)benzene, and combinations thereof. A preferred organic peroxide is dibenzoyl peroxide (BPO). The amount of initiator is preferably about 0.50% to about 20% by weight based on the weight of the composition to be applied. The initiator initiates the polymerization of the monomers and therefore remains separate from the at least one reactive (meth)acrylate monomer until just prior to mixing for the application step, and thus constitutes the at least one second component. The polymerization initiator can be added as a powder or a suspension.

[0030] As an optional component, the composition may include a polymerization accelerator or a hardening accelerator. Preferably, the amines include, but are not limited to, diisopropyl toluidine, dimethylpropyl toluidine, trimethylamine, methylhydroxypropyl toluidine, methyldimethanolamine, triethanolamine, p-diethylaminoacetophenone, p-dimethylaminoethyl benzoate, p-dimethylaminobenzoate-2-ethylhexyl, N,N-dimethylbenzylamine, and 4,4'-bis(diethylamino)benzophenone. In one embodiment, the polymerization accelerator is selected from the group consisting of dimethylpropyl toluidine, diisopropyl toluidine, and methylhydroxypropyl toluidine. The hardening accelerator may be present with at least one second component. When the hardening accelerator is present, the amount is preferably about 0.01% by weight to about 1.5% by weight, preferably 0.5% by weight, based on the weight of the composition to be applied.

[0031] Another optional ingredient is a methacrylate-based polymer, such as, for example, polymethyl methacrylate and polyurethane acrylate polymers, which function to improve physical properties and cure times, and when used, are present at 0.5% to 20% by weight, preferably 1.0% to 15% by weight.

[0032] Another optional but preferred component of the liquid curable composition is inorganic filler particles. The inorganic filler particles function to provide additional strength and trample and skid resistance to the ballast protective film. Examples of inorganic fillers include, but are not limited to, silica (fumed silica, non-fumed silica, porous silica, hollow silica), silicon oxide, aluminum oxide, aluminum hydroxide, magnesium oxide, magnesium hydroxide, calcium carbonate, aluminum nitride, boron nitride, aluminum silicon carbide, silicon carbide, titanium dioxide, zinc oxide, zirconium oxide, mica, boehmite (AlOOOH), calcined talc, talc, silicon nitride, stone, aggregate, calcined kaolin, and the like. In one embodiment, the inorganic particles are selected from the group consisting of calcium carbonate, silicon oxide, fumed silica, stone, aggregate, and mixtures thereof. Furthermore, the inorganic filler may be in the form of spheres, fibers, plates, particles, sheets, or whiskers, and may be optionally pretreated with a silane coupling agent. When inorganic filler particles are present, the amount thereof is preferably about 10% by weight to about 90% by weight, about 25% by weight to about 80% by weight, about 35% by weight to about 80% by weight, about 45% by weight to about 80% by weight, about 55% by weight to about 80% by weight, about 65% by weight to about 80% by weight, and preferably about 75% by weight to about 80% by weight.

[0033] Preferably, the inorganic filler particles have an average D50 particle size of 0.10 mm to 2.0 mm, preferably 0.145 mm to 0.70 mm. In some embodiments, the average D50 particle size is 0.004 mm. The average D50 particle size is the particle size corresponding to the cumulative percentage measured using sieve analysis reaching 50%. The shape of each of the inorganic particles is not particularly limited and can be appropriately selected from spherical, approximately spherical, irregular, acicular, aggregate, cluster, etc. In general, it is preferable to use spherical or approximately spherical inorganic particles, or a powder obtained by agglomerating spherical or approximately spherical inorganic particles by heat treatment or the like.

[0034] In one embodiment, the liquid curable composition further comprises at least one glycol additive in an amount of 0.25 to 10% based on the weight of the final composition. The liquid curable composition may contain other optional ingredients, such as pigments, plasticizers, dispersants, surfactants, thickeners, anti-agglomerating agents, defoamers, dyes, polymerization inhibitors, anti-fungal agents, antioxidants, UV absorbers, pH adjusters, and the like, as needed. Preferably, the liquid curable composition does not include sealers, rubbers, and foaming agents. If such ingredients are used, they are used at less than 5% by weight of the composition. Rheology modifiers include fumed silica, dispersing aids, and anti-settling aids, and may be added with other optional ingredients to provide desired rheological or performance properties.

[0035] In another embodiment, a method for providing a ballast protective membrane on a waterproof membrane is disclosed, the method comprising the steps of: a. providing at least one layer of a waterproof membrane on a surface to form a waterproof seal on the surface; b. mixing together at least two components, one component comprising at least one reactive (meth)acrylate monomer and another component comprising at least one polymerization initiator, to activate polymerization of the reactive (meth)acrylate monomer to form a liquid curable composition; and c. depositing a liquid curable composition on the surface of the waterproof membrane. and applying a liquid curable composition to an average uncured thickness of at least about 0.5 mm, the liquid curable composition comprising: (i) about 1 to about 20% by weight of at least one reactive (meth)acrylate monomer; (ii) about 1.0 to about 10% by weight of a polymerization initiator added to activate polymerization of the reactive (meth)acrylate monomer, the liquid curable composition curing to form a resin film when applied to the surface of the waterproof membrane, and (iii) about 55% to about 80% by weight of inorganic particles.

[0036] As mentioned above, the components are mixed just before applying the ballast protective membrane. A mixer can be used, for example, to mix the liquid curable composition. The exemplary liquid curable composition disclosed herein can be made, for example, using two or more components that are blended together and further combined with inorganic particles to form a slurry composition, which can be shipped or otherwise transported to a building site, and then applied to the waterproofing membrane at the building site to form the ballast protective membrane(s). The liquid curable composition can be extruded in wet form, for example, through a hose (and optionally a die or pipe) onto the waterproofing membrane surface in any number of cross-sectional shapes, such as cylindrical, square, rectangular, or other cross-sectional shapes, while the forming resin is malleable or moldable and can bond to the waterproofing membrane before solidifying (curing). Preferably, the composition is applied by extrusion (e.g., by using a pressurized hose or pipe with a spray nozzle), but application by a screed bar, brush, trowel, sponge, mop, or other mode for applying a liquid coating can also be included. As used herein, "extrusion" means that a two- or three-component resin system is pumped using 98:2 or 1:1 or another desired ratio. The components are mixed in-line and applied or extruded through a hose. The material extruding from the hose nozzle or spray tip is applied onto a substrate and hardens within an hour. Hardening of the material completes the extrusion process. Application of the polymerizing liquid composition can be done at ambient temperature, or the composition can be passed through, for example, a heat exchanger to increase the temperature and speed up the polymerization.

[0037] The ballast protection layer can be applied in one coat onto a flat or stepped substrate with a typical thickness of at least about 50 mm, in some embodiments, the thickness of the as-applied (uncured) layer is from about 0.5 mm to about 50 mm, or more if desired.

[0038] Once the ballast protection layer is fully cured, no further sealer coats are required and it is ready to be trafficked or to receive stone ballast.

[0039] The ballast protection layer can be cured in less than an hour at a variety of temperatures ranging from -20°C to +50°C.

[0040] An example of a three-component liquid curable composition can be made as follows: a first component can be made in which at least one polymerizable acrylic monomer is present at a concentration of 1-20%, a second component contains an organic peroxide initiator present in an amount of 0.5% to 10%, and a third component contains the same monomers as the first component, typically present at a concentration of 1-20%, all percentages by weight. In this embodiment, the first component typically contains an accelerator. The second and third components can be mixed in situ to produce an activated third component. When the activated third component and the first component are mixed, the reaction begins. The mixing of the components can be done in a mechanical mixer or pump and extruded or sprayed.

[0041] Examples of two-component liquid curable compositions include those in which a first component "A" containing a polymerizable acrylate monomer is combined with a second component "B" having a free radical initiator such that a polymerization reaction results in curing. In addition to the acrylate monomer, component A may further include other components such as a polymethylmethacrylate ("PMMA") polymer and an accelerator (e.g., dimethyl-p-toluidine, or "DMPT").

[0042] When the above-mentioned components are combined, specifically the acrylate-based components, the resulting material is fluid and easily applied at an appropriate thickness onto a substrate (e.g., waterproof membrane). The radical initiator and acrylate mixture form the basis of the reaction that results in polymerization. The mixture is sprayed (or otherwise applied) onto the substrate before curing. Before curing occurs, a screed bar can be used to form a flat or stepped, passable coating layer without the need for additional layers or sealers, due to the unique rheology of the resin. Furthermore, when the resin cures, a wear-resistant and slip-resistant surface is obtained.

[0043] More broadly, using a railroad deck as an exemplary application, a base layer or surface of a bridge deck is provided, a primer is applied over the bridge deck substrate, one or more layers of a waterproofing membrane are applied over the primer, a ballast protection membrane of certain embodiments of the present invention is applied over the waterproofing membrane, and optionally ballast is applied over the ballast protection membrane.

[0044] In certain exemplary embodiments, the present invention teaches a liquid curable composition that has excellent rheological properties and can be applied by spraying, extrusion, or hand coating to various coating weights or thicknesses. The resin has a wide application temperature range and can be applied cold using single-leg, 1:1 or 98:2 ratio pumps. Once applied, the system cures seamlessly to provide strong adhesion to the waterproofing membrane and, if inorganic particles are used, a rough surface texture. The rheology is such that stepped shapes can be formed in one layer application. Furthermore, the resulting cured coating provides skid resistance that allows low to moderate traffic on the deck. The rough surface texture is formed due to the special rheology of the formulation. This is a unique property of the resin that allows the aggregates to be mixed homogeneously in the container without settling. Exemplary embodiments have a cure time of 2 hours or less, preferably 1 hour or less, at -20°C to 50°C, are 100% solids reactive systems, and have low volatile organic content (VOC) when tested according to standard ASTM D2369, Method B, with results of less than 100 g / l. Shear and tensile adhesion values ​​of exemplary embodiments to membranes have been found to be excellent (ETAG 033 standard). In certain embodiments, the compositions are particularly useful for waterproofing membranes and can be applied under normal conditions experienced on concrete and steel bridge decks.

[0045] In some embodiments, the step of applying the slurry composition onto the installed membrane is applied at a temperature ranging from -20°C to +50°C. The slurry composition has a cure window of 20 minutes to 120 minutes. Within the context of this disclosure, the term "cure time" refers to the time required for a fully initiated composition to solidify and have a tack-free surface. Cure time is recorded in any unit of time, such as seconds, minutes, or hours. Within the context of this disclosure, unless otherwise stated, cure time is taken according to ASTM D5895 standard and / or recorded when the material is dry to physical contact.

[0046] Within the context of this disclosure, the term "low temperature application" refers to the ability of the composition to be applied at ambient temperatures without the use of a boiler or heated lines for melting prior to application. The use of boilers or other heating means is undesirable due to the high energy requirements on-site, the risks associated with manual handling of the molten liquid, and the potentially toxic fumes released during application. In contrast, embodiments of the present passable coating compositions can be applied at a range of ambient temperatures (e.g., from about -20°C to about 50°C) without the need for heating.

[0047] Within the context of this disclosure, the term "screed bar or screed" can refer to a variety of application techniques. After the resin is activated and extruded or poured onto the deck, it can be spread using a variety of screeding techniques. For example, a large screed bar that runs the width of the deck can be used with molded strips on the sides to control the thickness. Alternatively, a pin bar rake with an adjustable height of 1mm to 20mm can be used. The pin rake can have a variety of widths depending on the area that needs to be covered. For example, a 1 meter wide pin rake set at 5mm can be used for the central longitudinal strip of the deck and once fully cured, the sides can be formed. For the sides, the pin rake can be set at a height of 2.5mm. This means that 3 meters of the deck is covered, but if the deck is wider, several configurations and combinations can be used to cover the deck. For very thin applications (less than 2mm), for example for the sides of the deck, a regular coating roller can also be used. In addition to pin rakes and rollers, flat or notched rubber squeegees of various sizes and heights can be used to apply the application.

[0048] In an exemplary embodiment, the shape can be established in one or two extrusions, as opposed to prior art spray techniques that required multiple successive spray passes to build up the desired shape. In other words, a triangular cross-sectional shape can be obtained in one extrusion using a triangular die. A rectangular cross-sectional shape can be obtained in one extrusion through a slot die. A stepped cross-sectional shape can be obtained by extruding a narrow rectangular shape on top of a wider rectangular shape. Or by extruding a taller rectangular cross-sectional shape next to a lower rectangular cross-sectional shape. The ability to extrude various shapes means that the ballast protection member or member unit can be extruded in a "longitudinal" direction that coincides, for example, with the direction of the train rail on a railway bridge deck or the direction of vehicle movement on a viaduct deck. Various cross-sectional shapes can be achieved using screed bars, squeegees, height-adjustable pin rakes, and coating rollers. Dies of various thicknesses can be used to obtain the desired thickness.

[0049] In one embodiment, the stepped cross-sectional shape of the ballast protection layer is formed by extruding a flat shape to form a first layer having a first edge-to-edge width, and then extruding a second flat shape having a narrower edge-to-edge width over the first layer.

[0050] In another embodiment, the stepped cross-sectional shape of the ballast protection layer is formed by extruding a taller square or rectangular member next to a shorter square or rectangular member.

[0051] Within the context of this disclosure, the term "viscosity" or "slump" refers to a measure of a fluid's resistance to deformation (flow) at a given shear rate. A liquid with a lower viscosity flows more easily than a liquid with a higher viscosity. Viscosity is typically measured in units of centipoise (cP), in which case a slump table can be used. Slump tables are commonly used to measure the flow rate of mortars and other viscous products. For liquid hardening compositions to be applied, the composition adjusted to 23°C is added to a hollow conical cylinder placed on a circular metal flat table. The cone has a height of 25 mm and has an upper internal diameter of 90 mm and a lower internal diameter of 100 mm. Excess slurry is scraped off the cone. The operator then gently lifts the cone and scrapes the inside with a spatula, ensuring that all the slurry is on the table. Thus, the starting diameter of the slurry is 90 mm, and depending on the flow characteristics of the slurry, the slurry spreads to a certain final diameter, measured after 1 minute. So for example, if there is no spreading (0) after 1 minute, i.e. the slurry diameter is still 90mm, this is 0% spreading. The present invention is unique in that the rheology can be modified to tailor the flow to reach various final flow diameters from 90mm to 230mm depending on the application requirements, in other words from no flow to completely self-leveling.

[0052] Within the context of this disclosure, the term "shear adhesion" refers to a measure of bond strength between two separate materials, such as between a waterproof membrane and the present invention, where the composite resists a shear force that would cause a passable coat to slide off the substrate / membrane. Shear adhesion is typically recorded in units of megapascals (MPa) and can be determined by methods known in the art. Within the context of this disclosure, shear adhesion measurements are taken according to ETAG 033 standards, specifically EN13653:2004, unless otherwise stated. Preferably, the ballast protection membrane of the present disclosure has a shear adhesion greater than 0.1 MPa, preferably greater than 1 MPa, more preferably greater than 2 MPa.

[0053] Within the context of this disclosure, the term "tensile adhesion" refers to a measure of bond strength between separate materials, more specifically between concrete or steel, primers, waterproofing membranes and passable coats, when subjected to a normal tensile force. Tensile adhesion is typically recorded in units of megapascals (MPa) and can be determined by methods known in the art. Within the context of this disclosure, tensile adhesion measurements are taken according to ETAG 033 standards, specifically EN13596, unless otherwise specified. Preferably, the ballast protection membrane of the present disclosure has a tensile adhesion greater than 0.1 MPa, preferably greater than 1 MPa, more preferably greater than 2 MPa.

[0054] Within the context of this disclosure, the term "surface texture, macro-texture or skid resistance" refers to the material properties that make a passable coating provide a skid-resistant surface. The roughness of the surface is measured using a portable skid resistance tester such as the Pendulum Skid Tester (BS EN 13036-4, ASTM E303). The Pendulum Skid Tester was originally designed in the United States in the 1940s and further developed for road surface testing at the UK Transport Research Laboratory in the 1960s. The Pendulum Skid Tester measures the frictional resistance between a rubber slider attached to the end of a pendulum arm and the test surface. This provides highway engineers with a routine way to check the resistance of wet and dry surfaces to slipping and skidding both in the laboratory and in the field. It is based on the Izod principle, where a pendulum rotates around a spindle attached to a vertical column. At the end of the tubular arm, a rubber slider is attached to a head of known mass. The pendulum is released from the horizontal position so that it strikes the sample surface at a constant speed. The distance traveled by the head after striking the sample is determined by the friction of the sample surface. A slip resistance reading is then obtained. Based on the UKSRG 2005 classification, a test value of 0-24 has high slip potential, a value of 25-35 has moderate slip potential, and a result of 36+ has low slip potential.

[0055] In an embodiment, the cured ballast overcoat has a surface skid resistance value of greater than 30, preferably close to 90. Within the context of this disclosure, the term "surface texture, macro-texture or skid resistance" refers to a material property whereby a passable coating provides a skid resistant surface. Surface roughness is measured using a portable skid resistance tester such as a pendulum tester (BS EN 13036-4, ASTM E303).

[0056] Skid resistance can be measured by a pendulum skid tester, originally designed in the United States in the 1940s, and the instrument was further developed in the 1960s by the British Transport Research Institute for road surface testing. The pendulum tester measures the frictional resistance between a rubber slider attached to the end of a pendulum arm and the test surface. This provides highway engineers with a routine method of checking the resistance of wet and dry surfaces to slipping and skidding, both in the laboratory and in the field. It is based on the Izod principle, where a pendulum rotates around a spindle attached to a vertical column. At the end of the tubular arm, a rubber slider is attached to a head of known mass. The pendulum is released from its horizontal position so that it strikes the sample surface at a constant speed. The distance traveled by the head after striking the sample is determined by the friction of the sample surface. A skid resistance reading is then obtained. Based on the UKSRG 2005 classification, a test value of 0-24 has a high slip potential, a value of 25-35 has a moderate slip potential, and a result of 36+ has a low slip potential.

[0057] It can be seen that the present ballast protection membrane embodiments exhibit excellent tailorable rheological properties. Resins with higher viscosity or narrower slump can be prepared for stepped 1-ply applications, while lower viscosity or wider slump can be prepared for 1-ply flat applications. The rheology can be modified by the use of different peroxide initiators, as the addition of a peroxide suspension was found to provide a narrower slump. Additionally, additives such as monopropylene glycol or water can be added to the peroxide suspension in the field to further increase the viscosity and narrow the slump. Additionally, exemplary skid resistance values ​​were obtained from a 1-ply amalgamated system. Mixing aggregate or stone into the acrylate-based resin prior to application further increases the skid resistance, if desired, for example, for permanently exposed highway applications. While conventional reactive ballast coat or sheet systems can provide a ballast layer that protects the waterproof membrane, they do not provide adequate skid resistance, simple amalgamated liquid application, abrasion resistance, and formation of a stepped structure in a one-pass application.

[0058] Traditionally, ballast protection systems require multiple layers, including a sealer coat, and do not have skid resistance properties. It was therefore surprising to discover that embodiments of the present invention provide a one-layer flat or stepped coating without the need for a sealer. Furthermore, the present invention provides a rough surface texture that allows for excellent skid resistance and passability. Without wishing to be bound by theory, it is hypothesized that this phenomenon occurs due to the combination of acrylate chemistry and rheological agents, such as fumed silica, which provide toughness and high modulus (good wear properties, thus eliminating the need for a sealer), ease of application, and surface texture.

[0059] Within the context of this disclosure, the term "robust and high modulus" refers to a material with a defined set of physical properties such as rut ​​resistance and retention of SRV after wheel tracking at 23°C and 50°C. The initial SRV should be greater than 20, but preferably greater than 35 (BBA Guidelines doc Appendix A, method 1). After wheel tracking, the SRV should be greater than 20, but preferably greater than 35 according to the BBA guidelines document for crack seal systems. A minimum SRV of 60 is required for heavy traffic coatings on highways that will be permanently exposed, whereas in railroad applications, only very light traffic is expected only during the application phase. After the application phase and ballast is applied, the passable coatings are not passed through. In highway applications, the passable coatings are permanently exposed to heavy traffic. Furthermore, after wheel tracking at 50 and 60°C, the change in spread and thickness of the system should be minimal, i.e., less than 5% (BBA Guidelines doc Appendix A, method 2). The modulus of elasticity of the cured coating should be greater than 200N, but preferably greater than 1000N (BBA Guidelines doc Appendix A, Method 7), with the exception to the test method that modulus or stress values ​​may be taken at any strain value. In one embodiment, the ballast protection layer has a modulus of elasticity of 200 Newtons (N) or greater, more preferably 500 or greater, and most preferably 1000N or greater.

[0060] In one embodiment, the resulting ballast protection layer has a VOC of less than 100 g / L when tested according to standard ASTM D2369 Method B.

[0061] It should be noted that the compositions and methods of the present invention are typically most useful for adhesion over waterproof membranes and various types of ballast in railroad bridge deck applications, although other suitable coating materials in lieu of ballast, as well as other application methods, are contemplated herein as well. EXAMPLES

[0062] 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 the embodiments of the invention claimed. It should be understood that the invention is not limited to the specific details shown in the examples. All parts and percentages in the examples, as well as those in the remainder of this specification, are by total weight of the passable coating / layer composition, unless otherwise specified. Example 1

[0063] An amalgamated passable coating was prepared according to the following formulation: (1) Component (A) is a.Containing 30-50% acrylate resin; The acrylate resins in component A include: 1) Acrylate monomers such as methyl methacrylate, n-butyl methacrylate and 2-ethylhexyl acrylate, the total proportion of which is 5% to 30%, preferably 12.85%; 2) Polymethyl methacrylate polymers, the proportion of which is between 0% and 15%, preferably 5%; 3) Paraffin beeswax, the proportion of which is between 0% and 1%, preferably 0.25%; 4) Polyurethane acrylate polymers, the proportion of which is between 0% and 40%, preferably 3%; 5) Free radical inhibitors such as Hydroxy-Tempo or Hydroxyquinone, the proportion of which is 0% or more and 0.5% or less, preferably 0.1%; 6) Dispersing agents such as Anti-Terra 204 or Solsperse 8000, the proportion of which is 0% to 0.5%, preferably 0.1%; 7) Fumed silica, the proportion of which is 0% or more and 3% or less, preferably 0.5%; 8) Plasticizers, the proportion of which is between 0% and 5%, preferably 2%; 9) Accelerators such as diisopropyl toluidine and dimethylpropyl toluidine, the proportion of which is 0% to 1.5%, preferably 0.5%; 10) Calcium carbonate, the proportion of which is between 10% and 50%, preferably 24%, with D50=0.004 mm (where D50 is the corresponding particle size when the cumulative percentage reaches 50%, measured using sieve analysis); 11) SP30 dry sand, the proportion of which is 0% to 25%, preferably 11.3%, and D50=0.4 mm; 12) Redhill 110 sand, the proportion of which is 0% to 25%, preferably 11.3%, and D50=0.145 mm; 13) Garside 16 / 30 sand, the proportion of which is between 0% and 50%, preferably 28%, and D50=0.7mm. (2) Component (B) is a. an initiator suspension or powder, such as a peroxide initiator, in an amount of about 0-10% by weight of the composition; Component B comprises: 1) Dibenzoyl peroxide, 50%, 20% or more and 60% or less. 2) Organic plasticizers or desensitizers, with a content of 50%, 40% or more and 80% or less. (3) Component (C) is a.Containing 30-50% acrylate resin; The acrylate resin in component (C) includes: 1) Acrylate monomers such as methyl methacrylate, n-butyl methacrylate and 2-ethylhexyl acrylate, the total proportion of which is 5% to 30%, preferably 12.85%; 2) Polymethyl methacrylate polymers, the proportion of which is between 0% and 15%, preferably 5%; 3) Paraffin beeswax, the proportion of which is between 0% and 1%, preferably 0.25%; 4) Polyurethane acrylate polymers, the proportion of which is between 0% and 40%, preferably 3%; 5) Free radical inhibitors such as Hydroxy-Tempo or Hydroxyquinone, the proportion of which is 0% or more and 0.5% or less, preferably 0.1%; 6) Dispersing agents such as Anti-Terra 204 or Solsperse 8000, the proportion of which is 0% to 0.5%, preferably 0.1%; 7) Fumed silica, the proportion of which is 0% or more and 3% or less, preferably 0.5%; 8) Plasticizers, the proportion of which is between 0% and 5%, preferably 2%; 9) Calcium carbonate, the proportion of which is between 10% and 50%, preferably 24%, with D50=0.004 mm (where D50 is the corresponding particle size when the cumulative percentage reaches 50%, measured using sieve analysis); 10) SP30 dry sand, the proportion of which is 0% to 25%, preferably 11.3%, and D50=0.4 mm; 11) Redhill 110 sand, the proportion of which is 0% to 25%, preferably 11.3%, and D50=0.145 mm; 12) Garside 16 / 30 sand, the proportion of which is 0% to 50%, preferably 28%, and D50=0.7 mm; 13) 20% high density silica (Sibelite) and not less than 0% nor more than 30%; 14) 10% glass beads (Spheriglass less than 0.5 mm) and not less than 0% nor more than 30%; 15) 10% aggregate (1-3 mm) and not less than 0% nor more than 30%; 16) Pigments in the 0.5% range and between 0% and 3%.

[0064] Testing of Component A and Component C (non-activated) showed that each resin provided slump measurements of 18.2 mm and 175 mm, respectively (90 mm cone, 350 g sample, 25 bumps, no peroxide). It should be noted that further changes in slump may be observed depending on the type of Component B added (i.e., powder vs. suspension). To ascertain gel time, Component C was activated by mixing in 2% of Component B (peroxide powder) for 30 seconds. The activated Component C was then mixed with Component A in a 50:50 ratio at 23° C., and the gel time was 12 minutes.

[0065] To prepare cured samples of the passable coating, Component C was activated with Component B and placed in a 1:1 ratio on the pump leg. Component A was placed under the adjacent leg and the combined materials were extruded onto the substrate. The substrate consisted of the following materials: concrete paving slab, primer, and waterproof membrane. The passable coating was applied directly onto the waterproof membrane.

[0066] The liquid trafficable coating was extruded onto the substrate at 23°C and immediately applied using a stepped screed bar to obtain a thickness of 4mm in the center and 2mm on the sides. The trafficable coating was fully cured in approximately 20 minutes at 23°C. In addition to preparing the trafficable coating samples, additional samples were prepared to test the physical properties and skid resistance. The physical properties of the cured trafficable coating showed a stress value of 1400N at 10% strain (BBA Guidelines doc Appendix A, Method 7). An average skid resistance value of 45 was obtained.

[0067] The liquid trafficable coating exhibited excellent rheological properties since it was liquid and flowable prior to activation with peroxide, and once activated, the slump was ideal for screeding using a stepped screed bar to form the desired shape. The gel time was relatively fast, and the trafficable coating did not lose its shape during the cure time. The fast gel time offers many advantages to the customer, including labor and time savings for the resulting trade. Considering that the slump of the material is ideal for forming stepped shapes in one pass, it offers a significant advantage over multi-layer systems from an application standpoint. The physical properties of the cured system strongly indicate that the system is robust and durable. Due to the thixotropic behavior of the resin, a rough surface texture was observed, resulting in a skid resistance value of 45, ideal for temporary trafficking. These performance characteristics and application methodology make this invention unique in the railroad and highway bridge deck field. Example 2

[0068] An amalgamated passable coating was prepared according to the following formulation: (1) Component (A) is a.Contains 90-100% acrylate resin; The acrylate resins in component A include: 1) Acrylate monomers such as methyl methacrylate, n-butyl methacrylate and 2-ethylhexyl acrylate, the total proportion of which is 5% to 30%, preferably 12.85%; 2) Polymethyl methacrylate polymers, the proportion of which is between 0% and 15%, preferably 5%; 3) Paraffin beeswax, the proportion of which is between 0% and 1%, preferably 0.25%; 4) Polyurethane acrylate polymers, the proportion of which is between 0% and 40%, preferably 3%; 5) Free radical inhibitors such as Hydroxy-Tempo or Hydroxyquinone, the proportion of which is 0% or more and 0.5% or less, preferably 0.1%; 6) Dispersing agents such as Anti-Terra 204 or Solsperse 8000, the proportion of which is 0% to 0.5%, preferably 0.1%; 7) Fumed silica, the proportion of which is 0% or more and 3% or less, preferably 0.5%; 8) Plasticizers, the proportion of which is between 0% and 5%, preferably 2%; 9) Accelerators such as diisopropyl toluidine and dimethylpropyl toluidine, the proportion of which is 0% to 1.5%, preferably 0.5%; 10) Calcium carbonate, the proportion of which is between 10% and 50%, preferably 24%, with D50=0.004 mm (where D50 is the corresponding particle size when the cumulative percentage reaches 50%, measured using sieve analysis); 11) SP30 dry sand, the proportion of which is 0% to 25%, preferably 11.3%, and D50=0.4 mm; 12) Redhill 110 sand, the proportion of which is 0% to 25%, preferably 11.3%, and D50=0.145 mm; 13) Garside 16 / 30 sand, the proportion of which is 0% to 50%, preferably 28%, and D50=0.7 mm; 14) Pigments in the 0.5% range and between 0% and 3%. (2) Component (B) is a. an initiator suspension or powder, such as a peroxide initiator, in an amount of about 0-10% by weight of the composition; Component B comprises: 1) Dibenzoyl peroxide, 50%, 20% or more and 60% or less. 2) Organic plasticizers or desensitizers, with a content of 50%, 40% or more and 80% or less.

[0069] Testing of Component A without Component B provided a slump measurement of 210 mm each (90 mm cone, 350 g sample, 25 bumps, no peroxide). To ascertain gel time, Component A was mixed with Component B in a 98:2 weight ratio (98 g sample, 2 g peroxide powder) at 23° C. for 30 seconds. The resulting gel time was 8 minutes.

[0070] To prepare a cured sample of the passable coating, component A was mixed with component B in a pump in a ratio of 98:2. The mixture was then extruded onto the substrate. The substrate consisted of the following materials: concrete paving slab, primer, and waterproof membrane. The passable coating was applied directly onto the waterproof membrane. The waterproof membrane in this case had been washed with water and had a damp surface, but was not wet. A surface is considered wet if the water soaks through the paper towel. The substrate is considered wet if the paper towel does not absorb any visible water. The present invention was found to cure and adhere strongly to wet substrates, which is another notable feature of the system.

[0071] The liquid trafficable coating was extruded onto the substrate at 23°C and immediately applied using a flat screed bar and mould to obtain a thickness of 4mm in the centre strip of the substrate. After 20 minutes the centre strip was fully cured, after which two additional coats were applied to each side of the strip using a singe mould and flat screed bar to obtain a coating thickness of 2mm. A pin rake with adjustable height was used to spread the resin on the substrate (4mm strip and 2mm strip). The trafficable coating was fully cured in approximately 20 minutes at 23°C. In addition to preparing the trafficable coating samples, additional samples were prepared to test the physical properties and skid resistance. The physical properties of the cured trafficable coating showed a stress value of 1000N at 10% strain (BBA Guidelines doc Appendix A, Method 7). An average skid resistance value of 45 was obtained.

[0072] The liquid trafficable coating exhibited excellent rheological properties since it was liquid and flowable prior to activation with BPO, and once activated, the slump was ideal for screeding using a stepped screed bar to form the desired shape. High speed mixing and pump application was observed. The gel time was relatively fast, allowing further applications to be made quickly. The fast gel time offers many benefits to the customer, including labor and time savings. The slump of the material allows for rapid extrusion and spreading ability on the deck, which is advantageous from an application standpoint over multi-layered, interspersed systems. The physical properties of the cured system strongly indicate that the system is robust and durable. Due to the thixotropic behavior of the resin, a rough surface texture was observed, resulting in a skid resistance value of 45, ideal for temporary trafficking. These performance characteristics and application methodology make the present invention unique in the railroad and highway bridge deck field.

[0073] The foregoing examples and embodiments have been presented for illustrative purposes only and are not intended to limit the scope of the present invention.

[0074] 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.

[0075] It is also to be understood that the following claims are intended to encompass all of the general and specific features of the invention described herein, as well as all statements of the scope of the invention that may be said to fall therebetween as a matter of language.

Claims

1. A method for forming a single-layer protective film on a waterproof film, a. A step of providing at least one layer of a waterproof film on the surface of a substrate to form a waterproof seal on the surface, b. The steps of forming a liquid curable composition by mixing (i) at least one reactive (meth)acrylate monomer, (ii) a polymerization initiator added to activate the polymerization of the reactive (meth)acrylate monomer, and (iii) inorganic particles having an average D50 particle size of 0.01 mm to 2.0 mm, and c. The step of applying the liquid curable composition onto the surface of the waterproof film to an average uncured thickness of at least about 0.5 mm, Includes, The liquid curable composition hardens to form a single-layer protective film. The lower surface of the protective film is adhered to the surface of the waterproof film such that, when measured according to Method EN13653:2004, the protective film exhibits a shear adhesion force of more than 1 MPa to the waterproof film, and The method described above does not include the step of applying a sealer coat to the surface of the protective film. The aforementioned method.

2. The method according to claim 1, further comprising the step of adding ballast to the surface of the protective film.

3. The method according to claim 1, wherein the step of providing at least one layer of a waterproof film on the surface of a substrate to form a waterproof seal on the surface comprises applying a liquid-curable waterproof layer to the substrate and curing it to form the waterproof film.

4. The method according to claim 1, wherein the step of providing at least one layer of a waterproof film on the surface of a substrate comprises providing at least one layer of a sheet waterproof film.

5. The method according to claim 1, wherein the at least one reactive (meth)acrylate monomer is present in the liquid curable composition in an amount of about 1 to about 40% by weight, the polymerization initiator is present in the liquid curable composition in an amount of about 1.0% to about 10% by weight, and the inorganic particles are present in the liquid curable composition in an amount of about 30 to 90% by weight.

6. The method according to claim 1, wherein the inorganic particles are selected from the group consisting of calcium carbonate, silicon oxide, fumed silica, stone, aggregate, and mixtures thereof.

7. The method according to claim 1, wherein the liquid curable composition containing the inorganic particles has a slump selected from the group consisting of 90 to 230 mm and 150 to 190 mm.

8. The method according to claim 1, wherein the liquid curable composition further comprises a polymerization accelerator.

9. The method according to claim 8, wherein the polymerization accelerator is selected from the group consisting of diisopropyltoluidine, dimethylpropyltoluidine, trimethylamine, methylhydroxypropyltoluidine, methyldimethanolamine, triethanolamine, p-diethylaminoacetophenone, p-dimethylaminoethylbenzoate, p-dimethylaminobenzoate-2-ethylhexyl, N,N-dimethylbenzylamine, and 4,4'-bis(diethylamino)benzophenone.

10. The method according to claim 1, wherein the at least one reactive (meth)acrylate monomer is selected from the group consisting of methyl methacrylate, butyl methacrylate, ethylhexyl acrylate, hydroxypropyl methacrylate, and lauryl methacrylate.

11. The method according to claim 10, wherein the at least one reactive (meth)acrylate monomer includes methyl methacrylate.

12. The method according to claim 1, wherein the polymerization initiator is an organic peroxide.

13. The method according to claim 12, wherein the polymerization initiator is dibenzoyl peroxide.

14. The method according to claim 1, wherein the step of applying the liquid curable composition onto the waterproof film comprises forming the protective film having a stepped cross-section or an inclined shape.

15. The method according to claim 1, wherein the base material includes a base plate made of concrete, steel, wood, or plastic.

16. A method for forming a single-layer protective film on a waterproof film, a. The step of providing at least one layer of primer on a substrate, b. The step of providing at least one layer of a waterproof film on the surface of the primer to form a waterproof seal on the surface of the railway deck, c. The steps of forming a liquid curable composition by mixing (i) at least one reactive (meth)acrylate monomer, (ii) about 1% to about 10% by weight of a polymerization initiator added to activate the polymerization of the reactive (meth)acrylate monomer, and (iii) about 30% to about 90% by weight of inorganic particles having an average D50 particle size of 0.01 mm to 4.0 mm, and d. A step of applying a single layer of the liquid curable composition onto the surface of the waterproof film with an average uncured thickness of at least about 0.5 mm, wherein the liquid curable composition exhibits a slump of 90 to 230 mm, and the liquid curable composition hardens to form a single-layer protective film, and The lower surface of the protective film is adhered to the surface of the waterproof film such that, when measured according to Method EN13653:2004, the protective film exhibits a shear adhesion force of more than 1 MPa to the waterproof film, and e. The step of applying ballast to the surface of the protective film, The method comprising the above.

17. The method according to claim 16, wherein the inorganic particles are selected from the group consisting of calcium carbonate, silicon oxide, fumed silica, stone, aggregate, and mixtures thereof.

18. The method according to claim 17, wherein the inorganic particles are selected from the group consisting of calcium carbonate, aggregate, silicon dioxide, and mixtures thereof.

19. The method according to claim 16, wherein the step of providing at least one layer of a waterproof film on the surface of a substrate to form a waterproof seal on the surface comprises applying a liquid-curable waterproof layer to the substrate and curing it to form the waterproof film.

20. The method according to claim 16, wherein the step of providing at least one layer of a waterproof film on the surface of a substrate comprises providing at least one layer of a sheet waterproof film.

21. The method according to claim 16, wherein the liquid curable composition further comprises about 0.1 to about 5.0% by weight of a polymerization accelerator.

22. The method according to claim 16, wherein the polymerization accelerator is selected from the group consisting of diisopropyltoluidine, dimethylpropyltoluidine, trimethylamine, methylhydroxypropyltoluidine, methyldimethanolamine, triethanolamine, p-diethylaminoacetophenone, p-dimethylaminoethylbenzoate, p-dimethylaminobenzoate-2-ethylhexyl, N,N-dimethylbenzylamine, and 4,4'-bis(diethylamino)benzophenone.

23. The method according to claim 22, wherein the polymerization accelerator is selected from the group consisting of dimethylpropyl toluidine, diisopropyl toluidine, and methylhydroxypropyl toluidine.

24. The method according to claim 16, wherein the at least one reactive (meth)acrylate monomer is selected from the group consisting of methyl methacrylate, butyl methacrylate, ethylhexyl acrylate, hydroxypropyl methacrylate, and lauryl methacrylate.

25. The method according to claim 24, wherein the at least one reactive (meth)acrylate monomer includes methyl methacrylate.

26. The method according to claim 16, wherein the polymerization initiator is an organic peroxide.

27. ​​The method according to claim 16, wherein the polymerization initiator is dibenzoyl peroxide.

28. The method according to claim 16, wherein the liquid curable composition is applied to the waterproof film such that the ballast protective film has a stepped cross-section.

29. The method according to claim 16, wherein the inorganic particles have an average D50 particle size of 0.5 mm to 3.0 mm.

30. The method according to claim 16, wherein the thickness of the uncured liquid curable composition is 0.5 mm to 50 mm.

31. The method according to claim 16, further comprising the step of curing the liquid curable composition at a temperature of -20°C to 50°C for less than one hour.

32. The method according to claim 16, further comprising the step of curing the liquid curable composition at a temperature of -20°C to 50°C for less than one hour.

33. The method according to claim 16, wherein the step of applying the liquid curable composition onto the waterproof film includes forming the protective film having a stepped cross-section or an inclined shape.

34. The method according to claim 16, wherein the base material includes a base plate made of concrete, steel, wood, or plastic.

35. A method for forming a single-layer ballast protective film on a waterproof film, a. The steps of providing at least one layer of a waterproof film on the surface of a substrate to form a waterproof seal on the surface, and b. At least one reactive (meth)acrylate monomer, A polymerization initiator configured to activate the polymerization of the reactive (meth)acrylate monomer, in an amount of about 1% to about 10% by weight based on the total weight of the liquid curable composition, Based on the total weight of the liquid curable composition, approximately 30% to approximately 90% by weight of silicon dioxide particles having an average D50 particle size of 0.01 mm to 4.0 mm, and optionally Paraffin beeswax in an amount of 1% by weight or less, one or more of the following: dispersant aid, calcium carbonate, plasticizer, accelerator, methacrylate copolymer or polyurethane acrylate, pigment, surfactant, thickener, anti-agglomerate, defoamer, dye, polymerization inhibitor, antifungal agent, antioxidant, UV absorber, and pH adjuster. The steps include: forming a liquid curable composition by mixing components consisting of, c. The step of applying the liquid curable composition to the surface of the waterproof membrane to an average uncured thickness of at least about 0.5 mm, wherein the liquid curable composition cures to form a single-layer protective film, and the underside of the protective film adheres to the surface of the waterproof membrane such that, when measured according to Method EN13653:2004, the protective film exhibits a shear adhesion force of more than 1 MPa to the waterproof membrane. The method, including the method described above.

36. The method according to claim 35, further comprising the step of adding a layer of ballast on the resin film.

37. The method according to claim 35, wherein the silicon dioxide particles have an average D50 particle size of 0.01 mm to 3.0 mm.

38. The method according to claim 35, wherein the liquid curable composition further comprises about 0.1 to about 5.0% by weight of a polymerization accelerator.

39. The method according to claim 38, wherein the polymerization accelerator is selected from the group consisting of dimethylpropyltoluidine, diisopropyltoluidine, and methylhydroxypropyltoluidine.

40. The method according to claim 35, wherein the at least one reactive (meth)acrylate monomer is selected from the group consisting of methyl methacrylate, butyl methacrylate, ethylhexyl acrylate, hydroxypropyl methacrylate, and lauryl methacrylate.