Composite waterproofing membrane

Abstract

A composite waterproofing membrane for waterproofing concrete slabs and foundation walls is disclosed. The waterproofing membrane comprises a rubberized asphalt layer, a polymeric bonding layer having one face bonded to one surface of the rubberized asphalt layer and having an opposing face with surface cavitations, and a vapor barrier layer bonded to the opposing surface of the rubberized asphalt layer. The surface cavitations of the bonding layer allow concrete poured against the bonding layer to fill in the cavitations and anchor the concrete to the bonding layer, thereby ensuring watertightness between the composite waterproofing membrane and the concrete. A method and system for waterproofing a blindside building foundation using the waterproofing membrane are also disclosed.

Description

COMPOSITE WATERPROOFING MEMBRANEFIELD OF THE INVENTION

[0001] The present technology relates generally to a composite waterproofing membrane for preventing water or moisture migration through concrete slabs and foundation walls. In particular, the present technology relates to a composite waterproofing membrane having improved adhesion to concrete that can minimize or prevent lateral water migration, particularly in blindside waterproofing applications.BACKGROUND

[0002] Waterproofing membranes are commonly used in the construction industry for keeping water and moisture away from concrete slabs and foundation walls. Current commercial moisture and vapor barriers are typically multilayer systems comprising a polymer-based barrier layer to limit moisture and water vapor migration. Polymers used in the barrier layer include thermoplastic polyolefins and elastomers. Additional layers in the multilayer systems may include a rubberized asphalt or bitumen layer, which can be modified with elastomers or polymers.

[0003] Blindside waterproofing is a method for waterproofing below ground structural concrete surfaces under continuous or intermittent hydrostatic pressure, where tight property lines do not allow access to the foundation wall for installation of conventional, post installed, selfadhering waterproofing. Conventional blindside waterproofing systems are pre-applied to the structural lag wall or concrete forms prior to pouring the below grade structural concrete foundations or retaining wall. The newly poured concrete contacts the waterproofing membrane and bonds to the waterproofing membrane as the concrete hardens. The outward facing surface of the membrane that receives the new concrete placement is an important aspect of a blindsidewaterproofing system since this surface (film or similar) must integrally bond to the new concrete pour to ensure watertightness.

[0004] One challenge with respect to waterproofing membranes is maintaining watertightness when disruptions in the integrity of the membrane occur. Disruptions may be caused by puncture or compromise during construction, such as, for example, from reinforcing steel intrusion or gravel puncture, tensile or shear forces against the membrane, or failure of the integrity of the bonding surface to the concrete. If watertightness is lost, water is able to flow laterally underneath or behind the membrane to infiltrate the building structure.

[0005] Significant research has been devoted to developing vapor barriers and waterproofing membranes having improved bonding layers that can provide sufficient bonding strength between the membrane and concrete to reduce or eliminate water vapor and moisture transmission and lateral water migration. Bonding layers that have been employed to promote bonding between the membrane and concrete include fleece materials and geotextile layers. Ideally, a blindside waterproofing membrane will meet ASTM D5385-Modified for Testing Lateral Water Migration, which specifies no water leaking at a pressure of at least 100 PSI, or higher, maintained for 1 hour or more.

[0006] It would be desirable to provide a composite waterproofing membrane that provides an improved adhesive bond with newly poured concrete thereby minimizing the potential for lateral water migration due to disruptions in the integrity of the membrane.SUMMARY OF THE INVENTION

[0007] The present technology relates to a composite waterproofing membrane that is particularly useful in blindside waterproofing applications. The waterproofing membrane includes a unique polymeric bonding layer having an irregular surface with depressions or cavitations thatallow concrete poured against the bonding layer to fill in the cavitations and anchor the concrete to the bonding layer. The cavitated surface structure advantageously decreases the potential for lateral water migration because the cavitations allow the cured concrete to be anchored in the polymeric bonding layer, ensuring a watertight seal that does not provide a pathway for water to migrate.F0008] One aspect of the present technology is a composite waterproofing membrane comprising (a) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations; (b) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and (c) a metallic barrier sheet adhered to the second face of the rubberized asphalt layer.

[0009] Another aspect of the present invention is a composite waterproofing membrane comprising (a) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations; (b) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and (c) a multilayer vapor barrier adhered to the second face of the rubberized asphalt layer.

[0010] In some embodiments, the composite waterproofing membrane mitigates lateral water movement at a pressure of at least 100 PSI, as determined by ASTM D5385 -Modified for Testing Lateral Water Migration.

[0011] Another aspect of the present technology is a method of waterproofing a blindside building foundation, the method comprising (a) forming a lagging wall; (b) applying a composite waterproofing membrane to the lagging wall, wherein the composite waterproofingmembrane comprises (i) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations; (ii) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and (iii) either a metallic barrier sheet or a multilayer vapor banner adhered to the second face of the rubberized asphalt layer; and wherein the metallic barrier sheet or multilayer vapor barrier of said composite waterproofing membrane is adjacent to the lagging wall and the polymeric bonding layer is facing the area into which concrete will be poured; (c) pouring the concrete against the polymeric bonding layer so that the concrete flows into the surface cavitations of the polymeric bonding layer to bond the composite waterproofing membrane to the concrete; and (d) allowing the concrete to harden.

[0012] Another aspect of the present invention is a system for waterproofing a blindside building foundation comprising (a) a lagging wall; (b) a composite waterproofing membrane adhered to the lagging wall, the composite waterproofing membrane comprising (i) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations; (ii) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and (iii) either a metallic barrier sheet having a first face and a second face, or a multilayer vapor barrier having a first face and a second face, wherein the first face of the metallic barrier sheet or multilayer vapor barrier is adhered to the second face of the rubberized asphalt layer, and the second face of the metallic barrier sheet or multilayer vapor barrier is adhered to the lagging wall; and (c) a concrete substrate embedded in the surface cavitations of the polymeric bonding layer.

[0013] A further aspect of the present invention is a kit for waterproofing a blindside building foundation, wherein the kit comprises (a) a composite waterproofing membrane comprising (i) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations; (ii) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and (iii) either a metallic barrier sheet or a multilayer vapor barrier adhered to the second face of the rubberized asphalt layer; and (b) instructions for installing the composite waterproofing membrane to waterproof the blindside building foundation. The kit may include additional items including measuring tools, cutting tools, and other components known in the art for installing a waterproofing membrane.BRIEF DESCRIPTION OF THE DRAWINGS

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

[0015] Figure 2 is a photograph showing the cavitated surface of the bonding layer of the composite membrane.

[0016] Figure 3 is an enlarged cross-section of an alternative embodiment of the composite layer of the present technology.

[0017] Figure 4 is a perspective view of a blindside installation of the composite membrane of the present technology showing the release strip for making an overlapped edge.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] While the presently described technology will be described in connection with one or more preferred embodiments, it will be understood by those skilled in the art that the technology is not limited to only those particular embodiments. To the contrary, the presentlydescribed technology includes all alternatives, modifications, and equivalents that can be included within the spirit and scope of the appended claims.

[0019] The term “about” means + / - 10% of the referenced value. In certain embodiments, about means + / - 5% of the referenced value, or + / - 4% of the referenced value, or + / - 3% of the referenced value, or + / - 3% of the referenced value, or + / - 2% of the referenced value, or + / - 1% of the referenced value.

[0020] The composite waterproofing membrane of the present technology comprises three principal layers: a rubberized asphalt layer, a polymeric bonding layer adhered to one side of the rubberized asphalt layer, and a vapor barrier adhered to the opposite side of the rubberized asphalt layer. The vapor barrier may be a single metallic sheet that exhibits a perm rating of less than 0.1 perms, or may be a multilayer vapor barrier having a perm rating of less than 0.1 perms. A perm is defined as the ability to allow one grain of water vapor to pass through one square foot of flat material in one hour at one inch of mercury. The multilayer vapor barrier can have at least two, alternatively, at least three, at least four, at least five, at least six, at least seven, or more layers, depending at least in part on the end use for the composite waterproofing membrane.

[0021] One embodiment of a composite waterproofing membrane of the present technology is shown in Figure 1, which depicts a cross-section of the membrane. The composite waterproofing membrane 10 comprises a rubberized asphalt layer 12 that is sandwiched between a polymeric bonding layer 20 on one side and a multilayer vapor barrier 30 on the opposite side. The rubberized asphalt layer 12 has a first face 14 that is bonded to a second face 24 of the polymeric bonding layer 20, and a second face 16 that is bonded to the multilayer vapor barrier30. Each of these layers will be described in further detail.Rubberized Asphalt Layer

[0022] The rubberized asphalt layer 12 of the waterproofing membrane 10 comprises a bituminous material modified with a polymeric material to provide elastomeric properties. The bituminous material comprises a mixture of hydrocarbons that may be obtained naturally or as a residue from petroleum distillation. Preferably, the bituminous material is a petroleum based homogeneous high softening point bituminous material and has a Pen Measurement of 0 to 400 dmm, as determined by ASTM D5. The polymeric material may comprise an atactic polypropylene, an isotactic polypropylene, a butyl rubber, ethylene-propylene-diene monomer (EPDM) rubber, a block copolymer, an isocyanate, polyphosphoric acid, sulfur, or a combination thereof. Examples of block copolymers that can be used to modify the bituminous material include, but are not limited to, styrene-butadiene- styrene, styrene-isoprene-styrene, styrene- ethylene-butylene-styrene, styrene-butadiene, and atactic polypropylene. The polymers in the block copolymer may be radial, linear, or a combination thereof, depending on the desired properties for the rubberized asphalt layer. Reclaimed tire rubber may also be used as a source of elastomeric polymeric material. The polymeric material in the rubberized asphalt layer may range from about 1 % to about 20% by weight, alternatively about 2% to about 20% by weight, based on the weight of the rubberized asphalt layer. The rubberized asphalt may also include plasticizing oils, such as aliphatic or aromatic oils, and inorganic fillers, such as silica, calcium carbonate, talc, or clay. The thickness of the rubberized asphalt layer can be in the range of about 125 microns to about 12,500 microns.Polymeric Bonding Layer

[0023] Referring to Figures 1 and 2, the polymeric bonding layer 20 of the waterproofing membrane 10 is a sheet-like film having a first face 22 having surface cavitations26, and a second, opposing face 24 that is bonded to the first face 14 of the rubberized asphalt layer 12. The polymeric bonding layer and the rubberized asphalt layer can be bonded together using heat and / or pressure. The surface cavitations 26 permit the polymeric bonding layer 20 to form an integral bond between the bonding layer of the waterproofing membrane 10 and concrete poured against the bonding layer. As best seen in Figure 2, the surface cavitations 26 are highly irregular, surface defects in the form of open, discrete craters or cavities that can have diameters or opening sizes of various dimensions ranging between about 1 mm and about 6 mm and a depth of up to about 175 microns. The cavitations can be formed by applying a foamed (large bubbles) warm polymeric material to the surface of a smooth polymeric sheet. The laminated polymeric material is then run through a set of pressure rollers where the foam bubbles break leaving behind the surface cavitations. Without being bound by theory, it is believed that the cavitations in the first face 22 of the polymeric bonding layer 20 allow wet concrete to fill in the craters and anchor the concrete to the bonding layer, thereby mechanically adhering the polymeric bonding layer to the concrete as the concrete dries. The cavitated surface structure also advantageously decreases the potential for lateral water migration because the cavitations allow the cured concrete to be anchored in the polymeric bonding layer, ensuring a watertight seal that does not provide a pathway for water to migrate.

[0024] The polymeric bonding layer 20 is preferably formed from one or more thermoplastic or thermosetting materials, or a combination thereof. Polymeric films having surface cavitations that are suitable for use herein are commercially available. Exemplary materials for the polymeric bonding layer include polyolefin materials, such as polypropylene or polyethylene, nylon, polyethylene terephthalate (PET), ethylene vinyl acetate, or kevlar. In one embodiment, the polymeric bonding layer comprises polypropylene. The polymeric bonding layermay also be a multi-layer laminated film having at least a polymeric substrate layer and one or more additional polymeric layers laminated or fused together to form the polymeric bonding layer. The polymeric layers may be formed from the same polymer or different polymers. In some embodiments, the substrate layer may be formed from a linear polyethylene polymer, and a second layer laminated to the substrate layer may be formed from a linear polypropylene polymer. In some embodiments, the polymeric bonding layer 20 may include one or more polymeric nonwoven porous webs melted into, fused, or otherwise adhered to the cavitated side of the polymeric bonding layer 20. The nonwoven web or webs can be formed from polyethylene, polypropylene, copolyester, copolyimide, polyurethane, ethylene vinyl acetate, polyolefin, or combinations thereof. The polymeric bonding layer 20 may also include up to about 10% by weight, alternatively up to about 5% by weight of inert mineral filler. Inert mineral fillers can include for example, calcium carbonate, crystalline silicas, clay, and talc.

[0025] The polymeric bonding layer 20 may have a total thickness in the range of about 25 microns to about 225 microns, alternatively about 25 microns to about 200 microns, alternatively about 25 microns to about 150 microns, alternatively about 25 microns to about 100 microns.Vapor Barrier

[0026] The multi-layer vapor barrier 30 of the waterproofing membrane 10 comprises a metallic sheet 32 laminated between two composite outer layers 34 and 36. The metallic sheet 32 forms a core of the multi-layer vapor barrier and can be any metal that limits water vapor transmission. Useful metals for the metallic sheet include aluminum, copper, tin, zinc, lead, or combinations thereof. The metallic sheet 32 has barrier properties that limit water vapor transmission and decrease the transmission of harmful gases, such as radon, methane, ethane andpropane. The metallic sheet 32 could be an aluminum vapor deposition film produced by forming a vapor deposition layer having a film thickness of 5 nm or more on a base material film surface. Such films typically have a base film thickness in the range of 40 to 125 nm and an oxide vapor deposition film thickness in the range of 10 to 25 nm. Alternatively, the metallic sheet 32 could be an aluminum film or foil having a thickness of about 2 microns or more, or 7 microns or more.10027] Each composite outer layer 34 and 36 comprises a polyolefin film layer 34a and 36a, respectively, a thermoplastic film layer 34c and 36c, respectively, and a primer layer 34b and 36b, respectively. The primer layer 34b and 36b are each sandwiched between the respective polyolefin film layer and the thermoplastic film layer in each composite outer layer, and bond each respective polyolefin film layer to the respective thermoplastic film layer. The composite outer layers 34 and 36 provide mechanical stability and puncture resistance properties and protect the metallic sheet from corrosion. Preferably, the composite outer layers arc formed from polymeric materials that are vapor- impervious to enhance the barrier properties of the metallic sheet.

[0028] The polyolefin film layer 34a of the composite outer layer 34 is adhered to one side of the metallic sheet 32, and the polyolefin film layer 36a of the composite outer layer 36 is adhered to the opposite side of the metallic sheet. The polyolefin layers 34a and 36a are preferably formed from a polyolefin resin, such as polyethylene, low density polyethylene, or a blend of polyethylene and low density polyethylene. Preferably, the polyolefin film layers 34a and 36a have adhesive properties enabling them to be securely adhered to the metallic sheet 32.

[0029] The primer layers 34b and 36b securely bond the respective thermoplastic film layers 34c and 36c to the respective polyolefin film layers 34a and 36a to form the composite outer layers 34 and 36. The primer layers 34b and 36b can be formed from any material that promotes bonding between the polyolefin film layer and the thermoplastic film layer.

[0030] The thermoplastic film layers 34c and 36c are the outermost layers of the composite outer layers 34 and 36, respectively, and are formed from a thermoplastic polymer resin such as polyethylene terephthalate (PET). The thermoplastic film layer 34c is adhered to the second face 16 of the rubberized asphalt layer 12 to join the multilayer vapor barrier 30 to the rubberized asphalt layer. Adhesion of the thermoplastic film layer 34c to the rubberized asphalt layer can be accomplished by laminating the multilayer vapor barrier and the rubberized asphalt layer together under heat and pressure. The thermoplastic film layer may also be physically surface treated to promote adhesion between the multilayer vapor barrier 30 and the rubberized asphalt layer 12. For example, physical surface treatment can be done by means of flame treatment or a corona treatment in which high frequency voltage is applied to the surface of the thermoplastic film. The corona treatment results in a change in the chemistry of the surface, enhancing bonding to the rubberized asphalt layer. Flame or plasma surface treatment could also be used to change the chemistry of the thermoplastic film surface to impart improved adhesion properties. Adhesion to the rubberized asphalt layer could also be promoted by applying a chemical adhesion promoter to the surface of the thermoplastic film layer 34c. For example, the adhesion promoter could be an acrylic coating, preferably selected from the group consisting of a cross linked copolymer of methacrylic acid ester and glycidyl acrylate, or methacrylate, or a copolymer of acrylonitrile and styrene. The multilayer vapor barrier may have a total thickness ranging from about 25 microns to about 1300 microns.

[0031] The multi-layer vapor barrier provides a water and vapor barrier that substantially prevents infiltration of moisture, with a perm rating of less than 0.1 perms, preferably less than 0.01 perms, and most preferably less than 0.002 perms. The multilayer vapor barrieralso has excellent tensile strength and puncture resistance, and decreases radon and methane transmission.

[0032] Referring to Figure 3, an alternative embodiment of a waterproofing membrane of the present technology is shown in which the multi-layer barrier layer is replaced by a metallic barrier sheet 50. In this embodiment, the waterproofing membrane 11 comprises a rubberized asphalt layer 12 and a polymeric bonding layer 20 as previously described, and a metallic barrier sheet 50 that is bonded to the second face 16 of the rubberized asphalt layer 12. Bonding of the metallic barrier sheet 50 to the rubberized asphalt layer can be accomplished by laminating the metallic barrier sheet and the rubberized asphalt layer together under heat and pressure.

[0033] The metallic barrier sheet is a film or foil layer that can be formed from any metal that limits water vapor transmission. Preferably, the metallic barrier sheet has a water vapor migration of less than 0.01 perms, as determined by ASTM E96 Method A and / or Method B. Useful metals for the metallic barrier sheet include aluminum, copper, tin, zinc, lead, or combinations thereof. In some embodiments, the metallic barrier sheet could be an aluminum vapor deposition film or aluminum foil or film as described above for the metallic sheet 32. In some embodiments, the metallic barrier sheet can have a thickness in the range of about 2 microns to about 130 microns.

[0034] The composite waterproofing membranes of the present technology have an overall thickness in the range of about 500 microns to about 12,700 microns. When properly installed, the waterproofing membranes provide several improvements and advantages over prior art waterproofing membranes. Without being bound by theory, it is believed that, because the cavitations in the bonding layer are discrete cavities and not interconnected, there is no pathway for lateral water migration if the composite waterproofing membrane is compromised. As a result,the composite waterproofing membranes of the present technology can mitigate lateral water movement at a pressure of at least 100 PSI, as determined by ASTM D5385-Modified for Lateral Water Migration. The composite waterproofing membranes can also resist hydrostatic water pressure of at least 100 PSI, as determined by ASTM D5385, have a puncture resistance ranging from 40 pounds to about 300 pounds, as determined by ASTM E154, and a water vapor migration of less than 0.01 perms, as determined by ASTM E96 Method A and / or Method B. In some embodiments, the waterproofing membranes have a water vapor migration of between 0.001 and 0.01 perms.

[0035] Another advantage of the waterproofing membrane is that installation of the membrane is not limited by temperature, precipitation (rain), humidity, atmospheric dew point, or surface cleanliness, since the bond between the polymeric bonding layer and the poured concrete is a mechanical bond. By contrast, the strength of an adhesive bond between a waterproofing membrane and a concrete substrate may be affected by temperature, humidity, dew point, or surface cleanliness, limiting the conditions under which an adhesively bonded waterproofing membrane may be installed. The cavitated polymeric bonding layer of the present technology is also advantageous over fleece, geotextile, and other fibrous bonding layers, since the cavitations of the polymeric bonding layer do not have fibers that can flatten or become water-saturated when interacting with ground water conditions during the life of the product.Methods of Use

[0036] Another aspect of the present technology is a method for waterproofing a concrete structure. The concrete structure can be any hardened concrete structure or substrate that needs to be sealed against moisture and / or water. The structure can be above grade or below grade and can be horizontal or vertical. The waterproofing membranes of the present technology areparticularly suitable for waterproofing below grade substrates and structures, such as a blindside building foundation, although the waterproofing membranes are suitable for other uses as well, such as waterproofing cured concrete structures.

[0037] The method of waterproofing a concrete structure comprises applying the composite waterproofing membrane of the present technology to a building substrate or concrete form, with the polymeric bonding layer of the membrane facing the area into which the concrete will be poured. Any of the embodiments of the waterproofing membrane described herein may be used for waterproofing the concrete structure. Fresh concrete is then poured against the surface cavitations of the polymeric bonding layer. The fresh concrete flows into the cavitations and is allowed to harden. As the concrete hardens, it forms a strong mechanical bond with the polymeric bonding layer, thereby securing the waterproofing membrane to the concrete structure.

[0038] A further aspect of the present technology is a method of waterproofing a blindside building foundation. The method comprises forming a lagging wall, and applying any embodiment of the composite waterproofing membrane of the present technology to the lagging wall, with the polymeric bonding layer facing the area into which the concrete will be poured. Concrete is then poured against the polymeric bonding layer so that the concrete flows into the surface cavitations of the bonding layer. The concrete is allowed to harden, thereby bonding the waterproofing membrane to the concrete. Generally, the lagging wall is installed vertically next to soil and is formed from a plurality of piles and a plurality of lagging planks placed between and spanning adjacent piles. The composite waterproofing membrane may be secured to the lagging wall using mechanical fasteners or the like, with the polymeric bonding layer facing away from the lagging wall. In some embodiments, the composite waterproofing membrane may be installed vertically by attaching the membrane to the lagging wall using fasteners applied about 12 inchesapart across the top, allowing the waterproofing membrane 10 to hang down the wall while awaiting the concrete pour. It should be appreciated that the waterproofing membrane can be installed in blindside applications that employ substrates other than a lagging wall. Other common substrates include cormgated steel piles, auger cast caissons, rock, and shotcrete, among others.

[0039] Referring to Figure 4, the waterproofing membrane 10 is typically installed with overlapping side seams. The overlap may be about 4 inches, alternatively about 6 inches, alternatively about 8 inches. Desirably, the waterproofing membrane includes a removable release strip 40 along the side edge of the waterproofing membrane. Removing the release paper exposes the rubberized asphalt layer of the membrane. A subsequent waterproofing membrane sheet can then be placed so that it overlaps the exposed rubberized asphalt, and roller pressure is applied to the overlapped side seam to ensure good adhesion.

[0040] In some embodiments, the composite waterproofing membrane may be installed horizontally. For a horizontal slab installation, the waterproofing membrane is applied to a substrate of compacted base materials or soil with the vapor barrier against the substrate and the polymeric bonding layer facing upward or away from the substrate. Subsequent waterproofing membrane sheets are typically installed with overlapping side seams and roll pressed to ensure good adhesion. For a horizontal foundation wall installation, membrane sheets are applied in rows from bottom to top so that each successive membrane sheet overlaps the adjacent lower membrane to achieve better water shedding. Once the waterproofing membrane sheets are installed, concrete is poured against the polymeric bonding layer so that the concrete flows into the surface cavitations of the bonding layer. The concrete is allowed to harden, thereby bonding the waterproofing membrane to the concrete.

[0041] In another embodiment, the composite waterproofing membrane may be part of a waterproofing system for waterproofing a blindside building foundation. The waterproofing system includes a lagging wall, a composite waterproofing membrane adhered to the lagging wall, wherein the composite waterproofing membrane may be any of the composite waterproofing membranes described above, and a concrete substrate embedded in the surface cavitations of the polymeric bonding layer of the composite waterproofing membrane.

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

[0043] The presently described technology and its advantages will be better understood by reference to the following examples. These examples are provided to describe specific embodiments of the present technology. By providing these specific examples, it is not intended to limit the scope and spirit of the present technology. It will be understood by those skilled in the art that the full scope of the presently described technology encompasses the subject matter defined by the claims appended to this specification, and any alterations, modifications, or equivalents of those claims.

[0044] The following test methods are used to determine properties of the composite waterproofing membrane of the present technology.

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

[0046] Membrane puncture resistance is measured according to ASTM El 54.

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

[0048] ASTM D5385-Modified for Testing Lateral Water Migration is used to determine lateral water migration of the composite waterproofing membrane tested up to a maximum pressure of 100 PSI exerted between the bonding layer and the concrete. For the modified ASTM D5385 test, a 1-inch square hole is cut out of the center of the waterproofing membrane to form a compromise, i.e. a direct, unobstructed pathway for the pressurized water to apply a hydrostatic force between the cavitated face of the waterproofing membrane and the concrete. The waterproofing membrane is placed in a concrete form with the cavitated surface layer facing up. On each opposite end of the concrete form, a half-inch diameter pipe is placed perpendicularly to the waterproofing membrane, with one open end of the pipe up against the cavitated surface of the waterproofing membrane prior to the concrete being poured, and the other open end extending out of the concrete form. The pipe forms a pathway for any water that may laterally migrate during the test. Concrete is then poured into the form, allowed to harden, and then cured for a minimum of 28 days. The cured concrete is removed from the form and mounted in the hydrostatic test equipment for testing. Testing occurs at incremental pressures up to a maximum of 100 psi and continues for at least one hour at a pressure of 100 psi. The test is a pass / fail test, and passes if no water has been recorded leaking from the inserted pipe up against the membrane face after at least one hour at a pressure of 100 psi.EXAMPLESExample 1 : Preparation of Example Membrane

[0049] A waterproofing membrane according to the present technology was prepared with the following layers. The polymeric bonding layer is a cavitated polymeric film having apolyethylene substrate and a polypropylene top layer. The top layer has surface cavitations as depicted in Figure 2. Total thickness of the polymeric bonding layer is about 100 microns. The rubberized asphalt layer is comprised of asphalt, styrene-butadiene-styrene rubber, reclaimed tire rubber, process oil, and inorganic filler, and has a thickness of about 1676 microns. The vapor barrier is a 7-layer composite sheet having the following layers: PET / primer / PE-LDPE / aluminum foil / PE-LDPE / primer / PET, and a thickness of about 76 microns. Total thickness of the waterproofing membrane is about 1854 microns. The waterproofing membrane has a water vapor migration of less than 0.10 perms as determined by ASTM E96 Method A and Method B and has a puncture resistance of at least 210 pounds, as determined by ASTM E154.Example 2: Lateral Water Migration Testing

[0050] The waterproofing membrane of Example 1 was tested for lateral water migration using the ASTM D5385-Modified for Testing Lateral Water Migration method described above. No pipe leaks were observed after one hour at a pressure of 100 psi.Example 3: Hydrostatic Pressure Resistance Testing

[0051] The waterproofing membrane of Example 1 was tested for hydrostatic pressure resistance in accordance with ASTM D5385. In this test, test samples of the waterproofing membrane were prepared with overlapping seams. After one hour, no leakage occurred in the test specimens between 0-100 psi.Example 4: Water Vapor Transmission

[0052] The waterproofing membrane of Example 1 was evaluated for water vapor migration in accordance with ASTM E96 Method A and Method B. For each test method, three 3-inch diameter samples were cut from one waterproofing membrane sheet. The average water vapor transmission for the waterproofing membrane according to Method A was 0.001 perms(grains / h-ft2-in Hg) and the average water vapor transmission according to Method B was 0.003 perms (grains / h-ft2-in Hg).Example 5 : Puncture Resistance

[0053] The waterproofing membrane of Example 1 was evaluated for puncture resistance in accordance with ASTM E154 Section 10. The waterproofing membrane had a puncture resistance of 210 pounds.Example 6: Alternative Embodiment

[0054] An alternative embodiment of the waterproofing membrane is prepared with an alternative embodiment of the polymeric bonding layer. The rubberized asphalt layer and vapor barrier layer are the same as in the Example 1 waterproofing membrane. In this alternative embodiment, a nonwoven porous polymeric web is applied to the cavitated surface of a cavitated polypropylene film. The non-cavitated side of the cavitated polypropylene film is heated to a temperature above the melt temperature of the polymeric web and the polymeric web is pressed onto and melts into the cavitated side of the cavitated polypropylene film. The cavitated polypropylene film is allowed to cool, and a second nonwoven porous polymeric web is applied to the cavitated surface in a manner such that the second polymeric web is not fully melted.

[0055] The present technology is now described in such full, clear and concise terms as to enable a person skilled in the art to which it pertains, to practice the same. It is to be understood that the foregoing describes preferred embodiments of the present technology and that modifications may be made therein without departing from the spirit or scope of the present technology as set forth in the appended claims. Further, the examples are provided to not be exhaustive but illustrative of several embodiments that fall within the scope of the claims.

Claims

What is claimed is:

1. A composite waterproofing membrane comprising:(a) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations;(b) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and(c) a metallic barrier sheet adhered to the second face of the rubberized asphalt layer.

2. A composite waterproofing membrane comprising:(a) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations;(b) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and(c) a multilayer vapor barrier adhered to the second face of the rubberized asphalt layer.

3. The membrane of claim 1 or 2, wherein the polymeric bonding layer comprises polypropylene, polyethylene, nylon, polyethylene terephthalate, ethylene vinyl acetate, Kevlar, or a combination thereof.

4. The membrane of any one of claims 1 -3, wherein the polymeric bonding layer has a thickness in the range of 25 microns to 225 microns, or 50 microns to 200 microns, or 50 microns to 175 microns.

5. The membrane of any one of claims 1-4, wherein the polymeric bonding layer comprises up to 10 wt% of inert mineral filler.

6. The membrane of any one of claims 1 -5, wherein the polymeric bonding layer is a multi-layer film.

7. The membrane of claim 6, wherein the multi-layer film comprises at least one polymeric web.

8. The membrane of any one of claims 1-7, wherein the rubberized asphalt layer comprises an elastomeric material comprising one or more of an atactic polypropylene, an isotactic polypropylene, a butyl rubber, ethylene-propylene-diene monomer (EPDM) rubber, a block copolymer, an isocyanate, polyphosphoric acid, sulfur, or a combination thereof.

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

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

11. The membrane of any one of claims 1 and 3-10, wherein the metallic barrier sheet comprises aluminum, copper, lead, tin, zinc or combinations thereof.

12. The membrane of any one of claims 1 and 3-11, wherein the metallic barrier sheet has a thickness in the range of about 2 microns to about 130 microns.

13. The membrane of any one of claims 1-12, wherein the membrane resists hydrostatic water pressure of at least 100 PSI, as determined by ASTM D5385.

14. The membrane of any one of claims 1-13, wherein the membrane mitigates lateral water movement at a pressure of at least 100 PSI, as determined by ASTM D5385 Modified for Testing Lateral Water Migration.

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

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

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

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

19. The membrane of any one of claims 17-18, wherein the metallic sheet is an aluminum foil sheet.

20. The membrane of any one of claims 2-19, wherein the multilayer vapor barrier has a thickness of about 25 microns to about 1300 microns.

21. A method of waterproofing a concrete structure comprising (a) applying a composite waterproofing membrane of any one of claims 1-20 to a building substrate or concrete form, with the polymeric bonding layer of said composite waterproofing membrane facing the area into which concrete will be poured, and (b) pouring the concrete against the surface cavitations of the polymeric bonding layer to bond the composite waterproofing membrane to the concrete.

22. A method of waterproofing a blindside building foundation, the method comprising:(a) forming a lagging wall;(b) applying a composite waterproofing membrane to the lagging wall, wherein the composite waterproofing membrane comprises (i) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations; (ii) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and (iii) either a metallic barrier sheet or a multilayer vapor barrier adhered to the second face of the rubberized asphaltlayer; and wherein the metallic barrier sheet or the multilayer vapor barrier of said composite waterproofing membrane is adjacent to the lagging wall and the polymeric bonding layer is facing the area into which concrete will be poured;(c) pouring the concrete against the polymeric bonding layer so that the concrete flows into the surface cavitations of the polymeric bonding layer to bond the composite waterproofing membrane to the concrete; and(d) allowing the concrete to harden.

23. A system for waterproofing a blindside building foundation comprising:(a) a lagging wall;(b) a composite waterproofing membrane adhered to the lagging wall, the composite waterproofing membrane comprising (i) a polymeric bonding layer comprising a first face and a second, opposing face, the first face of the polymeric bonding layer having surface cavitations; (ii) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and (iii) either a metallic barrier sheet having a first face and a second face or a multilayer vapor barrier having a first face and a second face, wherein the first face of the metallic barrier sheet or the first face of the multilayer vapor barrier is adhered to the second face of the rubberized asphalt layer, and the second face of the metallic barrier sheet or the second face of the multilayer vapor barrier is adhered to the lagging wall; and(c) a concrete substrate embedded in the surface cavitations of the polymeric bonding layer.

24. A kit for waterproofing a blindside building foundation comprising:(a) a composite waterproofing membrane comprising (i) a polymeric bonding layer comprising a first face and a second, opposing face, the first face ofthe polymeric bonding layer having surface cavitations; (ii) a rubberized asphalt layer having a first face and a second, opposing face, the first face of the rubberized asphalt layer being directly bonded to the second face of the polymeric bonding layer; and (iii) a metallic barrier sheet or a multilayer vapor barrier adhered to the second face of the rubberized asphalt layer; and(b) instructions for installing the composite waterproofing membrane to waterproof the blindside building foundation.

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

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