Epoxy Methane Barrier Coating for Concrete Retrofit
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Solution Overview
Problem
Existing methods for mitigating methane gas penetration in structures, such as those near landfills, are inadequate for preventing methane from passing through concrete floors and walls, especially in existing buildings where retrofitting is necessary without complete removal and re-pouring of concrete.
Innovation Solution
A dual mixture of a hardener and a resin, when mixed, forms an epoxy methane barrier layer that can be applied to concrete or shotcrete surfaces to prevent methane and VOCs from passing through, offering a topical solution for both new and existing structures without the need for extensive renovation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ventilation and capture systems are used to mitigate methane, then methane can be vented away from structures, but the systems are complex and require active mechanical components
Solution Approach 1:
The patent extracts the methane barrier function from complex active systems (ventilation fans, capture mechanisms) and embeds it directly into the concrete structure itself through a topical epoxy coating applied to the interior surfaces, eliminating the need for separate mechanical mitigation systems
Solution Approach 2:
The epoxy coating acts as an intermediary barrier layer between the concrete structure and methane gas, providing a chemical and physical barrier that prevents methane penetration without requiring active mechanical intervention
2Reliability
If complete removal and re-pouring of concrete is performed to install methane barriers, then effective methane proofing can be achieved, but the process is extremely time-consuming and disruptive
Solution Approach 1:
The epoxy coating is applied as a preliminary protective layer to the interior concrete surfaces before final flooring installation, establishing the methane barrier function in advance without requiring subsequent demolition or reconstruction
Solution Approach 2:
The patent uses a thin film epoxy coating applied to concrete surfaces to provide methane barrier functionality, replacing the need for thick structural modifications or complete concrete removal while maintaining effective gas prevention
3Adaptability or versatility
If existing concrete structures are retrofitted with methane barriers, then existing buildings can be protected, but conventional methods require extensive renovation and removal of existing surfaces
Solution Approach 1:
The epoxy coating is applied as a flexible thin film over existing concrete surfaces, allowing retrofit of existing structures without requiring removal or extensive renovation of the original concrete, simply requiring surface preparation and coating application
Solution Approach 2:
The epoxy coating system serves multiple functions simultaneously: it provides methane barrier protection, acts as a moisture barrier, and can serve as a preparatory layer for final flooring, making it universally applicable to various retrofit scenarios without requiring separate systems for each function
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The epoxy methane barrier effectively blocks methane and VOCs, providing a high-adhesion, moisture-resistant coating that can be quickly applied to cured concrete surfaces, extending the structure's usability without the need for complete reconstruction, and is suitable for both interior and exterior applications.
Implementation Method 1
providing a high-adhesion, moisture-resistant coating
Implementation Method 2
acts as a barrier, and prevents, and blocks methane, and VOC (Volatile Organic Compounds) from passing from one side of a structure to the other side
Data Source
AI summary
The present invention relates generally to an epoxy methane barrier for concrete floors and walls, and a method of making, and using same. More particularly, the invention encompasses a dual mixture of at least one hardener, and at least one resin, which when mixed together create an inventive methane barrier layer that acts as a barrier, and prevents, and blocks methane, and VOC (Volatile Organic Compounds) from passing from one side of a structure to the other side of the structure. The innovative barrier layer system can be used or applied along the insides of a wall, and on the top surface of a completed or cured floor or a foundation. This invention can be used on interior floors and walls of existing structures, such as, commercial and residential structures, and ADUs (Additional Dwelling Units) to methane proof the existing structures.