US20080104917A1 - Self-adhering waterproofing membrane - Google Patents
Self-adhering waterproofing membrane Download PDFInfo
- Publication number
- US20080104917A1 US20080104917A1 US11/881,245 US88124507A US2008104917A1 US 20080104917 A1 US20080104917 A1 US 20080104917A1 US 88124507 A US88124507 A US 88124507A US 2008104917 A1 US2008104917 A1 US 2008104917A1
- Authority
- US
- United States
- Prior art keywords
- layer
- membrane
- accordance
- cushion material
- waterproof
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D5/00—Roof covering by making use of flexible material, e.g. supplied in roll form
- E04D5/10—Roof covering by making use of flexible material, e.g. supplied in roll form by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
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- Engineering & Computer Science (AREA)
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- Laminated Bodies (AREA)
Abstract
A membrane for application to a surface of a structure to provide waterproofing protection to the structure, the membrane including a surface layer of thermoplastic or elastomeric material, a layer of cushion material sealed to the layer of thermoplastic or elastomeric material, a pressure sensitive adhesive bound to a side of the cushion material remote from the thermoplastic or elastomeric material, and a release liner removably mounted on the pressure sensitive adhesive.
Description
- This application claims priority from U.S. Provisional Patent Application No. 60/856,155, filed Nov. 2, 2006, and U.S. Provisional Application No. 60/934,785, filed Jun. 15, 2007, both filed in the names of Brian J. Whelan, Gary W. Whittemore, Dan Ben-Daat, and Jon M. Jensen.
- 1. Field of the Invention
- The invention is directed to a self-adhering membrane which may be applied to roof and/or wall structures, particularly “green” roof and plaza deck constructions, including planters, balconies, terraces, foundation walls, tunnel structures, and the like.
- 2. Description of the Prior Art
- It has become increasingly popular to provide new building and other constructions with green roofs, that is, roofs supporting earth, grass, and plantings, often with walk-ways and/or terraces. The roof decks frequently are made of structural concrete or metal decking covered with a rigid hardboard, sometimes metal-covered, and covered with a water-proof thermoplastic membrane applied to the outside surface of the concrete, rigid hardboard, or other substrate. Inasmuch as the membrane is typically of the type customarily used on conventional non-green rooftops, and having a thickness of about 60 or more mils, the membrane must be applied to a very smooth and clean concrete, rigid hardboard, or other rigid surface. Irregularities in the smoothness of the outside surface of the substrate can produce perforations and punctures in the membrane which breach the water-tight integrity of the membrane. The same problem applies to foundation walls, tunnel structures, and the like, of structural concrete or masonry.
- In an effort to better absorb and conform to irregularities in the substrate surface, a layer of felt-like material has been used to form a cushion layer of sorts between the substrate surface and the waterproof membrane. However, it has been discovered that while perforations and punctures in the membrane are reduced, any that remain or occur allow water passing therethrough to flow into the felt-like material which acts like a wick and spreads the water out in directions not easy to determine. Because of lateral migration of the water, a leak in the membrane in a first area may make itself known in remote second areas. Determining the location of the leak into the underlying structure can be extremely difficult, expensive and time-consuming to accomplish, inasmuch as removal of the overburden is required to gain access to a breach in the membrane.
- To overcome the above-noted problems, resort has been made to adhered liquid materials, such as hot rubberized asphalt (HRA), a system which, as the name implies, involves the laying down of HRA in the form of a hot liquid, usually of about 150-215 mils thickness. In such procedures, precautions must be taken with respect to workers inhaling fumes, handling hot kettles, and the hot asphalt. The odor and smell of asphalt tends to travel and irritate nearby site workers, building occupants and general public. Further, usually no portion of the area can be used during installation of HRA nor after installation until the HRA cools and solidifies.
- Cold-applied liquid products are also used in such applications, best installed in thinner coatings of around 60 mils thickness. Such materials have fewer application issues inasmuch as they are applied at ambient temperatures, but often contain solvents which have odors and repugnant smells, or, when spray-applied, produce air-borne particulates that create a potential hazard for installers, site workers, and building occupants.
- Thus, there is a need for an effective, efficient, less expensive, odor and solvent-free, and less hazardous material and method for laying a waterproofing membrane down over a structure that is subject to a wet or moist external environment.
- Accordingly, an object of the invention is to provide a waterproofing membrane for application to a surface of a structure to provide waterproofing and moisture protection to the structure, and which does not provide a medium for lateral migration of water therethrough.
- A further object of the invention is to provide a method for making a waterproof membrane for application to a surface of a structure.
- A further object of the invention is to provide a roof/wall, foundation or tunnel structure providing watertight integrity.
- A still further object of the invention is to provide a method for waterproofing a roof and/or a wall, foundation or tunnel structure.
- A still further object of the invention is to provide a method for increasing puncture resistance of a thermoplastic membrane for use in water proofing subterranean structures and surfaces.
- With the above and other objects in view, as will hereinafter appear, a feature of the present invention is the provision of a membrane for application to a surface of a structure to provide waterproofing and moisture protection to the structure. The membrane includes an outer surface layer of thermoplastic material, a layer of cushion material laminated to, or fused to, or adhered to, an inner surface of the layer of thermoplastic material, a pressure sensitive adhesive bound to a side of the cushion material remote from the thermoplastic layer, and a release liner removably mounted on the remote side of the pressure sensitive adhesive.
- In accordance with a further feature of the invention, there is provided a method for making a waterproof membrane, the method comprising the steps of providing a layer of cushion material, bonding a layer of waterproof thermoplastic material to a first side of the layer of cushion material, affixing a layer of pressure sensitive adhesive to a second side of the layer of cushion material, and mounting a release liner on a side of the pressure sensitive adhesive remote from the cushion material.
- In accordance with a further feature of the invention, there is provided a roof/wall, foundation or tunnel structure (hereinafter “roof/wall”) comprising a substantially rigid substrate, and a laminar membrane adhesively bonded to an outer surface of the substrate. The membrane comprises an outer surface layer of thermoplastic material, a layer of cushion material bound to an inner surface of the layer of thermoplastic material, and a pressure sensitive adhesive bound to a side of the cushion material remote from the thermoplastic layer, and bound to the substrate.
- In accordance with a still further feature of the invention, there is provided a method for waterproofing a structural surface. The method comprises the steps of providing a membrane for application to the surface, the membrane comprising an outer surface layer of thermoplastic material, a layer of cushion material laminated to, or fused to, or adhered to an inner surface of the layer of thermoplastic material, a pressure sensitive adhesive bound to a surface of the cushion material remote from the thermoplastic layer, and a release liner removably mounted on the remote side of the pressure sensitive adhesive, removing the release liner to expose the pressure sensitive adhesive, and pressing the pressure sensitive adhesive against the structural surface to conform the layer of cushion material to the structural surface and bind the waterproofing membrane to the structural surface.
- In accordance with a still further feature of the invention, there is provided a method for increasing puncture resistance of a thermoplastic membrane for use in water proofing of subterranean structural substrates. The method comprises bonding a layer of cushion material to the thermoplastic membrane, the cushion material comprising a cellular foam material, the cushion material being adapted to conform around minor irregularities in a surface of the structural substrate.
- The above and other features of the invention, including various novel details of construction, combinations of parts, and method steps, will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular laminar combinations and methods embodying the invention are shown by way of illustration only and not as limitations of the invention. The principles and features of this invention may be employed in various and numerous embodiments without departing from the scope of the invention.
- Reference is made to the accompanying drawings in which are shown illustrative embodiments of the invention, from which its novel features and advantages will be apparent.
- In the drawings:
-
FIG. 1 is a diagrammatic sectional view of one form of a portion of a waterproofing membrane illustrative of an embodiment of the invention; and -
FIG. 2 is a diagrammatic sectional view of one form of a portion of a waterproofed roof/wall structure illustrative of a further embodiment of the invention. - Referring to
FIG. 1 , it will be seen that theillustrative waterproofing membrane 10 includes anouter surface layer 12 of thermoplastic waterproof material, such as vinyl or polyolefin, bonded to a cellularfoam backing layer 14 coated with a pressuresensitive adhesive 16. The bonding of thebacking layer 14 to thesurface layer 12 may be accomplished by adhesive adhering, laminating, extrusion coating, heat sealing, gluing or taping, or the like. A manuallyremovable release liner 18 is mounted on anundersurface 17 of the pressuresensitive adhesive 16 prior to application of themembrane 10 to a roof/wall structure 20 (FIG. 2 ). - The total
composite membrane 10 may be about 120-140 mils or greater, in thickness, including the layer ofwaterproof material 12, which may be about 60 mils, or greater, in thickness, and thefoam backing layer 14, which may be also about 60 mils, or greater, in thickness. Alternatively, thelayer 12 may be 0.015-0.080 inch in thickness, and thebacking layer 14 may be 0.015-0.375 inch in thickness, depending upon the particulars of a specific application or project. - The flexible foam backing 14 conforms around minor irregularities in the roof/
wall structure 20. The pressuresensitive adhesive 16 provides a strong bond between themembrane 10 and the roof/wall structure 20, even in the presence of water and concrete alkalis. - The
structure 20 typically is a green roof and/or a plaza deck serving as a roof structure for a work space or habitat therebeneath. Because of the heavy loads associated with such applications, the supportingdeck 20 is most often structural concrete. The external environment for such roofs is generally at least damp and often subject to wetness, including pooling or ponding. The structure may also be a foundation wall or an earth sheltered structure or tunnel. Themembrane 10 accordingly is designed to protect thestructure 20 from the effects of water infiltration which can lead to structural deterioration and interior water damage. - In one embodiment, the
outer surface layer 12 is a thermoplastic flexible sheet, made of vinyl or polyolefin, most commonly with an integral reinforcing material, such as glass fiber, polyester, nylon, or similar material. Thebacking layer 14 preferably is a cellular foam, such as a non-absorptive closed cell foam. Thebacking layer 14 is provided with the pressuresensitive adhesive 16 which is factory-applied and protected by therelease liner 18 which is removed during application. Thelaminar membrane 10 has been found to substantially increase puncture resistance, compared to standard prior art membranes which do not include a backing layer. - Preferably, the
surface layer 12 extends beyond aside edge 22 of the foam backing layer by about 2-4 inches to provide aselvedge 24. Themembrane 10 is shown in width-wise cross section inFIGS. 1 and 2 and is typically provided in rolls which are 6.5-12.0 feet in width with, additionally, the 2-4inch selvedge 24 on one side. In positioning themembrane 10 on thestructure 20, the membrane sheets are disposed side-by-side with the foam backing layers 14 tightly abutting each other, and with theselvedge 24 overlapping the top of an adjoining membrane. Theselvedge 24 is bonded, as by adhesives, glues, tapes, hot-air or solvent welding, to the overlapped membrane surface layer to provide bonded seams which will not deteriorate in the presence of water, moisture, roots, micro-organisms, and the like. - There is thus provided a waterproofing membrane which can be applied directly to concrete and other substances. The membrane finds particular application to green roof, plaza deck, planter, balcony and terrace substrates, foundation walls and tunnels, and is highly resistant to sub-grade environments of constant dampness, high alkalinity, exposure to plant roots, fungi, and bacterial organisms, as well as hydrostatic pressure, including ponded water conditions.
- The
membrane 10 is factory produced in its entirety. There is no assembly of the membrane at the work site; even the adhesive 16 by which themembrane 10 is applied to thestructural substrate 20, is provided on the membrane and protected until the point of attachment by a readilyremovable release liner 18. - The membrane is made by providing the cellular foam backing, or
cushion layer 14, of a selected length and width suitable for subsequent packaging in roll form. The layer of thermoplasticwaterproof material 12 is bonded to a first side of thecushion layer 14. The layer of pressuresensitive adhesive 16 is deposited on a second side of thecushion layer 14, and therelease liner 18 is mounted on the pressure sensitive adhesive 16 to completely cover the adhesive. - Preferably, the layer of thermoplastic
waterproof material 12 extends beyond oneside edge 22 of thecushion layer 14 to provide theaforementioned selvedge 24. - In the event of any incompatibility between the
cushion material 14 and the pressuresensitive adhesive 16, abarrier film 26 may be interposed therebetween. - The assembled membrane components are then wound into roll form suitable for placing on a substrate and unrolled on the substrate, while manually removing the
release liner 18 to place themembrane 10, adhesive side down, on the surface of thesubstrate 20. - Upon application of the
membrane 10 to thesubstrate 20, there is provided a roof/wall structure 30 (FIG. 2 ) including the substantiallyrigid substrate 20 and thewaterproof membrane 10 adhesively bonded to an outer surface of the substrate, the membrane including thesurface layer 12 of thermoplastic waterproof material, thelayer 14 of cushion material bound to thesurface layer 12, and the pressure sensitive adhesive 16 bound to a side of thecushion material 14 remote from the layer of thermoplasticwaterproof material 12, and bound to thesubstrate 20. - The waterproof
membrane surface layer 12 is in the form of an elongated strip which extends sideways outwardly from theside edge 22 of thelayer 14 of cushion material to form the selvedge 24 (FIG. 1 ). The roof/wall structure includes a plurality of the strips ofmembrane 10 disposed on thesubstrate 20 lengthwise side-by-side withside edges 22 of theirrespective cushion portions 14 abutting each other, and theselvedge 24 of one elongated strip overlapping, and heat welded or otherwise adhered to, thesurface layer 12 of another elongated strip of like structure. - The roof/wall structure thus formed is highly resistant to the aforementioned sub-grade environments.
- There is further provided a method for waterproofing a structural surface. The method includes providing the
waterproof membrane 10 for application to the surface, the membrane comprising theouter surface layer 12 of thermoplastic material, the layer ofcushion material 14 bound to an inner surface of the layer of thermoplastic material, the pressure sensitive adhesive 16 bound to a side of thecushion material 14 remote from thesurface layer 12 of thermoplastic material, and therelease liner 18 removably mounted on the pressuresensitive adhesive 16. - The method includes the steps of removing the
release liner 18 to expose the pressuresensitive adhesive 16, and pressing the pressure sensitive adhesive 16 against the structural surface to conform the layer ofcushion material 14 to thestructural surface 20 and bind thewaterproofing membrane 10 to the structural surface. - The method for waterproofing the structural surface further comprises providing the
layer 12 of thermoplastic material with aselvedge 24 comprising an extension of the outer layer ofwaterproof material 12 beyond aside edge 22 of thecellular foam cushion 14, preferably by about 2-4 inches. Theselvedge 24 overlaps a neighboring strip of membrane, while thecushion portion 14 of the two strips are in abutting relationship. The selvedge is bound to the neighboring waterproof surface layer, as by heat-welding, adhesively, and the like. - Finally, there is provided a method for increasing puncture resistance of a
thermoplastic membrane 10 for use in water proofing ofstructural substrates 20, the method comprising bonding a layer ofcushion material 14 to thethermoplastic membrane 10, thecushion material 14 comprising a cellular foam material, the cushion material being adapted to conform around minor irregularities in a surface of thestructural substrate 20. - There is thus provided a membrane for application to a surface of a structure to provide waterproof protection to the structure, a method for making such a membrane, a roof/wall structure including the membrane, a method for waterproofing a structured surface using the aforementioned membrane, and a method for providing increased puncture resistance to a thermoplastic membrane.
- It will be understood that many additional changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principles and scope of the invention as expressed in the appended claims.
- For example, while the laminar structure described above is said to include a waterproof thermoplastic layer, and while such is regarded as a preferred embodiment, it will be apparent to those skilled in the art that a waterproof elastomeric material could also serve as a waterproof layer.
Claims (27)
1. A membrane for application to a surface of a structure to provide waterproofing protection to the structure surface, the membrane comprising:
an outer surface layer of a selected one of thermoplastic and elastomeric waterproof material;
a layer of cushion material fixed to an inner surface of said layer of waterproof material;
a pressure sensitive adhesive bound to a side of said cushion material layer remote from said layer of waterproof material; and
a release liner removably mounted on a side of said pressure sensitive adhesive remote from said layer of cushion material.
2. The membrane in accordance with claim 1 , wherein said layer of waterproof material is provided with selvedge structure facilitating overlapping and bonding of the membrane to an adjoining membrane of like construction.
3. The membrane in accordance with claim 1 , wherein said layer of cushion material comprises a cellular foam material.
4. The membrane in accordance with claim 1 , wherein said pressure sensitive adhesive layer retains adhesive properties in the presence of water and concrete alkalis.
5. The membrane in accordance with claim 1 , wherein said release liner is manually separable from said pressure sensitive adhesive.
6. The membrane in accordance with claim 1 , wherein said outer surface thermoplastic layer comprises at least in part a selected one of vinyl and polyolefin.
7. The membrane in accordance with claim 1 , wherein said surface layer is at least about 0.015-0.080 inch in thickness.
8. The membrane in accordance with claim 1 , wherein said layer of cushion material is at least about 0.015-0.375 inch in thickness.
9. The membrane in accordance with claim 3 , wherein said outer layer of waterproof material is bound to said layer of cushion material by a selected one of adhesive adhering, laminating, extrusion coating, heat sealing, gluing, and taping.
10. The membrane in accordance with claim 5 , wherein said pressure sensitive adhesive layer is adapted to be manually adhered to the surface of the structure by the manual removal of said release liner and placement of the adhesive layer on the surface of the structure.
11. The membrane in accordance with claim 1 , and further comprising a barrier film disposed between said layer of cushion material and said pressure sensitive adhesive.
12. The membrane in accordance with claim 6 , wherein said surface layer further comprises integral reinforcing material.
13. The membrane in accordance with claim 12 wherein said integral reinforcing material comprises a selected one of glass fiber, polyester, and nylon.
14. The membrane in accordance with claim 1 wherein said layer of cushion material is adapted to conform around minor irregularities in the surface of the structure, adapted to retain conforming properties in the presence of water and alkalis, and adapted to inhibit lateral water migration.
15. The membrane in accordance with claim 2 , wherein the selvedge structure is adapted to overlap the waterproof layer of the adjoining membrane and to be secured thereto.
16. A method for making a waterproof membrane, the method comprising the steps of:
providing a layer of cushion material;
bonding a layer of waterproof thermoplastic or elastomeric material to a first side of the layer of cushion material;
affixing a layer of pressure sensitive adhesive to a second side of the layer of cushion material; and
mounting a release liner on a side of the pressure sensitive adhesive remote from the cushion material.
17. The method in accordance with claim 16 , wherein the cushion material comprises a cellular foam material of at least about 0.015-0.375 inch thickness.
18. The method in accordance with claim 16 , wherein the layer of waterproof material extends on a side thereof beyond a side edge of adjoining cushion material of the membrane to form a selvedge, and comprising the further step of bonding the selvedge to an edge portion of an abutting layer of waterproof thermoplastic or elastomeric material of a second membrane.
19. The method in accordance with claim 18 , wherein the step of bonding the selvedge comprises bonding the selvedge to the edge portion of the abutting layer of thermoplastic or elastomeric material of the second membrane by a selected one of adhesive, glue, tape, and hot-air welding.
20. The method in accordance with claim 16 , wherein the step of bonding the layer of waterproof thermoplastic or elastomeric material to the layer of cushion material comprises a selected one of adhesively adhering, laminating, extrusion coating, heat sealing, gluing and taping of the waterproof material to the cushion material.
21-36. (canceled)
37. The membrane in accordance with claim 3 wherein said cellular foam material comprises a non-absorptive closed cell foam.
38. (canceled)
39. The method in accordance with claim 16 wherein the cushion material comprises a cellular foam material.
40. The method in accordance with claim 39 wherein the cellular foam material comprises a non-absorptive closed cell foam.
41. The method in accordance with claim 16 wherein the thermoplastic material comprises at least one of vinyl and polyolefin.
42-47. (canceled)
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CA2598886A CA2598886C (en) | 2006-11-02 | 2007-08-24 | Self-adhering waterproofing membrane |
EP07839853A EP2091726A4 (en) | 2006-11-02 | 2007-10-30 | Self-adhering waterproofing membrane |
PCT/US2007/022938 WO2008057343A2 (en) | 2006-11-02 | 2007-10-30 | Self-adhering waterproofing membrane |
US11/983,994 US20080309014A1 (en) | 2006-11-02 | 2007-11-13 | Method for increasing puncture resistance of a waterproof membrane |
US11/983,995 US8061098B2 (en) | 2006-11-02 | 2007-11-13 | Roof/wall structure |
US12/317,615 US8104245B2 (en) | 2006-11-02 | 2008-12-24 | Method for waterproofing a structural surface |
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US11/983,995 Expired - Fee Related US8061098B2 (en) | 2006-11-02 | 2007-11-13 | Roof/wall structure |
US12/317,615 Expired - Fee Related US8104245B2 (en) | 2006-11-02 | 2008-12-24 | Method for waterproofing a structural surface |
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US12/317,615 Expired - Fee Related US8104245B2 (en) | 2006-11-02 | 2008-12-24 | Method for waterproofing a structural surface |
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Also Published As
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US20080307734A1 (en) | 2008-12-18 |
US8104245B2 (en) | 2012-01-31 |
US8061098B2 (en) | 2011-11-22 |
US20090113841A1 (en) | 2009-05-07 |
US20080309014A1 (en) | 2008-12-18 |
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Owner name: SIKA TECHNOLOGY AG, SWITZERLAND Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:WHELAN, BRIAN J.;WHITTEMORE, GARY W.;BEN-DAAT, DAN;AND OTHERS;REEL/FRAME:019670/0319 Effective date: 20070716 |
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STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |