WATERPROOFING SYSTEM FOR EXPOSED ROCK SURFACES

Abstract

Polymer Rubber Gel is heated to an elevated temperature and sprayed against the exposed rock to form a generally uniform surface. The Polymer Rubber Gel can be sprayed on the rock surface using a heated want coupled to a heated kettle. Then, a layer of I polyethylene is formed against the polymer rubber gel layer. Finally, a finish layer such as concrete, tile, brick or segmental wall block is placed against the outer side of the polyethylene layer.

Description

PRIORITY

This application claims the priority benefit of U.S. Provisional Application No. 62/060,667 filed on Oct. 7, 2014, which is hereby incorporated herein by reference in its entirety.

FIELD

The present invention relates generally to systems and methods for waterproofing structures having exposed rock surfaces.

BACKGROUND

Exposed rock walls are formed when roads and tunnels are carved out of or into rock formations. In such situations, it is often necessary to cover the rock wall. Typically this is done by spreading concrete over the rock wall to make it smooth and then covering the concrete layer with a lining material. However, such methods are slow, labor intensive and expensive to install. Moreover, there is a risk that the concrete layer will not adequately adhere to the exposed rock, or that the concrete layer will separate from the rock in the future. Additionally, the concrete layer is not an effective waterproofing layer.

Thus, there is a need to provide a system that addresses some or all of the deficiencies discussed above.

SUMMARY

The present invention provides a unique finishing and waterproofing system for exposed rock surfaces. Polymer Rubber Gel is heated to an elevated temperature and sprayed against the exposed rock to form a generally uniform surface. The Polymer Rubber Gel can be sprayed on the rock surface using a heated want coupled to a heated kettle. Then, a layer of I polyethylene is formed against the polymer rubber gel layer. Finally, a finish layer such as concrete, tile, brick or segmental wall block is placed against the outer side of the polyethylene layer.

The disclosure includes a method of providing a waterproofing and vapor barrier to an exposed rock surface. The method includes heating a non-curing polymer rubber gel to a temperature to allow the non-curing polymer rubber gel to be sprayed with a spray wand applicator. The polymer rubber gel is sprayed onto the exposed rock surface until a continuous layer of the polymer rubber gel material is formed over the exposed rock surface. A layer of polyethylene sheet is disposed against the layer of polymer rubber gel. The polyethylene sheet has a first side and an opposing second side. The first side of the sheet is in contact with the continuous layer of the polymer rubber gel. A concrete layer is formed adjacent the polyethylene sheet such that the concrete layer contacts the second side of the polyethylene sheet.

The disclosure also includes a method of providing a waterproofing barrier to an exposed natural rock surface. The method includes heating a non-curing polymer rubber gel comprising 99% solids to a temperature sufficient to allow the non-curing polymer rubber gel to be sprayed onto the exposed natural rock surface with a spray wand applicator. The polymer rubber gel is sprayed onto the exposed natural rock surface until a continuous layer of the polymer rubber gel material is formed over the exposed natural rock surface. A layer of polyethylene sheet is disposed against the layer of polymer rubber gel. The polyethylene sheet has a first side and an opposing second side. The first side of the sheet is in contact with the continuous layer of the polymer rubber gel. A finish layer is formed adjacent the polyethylene sheet such that the finish layer contacts the second side of the polyethylene sheet.

The disclosure further includes a method of waterproofing a tunnel formed through rock to define an exposed rock surface. The method includes heating a non-curing polymer rubber gel to a temperature sufficient to allow the non-curing polymer rubber gel to be sprayed onto the exposed rock surface of the tunnel with a spray wand applicator. The polymer rubber gel is sprayed onto the exposed rock surface of the tunnel until a continuous layer of the polymer rubber gel material is formed over the exposed rock surface of the tunnel. A continuous layer of polyethylene is formed over the layer of polymer rubber gel. The polyethylene layer has a first side and an opposing second side. The first side of the polyethylene layer is in contact with the continuous layer of the polymer rubber gel. A finish layer is formed adjacent the polyethylene layer such that the finish layer contacts the second side of the polyethylene layer.

The above summary is not intended to limit the scope of the invention, or describe each embodiment, aspect, implementation, feature or advantage of the invention. The detailed technology and preferred embodiments for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic side cross-sectional view of a waterproofing system for exposed rock surfaces according to certain example embodiments.

FIG. 2 is a schematic perspective view of an exposed rock surface waterproofing system applied to the inside of a tunnel according to certain example embodiments.

FIG. 3 illustrates spray application of Polymer Rubber Gel using an application wand according to certain example embodiments.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION

In the following descriptions, the present invention will be explained with reference to various exemplary embodiments. Nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention.

Referring to FIG. 1, the wall system 100 is shown according to one example embodiment. The rock surface 102 is covered with a layer of Polymer Rubber Gel 104, preferably by spraying, to a thickness or depth such that the layer is at least about 90-100 mils thick at its thinnest point, while presenting generally continuous smooth surface for receiving a sheet layer of material.

Next, the sheet layer of material 106 is applied to the exposed polymer rubber gel layer 104. The sheet material 106 is Geo Textile Fleece High-density polyethylene (HDPE) or Linear low-density polyethylene (LLDPE). The sheet material 106 is laid directly against the polymer rubber gel layer 104 with the fleece side facing outward away from the gel layer 104. The sheet material 106 provides a vapor barrier.

The HDPE or LLDPE material is commercially available in 12×30 foot rolls. The sheets are overlapped 6-12 inches on the seam. Bitumen tape or heat welding is used to bond the separate sheets so that they are connected to form a single continuous sheet.

In certain example embodiments, the sheet material 106 is approximately 20 mils thick and may or may not include a textile backing. However, other thicknesses and compositions of the sheet material can be used in certain embodiments without departing from the scope of the invention.

The gel 102 and sheet material 106 layers form a water and vapor barrier sandwich. Finally, a concrete slab 108 layer can be poured directly atop/against the sandwich. Rebar can be placed within the concrete slab, if desired. Alternative finish coverings other than concrete slab can be used without departing from the scope of the invention, including segmental concrete wall blocks, bricks, tiles, etc.

The Polymer Rubber Gel material is a non-curing rubber emulsion with adhesive and cohesive physical characteristics. Such material is commercially available from a variety of sources. The Polymer Rubber Gel material is applied monolithically to create an impervious waterproofing membrane. The Polymer Rubber Gel actively responds to movement of the HDPE/LLDPE substrate, while maintaining its exceptionally strong adhesive bond to both the exposed rock and sheet material surfaces.

Polymer Rubber Gel also exhibits the ability to self heal under direct hydrostatic pressure due to its non-curing nature. Polymer Rubber Gel never completely cures and remains as a flexible gel. Since it never cures, it self-heals under hydrostatic pressure. Thus, if the waterproofing and providing vapor barrier system 100 were accidentally punctured or cut, or if the rock surface shifts or splits, during or after installation, the Polymer Rubber Gel membrane will automatically heal itself and maintain its water-tight and vapor-proof integrity.

Due to Polymer Rubber Gel's responsiveness to substrate movement and vibration, there is no need for repair of cracks/separation in the waterproofing membrane. In contrast, concrete, and other conventional waterproofing applications cure and crack, leading to water intrusion. Polymer Rubber Gel never completely cures, so it self-heals and can weather the constant stress of thermal expansion/contraction, seismic activity and vibration that might be experienced in a wide variety if applications.

The Polymer Rubber Gel layer 104 also provides for creation of a seamless or continuous layer. Thus, there are no seams or gaps between sections of the sandwich. There is formed a continuous membrane throughout the entire extent of the rock surface, and beyond. Thus, there are no seams or gaps where water and vapors can easily escape from the rock.

Not all Polymer Rubber Gels are the same. For example, different gels have widely differing amounts of solids in their content. Thus, any two given gels will have very different material properties. Clearly, the higher the solids content, the more viscous the gel material.

Polymer rubber gel is typically not flowable at room temperature. In one aspect of certain embodiments of the invention, the polymer rubber gel is sprayed onto the exposed rock. To achieve flowability at room temperature to be able to spray the gel onto the exposed rock, a polymer rubber gel with high solids content such as 99% solids is preferred. The high solids content is preferred because relatively thin polymer rubber gels, such as TURBOSEAL, which has approximately 78% solids, cannot be reliably heated and sprayed. The inventor has found that TURBOSEAL gel only squirts from the wand when heated, rather than sprays. Further heating of the TURBOSEAL gel simply causes the material to break down.

By using a polymer rubber gel with a much higher solids content than TURBOSEAL gel and the like, such as one with 99% solids, and heating the polymer rubber gel to an elevated temperature of between 150-200° F., the gel does not break down because it is almost entirely solids, but it is able to be successfully sprayed with a wand.

Referring to FIG. 2, the present system is shown being applied to a tunnel formed through rock. The polymer rubber gel layer 104 is applied to the inside exposed rock surfaces 102. Then the gel layer 104 is covered with the vapor barrier sheet material 106 as discussed herein above. A finish layer of concrete, tile or other material can, but need not be, applied to the sheet material's exposed surface.

By overlapping and detailing any joints and the corners of the HDPE/LDPE sheet with tape, or other seam closing means, the wall system becomes continuous. This results in an encapsulating barrier surrounding the entire rock surface.

The wall system and method described herein offers numerous advantages over other such systems. For example, the ease and effectiveness of installation is superior. Thus the installer can be more productive and the system is more cost effective doe to reduced labor costs, speed of time to project completion and reduced mistakes in application. The present invention also offers long-term effectiveness.

Additional advantages include, the sheet membrane does not require chemical reaction, hydration, or compaction to bond to concrete. The combination of gel and sheet described herein creates an exceptionally durable, dynamically responsive high performance waterproofing and vapor barrier system that is effective in many adverse environments and conditions. Waterproofing integrity is maintained without loss of adhesion to substrate or failure from membrane punctures as happens with conventional rock wall covering systems. Thus, a more effective wall and waterproofing system is provided.

An additional aspect of the invention is a novel method of spraying the application of Polymer Rubber Gel (non-curing, self-healing rubber mastic spray material) to the exposed rock surface using modified asphalt crack sealing equipment (e.g., from Crafco).

In use, the procedure for the present system comprises:

• • 1. Utilize oil jacketed kettle and pump system (e.g. crack seal melter);
  • 2. Load Polymer Rubber Gel (with 99% solids) into the hopper of the kettle;
  • 3. Turn on the kettle and run the kettle temperature to 260-270 degrees F.;
  • 4. Wait until the Polymer Rubber Gel liquefies; and
  • 5. Spray the Polymer Rubber Gel from a hydraulic pressure pump to a thickness of 90-100 mils minimum.

FIG. 3 illustrates the spray application of Polymer Rubber Gel using the application wand of the modified asphalt crack sealing equipment. Note that the wand and feed hose are both preferably heated as well, so that the temperature of the liquefied gel can be maintained.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. Moreover, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention.

Claims

1. A method of providing a waterproofing and vapor barrier to an exposed rock surface, the method comprising:

heating a non-curing polymer rubber gel to a temperature to allow the non-curing polymer rubber gel to be sprayed with a spray wand applicator;

spraying the polymer rubber gel onto the exposed rock surface until a continuous layer of the polymer rubber gel material is formed over the exposed rock surface;

disposing a layer of polyethylene sheet against the layer of polymer rubber gel, the polyethylene sheet having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and

forming a concrete layer adjacent the polyethylene sheet such that the concrete layer contacts the second side of the polyethylene sheet.

2. The method of claim 1, wherein the second side of the polyethylene sheet comprises fleece material.

3. The method of claim 1, wherein the polyethylene sheet comprises High-density polyethylene (HDPE).

4. The method of claim 1, wherein the polyethylene sheet comprises Linear low-density polyethylene (LLDPE).

5. The method of claim 1, further comprising:

disposing as second polyethylene sheet against the layer of polymer rubber gel such that the second sheet partially overlaps the first sheet to define a seam; and

sealing the seam of the overlapped first and second polyethylene sheets to form a continuous polyethylene layer.

6. The method of claim 5, further comprising sealing the seam by applying bitumen tape to the seam.

7. The method of claim 5, further comprising sealing the seam by heat welding the seam.

8. The method of claim 1, wherein the polymer rubber gel comprises 99% solids.

9. The method of claim 1, further comprising heating the polymer rubber gel to a temperature in the range of 150-200 degrees Fahrenheit before spraying the polymer rubber gel onto the exposed rock surface.

10. The method of claim 1, further comprising:

loading the polymer rubber gel into an oil jacketed kettle, the kettle including a pump coupled to the spray wand applicator, wherein the spray want applicator is heated to at least the same temperature as the polymer rubber gel;

elevating the temperature of the polymer rubber gel inside of the kettle to liquefy the polymer rubber gel; and

delivering the liquefied polymer rubber gel to the heated spray wand applicator under pressure.

11. A method of providing a waterproofing barrier to an exposed natural rock surface, the method comprising:

heating a non-curing polymer rubber gel comprising 99% solids to a temperature sufficient to allow the non-curing polymer rubber gel to be sprayed onto the exposed natural rock surface with a spray wand applicator;

spraying the polymer rubber gel onto the exposed natural rock surface until a continuous layer of the polymer rubber gel material is formed over the exposed natural rock surface;

disposing a layer of polyethylene sheet against the layer of polymer rubber gel, the polyethylene sheet having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and

forming a finish layer adjacent the polyethylene sheet such that the finish layer contacts the second side of the polyethylene sheet.

12. The method of claim 11, wherein the finish layer comprises a layer of concrete.

13. The method of claim 11, wherein the finish layer comprises tiles.

14. The method of claim 11, wherein the finish layer comprises bricks.

15. The method of claim 11, wherein the second side of the polyethylene sheet comprises fleece material.

16. The method of claim 11, further comprising:

disposing as second polyethylene sheet against the layer of polymer rubber gel such that the second sheet partially overlaps the first sheet to define a seam; and

sealing the seam of the overlapped first and second polyethylene sheets to form a continuous polyethylene layer.

17. The method of claim 11, further comprising heating the polymer rubber gel to a temperature above 150 degrees Fahrenheit before spraying the polymer rubber gel onto the exposed natural rock surface.

18. The method of claim 11, further comprising:

loading the polymer rubber gel into an oil jacketed kettle, the kettle including a pump coupled to the spray wand applicator, wherein the spray want applicator is heated to at least the same temperature as the polymer rubber gel;

elevating the temperature of the polymer rubber gel inside of the kettle to liquefy the polymer rubber gel; and

delivering the liquefied polymer rubber gel to the heated spray wand applicator under pressure.

19. A method of waterproofing a tunnel formed through rock to define an exposed rock surface, the method comprising:

heating a non-curing polymer rubber gel to a temperature sufficient to allow the non-curing polymer rubber gel to be sprayed onto the exposed rock surface of the tunnel with a spray wand applicator;

spraying the polymer rubber gel onto the exposed rock surface of the tunnel until a continuous layer of the polymer rubber gel material is formed over the exposed rock surface of the tunnel;

forming a continuous layer of polyethylene over the layer of polymer rubber gel, the polyethylene layer having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and

forming a finish layer adjacent the polyethylene layer such that the finish layer contacts the second side of the polyethylene layer.

20. The method of claim 19, wherein the finish layer consists of one or more of the following materials: concrete, tile, brick and segmental wall block.