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GB2030892A - Method of insulating building structures and water-activatable cement webs useful for such purpose - Google Patents

Method of insulating building structures and water-activatable cement webs useful for such purpose Download PDF

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Publication number
GB2030892A
GB2030892A GB7931923A GB7931923A GB2030892A GB 2030892 A GB2030892 A GB 2030892A GB 7931923 A GB7931923 A GB 7931923A GB 7931923 A GB7931923 A GB 7931923A GB 2030892 A GB2030892 A GB 2030892A
Authority
GB
United Kingdom
Prior art keywords
web
cement
insulating material
building structure
slab
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.)
Granted
Application number
GB7931923A
Other versions
GB2030892B (en
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Evode Ltd
Original Assignee
Evode Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Evode Ltd filed Critical Evode Ltd
Priority to GB7931923A priority Critical patent/GB2030892B/en
Publication of GB2030892A publication Critical patent/GB2030892A/en
Application granted granted Critical
Publication of GB2030892B publication Critical patent/GB2030892B/en
Expired legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B40/00Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
    • C04B40/06Inhibiting the setting, e.g. mortars of the deferred action type containing water in breakable containers ; Inhibiting the action of active ingredients
    • C04B40/0608Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use
    • C04B40/0616Dry ready-made mixtures, e.g. mortars at which only water or a water solution has to be added before use preformed, e.g. bandages
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/76Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
    • E04B1/762Exterior insulation of exterior walls
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00Coverings or linings, e.g. for walls or ceilings
    • E04F13/07Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/08Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
    • E04F13/14Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
    • E04F13/141Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of concrete

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Civil Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

A method of insulating a building structure which comprises attaching a laminar insulating material to the building structure and applying over the insulating material a cement web comprising a web of fibrous material or foamed plastics material impregnated with a cementitious composition, the cement web being wetted so that the cement is activated and the web ultimately sets to a hard, reinforced cement membrane which covers the insulating material. The invention also includes a water- activatable cement web for construction purposes which comprises a substrate of fibrous material or foamed plastic material partially impregnated with a cementitious composition which is reactive with water to form a set mass, at least one side of said material being substantially free from cement.

Description

SPECIFICATION Method of insulating building structures and water activatable cement webs useful for such purpose There is now great emphasis on the need to improve insulation of existing building structures and one common process involves introduction of foamed plastics material within the cavity of a cavity brick wall. In the case of older building structures, the external walls are usually fabricated from solid brick, stone, etc. and provision of additional insulation is only possible by attaching this either to the external or to the internal walls. Addition of insulation to the internal walls has several disadvantages including reduction in the size of the rooms, interference with decorations and internal fixtures and fittings.
Internal insulation also means that external walls are heated less and therefore more subject to frost damage.
One known method of applying external insulation to buildings involves mechanically fixing or bonding with adhesives, blocks or slabs of foamed plastics material, such as polystyrene, to the outside of the wall, applying a cement screed over the layer of foamed insulation, followed by a reinforcing membrane and then a further cement screed and finally applying a decorative coating to the finished layer of insulation. This procedure has several disadvantages, one of which is that it is difficult and time consuming to apply a cement screed over the blocks or slabs of foamed insulation and this cement screed frequently cracks and exposes the insulation to the weather.
It is axiomatic that for the insulation to maintain its maximum effect, it should be maintained in a dry condition.
One object of the present invention therefore is to provide an improved method of applying foamed insulation to wall surfaces of buildings.
In accordance with one aspect of the invention there is provided a method of insulating a building structure which comprises attaching a laminar insulating material to the building structure and applying over the insulating material a cement web comprising a web of fibrous material or foamed plastics material impregnated with a cementitious composition, the cement web being wetted so that the cement is activated and the web ultimately sets to a hard, reinforced cement membrane which cover the insulating material.
Normally, the insulating material is in the form of slabs or blocks of foamed plastics material, e.g.
metre square and 25 mm or 40 mm in thickness, which are attached to the building structure in abutting fashion by means of a gap-filling adhesive or mechanical fixing means or a combination of both. A membrane of reinforced cement may be formed over the insulation by applying the uncured cement web to the insulation and activating the cement. Preferably, the cement web is activated by wetting with water or an aqueous solution just prior to application to the insulating material. The wetted cement web will adhere sufficiently to the insulating material to form a temporary bond pending developing a permanent bond by the setting of the cement.
However, an adhesive or adhesion promoter, such as a polyvinyl ether may be included in the cementitious composition.
Instead of forming the reinforced membrane covering over the insulating material after attaching the insulating material to the building structure, it is also possible to pre-bond the cement web to the slab or block of insulating material and then attach the resulting composite building element to the structure to be insulated.
Continuity in the reinforced membrane may be ensured by subsequent application in situ of overlapping strips of cement web to the insulating material so as to bridge over the joins between adjacent building elements.
Instead of using a separate adhesive to bond the insulating material to the building structure, the blocks or siabs of insulating material (which may be in the form of composite building elements as described above) may carry adhesive, e.g. in the form of strips or beads to enable them to be attached to the wall. Such adhesive coating may be protected with a removable release film during storage and transport.
The cement impregnated web used in the method of the present invention is preferably of the same general character as described in our British Patent No. 1.504,124. This prior patent describes water activatable tapes comprising a substrate of fibrous or foamed plastics material impregnated with a cement, an organic binder which binds the cement to the substrate while the cement is in its uncured state and a hydrophilic thickener. The purpose of the hydrophilic thickener is to assist the penetration of the water into the tape on activation. In some circumstances, the organic binder can be dispensed with, but preferably the organic binder is an elastomeric polymer such as a natural or synthetic rubber.
While a fully impregnated cement web may be used in the method of the present invention, we have found that substantial advantages are obtained if a partially impregnated tape or web is used. There are two main reasons for this. Firstly, it has been found that if a tape issued which. is fully impregnated with cement, such as is obtained by total immersion of the substrate in a cement slurry as described in our above British Patent the tape when wetted becomes very heavy and difficult to apply in long lengths to a wall structure. Secondly, the cement impregnated tape does not accept many kinds of decorative coating, particularly high build decorative coatings very readily. We have found that by applying the cement slurry to the web in such a way that only partial impregnation takes place, the above difficulties can be reduced or overcome.Indeed it has been found that decorative surface coatings, including non-aqueous coatings, may be applied to the cement membrane while it is still damp with activating water. This significantly reduces the total installation time for the system.
A water-activable cement web wherein the cementitious composition is only partially impregnated into the fibrous or foamed plastics web so that one surface is substantially free from cement is believed to constitute a novel material.
According to a further aspect of the present invention therefore there is provided a water activatable cement web for construction purposes which comprises a substrate of fibrous material or foamed plastics material partially impregnated with a cementitious composition which is reactive with water to form a set mass, at least one side of said material being substantially free from cement.
Preferably the web is impregnated from one side only of the web with the composition. Partial impregnation of the web or tape may be achieved by coating a cement slurry of the kind described in our prior patent 1,504,124 onto only one side of a web of fibrous material or foamed plastics material using a flat bed coating machine, e.g. as described in our co-pending patent application No.
37005/78. The coated web is then dried and results in an impregnated tape or web in which one side has a coating of dry cementitious slurry, while the other is substantially free from cement.
An alternative method of producing a partially impregnated web involves fully impregnating a suitable substrate, e.g. by the dip coating method described in British Patent No. 1,504,124 and iaminating the impregnated web with a second, unimpregnated web so as to form a composite web in which one face is free from cement. If the two webs are brought together while the impregnated web is still wet, the two webs will stick together and remain bonded on drying without the need for additional adhesive.
A further alternative method of producing a partially impregnated web involves forming the web as a tube or sleeve (e.g. by knitting the web directly in tubular form or sewing the edges of an elongate web together) and impregnating the flattened tube by dip-coating or roller-coating from both sides or by any other convenient method. If the thickness of the fabrics is chosen so that the composition does not penetrate to the interior, the tube can be opened out again by slitting the edge to form a partially impregnated web having one surface uncontaminated with cement.
According to the preferred technique, the partially impregnated web is thoroughly wetted just prior to use and applied with the cement side to the foamed insulation, either by overlapping or butting adjacent strips of material. As an alternative the web may be applied in a dry or partially wetted condition and thoroughly wetted when in position on the insulating material. Very little cement is washed through to the uncoated side of the web and decorative coatings can be applied to the cement impregnated web before the web has dried. This is advantageous since the decorative coating (being substantially water impermeable) will slow down the escape of water from the activated cement composition in the impregnated web, and this will result in improved curing of the cement.Surprisingly, both water based and solvent-based decorative coatings can be applied to the outer surface of the cement impregnated web before the impregnated web has dried. Although the fibrous substrate is still apparently damp, we have successfully applied chlorinated rubber based paints to a wall insulation covered with cement impregnated web immediately after application of the web.
When activating the web, an aqueous solution may be employed which contains substances which promote or retard the rate of cure of the cement.
Instead of producing a factory made laminated cement web, it is also possible to produce essentially the same kind of structure in situ by first applying a fully impregnated cement web to the insulating material and subsequently applying a partially impregnated cement web, with the cement side innermost, onto the first web while the latter is still damp. This procedure has the disadvantage however that it introduces a further step.
The cementitious compositions used to impregnate the webs of fibrous or foamed plastics material are preferably as described in British Patent No. 1,504,124. The nature of the fibrous or foamed plastics material may also be as described in our earlier Patent. We prefer however to employ web substrates having a high absorbency and the preferred substrates are stitch-bonded polyester or viscose fabrics which are high bulk fabrics which are produced as a felt and then stitched.
The insulating material is preferably a polystyrene or polyurethane foam, the most preferred material being expanded, rigid, polystyrene foam, such as the material supplied by Dow Chemical Company under the trade name "Styrofoam". Other useful insulating materials include foamed polyethylene, wood wool, glass fibre wool and mineral wool.
The following Example will illustrate the preparation of a cement web in accordance with the invention and the insulation of the wall of a building in accordance with the method of the invention.
EXAMPLE 85 parts by weight of Portland cement were dispersed in methyl ethyl acetate with 5 parts by weight of methyl cellulose. One part by weight of nitrile rubber was added to the dispersion to achieve a total solids content of about 75 mass per cent. A web of stitch-bonded polyester fabric about 25 cms wide was fully impregnated with the resulting cementitious composition by drawing the web through a bath filled with the slurry and regulating the thickness of the coating on both sides of the web using a doctor blade set to a gap of 2 mms. Immediately upon leaving the bath, the impregnated web was laminated to a similar but unimpregnated polyester fabric by passing the two lengths of fabric between a pair of rollers. The composite fabric strip was then passed to a drying tunnel, including a solvent recovery plant, and then reeled.
The wall of a small house was insulated with expanded foamed polystyrene sheets using the following technique. Sheets of foamed polystyrene approximately 1 metre square and 25 mms thick were attached to the wall using a heavily-filled polyvinyl acetate adhesive.
Alternatively, a cross-linking adhesive, such as an acrylic based adhesive could be used. Preferred adhesives of this type are styrene-acrylate copolymer adhesives.
The adhesive was applied by coating onto the polystyrene and positioning the sheets in closely abutting fashion so as to completely cover the wall. The cement web, prepared as described above, was thoroughly soaked by immersion in water for a few mintues and applied to the polystyrene sheets with the cement-free side outermost. The strips of cement web were overlapped with the joins extending vertically and a hand-held roller was used to ensure that the strips of cement web were pressed firmly onto the insulation and bonded thereto. A resin based textured surface coating was applied by roller immediately over the cement web to complete the installation.
While the invention has been described with particular reference to the insulation of wall surfaces, it will be appreciated that any parts of building structures can be insulated by the process described above, including particularly roof structures. Also the partially impregnated webs of this invention may be used for purposes other than for securing insulation to building structures, e.g.
for any of the purposes mentioned in British Patent No. 1,504,124.

Claims (21)

1. A water-activatable cement web for construction purposes which comprise a substrate of fibrous material or foamed plastics material partially impregnated with a cementitious composition which is reactive with water to form a set mass, at least one side of said material being substantially free from cement.
2. A web according to Claim 1 which comprises a web of fibrous material or foamed plastics material which is impregnated throughout with a cementitious composition and which is laminated to a second web of fibrous or foamed plastics material which is substantially free from cement.
3. A web according to Claim 1 or Claim 2 wherein the cementitious composition includes at least one cement, a binder which binds the cement to the fibrous or foamed plastics material while the web is in its uncured state, and a hydrophilic thickener.
4. A web according to Claim 3 wherein the binder is a natural or synthetic rubber.
5. A web according to Claim 3 or Claim 4 wherein the hdyrophilic thickener is a cellulose ether, polyvinly alcohol or polyvinyl pyrrolidone.
6. A building element which comprises a slab or block of insulating material having a web as claimed in any one of the preceding claims bonded to the surface, so that the side of the web which is substantially free form cement faces outwardly.
7. An element according to Claim 6, wherein the insulating material comprises a foamed styrene or urethane polymer.
8. An element according to Claim 6 of Claim 7 wherein the cement web is cured over substantially the whole of the area in contact with the surface of the block or slab, the web including an edge strip which is uncured and is adapted in use to overlap onto and cover the free edge of an adjoining slab or block.
9. A method of insulating a building structure which comprises attaching a laminar insulating material to the building structure and applying over the insulating material a cement web comprising a web of fibrous material or foamed plastics material, impregnated with a cementitious composition, the cement web being wetted so that the cement is activated and the web ultimately sets to a hard, reinforced cement membrane which covers the insulating material.
1 0. A method according to Claim 9 wherein the cement web is wetted just prior to application to the insulating material.
11. A method according to Claim 9 of Claim 10 wherein the web includes an adhesive or adhesive promoter to assist adhesion of the web to the insulating material.
12. A method according to any one of the preceding Claims wherein the insulating material is attached to the building structure by means of a gap-filling adhesive composition applied to the structure and/or to the insulating material.
1 3. A method according to Claim 12 wherein the adhesive is a filled, polyvinyl acetate or styrene-acrylate copolymer.
14. A method according to any one of Claims 9 to 1 3 wherein the cement web has one surface which is substantially free from cement and is applied to the insulating material so that the cement-free surface faces outwardly from the building structure.
1 5. A method according to any one of Claims 9 to 14 wherein a decorative coating is applied to the outer surface of the cement web.
1 6. A method according to Claim 1 5 when appendant to Claim 14 wherein the decorative coating is applied to the cement web while the latter is still wet.
1 7. A method according to any one of Claims 9 to 16 wherein the cement web is in the form of a tape which is applied so that joins are abutting or overlapping and extend substantially vertically.
18. A modification of the method claimed in any one of Claims 9 to 1 7 wherein the cement web is applied to the insulating material prior to attaching the insulating material to the building structure.
19. A method according to Claim 1 8 wherein the cement web is bonded in a cured condition to slabs or blocks of the insulating material.
20. A method according to Claim 1 9 wherein each slab or blockofinsulating material is left free from cement web along one edge and the opposite edge is provided with a strip of cement web which is uncured and is so dimensioned that when the slab or block is positioned adjacent to a similar slab or block, the strip can be overlapped onto and cover the free edge of the adjoining slab or block.
21. A building structure when insulated by the method claimed in any one of Claims 9 to 20.
GB7931923A 1978-09-15 1979-09-14 Mehtod of insulating building structures and water-activa-table cement webs useful for such purpose Expired GB2030892B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB7931923A GB2030892B (en) 1978-09-15 1979-09-14 Mehtod of insulating building structures and water-activa-table cement webs useful for such purpose

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB7837004 1978-09-15
GB7931923A GB2030892B (en) 1978-09-15 1979-09-14 Mehtod of insulating building structures and water-activa-table cement webs useful for such purpose

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GB2030892A true GB2030892A (en) 1980-04-16
GB2030892B GB2030892B (en) 1982-09-08

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2118588A (en) * 1982-04-08 1983-11-02 Cyril Oury Duke Elements for use in landscaping and building

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2118588A (en) * 1982-04-08 1983-11-02 Cyril Oury Duke Elements for use in landscaping and building

Also Published As

Publication number Publication date
GB2030892B (en) 1982-09-08

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