WO2017037728A1

WO2017037728A1 - Premixed coating formulation and method of making and use thereof

Info

Publication number: WO2017037728A1
Application number: PCT/IN2016/000101
Authority: WO
Inventors: Santosh R NANDAN
Original assignee: Individual
Current assignee: Individual
Priority date: 2015-08-31
Filing date: 2016-04-18
Publication date: 2017-03-09
Anticipated expiration: 2018-02-28

Abstract

Disclosed herein a premixed plastering/polishing formulation employed as a protective and decorative element on the walls or any surfaces, wherein said formulation comprises a synergistic blend of Portland Cement 063, Calcium carbonate, Silica sand and a Cement Hardener 369, wherein said premixed formulation is characterized in that capable of having water resistant and withstanding high heat during drying, attains fast hardening in a single application of less than 5mm thickness.

Description

PREMIXED COATING FORMULATION AND METHOD OF MAKING AND USE THEREOF

Field of the Invention

This invention, in general relates to a coating formulation and method of making the same. In particular, the present invention is directed to a premixed plastering/polishing formulation employed as a protective and decorative element on the walls or any surfaces.

Background of the Invention

The current practice followed for plastering and finishing of the exterior and the interior of the walls consists of applying multiple layers of plaster with each layer performing different functions. Usually, an exterior of the wall is layered by applying a water proofing mix, followed by normal cement plaster followed by paint and finally upper most coat for weather protection. This process is time consuming and labour intensive. Therefore, there is a need for a simple solution to this time consuming and labour intensive practise of applying plaster as a protective and decorative element to the walls.

There are various approaches as indicated in the below mentioned prior arts that has been worked on improving each of the application layers individually by improving on the ingredients used in each of these layers; for e.g. newer polymers and additives are constantly being tried out to offer an improved performance with respect to either water proofing or the crack resistance of the plaster being applied. In other areas paints and other finishes are being used to provide a decorative finish.

CN102491710 (a) discloses a textured decorative mortar comprising parts by weight of portland cement 130-170 lime 130-170 quartz sand 580-760, wherein the decorative mortar, characterized by further comprising 0.5-1 parts by weight of cellulose ether, and 0.1 to 0.3 parts by weight of a starch ether. Further, the construction process comprises diluting the texture decorative mortar by adding water based on the weight of the texture decorative mortar, and mechanically or manually stirring till the mortar and the water are mixed uniformly and coating the stirred mortar onto a pretreated exterior wall by means of mechanical spraying or manual construction till a certain thickness, and flattening the surface of the coating by using a spatula. According to this prior art the prepared mortar has excellent anticracking, waterproof, durable and decorative performance, and the cost is reduced.

CN 03570304 (a) discloses a concrete protective coating comprises ingredients, by weight, 30 to 40 parts of ordinary portland cement, 5 to 15 parts of mineral powder, 30 to 40 parts of quartz sand (100 meshes), 15 to 25 parts of quartz sand (200 meshes), 0.5 to 1.5 parts of redispersible latex powder, trace to 0.1 part of silicon resin powder, trace to 0.1 part of a middle-efficient water reducing agent, and trace to 0.1 part of an antifoaming agent, the concrete protective coating is suitable for repairing surface defects, such as honeycomb structures, pitted surfaces, damaged parts and damaged edges and corners, on large concrete structures such as roads and bridges; is capable of eliminating hidden dangers caused by damaged parts of surfaces of the road and bridge concrete structures, increasing durability of the structures, and realizing decorative performance of the concrete structures

RU2122532 (c1 ) discloses a dry building mix wherein said mix comprises (wt parts): 4.0- 2.0 lime; 18.0- 36.0 portland cement; 40.0-60.0 quarts sand; 3.3-5.0 mica. Further said mix comprises 0.01-30.0 wt parts of pigment, wherein the resultant mix is providing greater strength and color stability of the coating.

RU2134248 (c1) discloses a composition comprising wt %: white portland cement, 25.0- 30.0, shell pigment, 0.15- 0.23; white activated sand with specific surface of 4500- 5000 sq. cm; plasticizer, 0.12-0.18; and filler, the balance, wherein said composition is having improved properties of the decorative mortars.

RU2514033 (c1) discloses a decorative plastering contains, wt %: portland cement 25.0- 30.0; quartz sand ground and sent through screen no.008 64.6-68.5, pigment 1.0-10.0 foaming agent pb-2000 0.2-0.25, liquid glass 0.2-0.25, at water-solid ratio of 1.1-1.3, wherein said composition is having increased heat insulation properties of plastering

RU201 1 1 13899 (a) discloses a dry plaster mixture for decorative finishing of building faces, which comprises quartz sand, additionally contains white portland cement m 400 and asphalt-concrete plant wastes - carbonate-silica dust, which contains compounds whose possible variations lie in the % range of caco- 55-60, mgco- 22-25, sio- 10-13, with the ratio of components, wt %: white portland cement m 400 28-37, carbonate-silica dust 10-15, quartz sand 48-62, wherein said composition is having improved adhesion-cohesion properties, high frost resistance, water resistance and whiteness for free colour toning of the plaster during decorative finishing of building faces.

US Patent no. 4,868,018 discloses a hard, durable, water-resistant simulated marble products are made by coating a support surface with a mixture of epoxy resin, epoxy resin hardener, pigment and a powdered material such as portland cement, powdered clay, a mix of portlant cement and lime, powdered lime, a mix of portland cement and silica sand or 75 mixtures thereof. The method disclosed herein comprising the steps of applying to the surface a coating comprising a mixture of effective amounts of liquid epoxy resin, epoxy hardener, pigment and essentially inorganic powdered material, selectively applying to the coating before it dries or hardens a pigmented acrylic polymer emulsion to provide the desired ornamental appearance and then permitting the coating to harden.

80

The abovementioned prior _ arL f oimulations- pose specific challenges of relatively low durability^' and colour retention. Also, while each formulation has some advantages, none of them is capable of obviating the multiple challenges that exist in said field. Further, the disclosed formulations are prepared using complex technology that makes its manufacturing 85 labour and time intensive.

Thus, there is a neea Tor a premixed formulation that is capable of providing waterproofing and decorative coating in a single layer, obviating the current practice of applying multiple layers thus providing an advantage with respect to time, cost and effort.

90

Summary of the invention

It is an object of the present invention to provide a premixed coating formulation which is suitable-foT use irra- number of different interior or exterior applications of any wall, wherein said premixed formulation is capable of providing multiple functional advantages in a single 95 application of 3mM thickness and avoid the drawback associated with the prior arts.

It is another object of the present invention to provide a premixed coating formulation which is suitable for use in any of a number of different interior or exterior applications of any wall, wherein said formulation is preferably plaster formulation and wherein the used ingredients 100 in said formulation is employed in a manner to achieve unprecedented advantages such as anti-cracking, quick setting, waterproofing etc.

It is one other object of the present invention to provide premixed coating formulation, wherein said formulation is having long shelf life and is cost efficient and time saving when 105 used during plastering walls.

It is another object of the present invention to provide premixed coating formulation for use in plastering walls wherein said formulation when is waterproof even with a single application of the plaster.

110 The above and other objects of the present invention are achieved by employing selective ratio of the ingredients like cement, and a cement hardener along with coloured pigments and method of employing the same, wherein the used ingredients are capable of withstanding high heat during drying, attains fast hardening and thus can be used in all the 115 atmospheric conditions. Further, all the ingredients used are easily / readily available, nontoxic, and stable during the manufacturing of the premixed, thus providing a decorative option to the user.

In accordance with a preferred embodiment of the present invention, there is provided a 120 premixed coating formulation comprising a synergistic blend of Portland Cement 063, Calcium carbonate, Silica sand and a Cement Hardener 369, wherein said premixed formulation is capable of having water resistant and withstanding high heat during drying, attains fast hardening in a single application of less than 5mm thickness, preferably coating is 3 mm, most preferably coating is 2mm.

125

In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation comprising a synergistic blend of Portland Cement 063, Calcium carbonate, Silica sand and a Cement Hardener 369, wherein said Portland Cement 063, Calcium carbonate, Silica sand, Cement Hardener 369 are having ratio of 35:10:45:8.

130

In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein the premixed coating formulation comprising a synergistic blend of Portland Cement 063, Calcium carbonate, Silica sand and a Cement Hardener 369, wherein said Calcium carbonate and the cement hardener are blended in a 135 ratio of 1.25: 1 to 1 :1.

In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein the premixed coating formulation comprising a synergistic blend of Portland Cement 063 of about 35+2 % by weight, Calcium carbonate of 140 about 10+0.5% by weight, Silica sand of about 45+2.5 % by weight, Cement Hardener 369 of about 8+0.5 by weight.

In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein the premixed coating formulation comprising a 145 synergistic blend of Portland Cement 063, Calcium carbonate, Silica sand and a Cement Hardener 369, wherein said formulation, characterised in that by blending Portland Cement 063 and Silica sand together homogenously and separately the Cement Hardener 369 and the calcium carbonate and blend the resultant to achieve the premixed coating formulation. In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein said formulation is prepared by a method comprising blending homogenously Portland Cement 063 with Silica sand to form blend A, blending homogenously a Cement Hardener 369 with the calcium carbonate to form blend B and blending the resultant blend A and B to achieve the premixed coating formulation.

In accordance with still another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein said formulation comprising a synergistic ratio of Portland Cement 063, Calcium carbonate, Silica sand, Cement Hardener 369, wherein the Portland Cement 063 is preferably 35+2 % by weight.

In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein said formulation comprising a synergistic ratio of Portland Cement 063, Calcium carbonate, Silica sand, Cement Hardener 369, wherein the Calcium carbonate is preferably 10+0.5% by weight.

In accordance with still another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein said formulation comprising a synergistic ratio of Portland Cement 063, Calciufn carbonate, Silica sand, Cement Hardener 369, wherein the Silica sand is preferably 45*2.5 % by weight.

In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein said formulation comprising a synergistic ratio of Portland Cement 063, Calcium carbonate, Silica sand, Cement Hardener 369, wherein the Cement Hardener 369 is preferably 8+0.5 by weight.

Description of the Invention

While this specification concludes with claims particularly pointing out and distinctly claiming that, which is regarded as the invention, it is anticipated that the invention can be more readily understood through reading the following detailed description of the invention and study of the included drawings and the experimental details. In accordance with one preferred embodiment of the present invention, there is provided a premixed coating formulation, preferably plastering formulation of walls, wherein said 185 formulation comprising a synergistic ratio of Portland Cement 063, Calcium carbonate, Silica sand, Cement Hardener 369, wherein silica sand and the cement hardener are mixed synergistically to provide quick setting and anti- cracking even when heated or hammered with nails and wherein waterproof characteristics of the formulation is achieved by synergistic combination of the silica sand, cement and hardener.

190

In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation, preferably policing formulation of walls, wherein said formulation comprising a synergistic ratio of Portland Cement 063, Calcium carbonate, Silica 195 sand, Cement Hardener 369, wherein silica sand and the cement hardener are mixed synergistically to provide polishing of the surface to give it a decorative application.

In accordance with another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein said formulation comprising Portland Cement 063 of 200 about 35+2 % by weight, Calcium carbonate of about 10+0.5% by weight, Silica sand of about 45+2.5 % by weight, Cement Hardener 369 of about 8+0.5 by weight.

In accordance with yet another preferred embodiment of the present invention, there is provided a premixed coating formulation, wherein said formulation comprising Portland 205 Cement 063, Calcium carbonate, Silica sand, Cement Hardener 369 having synergistic ratio of 35:10:45:8.

In accordance with another embodiment of the present invention, there is provided a method of making the premixed coating formulation, wherein the Portland Cement 063 and Silica 210 sand is mixed together homogenously to form blend A. Separately the Cement Hardener 369 is homogenously mixed with the calcium carbonate form blend B, and there after these two blend A and B are mixed to make the premixed formulation.

According to the present invention the formulated premixed is agitated with the addition of 215 30% water creating a thick slurry ready for application to the wall. Typically 2 coats are applied, the first coat is applied and allowed to dry for an hour before application of the second coat. According to the present invention^ the premixed formulation preferably formulated for 220 plastering, policing or any desired / general uses, wherein the ingredients used in the formulation provide superior bonding and water retention and accordingly enhances the shelf life and anti-cracking property.

According to the present invention, the ingredients used in the present coating formulation 225 can also be used on site with conventional mixing of water using a conventional stirrer and conventional tools. This allows material to be used at remote locations. The formulation also works equally well on wet surfaces.

According to the present invention, the disclosed formulation is unique as it allows one to 230 use a single application of two layers of thickness less than 5mm, preferably 3 mm, most preferably 2 mm for waterproofing, crack resistance, and addition to the normal protective properties of cement plaster. Importantly this formulation does not require painting thus saving on time and labour.

235 According to the present invention, the coating formulation can be considered as plastering or any other desired formulation.

According to the present invention, said plastering formulation is used for a number of different interior or exterior applications of any wall or surface. Further, said premixed 240 formulation is having a property ^ polishing the material to a marble like finish.

The wall or surface according to the present invention can be any kind of surface or wall, including but not excluding concrete, wood, glass and the like. Further, it can also be applied on paper or on thin sheets of wood to give an aspect of decoration.

245

The premix formulations can also have use in forming molds made of plaster for casting pottery figurines and the like. Also, said formulation can be used in spray applications, including glass fiber reinforced gypsum and the like.

250 Experimental details:

According to the present invention various experiments have been done to stabilise the effectiveness of the said premixed formulation. Below tables are detailing the comparative of the properties such as hardness, permeability strength and the Compressive strength.

255 Sample preparation: 35 parts of Portland Cement 063 and 10 parts of Silica sand are blended together till it is a homogenous powder A.

Separately 3 parts of the Cement Hardener 369 is homogenously mixed with 45 parts of calcium carbonate. This mixture is then blended with the homogenous powder A; blended by hand and 28 parts of water are then added to develop a slurry. The slurry is then agitated by hand till an even mixture is obtained. This is now ready for application to any surface.

Separately 8 parts of the Cement Hardener 369 is homogenously mixed with 45 parts of calcium carbonate. This mixture is then blended with the homogenous powder A; blended by hand and 29.5 parts of water are then added to develop a slurry. The slurry is then agitated by hand till an even blend is obtained. This is now ready for application to any surface.

Separately 12 parts of the Cement Hardener 369 is homogenously mixed with 45 parts of calcium carbonate. This mixture is then blended with the homogenous powder A; blended by hand and 30.5 parts of water are then added to develop slurry. The slurry is then agitated by hand till an even mixture is obtained. This is now ready for application to any surface.

Tests were carried out at Bureau Veritas (an external NABL accredited laboratory). The three premixes prior to addition of water was sent to them along with the instructions on how much water is to be added. Testing of the samples was done on a 2mm thick coating on a wooden board for Hardness, Water Permeability and Compressive strength.

1) Hardness as measured by IS: 1706:1972 RA 2013 and IS-13630 (Part13)-2006(RA2012)

2) Permeability test IS:2645-2003 (Reaffirmed 2012)

Preparation of Concrete Cubes using the above formulation

3) Compressive strength (Mpa) 35/10/45/8

3 days: 7.2

7 days: 10.7

28 days: 14.0

The above and other features of the invention will become more apparent the detailed description when read in conjunction with the accompanying drawing, wherein further exemplary properties of the present formulation is illustrated according to figure 1 and figure 2.

While this invention has been described in detail with reference to certain preferred embodiments, it should be appreciated that the present invention is not limited to those precise embodiments. Rather, in view of the present disclosure, which describes the current best mode for practicing the invention, many modifications and variations would present themselves to those skilled in the art, without departing from the scope and spirit of this invention.

Claims

We Claim: 305

1. A premixed coating formulation comprising a synergistic blend of Portland Cement 063, Calcium carbonate, Silica sand and a Cement Hardener 369, wherein said premixed formulation is characterized in that capable of having water resistant and withstanding high heat during drying, attains fast hardening in a single application of less than 5mm thickness.

310

2. The premixed coating formulation as claimed in claim 1 , wherein said thickness of coating is preferably 3 mm.

3. The premixed coating formulation as claimed in claim 1 , wherein said thickness of 315 coating is preferably 2 mm.

4. The premixed coating formulation as claimed in claim 1 , wherein said Portland Cement 063, Calcium carbonate, Silica sand, Cement Hardener 369 are having ratio of 35:10:45:8.

320

5. The premixed coating formulation as claimed in claim 1 , wherein the Portland Cement 063 is preferably 35+2 % by weight.

6. The premixed coating formulation as claimed in claim 1, wherein the Calcium 325 carbonate is preferably 10+0.5% by weight.

7. The premixed coating formulation as claimed in claim 1 , wherein the Silica sand is preferably 45+2.5 % by weight.

330 8. The premixed coating formulation as claimed in claim 1 , wherein the Cement Hardener 369 is preferably 8+0.5 by weight.

9. A premixed coating formulation comprising a synergistic blend of Portland Cement 063, Calcium carbonate, Silica sand and a Cement Hardener 369, wherein said Calcium

335 carbonate and the cement hardener are blended in a ratio of 1.25: 1 to 1:1.

10. A premixed coating formulation comprising a synergistic blend of Portland Cement 063 of about 35+2 % by weight, Calcium carbonate of about 10+0.5% by weight, Silica sand of about 45+2.5 % by weight, Cement Hardener 369 of about 8+0.5 by weight. 340

11. A premixed coating formulation comprising a synergistic blend of Portland Cement 063, Calcium carbonate, Silica sand and a Cement Hardener 369, wherein said formulation, characterised in that by blending- Portland Cement 063 and Silica sand together homogenously and separately the Cement Hardener 369 and the calcium carbonate and

345 blend the resultant to achieve the premixed coating formulation.

12. The premixed coating formulation as claimed as any of the above claims, wherein said formulation is prepared by a method comprising:

350 Blending homogenously Portland Cement 063 with Silica sand to form blend A;

Blending homogenously a Cement Hardener 369 with the calcium carbonate to form blend B, and

Blending the resultant blend A and B to achieve the premixed coating formulation.

355

13. The premixed coating formulation as claimed in any of the above claims, wherein said formulation is used in different interior or exterior applications of any wall or surface.

14. The premixed coating formulation as claimed in any of the above claims, wherein 360 said formulation is waterproof even with a single application of the plaster.

15. The premixed formulation as claimed in any of the above claims, wherein the. formulation provides superior bonding and water retention and accordingly enhances the shelf life.

365

16. The premixed formulation as claimed in any of the above claims, wherein the formulation is preferably plastering/polishing formulation.

17. A method of making a premixed coating formulation, wherein the method comprising:

370

blending homogenously Portland Cement 063 with Silica sand to form blend A;

375

18. The method as claimed^' in claim 17, wherein said Portland Cement 063, Calcium carbonate, Silica sand, Cement Hardener 369 are having ratio of 35:10:45:8.

19. The method as claimed in claim 17, wherein the Portland Cement 063 is preferably

380 35+2 % by weight.

20. The method as claimed in claim 17, wherein the Calcium carbonate is preferably 10+0.5% by weight.

385 21. The method as claimed in claim 17, wherein the Silica sand is preferably 45+2.5 % by weight.

22. The method as claimed in claim 17, wherein the Cement Hardener 369 is preferably 8+0.5 by weight.

390

23. The method as claimed in claim 17, wherein the formulation comprising Portland Cement 063 of about 35+2 % by weight, Calcium carbonate of about 10+0.5% by weight, Silica sand of about 45+2.5 % by weight and Cement Hardener 369 of about 8+0.5 by weight.

395