Patent Application
20240344320
The present invention relates generally to an epoxy methane barrier for concrete floors and walls, and a method of making, and using same. More particularly, the invention encompasses a dual mixture of at least one hardener, and at least one resin, which when mixed together create an inventive methane barrier layer that acts as a barrier, and prevents, and blocks methane, and VOC (Volatile Organic Compounds) from passing from one side of a structure to the other side of the structure. The innovative barrier layer system can be used or applied along the insides of a wall, and on the top surface of a completed or cured floor or a foundation. This invention can be used on interior floors and walls of existing structures, such as, commercial and residential structures, and ADUs (Additional Dwelling Units) to methane proof the existing structures.
Methane (CH4) is a colorless, odorless and highly flammable gas, and methane gas has been known to penetrate into structures, and has been known to be harmful to humans and animals, especially in a closed environment, and the industry has been addressing this well-known problem in a variety of ways.
Naturally occurring methane is found both below ground and under the seafloor and is formed by both geological and biological processes. Methane is nontoxic, yet it is extremely flammable and may form explosive mixtures with air. Methane is also an asphyxiant if the oxygen concentration is reduced to below about 16% by displacement, as most people can tolerate a reduction from 21% to 16% without ill effects. The concentration of methane at which asphyxiation risk becomes significant is much higher than the 5-15% concentration in a flammable or explosive mixture. Methane off-gas can penetrate the interiors of buildings near landfills and expose occupants to significant levels of methane. Some buildings have specially engineered recovery systems below their basements to actively capture this gas and vent it away from the building.
Methane gas dangers can be mitigated through a number of ways, such as, for example, venting of the confined spaces (like basements), removing any ignition sources, to name a few.
U.S. Pat. No. 4,843,786 (Walkinshaw et al.) describes a continuous building basement wall and floor cavity, formed by the foundation wall and floor enclosure on the outside, and an attached inner air and vapor barrier structure, insulated as appropriate, is drained and ventilated to inhibit and prevent soil moisture and gases, such as radon and methane, from entering the basement living space. The air exhausted from the cavity can be drawn from the basement living space, as well as from the surrounding soil and the outdoors. This ventilation of the cavity serves to thermally condition the basement enclosure structure and, coincidentally, to beneficially augment the ventilation rate of the living space. Cavity exhaust air can be used for combustion air supply and heat recovery purposes. Such a cavity can be economically constructed, using novel modifications to current construction practices, in both new and existing building structures. Introduction of this ventilated cavity in building basements serves to create basement living space of a thermal and environmental quality which is comparable to that of above-ground space.
However, this invention improves on the deficiencies of the prior art and provides an inventive epoxy methane barrier for concrete floors and walls, completed foundations, and a method of making, and using same.
The invention is a novel epoxy methane barrier for concrete floors and walls, a method of making, and using same.
Therefore, one purpose of this invention is to provide a novel epoxy methane barrier for concrete/shotcrete floors, completed or cured foundations and/or concrete or shotcrete walls, and a method of making, and using same.
Another purpose of this invention is to provide a mixture that is ready to use in the field to methane proof a structure or room.
Yet another purpose of this invention is to provide an innovative mixture that can be applied in the field to prevent methane gas from passing from one side of a structure to the other side.
Yet another purpose of this invention is to provide an innovative mixture that can be topically applied on an already installed structure, such as, a floor, a wall, a foundation, so as to prevent or stop methane gas from passing from one side of the existing structure to the other side.
Still yet another purpose of this invention is to provide an innovative mixture that can be topically applied after an existing methane barrier has failed on an already installed structure, such as, a floor, a wall, a foundation, so as to prevent or stop methane gas from passing from one side of the existing structure to the other side.
Yet another purpose of this invention is to provide an innovative mixture that can be topically applied after an existing methane barrier has failed on an already installed structure, such as, a floor, a wall, a foundation, so as to prevent or stop methane gas from passing from one side of the existing structure to the other side, and to avoid the need to completely remove the failed concrete floor/slab/wall, installing a new methane barrier, and then re-pouring a new layer of concrete/shotcrete.
Therefore, in one aspect this invention comprises an epoxy methane barrier for cured concrete/shotcrete surface, comprising the steps of:
In another aspect this invention comprises an epoxy methane barrier for cured concrete/shotcrete surface, comprising at least one mixture, and wherein said mixture consists of at least one hardener, and at least one resin.
In yet another aspect this invention comprises a building structure having a methane barrier, comprising:
The inventive epoxy methane barrier for concrete/shotcrete for completed or cured foundations and/or walls and floors, and a method of making, and using same, will now be discussed in more detail with reference to
In summary the invention is an epoxy methane barrier for concrete/shotcrete for concrete floors, completed or cured foundations, and a method of making, and using same, and more particularly, the invention encompasses a dual mixture of at least one hardener, and at least one resin, which when mixed together create an inventive methane barrier layer or membrane system that acts as a barrier, and prevents, and blocks methane, and VOC (Volatile Organic Compounds) from passing from one side of a structure to the other side of the structure. The innovative barrier layer system can be used or applied along the sides of a wall, on the top surface of a completed or cured floor or a foundation. The inventive dual mixture can be applied on the inside of a side wall, on the outside of a side wall, or on both inside surface and outside surfaces of a side wall.
As one can see in
The number of layers of the inventive epoxy methane barrier 23A, 23B, 23C, or the thickness of the mixture 15, that is applied on the surface of the of the structure 40, 45, 50. would depend on the needs of the structure 40, 45, 50, to create the desired methane proof barrier. It should be appreciated that the thickness of the at least one layer 23A, 23B, 23C, is between about 5 mil (about 0.125 mm) to about 240 mil (about 6 mm). It should also be appreciated that the desired thickness for the layer 23A, 23B, 23C, could be achieved by pouring or applying multiple or plurality of thinner coats of the inventive epoxy coating 23, and then building up to the desired thickness for the layer 23A, 23B, 23C.
The inventive mixture 15, is also known as Aussie Gas-Lock 420, which is an epoxy type mixture containing at least two components 12, 14, the inventive mixture 12, 14, provides a high-adhesion to concrete/shotcrete, and once applied creates an effective moisture, vapor, methane and VOC (Volatile Organic Compounds) barrier. It has been discovered that the inventive mixture 15, is very effective in blocking the intrusion of moisture, vapor, methane gas, and VOC (volatile organic compounds). The inventive mixture 15, is very easy to spread over finished or completed or cured concrete and shotcrete surfaces of the structures 40, 45, 50. For some applications, it is preferred that the mixing ratio by volume of the at least one first component 12, namely, the hardener 12, and the at least second component 14, namely, the resin 14, is about 2.43:1, however, this ratio could have a fluctuation or deviation of plus or minus 20 percent, depending upon the application, and other environmental conditions. It has been discovered that the compressive strength of the inventive mixture 15, is between about 8,000 psi and about 18,000 psi, preferably between 12,000 psi and 16,000 psi and preferably about 14,500 psi. Similarly, it has been discovered that the tensile strength of the inventive mixture 15, is between about 3,000 psi and about 6,500 psi, and preferably about 4,300 psi. It should be appreciated that these range(s) depend upon the application, and other environmental conditions.
It should also be appreciated that the inventive mixture 15, is ideal for sealing out harmful methane gases, moisture, vapor, and harmful VOCs when retrofitting existing structures 40, 45, 50, namely, concrete floors, foundations, sidewalls, to name a few. This inventive mixture 15, can also easily be used when one is repurposing warehouses, garages, or formerly unoccupied spaces into occupied spaces. As stated earlier that the inventive mixture 15, can be applied rather quickly, allowing the team or crew to maintain schedule and install practically any finished flooring as desired by the user or occupier of the space. In addition, the inventive mixture 15, can also be used to seal green or semi-cured concrete structure 40, 45, 50, thus allowing for membrane/coating applications sooner than the required 28 days concrete cure time when used in conjunction with other coatings, such as, for example, AVM Hot Rubber 570, Deck Coatings, Polyurethane 520, Aussie Membrane 500, Under-Tile membranes, to name a few.
This invention allows the installation of the inventive methane barrier in many situations, such as, for example, it can be topically applied on a floor or wall of an existing structure that never had a methane gas or VOC barrier installed in the first place or after an existing methane barrier has failed on an already installed structure, such as, a floor, a wall, a foundation, so as to prevent or stop methane gas from passing from one side of the existing structure to the other side. This innovative feature of the instant invention allows the use of an existing structure without the need to completely remove the failed membrane under the concrete floor/slab/wall or structure, and the need to install a new methane barrier, and then re-pouring a new layer of concrete/shotcrete to recreate the failed structure or surface. Another application of this invention is that it can be used in ADU (Accessory Dwelling Unit) conditions. An accessory dwelling unit (ADU) is a condition when a primary resident needs additional space for a variety of reasons, such as, for example, creating a living space for a loved one or to generate additional income through rent or to house a family member, such as, for example, an elderly parent could live in a smaller unit and avoid having to move to an assisted living facility, etc. The ADU could be, for example, a conversion of a car garage into living space, a basement into a living space, to name a few, and in these and similar conditions one would need methane abatement. With this invention one could be topically apply the inventive mixture 15, forming the inventive methane barrier 23, along the needed locations, such as, the floor, sidewall, etc., and easily repurpose the structure, without the need to rebuild the new structure to stop the ingress of methane or VOC inside the repurposed structure.
Both of the components 12, 14, that make up the inventive mixture 15, forming the inventive methane barrier 23, should be delivered to the job site in their original sealed containers. Each of the components 12, 14, should be stored at temperatures between about 50° F. and about 90° F. Each of the component materials 12, 14, needs to be kept away from direct sunlight, and also from areas where the components 12, 14, could be damaged by water or rain, or other similar other environmental elements.
For some applications the substrate or concrete or shotcrete or structure 40, 45, 50, where the inventive mixture 15, needs to be applied, is preferably absorbent when one applies the at least one coating of the inventive mixture 15. One simple test for absorbency of a material is a Water Drop Test, as stated in ASTM F3191, which is basically to determine and document absorbency of the material into the concrete or shotcrete substrate 40, 45, 50. If the water drop does not absorb/penetrate the concrete or shotcrete 40, 45, 50, within a minute of being placed on the surface of the concrete or shotcrete 40, 45, 50, then the surface might be insufficiently porous and might need additional preparation. It should be noted that shotblasting is the preferred method for surface preparation, however, other preparation methods may also be used. For example, if grinding is performed, then it must deliver a consistent dust-free profile.
For an existing concrete or shotcrete structure 40, 45, 50, one must first remove all existing coatings, sealers, coverings, roofing materials, etc., so as to create a clean bonding surface 40A, 40B, 50A. It should be understood that when one is finished cleaning the surface 40A, 40B, 50A, of the structure 40, 45, 50, using, for example, shotblasting, grinding, etc., one must remove all fugitive shot, dust, debris, etc., from the prepared surface 40A, 40B, 50A.
It should be understood that the material for the wall 40, and the foundation 50, is selected from a group comprising, concrete, and shotcrete. Shotcrete or sprayed concrete is concrete or mortar that is conveyed through a hose (not shown) and pneumatically projected at high velocity onto a surface as a construction technique. For some applications the sprayed concrete or shotcrete is typically reinforced by conventional steel rods, steel mesh, or fibers, such as, for example, a rebar cage. Shotcrete can be placed, and compacted at the same time, due to the force with the nozzle, and it can be sprayed onto any type or shape of surface including vertical surface, horizontal surface, or overhead areas (not shown), such as, along a roof or ceiling. It should also be appreciated that the instant invention can also be applied onto existing or already installed concrete blocks, or Concrete Masonry Units (CMU). Concrete Blocks, or Concrete Masonry Units (CMU) are typically used for walls 40.
It should be appreciated that prior to laying a foundation of a building or a structure, the builder is sometimes aware of the presence of methane or VOC, and thus the builder then installs at least one membrane or some abatement system prior to laying or installing the foundation, or in other words membranes are installed under the slabs before the concrete is poured. However, the instant invention is the only currently “City of Los Angeles Approved” (Los Angeles Research Report #26218) topical methane membrane/barrier that can be installed on the inside of an erected or already existing building or structure, or “over” an existing concrete. This can be done when in a situation where there is no methane barrier at all or the existing methane barrier has failed, relieving the need to completely remove the concrete floor/slab, and then installing a new methane barrier, and re-pouring concrete.
Thus, the present invention is not limited to the embodiments described herein and the constituent elements of the invention can be modified in various manners without departing from the spirit and scope of the invention. Various aspects of the invention can also be extracted from any appropriate combination of a plurality of constituent elements disclosed in the embodiments. Some constituent elements may be deleted in all of the constituent elements disclosed in the embodiments. The constituent elements described in different embodiments may be combined arbitrarily.
Still further, while certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions.
It should be further understood that throughout the specification and claims several terms have been used and they take the meanings explicitly associated herein, unless the context clearly dictates otherwise. For example, the phrase “in one embodiment” as used herein does not necessarily refer to the same embodiment, though it may. Additionally, the phrase “in another embodiment” as used herein does not necessarily refer to a different embodiment, although it may. Thus, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention.
While the present invention has been particularly described in conjunction with a specific preferred embodiment, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications and variations as falling within the true scope and spirit of the present invention.
