NZ712014B2 - Textile reinforced membranes - Google Patents

Abstract

Described herein is a textile reinforced membrane (TRM). The TRM contains a unique combination of surface preparation techniques, primers, adhesives, reinforcing mesh and elastomeric membrane that allows it to adhere to a wide range of materials and to provide a highly durable weather-tight elastomeric seal. The TRM also minimises work needed to complete a repair, simplifies the installation process and avoids the need to further damage the area being repaired as may be required for other methods.

Description

TEXTILE REINFORCED MEMBRANES RELATED APPLICATIONS This application derives priority from New Zealand patent application number 630461 incorporated herein by reference.

TECHNICAL FIELD Described herein is a textile reinforced membrane (TRM). The TRM contains a unique combination of surface preparation methodology, primers, adhesives and reinforced membrane that allows the TRM to adhere to a wide range of building materials so as to provide a highly durable elastometric waterproof seal between diverse building elements.

BACKGROUND ART Textile reinforced membranes (TRMs) are used in the art to seal junctions in building construction between disparate building elements. TRMs are used in the art on both new and existing structures although, at least in New Zealand, sealing junctions in structures has taken more prominence in the wake of the so-called ‘leaky building’ issues and the Christchurch earthquake sequence that caused extensive damage to existing structures. A need exists to face seal the junction between for example, window perimeters and their surrounding cladding as well seal around penetrations through claddings, over and around saddle flashings, scupper outlets and overflows from decks, balconies and gutters. TRM’s have the capacity to remove or limit the need to replace a building component or rebuild or re-clad a structure.

Typically TRM’s minimise the amount of work needed to correct a defect and render a building component, window, disparate material junction, or penetration weather tight.

Existing methods of sealing the junction between a window perimeter and its adjacent cladding involve: 1). Paint; 2). A painted sealant bead; 3). The cutting back of the cladding from around the window perimeter and the installation of uPVC flashings and the application of in-fill plaster or installation of polystyrene and plaster coating to flush out to the same plane as the existing cladding, thus requiring the wall to be overclad with a reinforced modified plaster system to cover the junction between the existing and new in-fill plaster.

Alternatively, the junction between new and old plaster could be covered with a plant-on pre-meshed polystyrene moulding; 4). The insertion of a surface adhered PVC flashing tucked behind the window flange, thus requiring the wall to be overclad with a reinforced plaster system to cover the exposed leg of the uPVC flashing.

For options 1) and 2) above, the application of paint or sealant and paint fails to meet a cladding system’s Durability requirement of 15years under Clause B2 of the New Zealand Building Code:1992 and thereby fails to attract building consent approval as a component of a code compliant cladding system.

Option 3) above, requires the existing cladding to be to cut back from the edge of the window approximately 50mm to 75mm and the installation of uPVC jamb and sill flashings and the installation of an in-fill plaster or polystyrene strip which is over-plastered with a modified plaster reinforced with mesh in order to cover the junction between the existing and new plaster installed around the windows. As may be appreciated, this method is difficult, time consuming, noisy, dusty and comparatively expensive. Further, particularly with solid plaster claddings, the solid plaster overlaps the flanges of the aluminium window and as such tends to leave a scratched ‘tide mark’ on the surface of the aluminium window on both the jambs and the sills of the window, which is covered by the application of the TRM. Without TRM, windows with scratched ‘tide-marks’ require stripping and re-spraying or replacing.

Option 4) above, often requires the surface of the exterior cladding to be ground back to allow the face fixed uPVC flashing to fit in behind the flush mounted window flange risking damage to the edge of the window or the window flange has to be ‘levered’ out in order to ease the leading edge of the uPVC flashing behind the window flange. Having inserted the uPVC flashing and glued it to the existing cladding surface the wall requires overcladding with a fibre glass mesh reinforced plaster to cover the exposed leg of the face fixed uPVC flashing. Further, particularly with solid plaster claddings, the solid plaster overlaps the flanges of the aluminium window and as such tends to leave a scratched/pitted ‘tide mark’ on the surface of the aluminium window on the jambs and the sills of the window, which is covered by the application of the TRM. Without TRM, windows with scratched and pitted ‘tide-marks’ require re-spraying or replacement.

The application of sealant and paint, if deemed to be part of the cladding system, is required to meet the same NZ Building Code:1992 Clause B2 Durability requirement as the cladding system (15 years). Sealant and paint have a Durability requirement under Clause B2 of 5 years and therefore fail to meet the cladding’s 15year Durability requirement. The installation of the surface mounted uPVC flashings or the cutting back of the cladding to retro-fit uPVC flashing are Alternative Solutions under the NZ Building Code:1992 and therefore require territorial authority endorsement if a building consent is to be approved.

It should be appreciated that it may be useful to provide a textile reinforced membrane solution (TRM) that addresses the above problems, meets the objectives, functional and performance of the NZ Building Code:1992 Clauses B2 and E2 and provides building owner’s with a an economical remedial methodology or at least provides the public with a choice.

Further aspects and advantages of TRM’s and their method of application will become apparent from the ensuing description that is given by way of example only.

SUMMARY Described herein is a textile reinforced membrane (TRM). The TRM system contains a unique amalgam of surface preparation, primers, adhesives and membrane that allows TRM to adhere to a wide range of disparate building materials to provide a highly durable weather-tight elastomeric seal. TRM also minimises work needed to complete a repair, simplifies the installation process and avoids the need to further damage to the area being repaired as may be required for art methods.

In a first aspect, there is provided a textile reinforced membrane (TRM) comprising: an intermediate layer of an textile mesh embedded within a mixture of elastomeric resin and cement, the elastomeric resin being a fibre reinforced styrene-acrylic ester copolymer; a primer coating on each side of the intermediate layer substantially sealing the first layer within the coating, the primer being a styrene-acrylic ester copolymer.

In a second aspect, there is provided a method of applying a textile reinforced membrane (TRM) to a building material surface, the method comprising the steps: a. prepare the surface to which the TRM is to be applied; b. apply a coat of primer to the surface, the primer being a styrene-acrylic ester copolymer; c. apply an intermediate layer of textile mesh embedded within an elastomeric resin and cement mixture to the primer, the elastomeric resin being a fibre reinforced styrene- acrylic ester copolymer; and d. apply a further coat of the primer to the intermediate layer.

Advantages of the above TRM and method of application includes the ability to adhere the membrane to a wide range of materials and to provide a highly durable elastomeric seal. The TRM described has shown unexpected durability providing a weather-tight seal over almost all typical building materials tested including powder coated or anodised aluminium, stainless steel, Zincalume™, galvanised steel, copper, Colorsteel™, wood, plywood, solid plaster, modified plaster, concrete, concrete block, fibre cement sheet, acrylic paint, membrane, ceramic and porcelain tiles, thermoplastic olefin (TPO) and torch-on membrane, synthetic butyl rubber such as Butynol™, and uPVC. Art TRM solutions in the inventor’s experience, do not have this variety and versatility of substrate application, durability or warranties.

The TRM also minimises work needed to complete a repair, simplifies the installation process and avoids the need to further damage to the area being repaired as may be required for other methods.

In the case of so-called ‘leaky buildings’ and earthquake strengthened historic buildings, TRM and methods described herein have the potential to save thousands of dollars on repairs as complete re-cladding or replastering are avoided since leaking sections or window/door cladding junctions can be remediated, obviating the need to remove and re-install or replace exterior joinery components. The same technique may be used for a wide variety of other scenarios such as seismically damaged structures, restoration of historic building facades and weathered structures needing remedial sealing repairs.

BRIEF DESCRIPTION OF THE DRAWINGS Further aspects of the textile reinforced membrane and method of application will become apparent from the following description that is given by way of example only and with reference to the accompanying drawings in which: Figure 1 is a photograph showing a crack repair around windows about to commence with the repair area having had a primer layer applied; Figure 2 is a photograph showing in more detail the priming of the window frame in preparation for the application of the textile reinforced membrane to seal the junction between the window frame and the cladding; Figure 3 is a photograph showing the intermediate layer (including the reinforcing mesh) being applied to the repair area; Figure 4 is a photograph showing the final coat of primer ready for the application of two acrylic paint coats; Figure 5 is a photograph showing the installation of a retrofitted uPVC diverter prior to TRM application; and, Figure 6 is a photograph showing the uPVC diverter installed and TRM coatings over the uPVC, Colorsteel™ apron flashings and TRM weatherproofing the timber fascia/solid plaster intersection.

DETAILED DESCRIPTION As noted above, described herein is a textile reinforced membrane (TRM). The TRM contains a unique combination of surface preparation techniques, primers, adhesives, reinforcing mesh and elastomeric membrane that allows it to adhere to a wide range of materials and to provide a highly durable weather-tight elastomeric seal. The TRM also minimises work needed to complete a repair, simplifies the installation process and avoids the need to further damage the area being repaired as may be required for other methods.

For the purposes of this specification, the term ‘about’ or ‘approximately’ and grammatical variations thereof mean a quantity, level, degree, value, number, frequency, percentage, dimension, size, amount, weight or length that varies by as much as 30, 25, 20, 15, 10, 9, 8, 7, 6, , 4, 3, 2, or 1% to a reference quantity, level, degree, value, number, frequency, percentage, dimension, size, amount, weight or length.

The term ‘substantially’ or grammatical variations thereof refers to at least about 50%, for example 75%, 85%, 95% or 98%.

The term 'comprise' and grammatical variations thereof shall have an inclusive meaning - i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components or elements.

In a first aspect, there is provided a textile reinforced membrane (TRM) comprising: an intermediate layer of an textile mesh embedded within a mixture of elastomeric resin and cement, the elastomeric resin being a fibre reinforced styrene-acrylic ester copolymer; a primer coating on each side of the intermediate layer substantially sealing the first layer within the coating, the primer being a styrene-acrylic ester copolymer.

The textile mesh may be a woven mesh. The textile mesh may be a polyester mesh. The mesh may provide a structural base for the TRM and helps to retain the different compounds together. The mesh may also be alkali resistant to withstand the alkali compounds used to form the TRM.

As noted above, the textile mesh is embedded within the elastomeric resin. Embedded refers to the mesh being fully encapsulated and covered by the elastomeric resin.

The elastomeric resin is a fibre reinforced styrene-acrylic ester copolymer. Historically, resins of this nature may have been used on their own but in the inventor’s experience, this resin alone does not provide the durability needed, particularly across the range of substrates, which the present TRM can adhere to nor do these individual applications carry a warranty. A key feature of the resin is a very high flexibility – in fact the resin alone once dried can be stretched to at least 1.5 times its normal shape or more and return to its original size without ripping or splitting.

In one embodiment, the elastomeric resin may be a modified styrene-butadiene-styrene (SBS) polymer.

Fibre reinforcement for the elastomeric resin may be provided by a synthetic fibre - one example being polyacrylonitril fibres.

The elastomeric resin may also comprise at least one clay or mineral. Example clays or minerals may comprise: quartz, calcium carbonate and combinations thereof.

One specific elastomeric resin that the inventor has found useful may comprise the following: Water <12.5% Quartz 20% Styrene-acrylic ester copolymer 57% in water >30% Calcium carbonate 10% Polyacrylonitril fibres <1.5% Cement as noted above, may be used as a curing agent to help dry and set the mixture. The inventor has found that an optimum speed of drying and durability ratio of elastomeric resin to cement may be a ratio of approximately 6, or 7, or 8, or 9, or 10 parts resin to approximately 1 part cement. Ratios outside the ranges described may also be used to suit manufacturer’s recommendations and differing compounds/compositions used.

The primer (termed below interchangeably as the TRM primer) may be a styrene-acrylic ester copolymer. In one embodiment, the TRM primer may be a modified styrene-butadiene-styrene (SBS) polymer.

The TRM primer may also comprise at least one clay or mineral. Example clays or minerals may comprise: quartz, limestone, calcium carbonate, talcum, titanium dioxide, and combinations thereof.

One specific TRM primer may comprise the following: Water <25% Quartz <10% Limestone >10% Styrene-acrylic ester copolymer 50% in water <20% Calcium carbonate 20% Talcum <5% Titanium dioxide >5% In a second aspect, there is provided a method of applying a textile reinforced membrane (TRM) to a building material surface, the method comprising the steps: a. prepare the surface to which the TRM is to be applied; b. apply a coat of primer to the surface, the primer being a styrene-acrylic ester copolymer; c. apply an intermediate layer of textile mesh embedded within an elastomeric resin and cement mixture to the primer, the elastomeric resin being a fibre reinforced styrene- acrylic ester copolymer; and d. apply a further coat of the primer to the intermediate layer.

The textile reinforced membrane may be applied to a surface selected from: powder coated or anodised aluminium, stainless steel, Zincalume™, galvanised steel, copper, Colorsteel™, wood, plywood, solid plaster, modified plaster, concrete, concrete block, brick, fibre cement sheet, acrylic paint, acrylic membrane, glazed and unglazed ceramic tiles and porcelain tiles, thermoplastic olefin (TPO) and torch-on membrane, synthetic butyl rubber membrane such as Butynol™, uPVC, and combinations thereof. As should be appreciated, this list represents a significant range of building materials that might be seen or observed. In the applicant’s experience, the TRM described may be used on many materials and achieve the desired level of sealing and durability unlike art TRM solutions that might only be sufficiently durable for a one of or a small range of materials.

The TRM once applied may be painted over or plastered over. This allows the repair to be effectively hidden and give a clean finish to the surface of the building structure.

Surface preparation in step (a) of the method noted above may comprise the step of roughening or keying the surface. The term ‘roughening or keying’ as used herein refers to the step of increasing surface adhesion through abrasion methods or other steps. As should be appreciated, the exact method of roughening or keying the surface may vary depending on the surface material to which TRM is to be applied.

By way of example, surface preparation for an aluminium surface may include the steps of: i. keying/scouring the surface with a diamond encrusted pad or grinding the surface abutting the window/door frame to ensure it provides a secure adhesion surface; ii. cleaning the surface with a solvent; iii. applying an etching primer (e.g. Wattyl Super Etch™) to the keyed surface; iv. applying a coat of TRM primer.

Surface preparation for a wall to concrete junction may include the steps of: i. cutting a blade width slot (3mm deep approx.) with a diamond saw [40mm (approx.) out from the wall] to drop the leading edge of the reinforcing mesh into the slot or stop the mesh just short of the slot and use the slot to protect the leading edge of the TRM; ii. keying the concrete surface with either a carbide blade or a grinder; iii. applying a coat of TRM primer.

For metal surfaces, the preparation steps may include: i. scuffing the metal surface with a diamond pad; ii. cleaning the bonding surfaces with a solvent; iii. applying an etching primer to the bonding surfaces; iv. applying a coat of TRM primer.

For wooden surfaces, preparation steps may include: i. using a carbide scraper, flat scraping the bonding surface, then ii. using the sharp edge of the carbide blade, cutting shallow grooves in the timber surface to make a diamond pattern (5mm to 10mm spacing) or similar process to key the timber surface so that it is rough to the touch; iii. applying an etching primer to the prepared surface; iv. applying a coat of TRM primer.

For uPVC surfaces, preparation steps may include: i. flat scraping the bonding surface using wet and dry sandpaper or a carbide scraper, then; ii. cutting shallow grooves in the uPVC surface using the sharp edge of a carbide blade and making a diamond pattern that is rough to touch; iii. apply etching primer to the prepared surface; iv. applying a coat of TRM primer.

The uPVC surfaces may also be further roughened or ‘livened up’ by application of thinners such as the product Valspar IK™ thinners or similar products and, once the thinners have flashed off but the surface of the uPVC is still tacky, applying an etch primer such as Wattyl Super Etch™ or similar products.

Optionally, a perimeter barrier such as masking tape may define the area to which the TRM is applied. A secondary layer of masking tape may be applied adjacent to the roughened prepared surface prior to application of the TRM to facilitate a neat straight edge to the TRM (i.e. double- tape lines).

Typically, each layer is left to dry before commencing placement of the additional layer. Step (c) of the method above may only be applied for example once the TRM primer applied in step (b) is fully dry. Further, step (d) may only commence once the elastomeric resin applied in step (c) is fully dry.

Porous surfaces such as wood, fibre cement sheet, precast concrete, tiles, brick et al. may require the application of a porous surface sealer (PSS) following the keying of the substrate surface to ensure complete adhesion of the TRM. This is because these types of materials can have a fine dust layer impregnated in the material that may need to be bound into the surface before TRM application to maximise adhesion bond strength.

As noted above with respect to the TRM itself, the applicant has found that for ideal results with respect to speed of drying and durability, the elastomeric resin and curing agent may be mixed at a ratio of approximately 6, or 7, or 8, or 9, or 10 parts resin to approximately 1 part curing agent. In one embodiment, the ratio may be approximately 8 parts resin to 1 part curing agent.

Ratios beyond the ranges described may also be used to suit manufacturer’s recommendations and differing compounds. The figures provided are for illustration only and should not be seen as limiting. The mixing of the resin and curing agent may be completed immediately prior to the time of application to the surface where the term ‘immediately’ refers to mixing occurring within approximately 30, or 25, or 20, or 15, or 10, or 5, or 4, or 3, or 2, or 1 minute/s of application.

The textile mesh may be embedded into the elastomeric resin and curing agent on the surface prior to the resin and agent hardening. For example, the resin and curing agent mixture may be applied to the surface and the mesh pushed into and embedded into the mixture.

More than one intermediate layer (resin, cement and optionally mesh) may be used. For example, once the first intermediate layer dries, a further intermediate layer or layers of elastomeric resin/cement and optionally mesh may be applied before commencing step (d).

Additional steps may also be taken to suit particular conditions and materials. For example, it may be advantageous in the case of aluminium joinery applications to apply a modified silicone bead to the intersection of the exterior joinery frame and the abutting surface to accommodate structural and thermal movement.

Advantages of the above TRM and method of application includes the ability to adhere the membrane to a wide range of materials and to provide a highly durable elastomeric seal. The TRM described has shown unexpected durability providing a weather-tight seal over almost all typical building materials tested including powder coated or anodised aluminium, stainless steel, Zincalume™, galvanised steel, copper, Colorsteel™, wood, plywood, solid plaster, modified plaster, concrete, concrete block, brick, fibre cement sheet, acrylic paint, acrylic membrane, glazed and unglazed ceramic tiles and porcelain tiles, thermoplastic olefin (TPO) and torch-on membrane, synthetic butyl rubber membrane such as Butynol™, uPVC, and combinations thereof. Art TRM solutions in the inventor’s experience do not have this durability.

The TRM also minimises work needed to complete a repair, simplifies the installation process and avoids the need to further damage the area being repaired as may be required for other methods.

In the case of so-called ‘leaky buildings’ TRM and method described herein has the potential to save thousands of dollars on repairs as complete re-cladding is avoided since leaking sections can be remediated and not replaced. The same technique may be used for a wide variety of other scenarios such as seismically damanged structures and weathered structures needing sealing repairs.

The embodiments described above may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more said parts, elements or features.

Further, where specific integers are mentioned herein which have known equivalents in the art to which the embodiments relate, such known equivalents are deemed to be incorporated herein as of individually set forth.

WORKING EXAMPLES The above described textile reinforced membrane and method of application are now described by reference to specific examples. Note that unless otherwise stated, the term primer as used below refers to a styrene-acrylic ester copolymer primer and the term elastomeric resin refers to a fibre reinforced styrene-acrylic ester copolymer.

EXAMPLE 1 In this example, a method of applying the membrane and adhesive to powder coated/anodised aluminium and steel exterior joinery is described.

The method comprises the following steps: a. Make sure the substrate abutting the window/door frame is sound b. If required remove loose material and re-plaster before commencing the TRM process c. Key the surface with a carbide scraper or grind the surface abutting the window/door frame to ensure it provides a secure adhesion surface d. Apply masking tape lines ensuring that drain holes from aluminium extrusion are not covered – if drain holes are covered by the TRM they can be re-drilled or cut through the TRM once the TRM is fully dried e. Use a diamond pad to scour the joinery surfaces where adhesive will be applied f. Wipe the scoured joinery clean with solvent g. Apply an etching primer to etch the surface h. When the etch primer is dry, thumb nail scratch the etch primer to ensure that the etch has adhered to the surface i. Place secondary masking tape 3mm from preliminary tape line so when tapes are removed there is a 3mm band of etch primer to paint onto j. Apply a coat of TRM primer to both the exterior joinery and the abutting adjacent surface k. Apply a modified silicone bead to the intersection of the exterior joinery frame and the abutting surface (optional) l. Whilst the modified silicone is still tacky but ‘skinned off’ and firm to touch, apply TRM primer to the sealant surface m. Mix elastomeric resin and cement at a ratio of 8 parts elastomer resin to 1 part cement and apply to both the exterior joinery and the abutting surface n. Lay the textile mesh in the wet elastomer resin ensuring it sits flat and is encapsulated in the first elastomer resin coat o. Once the first coat is dry, apply a second coat of elastomer resin p. Apply TRM primer coating to all surfaces once the second coat of elastomer resin is fully dry q. Remove masking tape leaving a 3mm wide band of the etch primer for the painter to paint to the leading edge of the etch primer r. Check work to ensure all junctions are sealed and that the leading edge of the elastomer resin to ensure this edge will not lift s. If necessary rub the leading edge of the elastomer resin to ‘flatten’ the leading edge slightly so it ‘rounds’ the leading edge.

EXAMPLE 2 In this example, a method of applying the membrane and adhesive from a wall cladding onto an adjacent concrete surface is described. For example where a dwelling wall abuts a path, driveway or retaining wall and a seal is necessary about the junction.

The method comprises the following steps: a. Make sure both surfaces are sound b. Cut a slot with a diamond saw (40mm out from the wall a blade width and 3mm deep) to drop the leading edge of the resin into c. Key the concrete surface with either a carbide blade or a grinder d. Tape a straight line of the masking tape along the edge of the slot cut into the concrete e. TRM primer both the concrete and the wall surface f. When the TRM primer coating is dry, it may be useful to apply a modified silicone at the junction between the cladding and the adjacent concrete surface coated with TRM primer whilst still tacky g. Apply a first intermediate layer coat of elastomer resin and cement reinforced with 100mm wide textile mesh embedded in the elastomer resin and cement h. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and cement to ensure the textile mesh is fully encapsulated in the elastomer resin and cement mixture i. When the elastomer resin/cement second coat is completely dry, apply a final coat of TRM primer coating.

EXAMPLE 3 In this example, a method of applying the membrane and adhesive to metal surfaces is described.

The method comprises the following steps: a. Ensure the bonding surface is free of dust and deleterious/foreign material b. Apply masking tape to form a primary line providing straight edges to the membrane and adhesive perimeter c. Scuff the metal surface with a diamond pad d. Clean the bonding surfaces with a solvent e. Apply an etch primer to the bonding surfaces up to the internal edges of the masking tape primary line f. After the etch primer has dried, ensure the etch primer has adhered to the metal surface by attempting to remove the etch primer by scraping the etch primer surface with a thumbnail g. If the etch primer has failed to adhere successfully repeat the process above h. When adhered, apply a secondary masking tape line approximately 3mm inside the primary tapeline. The secondary line masking tape should cover the etch primer surface by approximately 3mm. This allows the final paint coating to encapsulate the leading edge of the elastomer resin at the same time adhering the to the final coat of acrylic based resin applied over the elastomer resin. i. Apply a first coat of TRM primer coating to the etched surface j. Apply a first intermediate layer coat of elastomer resin and cement reinforced with 100mm wide textile mesh embedded in the elastomer resin and cement k. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and cement to ensure the textile mesh is fully encapsulated in the elastomer resin and cement mixture l. When the elastomer resin/cement second coat is completely dry, apply a final coat of TRM primer coating. m. Carefully remove the masking tape from the perimeter of the membrane and adhesive coated area and flatten the leading edge of the membrane and adhesive by rubbing it flat as required.

EXAMPLE 4 In this example, a method of applying the membrane and adhesive to wooden surfaces is described. The wooden surfaces may be timber, timber profiles, plywood surfaces including construction areas such as facings, soffit moulds, door jambs/heads and scuppers.

The method comprises the following steps: a. Ensure the bonding surface is free of dust, oil and deleterious/foreign material b. Establish the bonding area margins by marking the area out with a pencil line c. Cut a slot with a diamond saw (40mm out from the wall a blade width and 3mm deep) to drop the leading edge of the resin into d. Using a carbide scraper, flat scrap the bonding surface, then using the sharp edge of the carbide blade, cut shallow grooves in the timber surface making a diamond pattern (5mm to 10mm spacing). Upon completion, ensure the timber surface is rough to the touch e. Apply masking tape to form a primary line providing straight edges to the membrane and adhesive perimeters f. Apply a coat of porous surface sealer g. Apply TRM primer coating to the keyed timber surfaces h. Once the TRM primer coating is dry, test the primer coating for strength of bond to the timber surface to ensure it is well bonded i. Apply a secondary masking tape line approximately 3mm inside the primary tapeline. In other words, cover the primer surface with the secondary masking tape by approximately 3mm. This allows the final paint coating to encapsulate the leading edge of the elastomer resin at the same time adhering the to the final coat of TRM primer. n. When the TRM primer coating is dry, lightly sand the surface then apply a first intermediate layer coat of elastomer resin and cement reinforced with 100mm wide textile mesh embedded in the elastomer resin and cement. o. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and cement to ensure the textile mesh is fully encapsulated in the elastomer resin and cement mixture j. When the second intermediate layer coat is completely dry, apply a final coat of TRM primer, carefully remove the masking tape from the perimeter of the membrane and adhesive coated area and flatten the leading edge of the membrane and adhesive by rubbing it flat as required.

EXAMPLE 5 In this example, a method of applying the membrane and adhesive to PVC surfaces is described.

The method comprises the following steps: a. Ensure the bonding surface is free of dust, oil and deleterious/foreign material b. Using wet and dry sandpaper or a carbide scraper, flat scrape the bonding surface, then using the sharp edge of the carbide blade, cut shallow grooves in the timber surface making a diamond pattern (5mm to 10mm spacing) c. Establish the bonding area margins by marking the area out with a pencil line d. Apply masking tape to form a primary line providing straight edges to the membrane and adhesive perimeters e. ‘Liven up’ the PVC surface with Valspar 1K™ or a similar product f. Once the thinners have flashed off but the surface of the PVC is still tacky, apply Wattyl Super Etch™ etch primer or a similar product g. Apply a secondary masking tape line approximately 3mm inside the primary tapeline. In other words, cover the etch primer surface with the secondary masking tape by approximately 3mm. This allows the final paint coating to encapsulate the leading edge of the elastomer resin at the same time adhering the to the final coat of TRM primer coating. Apply TRM primer coating to the keyed PVC etch primed surface h. Once the TRM primer coating is dry, test the TRM primer for bond strength i. Apply a first intermediate layer coat of elastomer resin and cement reinforced with 100mm wide textile mesh embedded in the elastomer resin and cement j. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and cement to ensure the textile mesh is fully encapsulated in the elastomer resin and cement mixture k. When the elastomer resin/cement second coat is completely dry, apply a final coat of TRM primer coating. l. Carefully remove the masking tape from the perimeter of the membrane and adhesive coated area and flatten the leading edge of the membrane and adhesive by rubbing if required.

EXAMPLE 6 In this example, a method of applying the membrane and adhesive to solid plaster and modified plaster surfaces is described.

The method comprises the following steps: a. Ensure the bonding surface is free of dust, oil and deleterious/foreign material b. Using a carbide scraper, flat scrape the bonding surface, then using the sharp edge of the carbide blade, cut shallow grooves in the timber surface making a diamond pattern (5mm to 10mm spacing) c. Apply masking tape to form a primary line providing straight edges to the membrane and adhesive perimeters d. Apply a coat of TRM primer coating to the prepared plaster surface e. Once the TRM primer coating is dry, test the acrylic base primer for bond strength p. When the TRM primer coating is dry, apply a first intermediate layer coat of elastomer resin and cement reinforced with 100mm wide textile mesh embedded in the elastomer resin and cement q. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and cement to ensure the textile mesh is fully encapsulated in the elastomer resin and cement mixture r. When the elastomer resin/cement second coat is completely dry, apply a final coat of TRM primer coating. f. Carefully remove the masking tape from the perimeter of the membrane and adhesive coated area and flatten the leading edge of the membrane and adhesive by rubbing it flat as required.

EXAMPLE 7 In this example, a method of applying the membrane and adhesive to fibre cement sheet surfaces is described.

The method comprises the following steps: a. Ensure the bonding surface is free of dust, oil and deleterious/foreign material b. Establish the bonding area margins by marking the area out with a pencil line c. Cut a slot with a diamond saw (40mm out from the wall a blade width and 3mm deep) to drop the leading edge of the resin into d. Using a carbide scraper, flat scrap the bonding surface, then using the sharp edge of the carbide blade, cut shallow grooves in the fibre cement sheet surface making a diamond pattern (5mm to 10mm spacing). Upon completion, ensure the fibre cement sheet surface is rough to the touch e. Apply masking tape to form a primary line providing straight edges to the membrane and adhesive perimeters f. Apply a coat of porous surface sealer g. Apply TRM primer coating to the keyed fibre cement sheet surfaces h. Once the TRM primer coating is dry, test the primer coating for strength of bond to the fibre cement sheet surface to ensure it is well bonded i. Apply a secondary masking tape line approximately 3mm inside the primary tapeline. In other words, cover the primer surface with the secondary masking tape by approximately 3mm. This allows the final paint coating to encapsulate the leading edge of the elastomer resin at the same time adhering to the final coat of TRM primer. s. When the TRM primer coating is dry, lightly sand the surface then apply a first intermediate layer coat of elastomer resin and cement reinforced with 100mm wide textile mesh embedded in the elastomer resin and cement t. When the first coat is dry, apply a second intermediate layer coat of elastomer resin and cement to ensure the textile mesh is fully encapsulated in the elastomer resin and cement mixture u. When the elastomer resin/cement second coat is completely dry, apply a final coat of TRM primer coating. j. Carefully remove the masking tape from the perimeter of the membrane and adhesive coated area and flatten the leading edge of the membrane and adhesive by rubbing it flat as required.

EXAMPLE 8 Referring to the Figures, a repair to cladding 1 about a window frame 2 is illustrated. Figure 1 shows the window area 2 with repairs about to commence. Masking tape 3 and an applied primer layer 4 define the repair area perimeter. Figure 2 shows the prepared area in more detail. Figure 3 shows the intermediate layer 5 being applied to the repair area, in this case with the mesh (not shown) already applied and the resin and cement being applied on over the mesh. Figure 4 shows the final repaired surface 6 prior to final paint coats being applied over the TRM illustrating how the repair is largely invisible and gives an aesthetically attractive result.

EXAMPLE 9 Figures 5 and 6 illustrate a retrofitted uPVC water diverter installation. The uPVC section has been attached to a timber fascia and runs under Coloursteel™ in order to divert water flow from the roof away from the roof/wall junction. Figure 5 illustrates the uPVC diverter mounted to the timber fascia and with the surfaces prepared for TRM application. Figure 6 illustrates the finished assembly with the TRM coating applied to all three surfaces (wood, uPVC and Coloursteel™ with all surfaces sealed and weather-tight. This example illustrates the versatility of the TRM being able to adhere to three very different surfaces all in a close relationship and accommodate the inherent structural and thermal movement between them.

EXAMPLE 10 Tests were completed by an independent testing authority to confirm the TRM strength, adhesion, durability for use on pre-cast concrete substrates. The aim of the tests was to ensure the TRM meets the performance requirements of Clause B2 of the New Zealand Building Code.

The test used the TRM as described above.

The test method used a pull off adhesion test, tested according to BTS Test Procedure 105, reference standard: AS/NZS 1580.408.5. Average adhesion to the specified substrate shall be at least 0.8MPa being a minimum adhesion level established by BEAL Testing based on experience with similar products.

The results found were as shown in Table 1 below where: C = failure mode by cohesive failure being a failure within a single coating layer (as opposed to glue failure, adhesive failure and substrate failure).

S = substrate failure where the adhesive strength of the coating exceeds the tensile strength of the substrate, causing the substrate to fail before adhesive failure.

G = glue failure between the adhesive used to glue the test rig dollies to the coating.

A = adhesive failure being a failure at the coating/substrate interface or between layers of coatings.

Table 1- Pre-cast concrete test data: Sample Number Area (mm ) Failure Mode Adhesion Strength (MPa) S497-2 1963 90% C, 10% S 1.51 S497-3 1963 90% C, 10% S 1.47 S497-4 1963 50% G, 50% A 1.41 S497-5 1963 90% C, 10% S 1.47 Mean 1.47 S.D. 0.04 C.o.V. 2.7% As can be seen from the above results, The TRM easily exceeded BEAL standards.

EXAMPLE 11 In this example, test results are shown using the same methods and testing regimes as that described in Example 10, this time using substrates terracotta, unglazed porcelain, glazed ceramic and glazed porcelain.

For terracotta, the test results are shown in Table 2 below where: PSS = refers to additional use of a porous surface sealer prior to TRM application.

PK = the TRM as described above without a porous surface sealer.

C = failure mode by cohesive failure being a failure within a single coating layer (as opposed to glue failure, adhesive failure) and S = substrate failure where the adhesive strength of the coating exceeds the tensile strength of the substrate, causing the substrate to fail before adhesive failure.

G = glue failure between the adhesive used to glue the test rig dollies to the coating.

Table 2 – Terracotta test data Note that the results for sample S377-7 are not included in the analysis as this failure was the result of a glue failure between the test dolly and the TRM surface (a test equipment failure and not TRM test).

For unglazed porcelain, the test results are shown in Table 3 below where: PSS = refers to additional use of a porous surface sealer prior to TRM application.

PK = the TRM as described above without a porous surface sealer.

C = failure mode by cohesive failure being a failure within a single coating layer (as opposed to glue failure, adhesive failure) and S = substrate failure where the adhesive strength of the coating exceeds the tensile strength of the substrate, causing the substrate to fail before adhesive failure.

G = glue failure between the adhesive used to glue the test rig dollies to the coating.

Table 3 – Unglazed porcelain test data Note that the results for sample S378-6 are not included in the analysis as this failure was the result of a glue failure between the test dolly and the TRM surface (a test equipment failure and not TRM test).

For glazed ceramic, the test results are shown in Table 4 below where: PSS = refers to additional use of a porous surface sealer prior to TRM application.

PK = the TRM as described above without a porous surface sealer.

C = failure mode by cohesive failure being a failure within a single coating layer (as opposed to glue failure, adhesive failure) and S = substrate failure where the adhesive strength of the coating exceeds the tensile strength of the substrate, causing the substrate to fail before adhesive failure.

G = glue failure between the adhesive used to glue the test rig dollies to the coating.

Table 4 – Glazed ceramic test data For glazed porcelain, the test results are shown in Table 5 below where: PSS = refers to additional use of a porous surface sealer prior to TRM application.

PK = the TRM as described above without a porous surface sealer.

C = failure mode by cohesive failure being a failure within a single coating layer (as opposed to glue failure, adhesive failure) and S = substrate failure where the adhesive strength of the coating exceeds the tensile strength of the substrate, causing the substrate to fail before adhesive failure.

G = glue failure between the adhesive used to glue the test rig dollies to the coating.

Table 5 – Glazed porcelain test data As can be seen from the above results, the TRM exceeded standards in terms of adhesion strength to several substrates. In addition, in the case of the tested substrates, surface preparation with a porous surface sealer did not make any significant difference to the adhesion strength.

EXAMPLE 12 In this example, strength adhesion results were tested for TRM as described above using the same methods and testing regimes as that described in Example 9 and Example 10, this time using various substrates including: • uPVC • Fibre cement • Zincalume™ • Stainless steel • Powder coating aluminium • Anodised aluminium • Coloursteel™ • Aluminium • Electro galv • Copper • Zinc (plain) • Quartz zinc • Galvanised steel • Anthra zinc • Timber weatherboard • TPO • Nuralite™ TPE • Sarnafil™ • Butynol™ • Plywood • Polyethylene The various substrates and TRM were also tested for adhesion strength post multiple freeze- thaw cycles. This was completed to confirm that naturally occurring weather extreme cycles would not be detrimental to adhesion strength. Freeze thaw cycle testing was completed by subjecting the samples to 20 freeze thaw cycles according to BS Test Procedure 108. Each cycle had a duration of 12 hours and consisted of 3 hours at 70°C, 3 hours off, 3 hours at -20°C and another 3 hours off. For brevity only a summary of results are provided below in Table 6.

Table 6 – Multiple substrate test data As can be seen from the above results, the TRM reached and exceeded the minimum adhesion strength standard (0.8MPa) for all substrates tested proving the durability of the TRM described herein. Further, the freeze thaw testing also showed that the TRM adhesive strength on all substrates tested did not degrade with freeze thaw conditioning confirming that the TRM is weather resistant.

Aspects of the textile reinforced membrane and method of application have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope of the claims herein.

Claims (12)

WHAT IS CLAIMED IS:

1. An elastomeric water proof cladding on a building substrate comprising: a building substrate to or part thereof to be water proofed; and a textile reinforced membrane (TRM) adhered to the substrate or part thereof, the TRM 5 comprising: a first coating of elastomeric modified styrene-butadiene-styrene (SBS) thermoplastic elastomer on the substrate; an intermediate layer on the first coating, the intermediate layer comprising of woven fibre textile mesh embedded within a mixture of thermoplastic elastomer and cement, the 10 thermoplastic elastomer being a fibre reinforced modified styrene-butadiene-styrene (SBS) polymer, and wherein the ratio of thermoplastic elastomer to cement in the intermediate layer is approximately 6 to 10 parts thermoplastic elastomer to approximately 1 part cement; and a second coating of elastomeric modified styrene-butadiene-styrene (SBS) 15 thermoplastic elastomer on the intermediate layer; wherein the TRM once set having an adhesion strength on the substrate greater than 0.8MPa.

2. The textile reinforced membrane as claimed in claim 1 wherein the textile mesh is manufactured from polyester fibres. 20

3. The textile reinforced membrane as claimed in any one of the above claims wherein the textile mesh is manufactured from polyacrylonitril fibres

4. The textile reinforced membrane as claimed in any one of the above claims wherein the intermediate layer further comprises at least one clay or mineral.

5. The textile reinforced membrane as claimed in claim 4 wherein the clay or mineral is 25 selected from: quartz, calcium carbonate, and combinations thereof.

6. The textile reinforced membrane as claimed in any one of the above claims wherein the first layer and/or second layer further comprises at least one clay or mineral.

7. The textile reinforced membrane as claimed in claim 6 wherein the clay or mineral is selected from: quartz, limestone, calcium carbonate, talcum, titanium dioxide, and 30 combinations thereof.

8. A method of applying an elastomeric water proof cladding as claimed in any one of the above claims to a building substrate, the method comprising the steps: a. prepare the substrate to which the TRM is to be applied; b. apply the first coating of elastomeric modified styrene-butadiene-styrene (SBS) polymer to the substrate; c. apply the intermediate layer to the first coating; and 5 d. apply the second coating to the intermediate layer.

9. The method as claimed in claim 8 wherein the substrate is selected from: powder coated or anodised aluminium, stainless steel, Zincalume™, galvanised steel, copper, Colorsteel™, wood, plywood, solid plaster, modified plaster, concrete, concrete block, brick, fibre cement sheet, acrylic paint, acrylic membrane, glazed and unglazed ceramic tiles and 10 porcelain tiles, thermoplastic olefin (TPO) and torch-on membrane, synthetic butyl rubber membrane, uPVC, and combinations thereof.

10. The method as claimed in claim 8 or claim 9 wherein surface preparation in step (a) comprises the step of roughening the surface.

11. The method as claimed in any one of claims 8 to 10 wherein step (c) only commences once 15 the first coating applied in step (b) is dry.

12. The method as claimed in any one of claims 8 to 11 wherein step (d) only commences once the intermediate layer applied in step (c) is dry.