AU2011304488B2

AU2011304488B2 - Coating agents for producing waterproof infrastructure coatings

Info

Publication number: AU2011304488B2
Application number: AU2011304488A
Authority: AU
Inventors: Stephen John Aggenbach; Hardy Herold; Harold Schoonbrood
Original assignee: Wacker Chemie AG
Current assignee: Wacker Chemie AG
Priority date: 2010-09-23
Filing date: 2011-09-13
Publication date: 2014-02-20
Anticipated expiration: 2031-09-13
Also published as: BR112013006884A2; WO2012038302A1; DE102010041291A1; AU2011304488A1

Abstract

The invention relates to the use of coating agents for producing water-conducting infrastructure coatings, characterized in that the coating agents contain one or more mineral binders, one or more polymers based on one or more ethylenically unsaturated monomers, one or more fillers, and optionally one or more additives, at least 60 wt% of the fillers having a diameter of ≥ 10 μm, with respect to the total weight of all the fillers used.

Description

1 Coating agents for producing waterproof infrastructure coatings TECHNICAL FIELD 5 The invention relates to the use of coating compositions for producing water-carrying infrastructure coatings, and also to methods for producing water-carrying infrastructure constructions. 10 BACKGROUND OF THE INVENTION Water-carrying infrastructure constructions are, for example, sewers or drinking water systems. Such systems are required to be watertight and robust. 15 In the construction sector, the use of coating compositions based on mineral binders, polymers and fillers for the coating of substrates is widespread. Coating compositions of this kind are described in US 4746365 for the production of 20 coatings for masonry. WO-A 2009/132967 advises the use of polymer-modified, cementitious sealants for the aftertreatment of concrete elements. The concrete elements thus treated serve as a base for the laying of tiles or slabs. JP-A 8-120192 advises the use, for the production of 25 flat roofs or balconies, of cementitious coating compositions which have a high cement content relative to polymers. CN-C 100364916 addresses water-resistant, heat-insulating coatings for buildings, and for this purpose advises the use of coating compositions based on cementitious mortars which are 30 enhanced with small amounts of polymers. US 2006/0054059 describes flexible coatings based on hydraulically setting binders and polymers as an underlayer for ceramic tiles. CA 1046361 advises mats comprising a layer based on cement and polymers for the surface coating of buildings. For 2 producing watertight coatings, JP-A 4-300231 advises the use of quick-hardening cementitious systems which contain 1 to 100 parts by weight of polymers per 100 parts by weight of cement. WO-A 2009/064369 advises measures for the repair of 5 concrete, for which cementitious systems are employed. Against this background, an aim of the invention was to provide water-carrying infrastructure constructions superior to the existing water-carrying infrastructure constructions in terms of their watertightness and also their mechanical or 10 crack-bridging properties. Cracks may come about in the infrastructure constructions, such as sewers, as a consequence of earthquakes, contraction processes, hygrothermal changes in length, ageing processes or other mechanical loads. Coatings should now be found which bridge 15 cracks of this kind, forming within the infrastructure constructions over the course of time, and thereby prevent the emergence of water from the water-carrying infrastructure constructions. Furthermore, the water-carrying infrastructure constructions are to withstand mechanical loads, such as when 20 animals fall into sewers, for example, or when objects, such as trees or branches, fall into sewers, for example. Overall, therefore, the intention is to provide durable and robust water-carrying infrastructure constructions. Moreover, 25 the water-carrying infrastructure coatings ought to adhere well to substrates. In the course of the production of the infrastructure coatings, aqueous coating compositions ought to cure rapidly and without a long drying time. 30 SUMMARY OF THE INVENTION The invention firstly provides for the use of coating compositions for producing water-carrying infrastructure coatings, characterized in that the coating compositions 2a comprise one or more mineral binders, one or more polymers based on one or more ethylenically unsaturated monomers, one or more fillers and optionally one or more additives, at least 60% by weight of the fillers having a diameter of 5 10 pm, based on the total weight of the fillers employed overall. In a further aspect of the invention there is provided use of at least one coating composition for producing coatings for 10 water-carrying infrastructure constructions selected from the group encompassing sewers, ponds, swimming pools, water channels and drinking water systems, characterized in that the at least one coating composition comprises: 15 (i) at least one mineral binder; (ii) at least one polymer based on one or more ethylenically unsaturated monomers; (iii)at least one filler; and optionally at least one of 20 a) at least one additive selected from the group consisting of highly disperse silicas, phyllosilicates and fibres; and b) at least one adjuvant selected from the group consisting of thickeners, retardants, metal oxides 25 or semimetal oxides, dialdehydes, alkali metal salts or alkaline earth metal salts of organic or inorganic acids, pigments, preservatives, film forming assistants, dispersants, foam stabilizers, defoamers, plasticizers, low control agents and 30 flame retardants, and wherein - at least 60% by weight of the at least one filler, based on the total weight of the fillers employed 2b overall, has particles with a diameter of 10 pm, and - the at least one coating composition comprises 10% to 60% by weight of polymers based on one or more 5 ethylenically unsaturated monomers, based on the dry weight of the coating compositions. In another aspect of the invention there is provided a method for producing water-carrying infrastructure constructions 10 selected from the group encompassing sewers, ponds, swimming pools, water channels and drinking water systems, the method comprising applying at least one aqueous coating composition to a substrate, characterized in that the at least one aqueous coating composition comprises: 15 (i) at least one mineral binder; (ii) at least one polymer based on one or more ethylenically unsaturated monomers; (iii) at least one filler; and optionally at least one of 20 (a) at least one additive selected from the group consisting of highly disperse silicas, phyllosilicates and fibres, and (b) at least one adjuvant selected from the group consisting of thickeners, retardants, metal oxides 25 or semimetal oxides, dihalides, alkali metal salts or alkaline earth metal salts of organic or inorganic acids, pigments, preservatives, film forming assistants, dispersants, foam stabilizers, defoamers, plasticizers, flow control agents and 30 flame retardants, and wherein - at least 60% by weight of the at least one filler, based on the total weight of the fillers employed 2c overall, has particles with a diameter of a 10 um, and - the at least one coating composition comprises 10% to 60% by weight of polymers based on one or more 5 ethylenically unsaturated monomers, based on the dry weight of the aqueous coating compositions. DETAILED DESCRIPTION OF THE INVENTION 10 The infrastructure coatings are preferably coatings for infrastructure constructions such as sewers, ponds, swimming pools, water channels or drinking water systems, more preferably sewers.

Polymers used are addition polymers of one or more ethylenically unsaturated monomers. Preferred ethylenically unsaturated monomers are selected from the group encompassing 5 vinyl esters, (meth)acrylic esters, vinylaromatics, olefins, 1,3-dienes and vinyl halides, and optionally further monomers copolymerizable therewith. Suitable vinyl esters are, for example, those of carboxylic 10 acids having 1 to 15 C atoms. Preferred are vinyl acetate, vinyl propionate, vinyl butyrate, vinyl 2-ethylhexanoate, vinyl laurate, 1-methylvinyl acetate, vinyl pivalate and vinyl esters of a-branched monocarboxylic acids having 9 to 11 C atoms, for example VeoVa9R or VeoValOR (trade names of 15 the company Resolution). Particularly preferred is vinyl acetate. Suitable monomers from the group of acrylic esters or methacrylic esters are, for example, esters of unbranched or 20 branched alcohols having 1 to 15 C atoms. Preferred meth acrylic esters or acrylic esters are methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, n-butyl methacrylate, tert-butyl acrylate, tert-butyl methacrylate, 25 2-ethylhexyl acrylate. Particularly preferred are methyl acrylate, methyl methacrylate, n-butyl acrylate, tert-butyl acrylate and 2-ethylhexyl acrylate. Preferred vinylaromatics are styrene, methylstyrene and 30 vinyltoluene. Preferred vinyl halide is vinyl chloride. The preferred olefins are ethylene, propylene, and the preferred dienes are 1,3-butadiene and isoprene. optionally it is possible for 0% to 10% by weight, based on 35 the total weight of the monomer mixture, of auxiliary monomers to be copolymerized. It is preferred to use 0.1% to 5% by weight of auxiliary monomers. Examples of auxiliary monomers are ethylenically unsaturated monocarboxylic and dicarboxylic acids, preferably acrylic acid, methacrylic acid, fumaric acid and maleic acid; ethylenically unsaturated carboxamides and carbonitriles, preferably acrylamide and acrylonitrile; monoesters and diesters of fumaric acid and 5 maleic acid, such as the diethyl and diisopropyl esters, and also maleic anhydride; ethylenically unsaturated sulphonic acids and/or their salts, preferably vinylsulphonic acid, 2-acrylamido-2-methylpropanesulphonic acid. Further examples are precrosslinking comonomers such as polyethylenically 10 unsaturated comonomers, examples being diallyl phthalate, divinyl adipate, diallyl maleate, allyl methacrylate or triallyl cyanurate, or postcrosslinking comonomers, examples being acrylamido glycolic acid (AGA), methylacrylamido glycolic acid methyl ester (MAGME), N-methylolacrylamide 15 (NMA), N-methylolmethacrylamide, N-methylol allylcarbamate, alkyl ethers such as the isobutoxy ether or esters of N-methylolacrylamide, of N-methylolmethacrylamide and of N-methylol allylcarbamate. Also suitable are epoxide functional comonomers such as glycidyl methacrylate and 20 glycidyl acrylate. Further examples are silicon-functional comonomers, such as acryloyloxypropyltri(alkoxy)- and methacryloyloxypropyltri(alkoxy)silanes, vinyltrialkoxy silanes and vinylmethyldialkoxysilanes, where alkoxy groups that may be present include, for example, ethoxy radicals and 25 ethoxypropylene glycol ether radicals. Mention may also be made of monomers having hydroxyl groups or CO groups, examples being hydroxyalkyl acrylates and methacrylates such as hydroxyethyl, hydroxypropyl or hydroxybutyl acrylate or methacrylate, and also compounds such as diacetoneacrylamide 30 and acetylacetoxyethyl acrylate or methacrylate. Preference is given to one or more polymers selected from the group encompassing vinyl ester homopolymers, vinyl ester copolymers comprising one or more monomer units from the 35 group encompassing vinyl esters, olefins, vinyl aromatics, vinyl halides, acrylic esters, methacrylic esters, fumaric and/or maleic monoesters or diesters; (meth)acrylic ester homopolymers, (meth)acrylic ester copolymers comprising one or more monomer units from the group encompassing methacrylic esters, acrylic esters, olefins, vinylaromatics, vinyl halides, fumaric and/or maleic monoesters or diesters; homopolymers or copolymers of dienes such as butadiene or & isoprene, and also of olefins such as ethene or propene, it being possible for the dienes to be copolymerized with, for example, styrene, (meth)acrylic esters or the esters of fumaric or maleic acid; homopolymers or copolymers of vinylaromatics, such as styrene, methylstyrene, vinyltoluene; 10 homopolymers or copolymers of vinylhalogen compounds such as vinyl chloride, it being possible for the polymers also to contain auxiliary monomers. Particular preference is given to copolymers of one or more -151 vinyl esters with 1% to 50% by weight of ethylene; copolymers of vinyl acetate with 1% to 50% by weight of ethylene and 1% to 50% by weight of one or more further comonomers from the group of vinyl esters having 1 to 12 C atoms in the carboxylic acid radical, such as vinyl propionate, vinyl 20 laurate, vinyl esters of alpha-branched carboxylic acids having 9 to 13 C atoms, such as VeoVa9, VeoVa1O, VeoVall; copolymers of one or more vinyl esters, 1% to 50% by weight of ethylene and preferably 1% to 60% by weight of (meth) acrylic esters of unbranched or branched alcohols having 1 to 15 C atoms, more particularly n-butyl acrylate or 2 ethylhexyl acrylate; and copolymers with 30% to 75% by weight of vinyl acetate, 1% to 30% by weight of vinyl laurate or vinyl esters of an alpha-branched carboxylic acid having 9 to 11 C atoms, and also 1% to 30% by weight of (meth)acrylic 30 esters of unbranched or branched alcohols having 1 to 15 C atoms, more particularly n-butyl acrylate or 2-ethylhexyl acrylate, which also contain 1% to 40% by weight of ethylene; copolymers with one or more vinyl esters, 1% to 50% by weight of ethylene and 1% to 60% by weight of vinyl chloride; the 35 polymers may further comprise the stated auxiliary monomers in the stated amounts, and the amounts in % by weight add up to 100% by weight in each case.

Particular preference is also given to (meth)acrylic ester polymers, such as copolymers of n-butyl acrylate or 2-ethylhexyl acrylate or copolymers of methyl methacrylate with n-butyl acrylate and/or 2-ethylhexyl acrylate; styrene 5. acrylic ester copolymers with one or more monomers from the group of methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate; vinyl acetate acrylic ester copolymers with one or more monomers from the group of methyl acrylate, ethyl acrylate, propyl acrylate, n-butyl acrylate, 2-ethylhexyl acrylate and optionally ethylene; styrene-1,3-butadiene copolymers; the polymers may further comprise auxiliary monomers in the stated amounts, and the amounts in % by weight add up to 100% by weight in each case. Examples of particularly preferred comonomers for vinyl chloride copolymers are a-olefins, such as ethylene or propylene, and/or vinyl esters, such as vinyl acetate, and/or acrylic esters or methacrylic esters of alcohols having 1 to 20 15 C atoms, such as methyl acrylate, methyl methacrylate, ethyl acrylate, ethyl methacrylate, propyl acrylate, propyl methacrylate, n-butyl acrylate, tert-butyl acrylate, n-butyl methacrylate, tert-butyl methacrylate, 2-ethylhexyl acrylate and/or fumaric and/or maleic monoesters or diesters such as 25 the dimethyl, methyl tert-butyl, di-n-butyl, di-tert-butyl and diethyl esters of maleic acid or fumaric acid, respectively. Most preferred are copolymers with vinyl acetate and 5% to 6 50% by weight of ethylene; or copolymers with vinyl acetate, 1% to 50% by weight of ethylene and 1% to 50% by weight of a vinyl ester of a-branched monocarboxylic acids having 9 to 11 C atoms; or copolymers with 30% to 75% by weight of vinyl acetate, 1% to 30% by weight of vinyl laurate or vinyl esters 35 of an alpha-branched carboxylic acid having 9 to 11 C atoms, and also 1% to 30% by weight of (meth)acrylic esters of unbranched or branched alcohols having 1 to 15 C atoms which further contain 1% to 40% by weight of ethylene; or copolymers with vinyl acetate, 5% to 50% by weight of ethylene and 1% to 60% by weight of vinyl chloride. The monomer selection, and the selection of the weight 5 fractions of the comonomers, are made such as to result in a glass transition temperature, Tg, of -500C to +30 0 C, preferably -40 0 C to +10 0 C, more preferably -30 0 C to OOC. The glass transition temperature Tg of the polymers can be determined in a known way by means of Differential Scanning 10 Calorimetry (DSC). The Tg may also be calculated approximately in advance by means of the Fox equation. According to Fox T. G., Bull. Am. Physics Soc. 1, 3, page 123 (1956), the following holds: 1/Tg = xl/Tgl + x2/Tg2 + ... + xn/Tgn, where xn is the mass fraction (% by weight/100) of 15 the monomer n, and Tgn is the glass transition temperature, in kelvins, of the homopolymer of the monomer n. Tg values for homopolymers are listed in Polymer Handbook 2nd Edition, J. Wiley & Sons, New York (1975). 20 The polymers are prepared generally in aqueous medium and preferably by the emulsion or suspension polymerization process - as described in DE-A 102008043988, for example. The polymers in these cases are obtained in the form of aqueous dispersions. During the polymerization it is possible to use 25 the common protective colloids and/or emulsifiers, as described in DE-A 102008043988. The protective colloids may be anionic or preferably cationic or nonionic. Preference is also given to combinations of cationic and nonionic protective colloids. Preferred nonionic protective colloids are polyvinyl alcohols. Preferred cationic protective colloids are polymers which carry one or more cationic charges, as described in E. W. Flick, Water Soluble Resins an Industrial Guide, Noyes Publications, Park Ridge, N.J., 1991, for example. Preferred as protective colloids are 35 partially hydrolysed or fully hydrolysed polyvinyl alcohols having a degree of hydrolysis of 80 to 100 mol%, more particularly partially hydrolysed polyvinyl alcohols having a degree of hydrolysis of 80 to 94 mol% and a H6ppler viscosity, in 4% strength aqueous solution, of 1 to 30 mPas (H6ppler method at 20 0 C, DIN 53015). The stated protective colloids are obtainable by means of processes known to the skilled person, and are added generally in an amount 5 totalling 1% to 20% by weight, based on the total weight of the monomers, in the polymerization. The polymers in the form of aqueous dispersions can be converted, as described in DE-A 102008043988, into 10 corresponding, water-redispersible powders. In this case, in general, a drying aid is used, in a total amount of 3% to 30% by weight, preferably 5% to 20% by weight, based on the polymeric constituents of the dispersion. Preferred drying aids are the aforementioned polyvinyl alcohols. 15 Suitable mineral binders are, for example, cement, more particularly portland cement, aluminate cement, especially calcium sulphoaluminate cement, trass cement, slag cement, magnesia cement, phosphate cement, or blast furnace cement, 20 and also mixed cements, filler cements, flyash, microsilica, slag sand, lime hydrate, white lime hydrate, calcium oxide (unslaked lime) and gypsum. Preference is given to portland cement, aluminate cement and slag cement and also mixed cements, filler cements, lime hydrate or gypsum. 25 Preference is also given to mixtures of aluminate cement and one or more further mineral binders, such as, more particularly, portland cement, blast furnace cement, mixed cements, filler cements, lime hydrate or gypsum. The mixtures 30 contain preferably 20% to 100% by weight, more preferably 20% to 80% by weight and most preferably 33% to 66% by weight of aluminate cement, based on the mineral binders. Examples of suitable fillers are quartz sand, finely ground 35 quartz, finely ground limestone, calcium carbonate, dolomite, clay, chalk, white lime hydrate, talc or mica, granulated rubber or hard fillers, such as aluminium silicates, corundum, basalt, carbides, such as silicon carbide or titanium carbide, or fillers which give a pozzolanic reaction, such as flyash, metakaolin, microsilica. As fillers, preference is given to quartz sand, finely ground quartz, finely ground limestone, calcium carbonate, calcium magnesium carbonate (dolomite), chalk or white lime hydrate. The fillers preferably comprise no gravel. Gravel generally has diameters of a 2 mm, in particular a 4 mm. It is also possible to use any desired mixtures of the stated 10 fillers. Preferred mixtures comprise one or more silicatic fillers, such as sand, and one or more carbonatic fillers selected from the group encompassing calcium carbonate, chalk, dolomite and limestone. Preferred mixtures comprise one or more silicatic fillers and one or more carbonatic 15 fillers in a ratio from 1:1 to 4:1. The fillers preferably have diameters of 0.01 to 3 mm, more preferably 0.02 to 2 mm and most preferably 0.1 to 1 mm. O Preferably 60% to 100% by weight of the fillers have a diameter of 10 pm to 1 mm; more preferably 70% to 100% by weight of the fillers have a diameter of 10 pm to 0.6 mm; these figures are based in each case on the total weight of the total fillers employed. 25 As a consequence of the filler diameters according to the invention, the water-carrying infrastructure coatings obtainable according to the invention undergo reduced shrinkage in the course of their production, and this 50 counteracts cracking within the coatings according to the invention and is conducive to the crack bridging properties of the infrastructure coatings. Typical formulas for the coating compositions comprise 35 preferably 10% to 60% by weight, more preferably 20% to 55% by weight and most preferably 25% to 50% by weight of polymers; preferably 2% to 40% by weight, more preferably 5% to 30% by weight, most preferably 5% to 20% by weight of mineral binders; preferably 10% to 70% by weight and more preferably 20% to 5 60% by weight of fillers; the amounts in % by weight here relate to the dry weight of the coating compositions and add up in total to 100% by weight. The coating compositions preferably contain 30% to 95% by 10 weight, more preferably 40% to 90% by weight and most preferably 50% to 88% by weight of polymers, based on the dry weight of the polymers and mineral binders. The coating compositions are accordingly preferably dry 15 mixes. Water is generally added to the coating compositions directly prior to their application. Aqueous coating compositions comprise preferably 15 to 40% by weight and more preferably 20 to 40% by weight of water, based on the dry weight of the coating compositions. 20 The performance properties of the coating compositions may be improved by means of additives or adjuvants. Examples of suitable additives are highly disperse silicas, also known under the abbreviation HDK, such as, for example, fumed 25 silica or precipitated silica. Highly disperse silicas are present in the coating compositions preferably at 0.1% to 3% and more preferably at 0.1% to 1% by weight, based on the dry weight of the respective coating compositions. Using highly disperse silicas leads to infrastructure coatings which are 30 more impermeable to the penetration of water. Furthermore, the highly disperse silicas also provide advantage in terms of processing properties, since corresponding aqueous coating compositions are less tacky and dry out more quickly in the course of the setting of the mineral binders. 35 A preferred additive also are phyllosilicates. Coating compositions comprising phyllosilicates lead to infrastructure coatings having a higher degree of imperviousness to water. Phyllosilicates are present preferably at 0% to 3% by weight and more preferably at 0.1% to 2% by weight, based on the dry weight of the coating compositions. 5 Preferred additives are also fibres. Examples of suitable fibres are Kevlar, viscose fibres, polyamide fibres, polyester fibres, polyacrylonitrile fibres, Dralon fibres, polyethylene fibres, polypropylene fibres, polyvinyl alcohol fibres, aramid fibres or carbon fibres. Fibres are present preferably at 0% to 3% by weight and more preferably at 0.1% to 2% by weight, based on the dry weight of the coating compositions. The use of fibres results in infrastructure coatings having more strongly crack-bridging properties. Typical adjuvants for the coating compositions are thickeners, examples being polysaccharides such as cellulose ethers and modified cellulose ethers, starch ethers, guar gum, xanthan gum, polycarboxylic acids such as polyacrylic 20 acid and the partial esters thereof, and also polyvinyl alcohols, which optionally may have been acetalized or hydrophobically modified, and casein and associative thickeners. Customary adjuvants also include retardants, such as hydroxycarboxylic acids, or dicarboxylic acids or salts 5 thereof, saccharides, oxalic acid, succinic acid, tartaric acid, gluconic acid, citric acid, sucrose, glucose, fructose, sorbitol and pentaerythritol. Customary adjuvants are also crosslinkers such as metal oxides or semimetal oxides, more particularly boric acid or polyborates, or dialdehydes, such 30 as glutaraldehyde; customary adjuvants are also setting accelerators, examples being alkali metal salts or alkaline earth metal salts of inorganic or organic acids. Further adjuvants are, for example, pigments, more particularly inorganic pigments, such as titanium dioxide. Mention may 35 also be made, furthermore, of the following: preservatives, film-forming assistants, dispersants, foam stabilizers, defoamers, plasticizers, flow control agents and flame retardants (e.g. aluminium hydroxide).

In general, the fraction of adjuvants as a proportion of the coating compositions overall is 0% to 20% by weight, preferably 0.1% to 15% by weight and more preferably 0.1% to 5 10% by weight, based in each case on the dry weight of the coating compositions. The preparation of the coating compositions based on mineral binders, polymers, fillers and optionally additives is not 101 tied to any particular procedure or mixing apparatus. Coating compositions are obtainable by mixing of the individual ingredients of the formula in conventional powder mixing apparatus, as for example by means of mortar mixers, concrete mixers or plaster machines or stirrers, and homogenization. 15 The individual ingredients are used generally in dry form at the mixing stage. The polymers can be used in the form of aqueous dispersions or, preferably, in the form of water-redispersible powders. 20 The coating compositions may be provided in, for example, the form of one-component systems or two-component systems. One component systems comprise all of the ingredients of the coating compositions. With one-component systems, the 25 formulations are generally dry formulations. One-component systems are preferably produced by premixing mineral binders, fillers, polymers, optionally additives and optionally adjuvants. To produce the aqueous coating compositions, the water may be admixed at any later point in time, generally 30 shortly prior to application of the coating compositions. Two-component systems comprise a first component and a second component. The first component comprises all of the ingredients of the coating compositions apart from polymers. 35 The first component is generally a dry formulation. The second component comprises the polymers, preferably in the form of aqueous dispersions. For preparing the coating compositions, which may be aqueous, the first component and the second component are mixed, where appropriate with addition of water or with subsequent addition of water. The invention further provides methods for producing water 5 carrying infrastructure constructions by application of one or more coating compositions to a substrate, characterized in that the coating compositions comprise one or more mineral binders, one or more polymers based on one or more ethylenically unsaturated monomers, one or more fillers 10 and optionally one or more additives, at least 60% by weight of the fillers having a diameter of 10 pm, based on the total weight of the fillers employed overall. 15 The substrates may be organic or inorganic, natural or synthetic. Examples of natural substrates are floors, rock, stone or scree. Examples of synthetic substrates are primarily substrates from the construction sector, such as substrates based on compositions comprising mineral binders, 20 more particularly concrete, but also timber materials, plastics materials, more particularly polyurethane foam boards, or metals, more particularly aluminium. Substrates from the construction sector are preferred. 25 The aqueous coating compositions may be applied by manual methods or mechanical methods. In the case of manual methods, the aqueous coating compositions are applied to the substrate with the aid of coarse brushes, fine brushes, rollers, knives, trowels, paddles or shovels. In the case of 30 mechanical methods, the aqueous coating compositions are applied to the substrate by means of spraying machines, plaster machines or robots. Two or more coats of coating compositions may be applied one above another. It is preferred to apply only one coat of the coating compositions 35 to a substrate. Following the application of coating compositions to the substrates, the surface of the applied coat may be smoothed, using smoothing discs or paddle smoothers, for example.

The coating compositions are applied typically at ambient temperatures, i.e. in general at temperatures from 0 to 50*C, more particularly from 5 to 350C. The substrates may be primed before the coating compositions are applied. Examples of suitable primers include aqueous dispersions of the abovementioned polymers, preferably with solids contents of 10% to 50%. 10 The coating compositions are applied to a substrate in a coat thickness of preferably 1 to 10 mm, more preferably 2 to 5 mm and most preferably 2 to 3 mm. 15 Lastly, further layers may be applied to the infrastructure coatings, such as, for example, paints, based more particularly on titanium dioxide pigments. The coatings of the invention, however, preferably form the topmost or finishing layer of the water-carrying infrastructure 20 constructions. The coatings produced in accordance with the invention are distinguished by advantageous performance properties and have, for example, outstanding mechanical properties and 25 watertightness. Surprisingly, the inventive use of coating compositions results in coatings which relative to conventional, mineral coatings exhibit an improved elongation at break and are therefore more flexible, resulting in improved crack bridging, meaning that cracks which form in 40 substrates are sealed and, accordingly, that coated, water carrying infrastructure constructions do not lose water. The coatings of the invention also adhere very well to a wide variety of substrates. Furthermore, the coatings originating from the coating compositions are obtainable through simple 35 and few operations, employing common building-site equipment, in a time-efficient manner. This is so not least because the coating compositions of the invention undergo rapid through drying, even if the coating compositions are applied at 15 relatively high thicknesses. Overall, through the procedure according to the invention, coatings are obtained which are especially suitable for the provision of water-carrying infrastructure coatings and infrastructure constructions. 5 Comprises/comprising and grammatical variations thereof when used in this specification are to be taken to specify the presence of stated features, integers, steps or components or groups thereof, but do not preclude the presence or addition 10 of one or more other features, integers, steps, components or groups thereof. The examples which follow serve for detailed elucidation of the invention and should in no way be understood to 15 constitute any restriction. Inventive Example 1 (IEx. 1): The coating composition was prepared by introducing the individual ingredients of the formula indicated below, in the 20 following order, with mixing, into a Hobart mixer (commercial laboratory mixer): first cement, then the fillers, the dispersion powder and lastly the remaining ingredients. This was followed by homogeneous mixing on setting 1 for 15 minutes. The aqueous coating composition was produced from 25 the resultant dry mix in the manner indicated in EN 196-1, with the amount of-water stated below. The aqueous coating composition was smoothed onto Teflon formwork components (base area: 30 x 15 cm) using a trowel. After storage for 24 hours under standard conditions in 30 accordance with DIN 50014, the films had cured and, following removal of the Teflon formwork components, were stored for 7 days under standard conditions (230C/50% relative humidity). 35 Formula of the coating composition (dry mixture): 12 parts by weight portland cement, 15a 42 parts by weight dispersion powder Vinnapas* 5044 N (vinyl acetate-ethylene copolymer, stabilized with polyvinyl alcohol), 0.46 part by weight highly disperse silica (Wacker HDK H 15), 5 22.3 parts by weight quartz sand (median diameter of sand particles: 150 pm), 22.2 parts by weight quartz sand (median diameter of sand particles: 600 pm). Water quantity: 35.2 g water per 100 g dry mixture.

Inventive Example 2 (IEx. 2): In analogy to Inventive Example 1, with the difference that, instead of the dispersion powder Vinnapas® 5044 N, the S dispersion powder Vinnapas® LL 4040 N (vinyl acetate-ethylene copolymer, stabilized with polyvinyl alcohol and a cationic protective colloid) and, instead of 35.2 g water per 100 g dry mixture, 34.5 g water per 100 g dry mixture were employed. Inventive Example 3 (IEx. 3) In analogy to Inventive Example 1, with the difference that the dry mixture and the water quantity used for preparing the coating composition were as follows: 15 12 parts by weight portland cement, 28 parts by weight dispersion powder Vinnapas® 5044 N (vinyl acetate-ethylene copolymer, stabilized with polyvinyl alcohol), 0.46 part by weight highly disperse silica (Wacker HDK H 15), 20 50.0 parts by weight quartz sand (median diameter of sand particles: 150 pm), 10.0 parts by weight quartz sand (median diameter of sand particles: 600 pm). Water quantity: 28.1 g water per 100 g dry mixture. Inventive Example 4 (IEx. 4): In analogy to Inventive Example 3, with the difference that, instead of the dispersion powder Vinnapas* 5044 N, the dispersion powder Vinnapas® LL 4040 N (vinyl acetate-ethylene 30 copolymer, stabilized with polyvinyl alcohol and a cationic protective colloid) and, instead of 28.1 g water per 100 g dry mixture, 28.0 g water per 100 g dry mixture were employed. 35 Comparative Example 5 (CEx. 5): In analogy to Inventive Example 1, with the difference that the coating composition used was an acrylate dispersion, i.e. not a cementitious coating composition.

Performance testing In accordance with ISO 527-3 (8/1995), type 1 B standard rods 5 were punched from each of the films obtained after dry storage, from Inventive Examples I to 4 and from Comparative Example 5, respectively. The tensile strength and elongation at break of the standard rods were then determined by means of a tensile test in 10 accordance with ISO 527-3 (8/1995). The standard rods were stretched to failure at a tensioning speed of 50 mm/min. The tensile adhesive strength was determined in accordance with DIN 1855S-6. The Shore A hardness was determined with a 15 needle penetrometer at 23 0 C and 50% atmospheric humidity. The results of the testing are set out in Table 1. Table 1: Tensile Elongation Tensile adhesive Shore A strength at break strength (N/mm 2 ) (%) (N/mm 2 ) IEx. 1 1.63 49 1.33 78 IEx. 2 1.20 69 1.36 78 IEx. 3 1.70 28 1.57 82 IEx. 4 1.35 37 1.54 82 CEx. 5 n.d.* n.d.* n.d.* 74 20 *: n.d. = not determined. The inventive products (Examples 1 to 4) are harder than the comparative example based on the acrylate dispersion (Comparative Example 5) and, moreover, exhibit outstanding 25 mechanical properties, for example a high elongation at break, which correlates with desired crack-bridging properties. Furthermore, the aqueous coating compositions of the invention dry rapidly and without cracking, even if applied in relatively high film thicknesses. 30

Claims

1. Use of at least one coating composition for producing coatings for water-carrying infrastructure constructions 5 selected from the group encompassing sewers, ponds, swimming pools, water channels and drinking water systems, characterized in that the at least one coating composition comprises: (i) at least one mineral binder; 10 (ii) at least one polymer based on one or more ethylenically unsaturated monomers; (iii) at least one filler; and optionally at least one of a) at least one additive selected from the group 15 consisting of highly disperse silicas, phyllosilicates and fibres; and b) at least one adjuvant selected from the group consisting of thickeners, retardants, metal oxides or semimetal oxides, dialdehydes, alkali metal salts 20 or alkaline earth metal salts of organic or inorganic acids, pigments, preservatives, film forming assistants, dispersants, foam stabilizers, defoamers, plasticizers, low control agents and flame retardants, 25 and wherein - at least 60% by weight of the at least one filler, based on the total weight of the fillers employed overall, has particles with a diameter of a 10 pm, and - the at least one coating composition comprises 10% to 30 60% by weight of polymers based on one or more ethylenically unsaturated monomers, based on the dry weight of the coating compositions. 19

2. Use of the at least one coating composition according to claim 1, characterized in that the at least one filler has particles with a diameter in the range of 0.01 to 3 mm. 5

3. Use of the at least one coating composition according to claim 1 or claim 2, characterized in that 60% to 100% by weight of the at least one filler has particles with a diameter in the range of 10 pm to 1 mm, based on the total weight of the fillers employed overall. 10

4. Use of the at least one coating composition according to any one of claims 1 to 3, characterized in that the at least one coating composition comprises 10% to 60% by weight of polymers, based on the dry weight of the coating 15 compositions.

5. Use of the coating compositions according to any one of claims 1 to 4, characterized in that the at least one coating composition comprises 30% to 95% by weight of 20 polymers, based on the dry weight of the polymers and of the mineral binders.

6. Use of the coating compositions according to any one of claims 1 to 5, characterized in that the at least one 25 coating composition comprises as an additive one or more highly disperse silicas.

7. A method for producing water-carrying infrastructure constructions selected from the group encompassing sewers, 30 ponds, swimming pools, water channels and drinking water systems, the method comprising applying at least one aqueous coating composition to a substrate, characterized in that the at least one aqueous coating composition comprises: 35 (i) at least one mineral binder; 20 (ii) at least one polymer based on one or more ethylenically unsaturated monomers; (iii) at least one filler; and optionally at least one of 5 (a) at least one additive selected from the group consisting of highly disperse silicas, phyllosilicates and fibres, and (b) at least one adjuvant selected from the group consisting of thickeners, retardants, metal oxides 10 or semimetal oxides, dihalides, alkali metal salts or alkaline earth metal salts of organic or inorganic acids, pigments, preservatives, film forming assistants, dispersants, foam stabilizers, defoamers, plasticizers, flow control agents and 15 flame retardants, and wherein - at least 60% by weight of the at least one filler, based on the total weight of the fillers employed overall, has particles with a diameter of 10 um, 20 and - the at least one coating composition comprises 10% to 60% by weight of polymers based on one or more ethylenically unsaturated monomers, based on the dry weight of the aqueous coating compositions. 25

8. The method for producing water-carrying infrastructure constructions according to claim 7, characterized in that the at least one aqueous coating composition is applied in a film thickness of 1 to 10 mm to a substrate. 30

9. The method for producing water-carrying infrastructure constructions according to claim 7 or 8, characterized in that the coating based on the at least one aqueous coating 21 composition forms the topmost layer of the water-carrying infrastructure constructions.

10. Use of at least one coating composition for producing 5 coatings for water-carrying infrastructure constructions according to claim 1 substantially as hereinbefore described with reference to the Examples but excluding Comparative Examples. 10

11. A method for producing water-carrying infrastructure constructions according to claim 7 substantially as hereinbefore described with reference to the Examples but excluding Comparative Examples. 15 WACKER CHEMIE AG WATERMARK PATENT AND TRADE MARKS ATTORNEYS P37243AU00