EP1033440A1 - Leakproof floor covering and process of making the same - Google Patents

Abstract

A liquid-proof floor covering on a load-bearing base, e.g. concrete or asphalt, especially for driveable areas of filling and emptying stations, consists of a liquid-proof barrier layer mechanically bonded to the base and an outer wear layer mechanically bonded to the barrier layer. An Independent claim is also included for a process for the production of this floor covering by applying a barrier layer (A) to the substrate (B) and fixing it mechanically, then laying a wear-resistant cover (C) on the barrier layer and fixing it mechanically.

Description

The invention relates to a liquid-tight floor covering over a stable subsurface, e.g. a concrete slab or an asphalt surface, in particular for passable areas in filling and filling stations, as well as a method for Making such.

In areas where environmentally hazardous liquids are decanted environmental protection regulations, and in particular, are becoming increasingly important of groundwater. It is required that these liquids, in In case of spillage, do not get into the ground and ground water can. To achieve this, dense flooring must be created for liquids become. Materials that meet the tightness requirement often meet however other requirements such as high resilience, abrasion resistance or electrical conductivity, or resistance to aggressive substances not.

In petrol station construction in particular, road surfaces are becoming increasingly common required, which are tight on the one hand, so that no liquid in the underground and possibly get into the groundwater. On the other hand, these rubbers should antistatic, i.e. be electrically conductive and grounded. The well-known Mastic asphalt surfaces meet the requirement for tightness, but they are electrically insulating. In addition, they can only be in a layer thickness in the range of Centimeters to be poured.

The common solution with which these two requirements are met is a cement coating with a cement content of at least 450 kg / ton. Such cement coatings cannot be in thinner layers than be applied at least 2 to 3 cm. When refurbishing existing petrol stations therefore the islands with the petrol pumps must also be raised or the subsoil around this layer thickness is removed by the prescribed curb height to be able to comply with the islands. They are also only suitable if the Has no working joints over which the covering breaks and could leak. Such joints between not rigidly connected Otherwise, parts must also be formed in the covering and with silicone or poured asphalt be sealed. Silicon and mastic asphalt, however, insulate the covering areas against each other, so that specifically on the electrical conductivity of all areas must be respected. Often these materials are liable to the Inadequate joint edges so that detachments and leaks can occur. These joint seals therefore have to be replaced frequently.

In addition, cement coverings with a very high proportion of cement are susceptible to Shrinkage cracks. It is therefore important to make sure that the covering is in place when creating it protected from direct sunlight and quick drying. Because of the Shrinkage behavior and the temperature-related expansion differences Cement coverings can only be produced in limited areas without joints. The production of cement floors is also expensive and their quality is not always that desired high level.

It is an object of the invention to provide a floor covering which overcomes the disadvantages of the prior art. He is supposed to be with one preferably thin layer both the required tightness, and one for Provide roads and squares with adequate abrasion resistance. He is said to be in one Further development also have antistatic properties.

According to the invention, this is achieved with a covering of the type mentioned at the beginning Genus achieved by a mechanically connected to the underground, liquid-tight barrier layer, and an overlying one, with the barrier layer mechanically connected wear layer.

A polymer layer is opposite to one as the liquid-tight barrier layer Bitumen layer is preferable. Polymers, especially polyureas, are extremely resistant to tearing and shearing. The polymer layer can be a very form dimensionally stable layer transferring forces to the substrate.

In order to achieve a seamless barrier layer, the liquid-tight Barrier layer advantageously a locally liquid applied and hardened on site Foil. This is either applied by hand or preferably as a spray film applied.

If the barrier layer consists of a two-component film, for example of polyurea, it is very largely resistant to substances. In addition, such a two-component film sets within minutes, so that the follow-up work can be started immediately. A film made of polyurea with a thickness of 2 to 3 mm is extremely tear-resistant, liquid-impermeable, pressure-resistant and elastic. Suitable plastic layers have an elongation at break of at least over 150%, preferably over 200, particularly preferably between 300 and 600%. They have at least a tensile strength of 4, preferably over 6, particularly preferably between 8 and 15 N / mm ² . With such a layer, joints up to 3 mm can be bridged.

Through an adhesive layer between the liquid-tight barrier layer and the substrate, or between the liquid-tight barrier layer and the The wear between the layers can be increased in such a way that the individual layers are not separated from one another by mere mechanical stress are to be separated. This is particularly in areas that are passable and heavily used important.

The fact that the adhesive layer is sanded is mechanical Connection of the layer applied to the primer improved. The Layers can neither be separated from one another nor shifted against each other.

The wear layer expediently contains a polymer Binder layer and a granulate bound by the binder. In a the preferred embodiment is the binder with electrically conductive pigments and fillers formulated and the conductive layer thereby grounded. This can a static charge on the electrically insulating barrier layer applied wear covering can be avoided.

Is the wear surface sprinkled with an abrasion resistant Granules, this is advantageously electrically conductive. This allows the derivation of electrical voltages across the granulate and the binder.

The wear layer advantageously has a silicon carbide layer Polymer layer on. Silicon carbide is not just because of its electrical Conductivity is a preferred bedding granulate, but it is also available in various Grain sizes commercially available and is extremely resistant to mechanical and chemical influences.

The binder is advantageously an epoxy resin. An epoxy resin can be used with electrically conductive additives are added. Such a layer is electrically conductive. Epoxy resin is sufficient in a layer thickness of 2 to 3 mm, around with a granulate up to the grain size 3 mm, but preferably in the range 0.3 to 0.6 mm to be sprinkled. Alternatively, the binder can also be a Two-component lacquer based on polyurethane. This varnish can also expediently with electrically conductive pigments and / or fillers be formulated. Polyurethane paint is available in a layer thickness of approx. 0.25 mm Roll up or spray paint. It is sprinkled with granules correspondingly finer grain size, preferably from 0.1 to 0.35 mm. Instead of Silicon carbide can also be used quartz sand. This is not itself The covering is nevertheless conductive, but provided with a conductive cover layer antistatic.

The wear covering with an electrically conductive is advantageous Provide top layer. This additionally binds the granules that are scattered in and shafts a conductive connection between the granules. In less stressed Areas can be sprinkled into the base layer of granules Wear pads can be completely dispensed with.

In a method for producing a liquid-tight floor covering, especially for passable areas e.g. in filling and filling stations, at which According to the invention, a wear covering is applied over a substrate a barrier layer is applied to the surface and mechanically with it connected. The wear layer is attached over the barrier layer and with the Barrier layer mechanically connected.

If the barrier layer can also be applied manually, it will sprayed on advantageously. Between the barrier layer and the subsurface, or between An adhesive bridge is applied and sanded over the barrier layer and wear layer.

An epoxy resin or a polyurethane paint is advantageous as a wear covering applied and sanded or split. It will be advantageous Wear surface sprinkled with silicon carbide. Sanded or split Surfaces of the wearing surface are advantageously covered with a top coat Mistake.

Coordinated products are e.g. the following: Depending on the surface, a sanded with quartz sand is suitable as a primer Two-component epoxy resin (concrete or asphalt surface), or one with Sanded quartz sand, formulated with anti-corrosion pigments and fillers Primer based on epoxy polyurethane resin (metal base); A sprayed two-component polyurea liquid film is suitable as a barrier layer or a hand-applied two-component polyurethane liquid film. A two-component varnish based on polyurethane can be applied over the barrier layer or epoxy polyurethane resin can be applied, which is sprinkled in directly and is sealed. This sprinkled base layer is advantageous with conductive pigments and fillers formulated. Between the barrier layer and this two-component paint can also be used as a sanded two-component polyurethane varnish Adhesive bridge can be applied.

Quartz sand with a grain size of 0.1 to 3 mm, preferably 0.3 to 0.8 mm, is a suitable bedding granulate on primer and primer.
Quartz sand and preferably silicon carbide with grain sizes of 0.1 to 3 mm, but preferably 0.3 to 0.8, or up to 0.6 mm, is sprinkled into the surface of the cover layers protecting the barrier layer as scattering granules. This abrasion-resistant surface is sealed with an epoxy polyurethane varnish formulated with conductive pigments and / or fillers, or with a similar varnish based on polyurethane.

A, preferably with, is suitable for a stronger wear layer electrically conductive pigments and / or fillers formulated, two-component epoxy resin on the sanded primer from a two-component polyurethane lacquer. The epoxy resin is in a layer thickness of 1 to 3 mm filled, and ideally with silicon carbide with a grain size of 0.3 to 0.6 mm interspersed. Above is a top coat of one with conductive pigments and / or fillers formulated two-component paint based on epoxy-polyurethane resin expedient.

Fig. 1

einen Belagsaufbau mit einem minimalen Verschleissbelag,

Fig. 2

den weitgehend identischen Belagsaufbau mit einem mächtigeren Verschleissbelag.

Fig. 3.

den Belagsaufbau gem. Figur 1 mit vereinfachtem, minimalem Verschleissbelag.

The invention is explained in more detail below with reference to the figures. It shows:

Fig. 1

a covering structure with a minimal wear covering,

Fig. 2

the largely identical covering structure with a more powerful wear covering.

Fig. 3.

the covering structure acc. Figure 1 with a simplified, minimal wear layer.

The covering structures 11, 11 'and 11' 'shown in the figures have a liquid-impermeable barrier layer 13 over a base 17. This barrier layer 13 is not conductive. It is through one, at most electrical conductive, very thin wear covering 15.15 'covered. The inventive Barrier layer can also, without sacrificing advantages, with a non-conductive or a thicker, e.g. mineral, wear covering to be covered.

In Figures 1 to 3, the structure according to the invention consists of a Barrier layer 13 and a wear layer 15 above it. On the supporting ground 17, e.g. a concrete slab, is a primer 19 matched to the base 17 rolled up. This primer 19 is used for better adhesion arranged layers on the supporting base 17. The quartz sand grains 21 are embedded in the primer 19 because the primer 19 was sanded in when wet. The sanding 21 causes mechanical interlocking between the upper one Layer and the primer 19. On the sanded surface of the dry primer 19 is a polyurea two-component film 23 sprayed. Alternatively, the Foil 23 also applied by hand, e.g. be filled or poured. The Two-component polyurea binds within a few minutes, so that the Workflow in the manufacture of the covering does not have to be interrupted.

The film 23 is in turn on the top with a Provide adhesive paint 25. In the examples acc. Figure 1 and 2 this is like that Primer 19 sanded with quartz sand 21 'of grain size 0.3 to 0.8 mm. As Adhesive paint 25 is expediently a two-component polyurethane paint used. The components of the covering structure under the binder layer 27, 29 can be electrically insulating without disadvantage. The plastic film forms one anyway electrically insulating layer. It can therefore also quartz sand for sanding the Adhesive coats 19 and 25 are used. The covering structure differs in the two Figures 1 and 2 only in the wear pads 15, 15 'above sanded adhesive paint 25.

Figure 1 shows the less expensive variant with a 0.2 to 0.3 mm strong, conductive base layer 27 made of one, advantageously with conductive pigments and fillers formulated, two-component paint based on epoxy polyurethane resin. The base layer 27, which is rolled up, is made of silicon carbide 31 of grain size 0.1-0.3 mm sprinkled. This conductive granulate 31 is then with a cover layer 33 made of a with conductive pigments and Fillers formulated two-component paint based on epoxy polyurethane resin overdrawn. This cover layer 33 can also be omitted or created from conductive formulated polyurethane lacquer.

FIG. 2 shows a more complex and resilient variant with a second up to 3 mm thick, preferably conductive, support layer 29 from a Two-component epoxy resin.

This carrier or base layer 29 is 1 to 3 mm thick and preferably sprinkled with silicon carbide 35 with a grain size of 0.3 to 0.6. This too Granulate 35 is provided with a top coat 33 to bond the surface to increase and possibly to establish the conductivity of the covering. Here, too Top layer 33, e.g. for reasons of cost, cannot be carried out.

In the construction variant shown in FIG. 3, the barrier layer 13 is on applied a two-component paint 25 based on polyurethane and directly with Sprinkled silicon carbide or quartz sand. This lacquer does not have to be conductive even then if the surface is to be antistatic. Even with a seal from one two-component paint formulated with conductive pigments and fillers, for example based on epoxy-polyurethane resin, this requirement can be met become. If the covering is simplified, even the granules can be sprinkled on to be dispensed with.

If the covering does not have to be antistatic, you can use the electrically conductive formation of the layers of the wear layer is dispensed with and the polymer layer or layers are designed to be electrically insulating.

In summary, it can be said that a liquid-tight Vehicle covering, especially for filling stations of tank systems and Filling stations for environmentally hazardous liquids, one with the carrying one Substrate 17 mechanically connected, liquid-tight, substance-resistant film 23 and an attached one mechanically connected to the film 23 Has wear covering 15, 15 '. The film 23 is preferably one Two-component spray film made of polyurea. The wear layer 15, 15 'points a, advantageously electrically conductive, two-component resin or lacquer layer 29 and a scattering of silicon carbide 35. For the mechanical connection of the A sanded intermediate coat 19, 21 is applied between each of the layers Epoxy resin or 25.21 'applied from a polyurethane paint.

Claims (11)

Liquid-tight floor covering (11, 11 ') over a load-bearing surface (17), e.g. a concrete slab or asphalt surface, especially for passable areas in filling and filling stations, marked by a liquid-tight mechanically connected to the substrate (17) Barrier layer (23), and an overlying one, with the barrier layer (23) mechanically connected wear lining (15, 15 '). Covering according to claim 1, characterized in that the liquid density Barrier layer (23) is a polymer layer. Covering according to claim 1 or 2, characterized in that the liquid-tight barrier layer (23) is a locally applied liquid film. Covering according to claim 3, characterized in that the film (23) a Two-component liquid film made of polyurea is. Covering according to claim 3 or 4, characterized in that the liquid-tight barrier layer (23) is a spray film. Covering according to one of claims 1 to 5, characterized by a Adhesive layer (19.21 / 25.21 ') between the liquid-tight barrier layer (23) and the substrate (17), or between the liquid-tight barrier layer (23) and the wear layer (29,35,33 / 27,31,33). Covering according to one of claims 1 to 6, characterized in that the Wear layer (15, 15 ') a layer of a with pigments and / or Fillers and polymeric binder formulated lacquer or resin (27, 29), e.g. an epoxy resin or a polyurethane paint. Covering according to claim 7, characterized in that the pigments and / or Fillers are electrically conductive and therefore the paint or resin layer is conductive. Covering according to claim 7 or 8, characterized in that the Wear pad (29,35,33 / 27,31,33) with an electrically conductive Granules (31, 35), in particular silicon carbide, are sprinkled in. Covering according to one of claims 1 to 9, characterized in that the Wear covering (15, 15 ') an electrically conductive cover layer (33) having. Process for producing a liquid-tight floor covering, in particular for passable areas in filling and filling stations, in which over one A wear covering (15, 15 ') is applied to the substrate (17), thereby characterized in that a barrier layer (23) over the substrate (17) applied and mechanically connected to it, and over the Barrier layer (23) a wear layer (15, 15 ') attached and with the Barrier layer (23) is mechanically connected.

Images