U.S. patent application number 13/964481 was filed with the patent office on 2015-02-12 for monolithic protective waterproofing system.
The applicant listed for this patent is The D.S. Brown Company, Inc.. Invention is credited to Larry D. Durain, William N. Kudrenski, Robert S. Rose.
Application Number | 20150040330 13/964481 |
Document ID | / |
Family ID | 52447304 |
Filed Date | 2015-02-12 |
United States Patent
Application |
20150040330 |
Kind Code |
A1 |
Kudrenski; William N. ; et
al. |
February 12, 2015 |
MONOLITHIC PROTECTIVE WATERPROOFING SYSTEM
Abstract
A monolithic protective waterproofing system for light rail and
intermodal class I railroad bridges comprehends a multiple layer
product installed in-situ. It includes a sprayed on primer, a
sprayed on membrane having a thickness of between 60 and 120 mils,
a second sprayed on layer of membrane having a thickness of about
20 mils that is utilized as an adhesive that is rapidly covered
with a resilient mat having a thickness of between approximately 6
and 12 mm, a second layer of a sprayed on primer and a top coat of
sprayed on membrane of approximately 30 to 50 mils. Both the
product and method of installation are disclosed.
Inventors: |
Kudrenski; William N.;
(Grimsby, CA) ; Durain; Larry D.; (Findlay,
OH) ; Rose; Robert S.; (Brick, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The D.S. Brown Company, Inc. |
North Baltimore |
OH |
US |
|
|
Family ID: |
52447304 |
Appl. No.: |
13/964481 |
Filed: |
August 12, 2013 |
Current U.S.
Class: |
14/77.1 ;
52/411 |
Current CPC
Class: |
E01D 19/083 20130101;
E01D 22/00 20130101 |
Class at
Publication: |
14/77.1 ;
52/411 |
International
Class: |
E01D 19/08 20060101
E01D019/08 |
Claims
1. A multiple layer waterproofing product for bridge decks
comprising, in combination, a first primer layer adhered to a
substrate, a first membrane layer thicker than said first primer
layer adhered to said first primer layer, a second membrane layer
adhered to said first membrane layer, a layer of resilient mat
defining air filled voids and having a thickness of at least 6 mm
adhered to said second membrane layer by flow of said second
membrane layer into said voids, a second primer layer adhered to
said resilient mat, and a third membrane layer thicker than said
second primer layer adhered to said second primer layer.
2. The multiple layer waterproofing product of claim 1 wherein said
primer and membrane layers are one of polyurethane, polyurea,
methyl methacrylate, a polyurethane hybrid, bitumen or an
acrylic.
3. The multiple layer waterproofing product of claim 1 wherein said
resilient mat includes virgin rubber, reclaimed rubber, ground
rubber, vinyl, polyvinylchloride or polyvinyl acetate.
4. The multiple layer waterproofing product of claim 1 wherein said
bridge deck is fabricated of wood, concrete or steel.
5. The multiple layer waterproofing product of claim 1 wherein said
resilient mat is disposed on such bridge deck in transverse or
longitudinal, parallel panels.
6. The multiple layer waterproofing product of claim 1 wherein said
resilient mat is disposed on such bridge deck in transverse or
longitudinal, parallel strips having a width of approximately four
feet.
7. The multiple layer waterproofing product of claim 1 further
including a third membrane layer disposed on said layer of
resilient mat and a second layer of resilient mat disposed on said
third membrane layer, said third membrane layer and said second
layer of resilient mat disposed between said layer of resilient mat
and said second primer layer.
8. A method of providing monolithic waterproof protection for a
bridge deck, comprising the steps of; applying a first primer layer
to such bridge deck, applying a first membrane layer thicker than
said first primer layer to said first primer layer and allowing
said first membrane layer to cure, applying a second membrane layer
to said first membrane layer, applying at least one layer of a
resilient mat containing air filled voids and having a thickness of
at least 6 mm to said second membrane layer while said second
membrane layer is liquid, applying a second primer layer to said
resilient mat, and applying a third membrane layer thicker than
said second primer layer to said second primer layer.
9. The method of providing monolithic waterproof protection of
claim 8 wherein said membrane layer applying steps are achieved by
spraying.
10. The method of providing monolithic waterproof protection of
claim 8 wherein said first and said second primer layers are
approximately 20 mils thick.
11. The method of providing monolithic waterproof protection of
claim 8 including the additional first step of cleaning such bridge
deck by sand or metal shot blasting.
12. The method of providing monolithic waterproof protection of
claim 8 including the additional steps of applying an additional
second membrane layer to said resilient mat layer and applying an
additional layer of said resilient mat to said additional second
membrane layer while said additional second membrane layer is
liquid.
13. The method of providing monolithic waterproof protection of
claim 8 wherein said first primer layer is applied by spraying,
squeegeeing or rolling.
14. A multiple layer waterproofing product for bridge decks and
similar structures comprising, in combination, a first membrane
layer disposed on said bridge deck having a thickness of
approximately 60 to 120 mils, a second membrane layer adhered to
said first membrane layer, a layer of resilient mat defining air
filled voids and having a thickness of from approximately 6 mm to
12 mm adhered to said second membrane layer by flow of said second
membrane layer into said voids, a primer layer adhered to said
resilient mat, and a third membrane layer thicker than said primer
layer adhered to said primer layer having a thickness of
approximately 30 to 50 mils.
15. The multiple layer waterproofing product for bridge decks and
similar structures of claim 14 wherein said resilient mat includes
virgin rubber, reclaimed rubber, ground rubber, vinyl,
polyvinylchloride or polyvinyl acetate and said air filled voids
constitute approximately 40% by volume.
16. The multiple layer waterproofing product for bridge decks and
similar structures of claim 14 wherein said resilient mat is
disposed on such bridge deck in transverse, parallel strips.
17. The multiple layer waterproofing product for bridge decks and
similar structures of claim 14 further including a third membrane
layer disposed on said layer of resilient mat and a second layer of
resilient mat disposed on said third membrane layer, said third
membrane layer and said second layer of resilient mat disposed
between said layer of resilient mat and said primer layer.
18. The multiple layer waterproofing product for bridge decks and
similar structures of claim 14 further including an additional
primer layer disposed between said bridge deck and said first
membrane layer.
19. The method of providing monolithic waterproof protection for a
bridge deck of claim 8 further including the step of applying
pressure to said resilient mat containing air filled voids to cause
a portion of said second membrane layer to flow into said voids of
said resilient mat.
20. The multiple layer waterproofing product for bridge decks and
similar structures of claim 14 further including a primer layer
adhered to such bridge deck and to which said first membrane layer
is adhered.
Description
FIELD
[0001] The present disclosure relates to a waterproofing system for
railroad bridge decks and similar structures and more particularly
to a monolithic protective waterproofing system or product for
light rail and intermodal class I railroad bridges and similar
structures and a method of installing same.
BACKGROUND
[0002] The statements in this section merely provide background
information related to the present disclosure and may or may not
constitute prior art.
[0003] As the nation's transportation infrastructure ages,
attention is returning to enhancing the service life of existing
structures and ensuring that new structures are built with the most
modern techniques and materials to provide the maximum attainable
service life.
[0004] One of the most difficult service environments exists on
light rail transit bridges and intermodal class I railroad bridges.
Heavy loads, exposure to high humidity and often salt spray and the
placement of rock ballast on the bridge deck which supports the
railway ties and track all contribute to aging of the structure.
The ballast has a particularly deleterious effect on concrete
bridge decks as sharp corners and edges of the ballast (which is
crushed rock) concentrates loads. What begins as surface cracking
and spalling leads to significant deterioration of the concrete as
water and often salt flows into the deck itself. Deterioration
through the freeze-thaw cycle and corrosion of reinforcing steel in
the concrete follow. Even steel bridge decks are not immune from
such deterioration as the ballast is capable of puncturing,
abrading and wearing even the most rugged deck coatings. Cracks,
gouges and discontinuities in a deck coating commence a process of
deterioration by rusting.
[0005] From this background, it is apparent that materials,
systems, products and processes of application which extend the
service life of railroad bridges and similar structures are highly
desirable. The present invention is so directed.
SUMMARY
[0006] The present invention provides a monolithic protective
waterproofing system or product for light rail and intermodal class
I railroad bridges and similar structures and a method of
installing same. The waterproofing system is a multi-layer product
installed in-situ on either new structures or structures previously
in service. It includes a primer, an elastomeric membrane having a
thickness of between approximately 60 and 120 mils, a second layer
of elastomeric membrane having a thickness of 20 mils that is
utilized as an adhesive that is rapidly covered and upon which is
pressed a rubber mat having a thickness of approximately 8 mm, a
second layer of a primer and a top coat of elastomeric membrane of
between approximately 30 to 50 mils.
[0007] Before the various layers are applied to a bridge deck, the
deck is cleaned by, for example, sand blasting to remove any loose
material such as rust, spalled or damaged concrete, previous
coatings and anything that might interfere with achieving a tight
and continuous bond between the bridge deck and the product. New
bridge decks or recently replaced decks may only require
inspection. Then, the first layer of primer is applied and allowed
to dry followed by the first layer of membrane which is also
allowed to dry. A second, thinner layer of membrane, which
functions as an adhesive, is next applied followed quickly by
application of adjacent strips of a resilient, preferably rubber,
mat. The resilient mat is supplied in rolls of, for example, four
or six feet by fifty feet (1.219 or 1.829 meters by 15.24 meters).
A second layer of primer is then applied to the top of the
resilient mats and a final layer of membrane is sprayed onto the
primer and mats, completing the installation process. The track
ballast, railroad ties and railroad track are then installed and
the bridge is placed in or returned to service.
[0008] It is thus an aspect of the present invention to provide a
monolithic protective waterproofing product for railroad bridges
and the like.
[0009] It is a further aspect of the present invention to provide a
method of building up a monolithic protective waterproofing product
in-situ on a railroad bridge or similar structure.
[0010] It is a still further aspect of the present invention to
provide a monolithic protective waterproofing product having layers
of primer, membrane and resilient mat.
[0011] It is a still further aspect of the present invention to
provide a monolithic protective waterproofing product having first
layers of primer and membrane, a resilient, rubber mat and
additional layers of primer and membrane on a railroad bridge or
similar structure.
[0012] It is a still further aspect of the present invention to
provide a method of building up a monolithic protective
waterproofing product having layers of primer, membrane and
resilient mat on a railroad bridge.
[0013] It is a still further aspect of the present invention to
provide a method of building up a monolithic protective
waterproofing product having first layers of primer and membrane, a
resilient, rubber mat and additional layers of primer and membrane
on a railroad bridge or similar structure.
[0014] Further aspects, advantages and areas of applicability will
become apparent from the description provided herein. It should be
understood that the description and specific examples are intended
for purposes of illustration only and are not intended to limit the
scope of the present disclosure.
DRAWINGS
[0015] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
disclosure in any way.
[0016] FIG. 1 is a perspective view of a light rail bridge or
similar structure from which the ballast, railroad ties and
railroad track have been removed which is undergoing a cleaning
step prior to installation of the waterproofing product of the
present invention;
[0017] FIG. 2 is a top, plan view of a railroad bridge or similar
structure schematically and sequentially showing certain steps of
the method of installation of the waterproofing product according
to the present invention;
[0018] FIG. 3 is a fragmentary, sectional, schematic view
illustrating the application of the first layer of primer and the
first layer of membrane to the bridge deck;
[0019] FIG. 4 is a fragmentary, sectional, schematic view
illustrating the application of the second layer of membrane and
the resilient mat to the bridge deck;
[0020] FIG. 5 is a fragmentary, sectional, schematic view
illustrating the application of the second layer of primer and the
second layer of membrane to the bridge deck;
[0021] FIG. 6 is a greatly enlarged, fragmentary, sectional view of
the layers of a monolithic waterproofing product according to the
present invention installed on a bridge deck or similar structure;
and
[0022] FIG. 7 is a flow chart presenting the installation steps of
a monolithic waterproofing product according to the present
invention, including a bridge deck preparation step.
DETAILED DESCRIPTION
[0023] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses.
[0024] With reference to FIG. 1, a railroad bridge or similar
structure either new or undergoing updating, repair, refurbishment
or rehabilitation is illustrated and generally designated by the
reference number 10. The bridge 10 may be disposed across a river
or a stream 12 or other obstacle and includes a horizontal deck 14
which may be fabricated of wood, concrete or steel upon which one
or multiple railroad tracks 20 are supported and carried. Each
railroad track 20 includes ballast (crushed rock) 22 which supports
ties 24 which, in turn support and locate the rails 26 of the track
20. Because the bridge 10 is undergoing repair or rehabilitation,
the ballast 22, the ties 24 and the rails 26 have been removed from
the bridge deck 14, as illustrated.
[0025] It will be appreciated that the product 40 and the method of
the present invention is intended for and is usable on both new
construction and bridges 10 that have been in service and are
undergoing updating, repair, refurbishment or rehabilitation. In
the latter case, a first or preliminary step to the in-situ
installation of the waterproofing product 40 of the present
invention is cleaning the bridge deck 14 and removal of any loose
material such as rust, spalled or damaged concrete, previous
coatings and anything that might interfere with achieving a tight
and continuous bond between the bridge deck 14 and the
waterproofing product 40. If the bridge deck 14 is concrete and is
spalled, pitted or contains other defects, it must be sand blasted
or metal shot blasted through the use of conventional sand or metal
shot blasting equipment 32 and an operator or technician 34 to
remove laitance and other contamination and then patched with a
concrete patching material. If the bridge deck 14 is steel it
should be prepared similarly to SP 6 or near white. If the bridge
deck 14 is new or has been recently replaced, this step may simply
involve inspection of the bridge deck surface to ensure its
integrity and relative smoothness and cleanliness.
[0026] Referring now to FIGS. 2 and 3 and 7, the building up or
in-situ installation of the waterproofing product 40 according to
the present invention begins with the spraying, squeegeeing or
rolling of a first layer of primer 42 onto the bridge deck 14. The
first layer of primer 42 is preferably applied at a rate of
approximately 130 to 200 square feet per gallon (3.12 to 4.8 square
meters per liter) over concrete surfaces and at a rate of
approximately 200 to 400 square feet per gallon (4.8 to 9.6 square
meters per liter) over steel surfaces. If the bridge deck 14 is
steel and has a 5 mil profile or better, i.e., less, use of the
first layer of primer 42 is not necessary. The first layer of
primer 42 is preferably one of polyurethane, polyurea, methyl
methacrylate, a polyurethane hybrid or an acrylic. The first layer
of primer 42 is preferably allowed to become tack free before the
next step is undertaken.
[0027] The first layer or base coat of membrane 44 is then sprayed
on the first layer of primer 42 at a rate of approximately 20
square feet per gallon (0.48 square meters per liter) to a minimum
thickness of approximately 80 mils and allowed to cure. The
thickness of the first layer or base coat of membrane 44 may be
increased to 120 mils and even thicker if desired. The first layer
of membrane 44 is preferably an elastomer and is one of
polyurethane, polyurea, methyl methacrylate, a polyurethane hybrid,
bitumen or an acrylic.
[0028] Referring now to FIGS. 2, 4, 6 and 7, a second, thinner
layer of elastomeric membrane 46 is sprayed onto the surface of the
first layer of membrane 44 by an operator or technician 34 just
prior to the application of a layer of a resilient mat 50. The
resilient mat 50 is unrolled, preferably in closely adjacent
transverse or longitudinal strips, on the bridge deck 14.
Transverse strips or panels of the resilient mat 50 are illustrated
in solid lines in FIG. 2 and longitudinal strips or panels of the
resilient mat 50 are illustrated by a phantom line in FIG. 2. The
strips or panels of the resilient mat 50 are pressed into position
by a cushioned roller 52 on a moveable frame or trolley 54 that
also carries a roll 56 of the resilient mat 50. As such, the second
layer of membrane 46 functions as an adhesive which, because it is
still liquid and the resilient mat 50 is pressed into it, will flow
and enter surface irregularities, interstices and voids 51 in the
resilient mat 50, intimately bonding it to the first layer of
membrane 44.
[0029] The resilient mat 50 (and the roll 56 thereof) is preferably
rubber and is, or is similar to, a product sold under the trademark
Regupol 6010 for a type of impact sound acoustic underlayment
manufactured by Regupol Pty. Ltd., Smeaton Grange, N.S.W. The
resilient mat 50 may also be constituted of or include reclaimed
rubber, ground rubber, virgin rubber, vinyl, polyvinylchloride or
polyvinyl acetate preferably having approximately 40% air filled
interstices or voids 51 by volume that has been formed into a
continuous sheet that, for ease of handling and installation, is
preferably four or six feet (1.219 or 1.829 meters) wide and is cut
and rolled into rolls of, for example, fifty feet (15.24 meters) in
length. It will be appreciated that the spring rate of the
resilient mat 50 may be increased by reducing the volume of the air
filled voids 51 to 30% or less or may be reduced by increasing the
volume of the air filled voids 51 to 50% or more. Different
materials and combinations thereof will also provide differing
spring rates. The thickness of the resilient mat 50 may be varied
from 6 millimeters (0.236 inches) or less to 12 millimeters (0.472
inches) or more, 8 millimeters (0.315 inches) having been found to
be a widely useful, nominal thickness.
[0030] If desired, the resilient mat 50, in the same or various
thicknesses, may be installed in additional layers depending upon
protection, sound transfer, vibration dampening and load carrying
requirements. To install multiple layers of the resilient mat 50,
an additional layer of the thinner membrane layer 46 is applied to
the upper surface of each previous layer of the resilient mat(s) 50
and an additional layer of resilient mat 50 is installed while the
additional thinner membrane layer 46 is still liquid and pressed
into intimate contact with the thinner membrane layer 46 on the
upper surface of the previous layer of the resilient mat 50 by the
cushioned roller 52 so that a portion of the additional thinner
membrane layer 46 is forced into the voids and interstices of the
resilient mat 50, as described above. If multiple layers of the
resilient mat 50 are installed, care should be taken to stagger or
offset the seams between adjacent resilient mats 50 of each
layer.
[0031] Referring now to FIGS. 5, 6 and 7, after the bridge deck 14
is completely covered by the resilient mats 50, a second layer of
primer 62 is sprayed onto the surface of the resilient mats 50 at a
rate of 30 to 50 square feet per gallon (0.72 to 1.2 square meters
per liter). When the second layer of primer 62 is only slightly
tacky, a third layer of elastomeric membrane 64 of one of the
materials previously listed is sprayed on the second layer of
primer 62 to a thickness of approximately 30 to 50 mils and
preferably about 40 mils.
[0032] After these steps, installation of the monolithic
waterproofing product 40 is complete and the ballast 22, the ties
24 and the rails 26 of the railroad track 20 may all be installed
or re-installed on the waterproofing product 40 on the bridge deck
14.
[0033] It will be appreciated that the monolithic waterproofing
product 40 of the present invention provides numerous benefits. The
waterproofing product 40, particularly because of the resilient
mat(s) 50, is thicker than similar products and the resilient mats
50 may be applied, as noted above, in multiple layers. Such
increased thickness is projected to provide better sound and
vibration attenuation than competing products. The preferred
resilient mat 50, described above, contains approximately 40% air
filled voids or interstices which allow the membrane layers to
penetrate the resilient mats 50 and achieve an intimate bond
therewith. This stiffens the entire waterproofing product 40 and
provides a mechanical lock with the resilient mats 50.
[0034] Additionally, because of the material and surface finish of
the third and final layer of membrane 64, namely tough and stiffly
resilient, which is also the result of the resilient mats 50, the
ballast 22 will create small depressions or pits in the surface of
the membrane 64 but will not puncture it. This action tends to hold
the ballast 22 in place, thereby providing a more stable roadbed
and generating less noise as trains pass. Finally, because of the
ease of building up the various layers of the waterproofing product
40 and the speed and uniformity with which the resilient mats 50
are installed, not only is the final product better from the
standpoints of strength, durability and resistance to water
penetration but its total cost (material and installation) is also
less than competing products.
[0035] The description of the invention is merely exemplary in
nature and variations that do not depart from the gist of the
invention are intended to be within the scope of the invention.
Such variations are not to be regarded as a departure from the
spirit and scope of the invention.
* * * * *