Claims:We Claim:

1. A multilayered insulation and waterproofing system comprising;
a first insulation layer 102 sprayed onto a surface 101 and a second insulation layer 103 sprayed onto the first insulation layer 102, wherein the first insulation layer 102 and the second insulation layer 103 are made of polyurethane material having a predefined density and predefined thickness;
a waterproofing layer 104 applied onto the second insulation layer 103;
a geotextile fabric layer 105 placed on the waterproofing layer 104;
a screed 106 laid on the geotextile fabric layer 105;
a sealant 107 filled in the screed 106 grooved; and
a final layer 108 applied optionally on the top of the screed 106, wherein the final layer is a waterproofing cum reflective layer or a china mosaic or a finished coating.

2. The system claimed in claim 1, wherein the waterproofing layer is made up of a neoprene based bituminous material or a polyurethane coat or an acrylic coat.

3. The system claimed in claim 1, wherein the predefined density of the polyurethane material is approx. 55 kilograms per cubic meter.

4. The system claimed in claim 1, wherein the predefined thickness of first insulation layer and the second insulation layer is at least 5mm.

5. The system claimed in claim 4, further comprising applying one or more additional insulation layers on the second insulation layer 103, wherein the thickness of each additional insulation layer is at least 5 mm.

6. The system claimed in claim 5, wherein the collective thickness of the first insulation layer 102, the second insulation layer 103 and the one or more additional insulation layers is within a predefined range of 10mm-20mm.
7. The system claimed in claim 1, wherein the thickness of geotextile fabric is at least 150 gsm.

8. The system claimed in claim 1, wherein the sealant is filled in the screed by
grooving the screed for a depth of 30mm and a width of 4mm and filling the screed grooved with the sealant ; or
pouring the screed in between a panel filler board placed over the geotextile layer wherein the panel filler board containing the screed is grooved and filled with a backer rod and the sealant.

9. The system claimed in claim 8, wherein the screed is grooved in a panel size of
3m x 4m (max).

10. The system claimed in claim 1, wherein the waterproofing layer qualifies a DIN 1048: Pt 5: 91 standard carried out for testing of Water Penetration @ 3 bar.

11. A method for multilayered insulation and waterproofing comprising;
spraying a first insulation layer 102 sprayed onto a surface 101 and a second insulation layer 103 onto the first insulation layer 102, wherein the first insulation layer 102 and the second insulation layer 103 are made of polyurethane material having a predefined density and predefined thickness;
applying a waterproofing layer 104 onto the second insulation layer 103;
placing a geotextile fabric layer 105 on the waterproofing layer 104;
laying a screed 106 on the geotextile fabric layer 105;
filling the screed grooved with a sealant 107; and
applying optionally, a final layer on the screed, wherein the final layer is one of a waterproofing cum reflective coating or a china mosaic or finished coating.

12. The method claimed in claim 11, wherein the waterproofing layer is made up of neoprene based bituminous material or a polyurethane coat or an acrylic coat.
13. The method claimed in claim 11, wherein the predefined density of the polyurethane material is approximately 55 kilograms per cubic meter.

14. The method claimed in claim 11 further comprising applying one or more additional insulation layers made of polyurethane material onto to the second insulation layer 103, wherein the thickness of each of the first insulation layer 102, the second insulation layer 103 and the one or more additional insulation layer is at least 5 mm, and wherein the collective thickness of the first insulation layer 102, the second insulation layer 103 and the one or more additional insulation layers is within a predefined range of 10mm-20mm.

15. The method claimed in claim 11, wherein the thickness of geotextile fabric is at least 150 gsm.

16. The method claimed in claim 11, wherein the sealant is filled in the screed by

grooving the screed for a depth of 30mm and a width of 4mm and filling the screed grooved with the sealant; or
pouring the screed in between a panel filler board placed over the geotextile layer, wherein the panel filler board containing the screed is grooved and filled with a backer rod and the sealant.

17. The method claimed in claim 16, wherein the screed is grooved in a panel size of 3m x 4m.

18. The method claimed in claim 11, wherein the waterproofing layer qualifies a DIN 1048: Pt 5: 91 standards carried out for testing of Water Penetration @ 3 bar.

19. A multilayer insulation and waterproofing kit comprising;
an insulating material made of polyurethane material having a predefined density of approx. 55 kilograms per cubic meter;
a waterproofing material, wherein the waterproofing material is a neoprene based bituminous material or a polyurethane coat or an acrylic coat;
a geotextile fabric, wherein the thickness of geotextile fabric is at least 150 gsm;
screed;
a sealant to be filled within the screed grooved; and
optionally a filler board, a backer rod and one of an acrylic waterproofing cum reflective top coating or a china mosaic or a finished coating material.
, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION

(See Section 10 and Rule 13)

Title of invention:
A MULTILAYERED SYSTEM FOR INSULATION AND WATERPROOFING AND METHOD OF APPLICATION THEREOF

Applicant:
PIDILITE INDUSTRIES LIMITED,
A company incorporated as per laws of India and having address as
Regent Chambers, 7th floor, Jamnalal Bajaj Marg, 208,
Nariman point,
Mumbai 400021

The following specification describes the invention and the manner in which it is to be performed.

CROSS-REFERENCE TO RELATED APPLICATIONS AND PRIORITY
[001] The present application does not claim priority from any patent application.

TECHNICAL FIELD
[002] The present invention relates to a multilayered insulation and waterproofing, and more particularly a system and a method for creating multiple layers for insulation and waterproofing with low energy consumption resulting in a sustainable structure.

BACKGROUND
[003] Increasing construction cost with increasing cost of labor and raw material requires implementation of advanced solutions for sustainable construction. Waterproofing is a crucial factor responsible for sustainable construction. If the various surfaces of building are not waterproofed properly, it leads to water seepage, thus impacting the durability of the structure. Inadequate waterproofing causes metal corrosion, decaying of wooden structures, electric hazards, distension of plasterboards, growth of fungus on surfaces causing various health issues and ultimately increases maintenance cost. Today along with the waterproofing, insulation is another major factor which is considered while construction of the building. Building insulation is required to reduce energy consumption in an effective manner.

[004] Widely adopted conventional method of waterproofing includes Brickbat coba or membranes which are not long lasting. Brickbat coba is inelastic in nature and hence cracks due to thermal stress. Further, it stores water and allows water seepage into interiors. It also has very low insulating properties. Due to these limitations brick bat coba is not a good solution for waterproofing and insulation of the building surfaces.

[005] The membranes used in construction waterproofing are generally loosely laid or full bonded with an overlap. One of the major problem associated with these membranes is that at some places, such as the position of the corners, where the membrane cannot provide proper waterproofing leads to water seepage which is difficult to repair. Also this system is prone to failure at joints. Seepage also significantly decreases the insulation effect.
[006] In order to overcome these limitations, the buildings are now waterproofed with a variety of polymer composite waterproofing and thermal insulation materials. The polyurethane foam insulation has been widely known to be used in the buildings, which has characteristics like a low thermal conductivity, high strength, low moisture absorption. Polyurethane foam insulation layer forms a steady, seamless, good insulation layer and also requires less time and cost when applied with simple site construction technology.

[007] Therefore, it is a long felt need to have a waterproofing and insulation solution which is energy efficient i.e. low energy consumption system with comprehensive sustainable structure. It is also important that such solution must come at lifecycle cost so that it can replace a relatively cheaper & inefficient existing alternative like Brickbat coba.

SUMMARY
[008] This summary is provided to introduce concepts related to a multilayered system for insulation and waterproofing and method of application thereof and the concepts are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter nor is it intended for use in determining or limiting the scope of the claimed subject matter.

[009] In one implementation, a multilayered insulation and waterproofing system is disclosed. The multilayered insulation and waterproofing system may comprise a first insulation layer sprayed onto a surface and a second insulation layer sprayed onto the first insulation layer, wherein the first insulation layer and the second insulation layer are made of Polyurethane material having a predefined density and predefined thickness. The system may further comprise a waterproofing layer applied onto the second insulation layer, wherein the waterproofing layer is a neoprene based bituminous material or a polyurethane coat, or an acrylic coat. The system may further comprise a geotextile fabric layer placed on the waterproofing layer, wherein the thickness of geotextile fabric is at least 150 gsm. The system may further comprise a screed laid on the geotextile fabric layer. The screed is grooved in a panel of 3m x 4m (max) for a depth of 30mm and a width of 4mm (or as per the specification) and an appropriate sealant is filled. In another embodiment, a filler board is placed over the geotextile layer, screed is poured in between the panel of the filler board and allowed to cure. The screed filled filler board is further grooved and filled with a backer rod and a suitable sealant. In one embodiment, a final layer may be optionally applied on the screed as per certain requirements, wherein the final layer may be a waterproofing cum reflective coating layer or a china mosaic or a finished coating.

[0010] In another implementation, a method for application of multiple layers for insulation and waterproofing is disclosed. The method may comprise spraying a first insulation layer onto a surface and a second insulation layer, wherein the first insulation layer and the second insulation layer are made of polyurethane material having a predefined density and predefined thickness. The method further may comprise applying a waterproofing layer on the second insulation layer, wherein the waterproofing layer is a neoprene based bituminous material or a polyurethane coat or an acrylic coat. The method may further comprise placing a geotextile fabric layer on the waterproofing layer, wherein the thickness of geotextile fabric is at least 150 gsm. The method may further comprise laying a screed on the geotextile fabric layer. The method may further comprise grooving the screed in a panel of 3m x 4m (max) for a depth of 30mm and a width of 4mm (or as per the specification) and filling the grooved screed with an appropriate sealant. In another embodiment, a filler board may be placed over the geotextile layer, screed is poured in between the panel of the filler board and allowed to cure. The filler board may be further grooved and filled with a backer rod and a suitable sealant. Further, the method may comprise applying, optionally, a final layer on the screed as per certain requirements, wherein the final layer may be a waterproofing cum reflective coating layer or a china mosaic or finished coating.

[0011] In yet another implementation, an insulation and waterproofing kit is disclosed. The multilayered insulation and waterproofing kit comprises an insulating material made of polyurethane material having a core density of approx. 55 kilograms per cubic meter. The kit further comprises a waterproofing material selected from one of a neoprene based bituminous material or a polyurethane coating material or an acrylic coat. The kit may further comprise a geotextile fabric, wherein the thickness of geotextile fabric is at least 150 gsm. The kit further comprises a screed, a filler board, a backer rod, a sealant, a waterproofing cum reflective coating material or china mosaic or finished coating material.

BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to refer like features and components.

[0013] Figure 1 illustrates, a multilayered insulation and waterproofing system 100, in accordance with an embodiment of the present disclosure.

[0014] Figure 2 illustrates, a method 200 for multilayered insulation and waterproofing, in accordance with an embodiment of the present disclosure.

[0015] Figure 3 illustrates, a perspective layered arrangement 300 for multilayered insulation and waterproofing, in accordance with an embodiment of the present disclosure

DETAILED DESCRIPTION
[0016] Multilayered system for insulation and waterproofing, and method of application thereof is now described in detail. The present subject matter discloses a robust, cost-effective and long lasting mechanism for providing waterproofing and insulation by forming a sustainable structure. Further the system may comprise at least two layers for insulation, one layer for waterproofing and one layer of geotextile. Further the multilayered insulation and waterproofing system may comprise a first insulation layer sprayed onto a surface and a second insulation layer sprayed onto the first insulation layer. The first insulation layer and the second insulation layer are made of material having a predefined density and predefined thickness. The material may be a polyurethane foam. The system may further comprise a waterproofing layer applied on the second insulation layer. The waterproofing layer may be made up of neoprene based bituminous material or a polyurethane coat or an acrylic coat. The system may further comprise a geotextile fabric layer placed on the waterproofing layer. The system may further comprise a screed laid on the geotextile fabric layer. The screed may be grooved in a panel of 3m x 4m (max) for a depth of 30mm and a width of 4mm (or as per the specification) and an appropriate sealant may be filled in the screed grooved. In another embodiment, a filler board is placed over the geotextile fabric layer, the screed is poured in between the panel of the filler board and allowed to cure. The screed filled filler board is further grooved and filled with a backer rod and suitable a sealant. The final layer applicable for certain requirements may be provided as an optional layer applied on the screed. The final layer may be a waterproofing cum reflective coating layer or a china mosaic or a finished coating.

[0017] Referring now to Figure 1, a multilayered insulation and waterproofing system 100 is illustrated, in accordance with an embodiment of the present subject matter. In one embodiment, the system 100 provides the multilayered waterproofing and insulating system comprising at least five layers. A first layer 102 is an insulation layer directly sprayed onto the surface 101. The surface 101 may be a roof slab made of concrete or other construction materials. A second layer 103 is a second insulation layer sprayed onto the first insulation layer 102. A third layer 104 is a waterproofing layer applied onto the second insulation layer 103. A fourth layer 105 is a layer of geotextile placed onto the waterproofing layer 104. A fifth layer 106 is a screed laid onto the geotextile fabric layer 105 or in between a panel of a filler board 109. A sixth layer is a sealant 107 and a backer rod 110 filled in groove. A seventh layer 108 is an optional layer comprising one of acrylic waterproofing cum reflective coating or a china mosaic or a finished coating.

[0018] In one embodiment, the third layer 104 (i.e. waterproofing layer) qualifies a DIN 1048: Pt 5: 91 standards carried out for testing of Water Penetration @ 3 bar. In one embodiment, the insulting layers are made of an insulating material having a predefined density and predefined thickness. In an embodiment, the insulating material is a polyurethane foam material. In an embodiment, the predefined core density of the insulating material may be approximately 55 kilograms per cubic meter. In an embodiment, the predefined thickness of each of the first insulation layer and the second insulation layer is at least 5 mm. The system may further comprise applying one or more additional insulation layers on the second insulation layer 103, wherein the thickness of each additional insulation layer is at least 5 mm. It is to be noted that the collective thickness of the first insulation layer 102, the second insulation layer 103 and the one or more additional insulation layers, sprayed in multiple layers, is within a predefined range of 10mm-20mm.In some embodiment the collective thickness may be greater than 20mm.
[0019] In one embodiment the insulation layer material (i.e. the polyurethane foam material) when sprayed on any surface, forms a layer of foam by virtue of an exothermic reaction. This first insulation layer adheres to the surface without use of any adhesive additive. It not only seals the cracks present in the surface (read concrete surface) but it also provides a base for formation of a subsequent insulation layer. The first insulation layer is thus also called as ‘flashing coat’.

[0020] In one embodiment the insulation layer is formed even at corners and sidewalls where, it is difficult to achieve a full-proof waterproofing solution with conventional waterproofing membranes. This significantly decreases water seepage and improves the insulation effect. Conventionally low density Polyurethane foam has been used for waterproofing and insulation. The following Table 1 depicts the Standard Specification for Spray Polyurethane Foam Used for Roofing Applications provided by ASTM (D7425-13). It is observed from the Table 1 that the present system achieves a better waterproofing and insulation as compared to conventional systems. A comparative data of the Physical Characteristics of Polyurethane as claimed in present invention vis-à-vis ASTM standard is presented in the Table 1 below.
Property Units ASTM standard Present Invention
Thermal resistance of 25 mm [1.0 in.] thickness aged
at mean temperature 24°C [75°F] for 180 days or at
mean temperature 60°C [140°F] for 90 days. K·m2/W 0.98, min 1.04 (not aged) as per ASTM C-518/91 (initial value @ 25 C)
Compressive strength, at yield or 10?% deformation KPa 276, min 411 as per ASTM 1621/94
Density Kg/m3 40, min 55 – 60 as per ASTM D-1622
Water absorption volume?% 5, max 0.009 per cm2 (gm/cc)
Dimensional stability, 70°C,?97?% RH, 2 weeks linear change % +6, max 2.5 as per ASTM D-2126
Water vapor permeability ng/Pa·s· 4.47, max 1 perm-inch [ Water vapor transmission as per ASTM C-518/91 ]

TABLE 1 ASTM International SPF standard vis a vis Present invention

[0021] The High density closed cell polyurethane foam has low thermal conductivity and excellent insulation properties. Thus it can effectively block the heat conduction and improves the energy saving effect. Due to the presence of two or more insulation layers collectively having a predefined thickness within a range of 10 mm-20 mm (each insulation layer having a predefined thickness of at least 5mm), the system provides good insulating property which meets the heat transfer demand of building surface, especially in countries with high solar exposure.

[0022] In another embodiment, a waterproofing layer 104 is applied on the second insulation layer 103, which is made up of a neoprene based bituminous material or a polyurethane coat or an acrylic coat. This coating can be applied easily by a brush or a roller or can be sprayed. Neoprene based bitumen comprises of Neoprene, which is a synthetic rubber (mainly polymer material) compounded with bitumen. The neoprene is combined with the bitumen to create a more viscous, less temperature-sensitive and highly ductile material compared to only bitumen. This material is self-adhering and eliminate the harmful toxins typically associated with bitumen adhesion. Thus, neoprene based bitumen material reduces the resultant risk of cracking due to thermal expansion and contraction over a wide temperature range. It also increases tensile strength of the layer. This layer acts like a sealer coat and also prevents water seepage.

[0023] In an embodiment, a geotextile fabric layer 105 is placed on the waterproofing layer 104. The geotextile fabric layer 105 provides support and protection to the layers below so the screed 106 can be cast over the said geotextile fabric layer 105. The geotextile fabric layer 105 also acts as a separation layer between waterproofing layer 104 and the screed 106. The thickness of geotextile fabric layer 105 is at least 150 gsm. The geotextile fabric layer 105 is placed on the waterproofing layer either by spot bonding method or it is loosely laid between the waterproofing layer 104 and the screed 106. For spot boding, bonding adhesives are used.
[0024] In one embodiment, the screed is grooved in a panel of 3m x 4m (max) for a depth of 30mm and a width of 4mm (or as per the specification) and thereafter the screed grooved is filled with an appropriate sealant. In an another embodiment, a filler board is placed over the geotextile fabric layer, the screed is poured in between the panel of the filler board and allowed to cure. The screed filler board filled with the screed is further grooved and filled with a backer rod and suitable sealant. The groove is initially filled with the backer rod followed by the sealant. The backer rod is an extruded round closed cell low density polyethylene foam backer rod with a skin-like outer texture.

[0025] In some embodiments, optionally, a final layer is placed on the screed as per certain requirements where the SRI value of the waterproofing and insulation system is required to be greater than 78%. The final layer may be a waterproofing cum reflective coating layer or a china mosaic or finished coating.

[0026] The multilayered insulation and waterproofing system described above has certain advantages over conventional methods. The advantages include the present system’s five times faster application, three times better life expectancy, at least two times better insulation and employing 1/10th of the manpower. Moreover, the present system is a seamless system without joints.

[0027] Referring to figure 2, a multilayered insulation and waterproofing method 200, is illustrated, in accordance with an embodiment of the present subject matter.

[0028] In step 201, surface preparation is done. The surface is cleaned thoroughly to get rid of all contaminants. All surface imperfections are removed and optionally repaired using a polymer modified mortar.
[0029] In step 202, a first insulation layer 102 having a thickness of at least 5mm is sprayed onto the prepared roof surface 101. The first insulation layer 102 is made of a polyurethane foam.

[0030] In step 203, a second insulation layer of 102 having a thickness of at least 5mm is sprayed onto the first insulation layer 102. The second insulation layer 103 is made of a polyurethane foam.

[0031] In step 204, a waterproofing layer 104 is applied onto the sec second insulation layer 103. The waterproofing layer 104 is neoprene based bituminous material or a polyurethane coat or an acrylic coat. In one embodiment the waterproofing layer qualifies a DIN 1048: Pt 5: 91 standard carried out for testing of Water Penetration @ 3 bar. In an embodiment, water may be poured on the waterproofing layer 104 and tested for seepage for at least 24 hours in order to carry out the water ponding test.

[0032] In step 205, geotextile fabric layer 105 is applied onto the waterproofing layer 104. The thickness of geotextile fabric is at least 150 gsm. The geotextile layer may be spot bounded using adhesive.

[0033] In step 206, screed 106 is laid on the geotextile fabric layer 105. An average slope of 1:100 (or as per the system’s requirement) towards the drain outlets may be maintained for effective and efficient drainage of water.

[0034] In step 207, screed is grooved with a cutter and filled with appropriate sealant 107.

[0035] In step 208, an optional layer 108 is applied as the final (top) coat. The optional layer may be an acrylic waterproofing cum reflective coating or a china mosaic or a finished coating

[0036] Referring to figure 3, a perspective arrangement 300 of the system 100 of the figure 1 is illustrated, in accordance with an embodiment of the present subject matter.

[0037] In one embodiment a multilayer insulation and waterproofing kit is disclosed. The multilayer insulation and waterproofing kit comprises:
an insulating material, preferably a polyurethane material, wherein such polyurethane material has a predefined density / density of approx. 55 kilograms per cubic meter;
a waterproofing material, wherein the waterproofing material is a neoprene based bituminous material or a polyurethane coat or an acrylic coat;
a geotextile fabric, wherein the thickness of geotextile fabric is at least 150 gsm;
screed;
a sealant to be filled within the screed grooved; and
optionally,
a filler board;
a backer rod; and
one of an acrylic waterproofing cum reflective top coating or a china mosaic or a finished coating material.