Field of the invention

This invention relates to complex polymer modified bitumen emulsion adhesive membrane which can be applied cold directly on the surface. Build-Up roofing (BUR) which consists of multiple plies of membranes soaked with asphalt or coal tar pitch, has existed in its present form for close to a century. It continues to be the standard against which all other roofing systems are compared, according to the Asphalt Roofing Manufacturers Association.

Background and Prior-art

Modified bitumen's (known as ^mod bits') are asphaltic roofing materials modified with an elastomeric compound that is compatible with roofing asphalt. This blending improves the asphalt's low temperature flexibility and extensibility characteristics. Although officially classified as single- ply membranes, the increasing incorporation of mod bits into BUR systems makes them an integral part of the BUR market. When elastomers are added to the bitumen, the bitumen can be used either as a mopping asphalt or to saturate glass or fiber scrims. These applications represent the most common uses of mod bits.

Modified bitumen systems originated in Europe during the 1950s, with the first atactic polypropylene modified (APP) system applied in Italy. In the 1960s, the first styrene- butadiene-styrene (SBS) modified) system was installed in
France. The first modified bitumen systems were seen in the United Stats in the mid 1970s.

United States Patent 6759454 teaches a polymer modified bituminous composition having improved phase stability, heat aging and viscosity characteristics. The bituminous compositions are blends comprising bitumen and from about 0.5 to about 25% of a novel anionic block copolymer where one of the blocks is a controlled distribution copolymer of a conjugated diene and a mono-alkenyl arene having a specific arrangement of the monomers in the copolymer block. The composition of the invention is useful for paving, roofing felts, water-proof membrane, adhesive, mopping asphalt, carpet backing and pipe coating applications United States Patent 401118,4 teaches a bitumen-polymer composition with improved elastomeric properties is prepared by chemically coupling a modified bitumen and a modified polymer; with a metal compound wherein the bitumen and polymer are first modified.
United States Patent 5414029 teaches a bitumen-polymer emulsion containing:
a) at least one bitumen,
b) at least one polymer having hydrocarbon chains with mobile hydrogens, said polymer being grafted 'and crosslinked in situ in said bitumen through a complex of at least one organic silicon compound, said complex being formed from a primary constituent and a secondary constituent, the latter being an organic silicon compound.
c) water, and
d) at least one emulsifier.
United States Patent 6451885 teaches an aqueous bitumen _ ^ emulsion adhesive membrane, consisting of the following constituents expressed in weight percentages of the emulsion total weight; 50% to 70% of bitumen; 0.5% to 10% of surfactant; 0% to 5% of thickening agent; 0% to . 1% of antifoaming agent; a sufficient quantity of water to make up 100%. Said emulsion is characterised in that the surfactant consists of at least a surfactant selected among the group consisting of an ethylene oxide and a propylene oxide copolymer, with PO/EO ratio ranging between 1.5 and 10, an ethoxylated and/or propoxylated epoxidized surfactant, and a polyvinyl alcohol having molecular mass ranging between 10000 and 150000. The invention also concerns the method for obtaining said emulsion, the compositions containing them, and the use of said bitumen emulsion adhesive membrane for the formulation of compositions comprising a hydraulic or organic binder, and/or a mineral or organi|C filler.
European Patent Application EP0604258 teaches a bitumen- polymer emulsion comprising: a) at least one bitumen, b) at least one polymer having hydrocarbon chains containing mobile hydrogen, the said polymer being grafted, and crosslinked in situ in the said bitumen complex of at least one organic silicon compound, the said complex formed from a primary constituent and from a secondary constituent, ._the latter being the organic silicon compound, c) water, and d) at least one emulsifying agent.
In our earlier patent we have discussed the disadvantages of using bitumen / asphalt and it is now well known that these are not suitable products from the point of durable materials or toxicity and they are not environmentally friendly. This was followed by polymer modified bituminous roofing membranes. Polymer-modified bituminous roofing membranes were first introduced to the European market, with several countries offering various types of sheets with several different polymer modifiers. Atactic polypropylene (APP), styrene butadiene styrene (SBS) and styrene butadiene rubber (SBR) were the initial primary modifiers for asphalt, with reinforcing material varying between products. Glass fibers, polyester fibers and polyethylene film were used individually or in combination to stabilize and form a "carrier" for the polymer-modified asphalt membrane. Surfacing materials varied from glass-fiber mats inherent in the membrane to mineral granules to metallic foils by individual product.
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STimmary of the invention
A cold applied water-based polymer modified bitumen emulsion adhesive membrane hereinafter called as protekta T- membrane comprising 25% to 55% of acrylic or styrene acrylic emulsion, 15% to 38% of DM water, 17% to 35% of a water based emulsion i.e. component A, 15% to 45% of component C ,10% to . 75% of component D,2% to 8% of biocide to obtain a cold applied
water-based polymer modified bitumen emulsion adhesive membrane thick paste material i.e. protekta T- membrane.
A cold applied water-based polymer modified bitumen emulsion adhesive membrane hereinafter called as protekta membrane 09 comprising 40% to 70% of component A , 35% to 65% of acrylic or styrene acrylic emulsion ,25% to 65% of DM water, 2% to 7% of cellulose binder, 1% to 9% of biocide and 25% to 75% of
component c to obtain a cold applied water-based polymer modified bitumen emulsion adhesive membrane thick paste material i.e. protekta membrane 09.
Detailed description of the invention
Modified bitumen membranes have been widely used throughout Canada for well over thirty years. A market survey conducted by CRCA in collaboration with NRCA revealed that SBS modified bitumen membrane (MBM) applications accounted for one half of the low-slope roofing sales of the survey respondents in 2000 and 2001 (Canadian Roofing Contractors' Association 2000-2001 Annual Market. Survey). There are several recognized methods used to apply MBMs, including hot bitumen mopping, torching, the use of cold adhesives and more recently, the use of self- adhering (peel and stick) materials.
It is also claimed that the interplay bond strength of torched membranes, when properly applied, is superior to that of any other application due to the homogeneity of, the layer of the polymer modified bitumen between adjoining sheets (Kersey, Tim et al. Performance Properties of Interply Adhesive Used with SBS-Modified Bitumen Membranes. 12th International Roofing and Waterproofing Conference. Orlando, 2002).
The pervasive use of torch on membranes has not been Without associated costs. These are primarily related to the relatively high number of incidences of roof fires, allegedly caused by torching operations. In one of the countries the largest single construction occurred in 1999, when an entire condominium complex of wood frame construction was reduced to ashes when purportedly ignited by a roofers' torch.
In addition torching would create heat and temperature and would initiate oxidation of poly aromatic compound which would result in the emission of toxic gases some of which are carcinogenic.
The risks associated with torch welding have led to renewed interest in cold adhesive applied and self-adhering (peel and stick) MBM applications.
Membrane
Coatings are used on concrete to prevent water seepage and environmental attack on structure / concrete where water with dissolved toxic products like chloride, carbon dioxide can find its way and damages the passivity of the reinforcement leads to corrosion. The applicant has made a break through in this field.
Bitumen coatings have been used for a very long time and are still used in many countries. Unfortunately, there are some serious drawbacks with bitumen and asphalt whether on roads
t
or roofs. In spite of this, in India alone the average annual demand for bitumen has been around 4 MMT and the demand is increasing. In fact, an aerial view of a metro town will give you glimpses of black roofs.
Other than its toxic effects on the environment, the major disadvantages with bitumen are Non-breathable coating. Blister formation etc., explained in our co pending Patent Applications titled. (Membranes for surface coating)
Notwithstanding these drawbacks and the growing criticism against bitumen, it still exists in the market in several ways. This led to introduction of asphalt which is still being used and gained popularity in the last 15 years or so. This has not served any significant advantage, however, asphalt is in simple language, the concrete of bitumen, a mixture of an aggregate and a binder which solidifies after curing and is also known as ''asphalt concrete" meaning a type of concrete made with bitumen as a binder.
Asphalt has also to be applied by torching at high temperature which, besides other disadvantages, is known to have caused fire resulting in several deaths. It is no longer debated now that bitumen and asphalt can expose the public at large and the workers in particular to cancers like lung cancer.
Another method of applying it is by mechanically fixing it on the roof.
SBS-modified bitumen sheet products have been used successfully in the United States since 1975. However, during the past several years, there has been a noticeable increase in the number of reports of blistering associated with mop- applied SBS-modified bitumen roof systems. Manufacturers typically claimed blistering probably resulted from phased application. Other possible causes of blisters, according to manufacturers, include the use of improper mopping asphalt, voids in mopping, moisture in substrates (e.g., insulation) and excessive internal building moisture.
Since the last several years modified bitumen membranes (MBMs) entered the market and have become very popular for various reasons. Modified bitumen membranes provide
excellent weathering and fire-resistant properties as would be expected from a conventional built-up roof, without the need to use a heavy gravel cover. They achieve their superior handling and weathering characteristics through the use of a modifier combined with high-quality asphalt. This unique blend, when used as a coating for the reinforcements of non- woven polyester, fiberglass mat, or a combination of fiberglass and polyester, creates tremendous strength, elasticity and weather ability.
SBS (Styrene-Butadiene-Styrene) "rubber" modifier additive is combined with a premium asphalt flux to provide an asphalt- blended coating that has elongation and recovery properties, better able to deal with the stresses created by wind, temperature fluctuation and normal roof-top expansion and contraction. While these 'products are typically ..applied with
hot-asphalt, they also can be heat-welded or applied with cold adhesive.
These polymer modified adhesive membranes are applied on the backside of the reinforced carrier. These adhesive membranes
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are applied without torching.
We are all aware of the craze of the construction industry for polymer modified bitumen like APS polyester. Polymer modified bituminous compositions have improved stability, heat aging and viscosity characteristics. In particular, relates to compositions containing a novel anionic block copolymer where one of the blocks is a controlled distribution copolymer of a conjugated diene and a mono- alkenyl arene having a specific arrangement of the monomers in the copolymer block.
Cold Adhesive
More recently cold adhesive applied modified bitumen systems are being promoted as a viable alternative to the more traditional torch or asphalt adhered installations. Polymer modified bituminous compositions also have improved phase stability, heat aging and viscosity characteristics. This failure of PMB and the fear and concern of the public at large about heat- and torch-applications brought into the market Cold Adhesive Membranes. Research indicates that the bond strength, peel strength and fatigue resistance of fully cured cold adhesive applied MEMs is comparable to that of torched on membranes.
Cold Applied Water-based Polymer Modified Bitumen Emulsion adhesive membrane
The applicant has been working on the concept of cold applied water-based polymer modified bitumen emulsion adhesive membrane products. This is a new concept which avoids all torching and heating. A thin membrane of 1-2 mm offers all the requirements, of breathable elastomeric membranes. Polymer Modified Bitumen often cannot meet the performance requirements and therefore approaches have been developed whereby polymers are added which are compatible with bitumen and change the properties of bitumen, such as making it breathable and elastic. Here it should be noted that the quality of the copolymers and their compatibility with bitumen is the most important and critical step.
The applicant has used compatible copolymers and blocks with other additives and catalysts, which increase the low temperature flexibility and high temperature softening point, increasing the temperature range for practical use. In addition improvements in fatigue resistance, thermal cracking and rutting resistance can all be achieved, as well as stress crack resistance of bitumen for cold temperature coating applications. The combination of certain crosslinking agents in conjunction with selected block copolymers exhibits excellent high and low temperature characteristics and changes the inherent character of bitumen from viscous to visco-elastic.
The copolymer block that is added and gains the properties of membrane making it breathable and elastic. For example, the applicant has tried different polymers, e.g. styrene- butadiene block copolymers. The objective was not only to increase flexibility, penetration and waterproofing, but to create a cross-linked multifunctional compound which provides chemical strength along with flexibility and the capability of withstanding the UV light, heat, not cracking and not shrinking. These water-based, cold bitumen membranes of the applicant differ in their capacity of mechanical strength and other factors. They are a different block of co-polymers and the biggest advantage is that they are cross-linked and compatible with bitumen of different origin. Tries had been carried out on bitumen from UK and Germany. Polymer
Modified Membranes may undergo significant changes to their properties when exposed to light and temperature. The applicant products have no such problems and give breathable membranes with all the properties of flexibility, waterproofing and no disadvantages. These coatings, are environmentally friendly products which are in line with the requirement.
The applicant has been working on the concept of cold polymer modified bitumen and has developed some excellent membranes which can be applied in cold, co.ated by brush or sprayed to the thickness of about 1 to 2 mm. The beauty of this
product is that it all depends on the selection of an appropriate polymer or polymixtures.
The applicant undertook first preparation of water based bitumen emulsion adhesive membrane modified by Styrene butadiene latex, acrylic ester and styrene, acrylic styrene co-polymer, acrylic acid ester co-polymer containing acrylonitrile, acrylic acid ester co-polymer, butyl acrylate styrene etc. etc.
Protekta Elastofelt, Protekta Plastofelt and Protekta Plastoflex are the applicant's proprietary items which the applicant have already filed patent application under Membranes for surface coating.
THE COLD APPLIED WATER-BASED POLYMER MODIFIED BITUMEN EMULSION ADHESIVE MEMBRANE CAN BE PROTEKTA T MEMBRANE OR PROTEKTA MEMBRANE 09
The process for the manufacturing of the products is as follows:-
COMPONENT - A
Taking a clean and dry 200 Itrs stainless steel open vessel fitted with a homogenizer with 2800 rmp. Taking 45 to 65 % of water based bitumen emulsion adhesive membrane was taken into the above vessel and add 2 0, .to..40% of DM-.water and stir for 5 minutes with 4000 rpm. Add 4 to 14% of non-ionic surfactant and 2 to 10% of colosing agent was added and stirred with material which are known as dispersion agent like polyacrylate and 2 to 8% of Alcohol ethoxylate. After
2 hours of stirring an water based emulsion was produced. This product is hereinafter called as Component A.
COMPONENT - B
Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogeniser with 2800 rmp Taking 10 to 15 kg of distilled water in the reactor, add 20 to 30 kg of acrylic or styrene, add 15-20 kg of acrylic emulsion and stir for 10 minutes. In a powder mixer make the mixture of 20-25 kg of inorganic fillers like metal carbonate and metal oxides, 2 to 4 kg of metal silicates and 0.4 to 0.6 kg of titanium dioxide, add this powder into the reaction vessel slowly, after adding half of the powder slowly add 0.2 kg - 04 kg fiber and 0.8 -010 kg dispersing agent and stir for 15 minutes. Add remaining powder and continue stirring. Add 10 -20 kg of distilled water and stir for 5 minutes. Add 0.20 to 0.25 kg of biocides and stir for 5 minutes. By stirring slowly add 0.200 to 0.400 kg of fiber and stir for 15 minutes. This product is hereinafter called as Component B.
COMPONENT - C
Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogeniser with 2800 rmp Taking 30 to 60% of component A and 30 to 60% of component B and add 2 to 20 % of DM water stir for 5 minutes, add 2 to 6 % of Pid Amine, and alcohol ethoxylate 2 to 8% , 3 to 12 % wax. emulsion and stir for 15 minutes. Add 4 to 8% of colosing agent (polyacrylate) and add 10 to 14 % of bisphinol and stir ^for 30 minutes This product is hereinafter called as Component C.
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COMPONENT - D
Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogeniser with 2800 rmp Taking 40 to 80% of acrylic or styrene or acrylic emulsion, Add 20 to 40% of DM Water stir for 5 minutes, add 2 to 6 % of thickener 0.5 to 2.5% of Anti foaming agent and 2 to 4% Biocide and stir for 15 minutes. This product is hereinafter called as Component D.
According to another embodiment the components can be processed as follows:-
COMPONENT - A
Taking a clean and dry 200 Itrs stainless steel open vessel fitted with a homogeni zer with 2800 rmp. Taking 45 to 65 % of water based bitumen emulsion adhesive membrane was taken into the above vessel and add 20 to 40% of DM water and stir for 5 minutes with 4000 rpm. Add 4 to 14% of non-ionic surfactant and 2 to 10% of colosing agent was added and stirred with material which are known as dispersion agent like polyacrylate and 2 to 8% of Alcohol ethoxylate. After 2 hours of stirring an water based emulsion was produced. This product is hereinafter called as Component A
COMPONENT - B
Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogeniser with 2800 rmp Taking 10 to 15 kg of distilled water in the reactor, add 20 to 30 kg of acrylic or styrene, add 15-20 kg of acrylic emulsion and stir for 10 minutes. In a powder mixer make the mixture of 20-25 kg of inorganic fillers like metal carbonate and metal oxides, 2 to
4 kg of metal silicates and 0.4 to 0.6 kg of titanium dioxide, add this powder into the reaction vessel slowly, after adding half of the powder slowly add 0.2 kg - 04 kg fiber and 0.8 -010 kg dispersing agent and stir for 15 minutes. Add remaining powder and continue stirring. Add 10 -20 kg of distilled water and stir for 5 minutes. Add 0.20 to 0.25 kg of biocides and stir for 5 minutes. By stirring slowly add 0.200 to 0.400 kg of fiber and stir for 15 minutes. This product is hereinafter called as Component B.
COMPONENT - C
Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogeniser with 2800 rmp Taking 30 to 60% of component A and 30 to 60% of component B and add 2 to 20 % of DM water stir for 5 minutes, add 2 to 6 % of Pid Amine, and alcohol ethoxylate 2 to 8% , 3 to 12 % wax emulsion and stir for 15 minutes. Add 4 to 8% of colosing agent (polyacrylate) and add 10 to 14 % of bisphinol and stir for 30 minutes This product is hereinafter called as Component C.
The invention will be described in brief with reference to
I
the accompanying examples without restricting the scope of the invention:-
EXAMPLE - 1
Taking a cle^an and dry 100 Itrs stainless steel reactor fitted with anchor stirrer. Taking 25 to 50% of acrylic or styrene acrylic emulsion and stir for .15. minutes Add 15 to 35% of DM Water stir for 20 minutes. Add 17 to 30% of component A add and stir for 15 minutes. Add 15 to 40% of component C add and stir for 15 minutes Add 25 to 75% of Component D stir for 15 minutes, Add' 2 to 8% of Biocide and stir for 5 minutes After you will get a thick past material Protekta T-Membrane.
EXAMPLE - 2
Taking a clean and dry 100 Itrs stainless steel reactor fitted with anchor stirrer. Taking 35 to 55% of acrylic or styrene acrylic emulsion and stir for 5 minutes Add. 18 to 38% of DM Water stir for 15 minutes, Add 20 to 35% of component A add and stir for 15 minutes. Add 25 to 45% of component C add and stir for 15 minutes Add 10 to 55% of Component D stir for 15 minutes. Add 2 to 6% of Biocide and stir for 5 minutes After you will get a thick past material Protekta T-Membrane.
EXAMPLE - 3
Taking a clean and dry 100 Itrs stainless steel reactor fitted with anchor stirrer. Taking 40 to 60% of component A and 40 to 60% of acrylic or styrene acrylic emulsion and stir for 15 minutes, Add 25 to 45% of DM Water stir for 15 minutes, add ,2 to 6 % of cellulose binder and 2 to 4% Biocide and stir for 15 minutes. Add 41 to 63% of Component C stir for 25 minutes. After you will get a thick past material Protekta Membrane 09.
EXAMPLE - 4
Taking a clean and dry 100 Itrs stainless steel reactor fitted with anchor stirrer. Taking 45 to 70% of component A and 35 to 65% of acrylic or styrene acrylic emulsion and stir for 25 minutes. Add 35 to 65% of DM Water stir for 20 minutes, add 3 to 7 % of cellulose binder and 1 to 9% Biocide and stir for 15 minutes. Add 25 to 75% of Component C stir for 15 minutes. After you will get a thick past material Protekta Meinbrane09
DESCRIPTION OF PROTEKTA T-MEMBRANE
Protekta T-Membrane. is polymer modified bitumen where a combination of 3 blocks of co-polymer namely Styrene butadiene latex, acrylic ester and styrene, acrylic styrene co-polymer, acrylic acid ester co-polymer containing acrylonitrile, acrylic acid ester co-polymer, butyl acrylate styrene under crosslink polymerization resulting in a flexible membrane. This membrane is brushed over the substrate like concrete and after curing gives a neutral elastomeric flexible material which is strongly bonded with a concrete and is breathable, allows vapour to go out and do not allow water to come in.
Uses
New & existing roofs, farming and animal sheds/storage,
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silos, external floors, facades, refrigerated vehicles, portable buildings, cabins and . workshops, shipping containers, wineries, warehouse and storage buildings, and structures requiring an effective barrier to thermal conduction.
Properties
• Water based
• Elastomeric & Flexible
• Waterproof & UV resistant
• Heat resistant
• Energy saving
• Resistant to Fungi & Algae growth
• Tough & Durable
• Light weight system
DESCRIPTION OF PROTEKTA MEMBRANE 09
Protekta Membrane 09 is a liquid polymer modified membrane designed for waterproofing range of vertical and horizontal surfaces in built environment. A water based compound, Elotex + Polymer acrylic ester. Protekta Membrane 09 demonstrates durable and elastomeric properties specifically designed to provide a seamless seal on building substrates and surfaces before tile or other suitable finishes / toppings are applied over. Once cured, this membrane not only withstands ponding water, but also can be applied in continuously immersed areas forming a waterproof film to treated surfaces.
Uses:
Internal wet areas, decks, podiums, balconies, terrace floors and similar areas that will be finished over with ceramic tiles or other trafficable topping and finishes. Suitable for immersed areas such as water features, ponds, fountains etc.
Properties
• Water based
• Elastomeric & Flexible
• Waterproof continuous immersion
• Resistant to Fungi & Algae growth Tough & Durable
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< V ^
statement of the invention
According to the invention a process for preparing cold applied water based polymer modified bitumen emulsion adhesive membrane hereinafter called^ as protekta membrane 09 comprises the following steps: Step A:
a) Taking a clean and dry 200 Itrs stainless steel open
\ t
vessel fitted with a homogenizer iat 2800 rpm,
f
b) Taking 45% to 65% of water based bitumen emulsion adhesive membrane into the above vessel,
c) Adding 20% to 40% of DM water into the emulsion and stirring it for 5 minutes at 4000 rpm to get a homogeneous solution,
d) Adding 4% to 14% of non-ionic surfactant and 2% to 10% of colosing agent,
e) Stirring the emulsion with dispersing agent and adding 2% to 8% of alcohol ethoxylate,
f) Stirring the solution for 2 hours to get a water based emulsion marked as component A.
Step B:
a) Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogenizer at 2800 rpm,
b) Taking 10 to 15 kg of distilled water into the reactor and adding 20 to 30 kg of acrylic or styrene and 15 to 20 kg of acrylic emulsion and stirring it for 10 minutes,
c) Making the mixture of 20 to 25 kg of inorganic fillers, 2 to 4 kg of metal silicates, 0.4 to 0.6 kg of titanium dioxide,
d) Adding half of this mixture into the reactor and adding 0.2 kg to 0.4kg of fiber and 0.8 to 1 kg of dispersing agent and stirring it for 15 minutes,
e) Adding again half of the mixture and stirring the solution,
f) Adding 10 to 20 kg of distilled water and stirring for 5 minutes,
g) Adding 0.2 to 0.25 kg of biocides and stirring for 5 minutes.
h) Adding 0.2 to 0.4 kg of fiber and stirring for 5 minutes to obtain a homogeneous product marked as component B.
Step C:
a) Taking a clean and dry 200 Itrs stainless steel reactor fitted with a homogenizer at 2800 rpm
b) Taking 30% to 60% of component A, 30% to 60 % of component B and 2% to 20% of DM water,
c) Stirring the solution for 5 minutes to obtain a homogeneous solution,
d) Adding 2% to 6% of pid amine, 2% to 8% of alcohol ethoxylate,3% to 12% of wax emulsion,
e) Stirring the solution for 15 minutes,
f) Adding 4% to 8% of colosing agent and 10% to 14% of bisphinol and stirring it for 30 minutes to obtain a homogeneous product marked as component C.
Step D:
a) Taking a clean and dry 100 Itrs stainless steel reactor fitted with anchor stirrer,
b) Taking 40% to 70% of component A and 35% to 65% of acrylic or styrene acrylic emulsion and stirring it for 25 minutes,
c) Adding 25% to 65% of DM water into the solution and stirring it for 20 minutes to get a homogeneous solution,
d) Adding 2% to 7% of cellulose bindpr and 1% to 9% of biocide and stirring it for 15 minutes,
e) Adding 25% to 75% of component C and stirring it for 15 minutes to obtain a thick paste material known as protekta membrane 09.
According to another embodiment of the invention , a process for preparing cold applied water-based polymer modified bitumen emulsion adhesive membrane hereinafter called as protekta T-membrane comprises the following steps: Step A:
a) Taking a clean and dry 200 Itrs stainless steel open vessel fitted with a homogenizer with 2800 rpm,
b) Taking 45% to 65% of water based bitumen emulsion adhesive membrane into the vessel,
c) Adding 20% to 40% of DM water and stirring it for 5 minutes at 4 000 rpm,
d) Adding 4% to 14% of non-ionic surfactant,
e) Adding 2% to 10% of colosing agent and stirring it with dispersing agent,
f) Adding 2% to 8% of alcohol ethoxylate into the solution,
g) Stirring the solution vigorously for 2 hours to obtain a water based emulsion marked as component A.
Step B:
a) Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogenizer at 2800 rpm,
b) Taking 10 to 15 kg of distilled water into the reactor,
c) Adding 20 to 30 kg of acrylic or styrene,
d) Adding 15 to 20 kg of acrylic emulsion and stirring the solution for 10 minutes,
e) Making a mixture of 20 to 25 kg of inorganic fillers like metal carbonate and metal oxide, 2 to 4 kg of
metal silicates and 0.4 to 0.6 kg of titanium di¬oxide,
f) Adding half of this mixture with 0.2 to 4 kg fiber and 0.8 to 10 kg of dispersing agent into the above solution and stirring for 15 minutes,
g) Adding half of the remaining powder and stirring the solution,
h) Adding 10 to 20 kg of distilled water and stirring it for 5 minutes,
i) Adding 0.2 to 0.25 kg of biocides and 0.2 to 0.4 kg of fiber and stirring the solution for 15 minutes to obtain a homogeneous product known as component B.
Step C:
a) Taking a clean and dry 200 Itrs stainless steel reactor fitted with a homogenizer with 2800 rpm,
b) Taking 30% to 60% of component A, 30% to 60% of component B and 2% to 20% of DM water,
c) Stirring the solution for 5 njinutes to get a homogeneous solution,
d) Adding 2% to 6% pid amine, 2% to 8% alcohol ethoxylate, 3% to 12% of wax emulsion and stirring the solution for 15 minutes,
e) Adding 4% to 8% of colosing agent and 10% to 14% bisphinol,
f) Stirring the solution for 30 minutes to get a homogeneous solution known as component C.
Step D:
a) Taking a clean and dry 200 Itrs stainless steel reactor fitted with a homogenizer with 2800 rpm.
b) Taking 40% to 80% of acrylic or styrene or acrylic emulsion into the reactor,
c) Adding 20% to 40% of DM water and stirring the solution for 5 minutes,
d) Adding 2% to 6% of thickener, 0.5% to 2.5% of anti foaming agent and 2% to 4% of biocide into the solution,
e) Stirring the solution for 15 minutes to obtain a homogeneous product known as component D.
Step E:
Taking a clean and dry 100 Itrs stainless steel reactor fitted with anchor stirrer,
Taking a 25% to 55% acrylic or styrene acrylic emulsion into the reactor,
Stirring it for 15 minutes to get a homogeneous solution,
Adding 15% to 38% of DM water and stirring it for 20 minutes to get a homogeneous solution,
Adding 17% to 35% of component ^ and stirring the solution for 15 minutes to get a homogeneous solution,
Adding 15% to 45% of component C and stirring for 15 minutes,
Adding 10% to 75% of component D and stirring it for 15 minutes,
Adding 2% to 8% of biocide into the solution,
Stirring for 5 minutes to obtain homogeneous thick paste material known as protekta T-membrane.
According to another embodiment of the invention, the
dispersing agent is polyacrylate.
According to another embodiment of the invention, the colosing agent is polyacrylate.
According to another embodiment of the invention ,a cold applied water-based polymer modified bitumen emulsion adhesive membrane hereinafter called as protekta T- membrane comprises 25% to 55% of acrylic or styrene acrylic emulsion, 15% to 38% of DM water, 17% to 35% of a water based emulsion i.e. component A, 15% to 45% of component C ,10% to 75% of component D,2% to 8% of biocide to obtain a thick paste material hereinafter called as protekta T-membrane.
According to another embodiment of the invention, a cold applied water-based polymer modified bitumen emulsion adhesive membrane hereinafter called as protekta membrane 09 comprises 40% to 70% of component A , 35% to 65% of acrylic or styrene acrylic emulsion ,25% to 65% of DM water, 2% to 7% of cellulose binder, 1% to 9% of biocide and 25% to 75% of component C to obtain a thick paste material known as protekta membrane 09.
According to another embodiment of the invention ,a water based emulsion i.e. component A comprises 45% to 65% of water based bitumen emulsion adhesive membrane, 20% to 40% of DM water, 4% to 14% of non ionic surfactant, 2% to 10% of colosing. agent, 2% to 8% of alcohol ethoxylate, wherein ingredients are mixed in a stainless steel open vessel fitted with a homogenizer at 2800 rpm to obtain component A.
According to another embodiment of the invention, a component B comprises 10 to 15 kg of distilled water, 20 to 30 kg of acrylic or styrene, 15 to 20 kg of acrylic emulsion, 20 to 25 kg of inorganic fillers like metal carbonate and metal oxide, 2 to 4 kg of metal silicates, 0.4 to 0.6 kg of titanium di-oxide,0.2 to 4 kg of fiber, 0.8 to 1 kg of dispersing agent, 10 to 20 kg of ' distilled water,0.2 to 0.25 kg of biocide,0.2 to 0.4 kg of fiber, wherein ingredients are mixed in a homogenizer at 2800 rpm to obtain a homogeneous product hereinafter called as component B.
According to another embodiment of the invention ,a component C comprises 30% to 60% of component A,30% to 60% of component B,2% to 20% of DM water, 2% to 6% of pid amine, 2% to 8% alcohol ethoxylate,3% to 12% of wax emulsion, 4% to 8% of colosing agent, 10% to 14% of bisphinol, wherein ingredients are mixed in a homogenizer at 2800 rpm to obtain a homogeneous solution hereinafter called as component C.
According to another embodiment of the invention ,a component D comprises40% to 80% of acrylic or styrene or acrylic emulsion, 20% to 40% of DM water, 2% to 6% of thickener, 0.5% to 2.5% of anti foaming agent, 2% to 4% of biocide wherein the ingredients are mixed in a homogenizer at 2800 rpm to obtain a homogeneous product hereinafter called as component D.

We claim:-

1. A process for preparing cold applied water based polymer modified bitumen emulsion adhesive membrane comprising the following steps:
Step A:

a) Taking a clean and dry 200 Itrs stainless steel open vessel fitted with a homogenizer at 2800 rpm,

b) Taking 45% to 65% of water based bitumen emulsion adhesive membrane into the above vessel,

c) Adding 20% to 40% of DM water into the emulsion and stirring it for 5 minutes at 4000 rpm to get a homogeneous solution,

d) Adding 4% to 14% of non-ionic surfactant and 2% to 10% of colosing agent,

e) Stirring the emulsion with dispersing agent and adding 2% to 8% of alcohol ethoxylate,

f) Stirring the solution for 2 hours to get a water based emulsion.hereinafter called as component A.

Step B:

a) Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogenizer at 2800 rpm,

b) Taking 10 to 15 kg of distilled water into the reactor and adding 20 to 30 kg of acrylic or styrene and 15 to 20 kg of acrylic emulsion and stirring it for 10 minutes,

c) Making the mixture of 20 to 25 kg of inorganic fillers,2 to 4 kg of metal silicates, 0.4 to 0.6 kg of titanium dioxide.

d) Adding half of this mixture into the reactor and adding 0.2 kg to 0.4kg of fiber and 0.8 to 1 kg of dispersing agent and stirring it for 15 minutes,

e) Adding again half of the mixture and stirring the solution,

f) Adding 10 to 20 kg of distilled water and stirring for 5 minutes,

g) Adding 0.2 to 0.25 kg of biocides and stirring for 5 minutes,

h) Adding 0.2 to 0.4 kg of fiber and stirring for 5 minutes to obtain a homogeneous product hereinafter called as component B.
Step C:

a) Taking a clean,and dry 200 Itrs stainless steel reactor fitted with a homogenizer at 2800 rpm

b) Taking 30% to 60% of component A, 30% to 60 % of component B and 2% to 20% of DM water,

c) Stirring the solution for 5 minutes to obtain a homogeneous solution,

d) Adding 2% to 6% of pid amine, 2% to 8% of alcohol ethoxylate,3% to 12% of wax emulsion,
e) Stirring the solution for 15 minutes,

f) Adding 4% to 8% of colosing agent and 10% to 14% of bisphinol and stirring it for 30 minutes to obtain a homogeneous product hereinafter called as component C.

Step D:
a) Taking a clean and dry 100 Itrs stainless steel reactor fitted with anchor stirrer.
b) Taking 40% to 70% of component A and 35% to 65% of acrylic or styrene acrylic emulsion and stirring it for 25 minutes,
c) Adding 25% to 65% of DM water into the solution and stirring . it for 20 minutes to get a homogeneous solution,
d) Adding 2% to 7% of cellulose binder and 1% to 9% of biocide and stirring it for 15 minutes,
e) Adding 25% to 75% of component C and stirring it for 15 minutes to obtain a thick paste material cold applied water-based polymer modified bitumen emulsion adhesive membrane.
f) A process for preparing cold applied water-based polymer modified bitumen emulsion adhesive membrane comprising the following steps:

Step A:
a) Taking a clean and dry 200 Itrs stainless steel open vessel fitted with a homogenizer with 2800 rpm,.
b) Taking 45% to 65% of water based bitumen emulsion adhesive membrane into the vessel,
c) Adding 20% to 40% of DM water and stirring it for 5 minutes at 4 000 rpm,
d) Adding 4% to 14% of non-ionic surfactant,
e) Adding 2% to 10% of colosing agent and stirring it with dispersing agent,
f) Adding 2% to 8% of alcohol ethoxylate into the solution,
g) Stirring the solution vigorously for 2 hours to obtain a water based emulsion hereinafter called as component A.

step B:
a) Taking a clean and dry 200 Itr stainless steel reactor fitted with a homogenizer at 2800 rpm,
b) Taking 10 to 15 kg of distilled water into the reactor,
c) c)Adding 20 to 30 kg of acrylic or styrene,
d) Adding 15 to 20 kg of acrylic emulsion and stirring the solution for 10 minutes,
e) Making a mixture of 20 to 25 kg of inorganic fillers like metal carbonate and metal oxide, 2 to 4 kg of metal silicates and 0.4 to 0.6 kg of titanium di¬oxide,
f) Adding half of this mixture with 0.2 to 4 kg fiber and 0.8 to 10 kg of dispersing agent into the above solution and stirring for 15 minutes,
g) Adding, half of the remaining powder and stirring the solution,
h) Adding 10 to 20 kg of distilled water and stirring it for 5 minutes,
i) Adding 0.2 to 0.25 kg of biocides and 0.2 to 0.4 kg of fiber and stirring the solution for 15 minutes to obtain a homogeneous product hereinafter called as component B. '

Step C:
a) Taking a clean and dry 200 Itrs stainless steel reactor fitted with a homogenizer with 2800 rpm,
b) Taking 30% to 60% of component A, 30% to 60% of component B and 2% to 20% of DM water.
f
c) stirring the solution for 5 minutes to get a homogeneous solution,
d) Adding 2% to 6% pid amine, 2% to 8% alcohol ethoxylate,3% to 12% of wax emulsion and stirring the solution for 15 minutes,
e) Adding 4% to 8% of colosing agent and 10% to 14% bisphinol,
f) Stirring the solution for 30 minutes to get a homogeneous solution hereinafter called as component
C.

Step D:
a) Taking a clean and dry 200 Itrs stainless steel reactor fitted with a homogenizer with 2800 rpm,
b) Taking 40% to 80% of acrylic or styrene or acrylic emulsion into the reactor,
c) Adding 20% to 40% of DM water and stirring the solution for 5 minutes,
d) Adding 2% to 6% of thickener, 0.5% to 2.5% of anti foaming agent and 2% to 4% of biocide into the solution,
e) Stirring the solution for 15 minutes to obtain a homogeneous product hereinafter called as component

Step E:
a) Taking a clean and dry 100 Itrs stainless steel reactor fitted with anchor stirrer,
b) Taking a 25% to 55% acrylic or styrene acrylic emulsion into the reactor,
c) Stirring it for 15 minutes to get a homogeneous solution.
d) Adding 15% to 38% of DM water and stirring it for 20 minutes to get a homogeneous solution,
e) Adding 17% to 35% of component A and stirring the solution for 15 minutes to get a homogeneous solution,
f) Adding 15% to 45% of component C and stirring for 15 minutes,
g) Adding 10% to 75% of component D and stirring it for 15 minutes,
h) Adding 2% to 8% of biocide into the solution,
i) Stirring for 5 minutes to obtain homogeneous thick paste material cold applied water-based polymer modified bitumen emulsion adhesive membrane.

2. A process as claimed in claim 1,wherein the dispersing agent/colosing agent is polyacrylate.

3. A cold applied water-based polymer modified bitumen emulsion adhesive membrane as claimed in claim 1 comprising 25% to 55% of acrylic or styrene acrylic emulsion, 15% to 38% of DM water, 17% to 35% of a water based emulsion i.e. component A, 15% to 45% of component C ,10% to 75% of component D,2% to 8% of biocide to obtain a thick paste material hereinafter called as protekta T-membrane.

4. A cold applied water-based polymer modified bitumen emulsion adhesive membrane as claimed in claim 1 comprising, 40% to 70% of component A , 35% to 65% of acrylic or styrene acrylic emulsion ,25% to 65% of DM water, 2% to 7% of cellulose binder, 1% to 9% of biocide and 25% to 75% of
component C to obtain a thick paste material hereinafter called as protekta membrane 09.

5. A cold applied water-based polymer modified bitumen emulsion adhesive membrane as claimed in claim 5 or 6, wherein component A comprises 45% to 65% of water based bitumen emulsion adhesive membrane, 2 0% to 4 0% of DM water, 4% to 14% of non ionic surfactant, 2% to 10% of colosing agent, 2% to 8% of alcohol ethoxylate, wherein ingredients are mixed in a stainless steel open vessel fitted with a homogenizer at 2800 rpm to obtain component A.

6. A cold applied water-based polymer modified bitumen emulsion adhesive membrane as claimed in claim 5 or 6,wherein component B comprises 10 to 15 kg of distilled water, 20 to 30 kg of acrylic or styrene, 15 to 20 kg of acrylic emulsion, 20 to 25 kg of inorganic fillers like metal carbonate and metal oxide, 2 to 4 kg of metal silicates, 0.4 to 0.6 kg of titanium di-oxide,0.2 to 4 kg of fiber, 0.8 to 1 kg of dispersing agent,10 to 20 kg of distilled water,0.2 to 0.25 kg of biocide,0.2 to 0.4 kg of fiber, wherein ingredients are mixed in a homogenizer at 2800 rpm to obtain a homogeneous product hereinafter called as component B.

7. A cold applied water-based polymer modified bitumen emulsion adhesive membrane as claimed in claim 5 or 6,wherein component C comprises 30% to 60% of component A, 30% to 60% of component B,2% to 20% of DM water,2% to 6% of pid amine, 2% to 8% alcohol ethoxylate, 3% to 12% of wax emulsion, 4% to 8% of colosing agent,10% to 14% of bisphinol.

wherein ingredients are mixed in a homogenizer at 2800 rpm to obtain a homogeneous solution hereinafter called as component C.

8. A cold applied water-based polymer modified bitumen emulsion adhesive membrane as claimed in claim 5 or 6, wherein component D comprises 40% to 80% of acrylic or styrene or acrylic emulsion, 20% to 40% of DM water, 2% to 6% of thickener, 0.5% to 2.5% of anti foaming agent, 2% to 4% of biocide wherein the ingredients are mixed in a homogenizer at 2800 rpm to obtain a homogeneous product hereinafter called as component D.

9. A process for preparing cold applied water-based polymer modified bitumen emulsion adhesive membrane hereinafter called as protekta T-membrane substantially as hereinbefore described with reference to the accompanying examples.

10. A cold applied water-based polymer modified bitumen emulsion adhesive membrane hereinafter called as protekta T- membrane substantially as hereinbefore described with reference to the accompanying examples.