Field of the invention:
The present invention relates to develop a non-toxic, non- hazardous, environmental friendly water based co polymer, more particularly a cross linked acrylic co-polymer and a process thereof, hereinafter called Protekta EJR. The invention is very useful for any surface where expansion and contraction is the major factor and where strong bonding with the old surface is required. The invention is used for both horizontal and vertical joints.
Background of the invention:
Expansion joints are periodical breaks in the structure of the building. An expansion joint is a gap in the buildings structure provided by the architect or engineer to allow for the movement of the building due to temperature fluctuations.
Expansion joints by their very nature are unique features of a building roof Expansion and control joints quite often pose some difficult problems. The expansion joint on roof, road etc., has to have the ability to meet and accommodate movement (horizontal vertical and in shear) while remaining waterproofed for the life of the substrate.
Expansion joints normally leaks and needs waterproofing. The leak is not only confined to water infiltrating the building interior but also to number of other environmental elements.
Successful expansion joints design depends on two very critical factors.
1. The accurate prediction of the building movement.
2. The choice of a proper sealant
Building undergoes physical movement because of variation in atmospheric temperature, interior conditions and movement arising from wind and sometime seismic events. These movements have to be accommodated by the structure as a whole or by splitting the structure into discrete sections.
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The accommodation of the movement arising from the above, is done by the purposeful introduction of a space gap i.e., a joint. This joint is called an "expansion joint", its singular purpose is to accommodate the movement of the building at a predetermined location.
There are different approaches to the construction and detailing of expansion joints, good expansion joint design must address the following specifics:
• Be able to accommodate the building movement, both expansion and contraction.
• Minimize or prevent water damming. The effect of pending water on roof should not be discounted, pounded water can have an adverse effect on the long term performance of roof membranes.
• Maintain building envelope continuity i.e., be waterproof, weather tight and air tight.
• Maintain the waterproofing integrity in the expansion joint material even when stressed. The failure of the waterproofing membrane at the joint seams is a common cause of water infiltration into the roof assembly.
• Be sufficiently robust to withstand roof traffic
• Constructed out of materials compatible with the roofing membrane system and of comparable quality.
Expansion joints are present in all types of building from the most simple box like designs to the most complex curvilinear buildings. An expansion joint is actually a gap, which allows space for a building to move in and out. The movement of the building is caused most frequently by temperature changes, the amount of expansion and contraction of building dependant upon the type of material it is constructed.
Roof expansion and control joints frequently pose a set of difficult if not unusual problems to the roof designer and installer.
In order for a building and its components to accommodate these movements, the extent of this contraction / expansion is usually limited to a maximum of 2" (50mm). Any

movement that is larger than 2" (50mm) within a building, can and will result in damage to the building and its external finishes (cracking, dislodgment of exterior panels).
In order to limit the expansion and contraction of the building, the building's designer (architect or structural engineer) incorporates a periodic and intentional break in the building structure. An expansion joint is in essence a joint that passes right through the entire building's cross section as if slicing through it. The idea is to provide a gap or space for the building to move. To further clarify this terminology, when reference is made to an expansion joint this refers to the actual gap in the building structure. This paper is concerned with waterproofing the expansion joint gap.
The variety of expansion joints available is almost as numerous as their failures. Leakage is so common and failure so expected that expansion joints are available with integral gutters to channel the water leaking through joints.
For a successful expansion joint to function properly it is important to find a suitable sealant system which can give complete waterproofing to expansion joint. There are several products in the market which are used like Acrylic, Butyl, Latex and the most commonly used product is Polysulphides and to some extent Polyurethane and Silicones.
The most commonly used polysulphide withstand an average of 16-20 percent joint movement with a joint design of six times anticipated movement versus a joint movement of 25 percent for urethanes and joint design of four times anticipated movements.
Polysulphides normally has a problem of bonding completely with the substrate and has the tendency to shrink. Polysulphide is not environmentally friendly and emits hazardous compound at high temperature. Moreover its durability is known to be questionable. Polysulphide normally need primers and gets brittle after some period. The other products used are polyurethane which is formed by using Isocynates and dangerous amines which are known to be carcinogenic compounds like Benzo[a]pyrene are emitted.
Epoxy: Epoxies are not much used because of their rigidity and non-flexibility. However wherever they have been used they have not been successful.

Silicones: Weatherproofing sealant is not recommended by manufacturer for use in continuous water immersion, nor for below ground or other joints where excessive abrasion and physical abuse are encountered.
Therefore effective and successful sealants have been the requirement of the industry, which is compatible with the substrate and proper sealant adhesion. Adhesion is essential without which all other properties are insignificant.
Prior Art
Patent WO/2006/016131 teaches us an expansion joint assembly for location in a gap defined between first and second structural members, such as sections of a road and/or bridge structure. Failure of the connection between the rail and reinforcing bars of a conventional joint is overcome by integrally forcing these components as a single part. Problems relating to physical and/or chemical incompatibility between components of a conventional joint are surmounted by forming all these components from organic polymer resin based materials, which also bestows the inventive joint with improved resistance to potentially harmful environmental conditions. The joint of the present invention is formed by locating an assembly comprised of an elastomeric sealing member and at least one anchor member in a gap defined between two structural members and casting mortar into said gap.
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Patent WO/2005/079137 teaches the invention relates to a combination of two materials, one of which is a rigid material known as EPDM (rubber) and the other being a moulded, vulcanized hydrophilic resin, forming a single body or single profile adapted to all necessary types of geometries, used in metal joinery profiles, wood or other materials which can be used to manufacture said piece of joinery.

. „ ^,^K,\jjiK)jL\jio leacnes expansion joint system, a compression seal for concrete
expansion joints is extruded as a one-piece unit from rubber-like material. The compression seal includes a compressible sealing portion and a pair of load-bearing wings that extend laterally from the compressible sealing portion. The one-piece design facilitates easy installation of the compression seal in an expansion joint. In use, the compressible sealing portion is inserted the expansion joint. Simple zipper-like motion may be used to press fit the compressible portion into the expansion joint. The lateral load-bearing wings are bonded to concrete surfaces adjoining the expansion joint to hold the compressible sealing portion in place.
Summary of the invention:
The present invention relates to a Cross linked acrylic co-polymer and process thereof, hereinafter called "Protekta EJR" wherein a process for the preparation of cross linked acrylic co-polymer comprising the following steps :-
\) Preparing the component A, prepared by means of the following steps: a). Carrying out the radical chain polymerization in a reactor filled with a stirrer of 35% 0 55% of aqueous plasticizer free anionic acrylic / styrene co-polymer, 0.2% to 8% lydroxyl propyl cellulose, culminal, starch cellulose, (b). initiating radical chain lolymerization of 0.1% to 5% of amines and 0.5% to 5% of oxidizing agents under ontrol conditions with 1% to 6% cross linkers and other cross-linkers and adding 5 to 5% of bisphenol to provide required hardness to the product thus obtaining the bmponent A.
) Preparing the component B, prepared by means of the following steps: ,). Conducting radical chain polymerization in a reaction vessel fitted with a stirrer of -J% to 60% aqueous plasticizer free anionic acrylic / styrene polymer dispersion, 2 to 18% hydroxyl propyl cellulose and culminating starch cellulose, (b). Generating reactive radical by initiating the generation by means of 1 to 15% as amines of any other ethanol and 5 to 15% and oxidizing element, (c). Conducting polymerization under controlled

condition and adding 1 to 16% cross linkers, and/or other cross linkers to obtain the component B. (d). Mixing component A, and component B and acrylic resin and after the reaction was over, adding some hardeners and amines to obtain the desired product.
According to another embodiment of the invention amines are triethanolamine, triethylamine or any other ethanols.
According to another embodiment of the invention oxidizing agents used are persulphate or peroxide.
According to another embodiment of the invention cross-linkers are Bisacrylamide and/or methacrylamide.
According to another embodiment of the invention after the reaction is over some hardeners like bisphenol and IPD amines are added to the reaction.
According to another embodiment of the invention a cross linked acrylic co-polymer comprising component A, component B acrylic resin and after the reaction is over some hardeners like bisphenol and IPD amines are added to it.
According to another embodiment of the invention the component A, is a product obtained by radical chain polymerization of 30 to 55% of aqueous plasticizer 0.2 to 8% hydroxyl propyl cellulose, culminal starch cellulose and a initiator 0.5% to 1% of amines and 1 to 6% cross linkers and the oxidizing agent.
Detailed description
This invehtion is to develop a non-toxic, non-hazardous, environmental friendly water based product. The objective was to develop for both horizontal and vertical joints.
According to the present invention a cross linked acrylic co-polymer comprising component A, component B acrylic resin and after the reaction is over some hardeners like bisphenol and IPD amines are added to it.

According to the invention the monomers are taken along with hydroxy propyl cellulose, culminal, starch cellulose with minor amounts of amines as initiators and oxidizing agents like persulphate or oxides and after the polymerization was complete which is indicated when the temperature which is exothermic comes to ambient temperature, at that stage bisphenol type products are added to give hardness to the products.
Component A
Aqueous plasticizer free anionic acrylic / styrene copolymer dispersion or similar soft polymers like Acrylic styrene co-polymer, thermoplastic acrylic resin or acrylic acid ester co-polymer with acrilonitrate are taken and a radical chain polymerization is conducted. The initiator generation of reactive radical is used; amines like triethanolamine, triethylamine or any other ethanols are used for initiating radical chain polymerization and the oxidizing agent used are persulphate or peroxides. The polymerization is conducted under control conditions and cross linkers like NN Bisacrylamide / methacrylamide and other cross linkers are used by utilizing controlled amount of initiators and oxidizing agents. The reaction time can be controlled and the resultant polymer has the following properties.
It can be used on any surface where expansion and contraction is the major factor and
where strong bonding with the old surface is required.
It does not block pores and allows normal breathing of the building.
Can be used as a durable and flexible coating for different parts of the building
including roof
Is an extremely useftil product for closing the joints of the blocks in the basement
Elongation % -925%
Tensile Strength -1.2 N/mm^
No water permeation through the block.
Dramatic reduction in efflorescence
Resistance to biological growth as the block remains dry (mould and moss etc.)
Colour retention
Properties close to natural stone can be produced

• The block exhibits high resistance to salts as water containing salt cannot enter
• Half the cost of liquid sealers
• Eliminates rising damps, therefore eliminating problems with applied finishes delaminating at lower ground level
• Easier to wash down as dirt and grime doesn't penetrate into the block
The complex nature of this structure with so many functional groups was confirmed by C nmr, which was studied with the kind courtesy of Tata Institute of Fimdamental Research (TIER), Mumbai.
Component B
Similar free radical cross linking polymerization were conducted with different monomers hke Acrylic styrene co-polymer, thermoplastic acrylic resin or acrylic acid ester co-polymer with acrilonitrate and some other small amount of amines and organic additives are polymerized with cross linkers and the conditions of the experiments are so controlled that an excellent expansion joint sealant Protekta EJR is produced.
However Protekta EJR (H) is produced by mixing Component A & Component B, Acrylic resin, and after the reaction is over some hardeners like bisphenol, IPD amines are added. The properties of both the inventions are studied both in-house and test houses like Civil Aid.
The '^carbon nmr for both the EJR's were taken which confirms the complexity of the polymer.
Properties
• Protekta EJR provides strong bonding, excellent adhesion, excellent weathering and excellent durability, heat and U.V resistant.
• Unlike silicones which also provides good movement.
• Protekta EJR can in addition withstand continuous water immersion.
• This forms a very durable, flexible seal

Application
1. Expose the joint and make a deep groove.
2. The depth of the joint should be no more than one-half the width without exceeding the minimum/maximum limits.
3. The maximum should be no more than 1.0 inch and minimum the depth of the joint should be no more than one-half the width without exceeding the minimum/maximum limits. Rest of it should be filled with back up like Shalicoat
4. Followed by 1:2 acrylic styrene copolymer b^sed mortar
5. Followed by highly waterproofing acrylic copolymer,
6. Once the highly waterproofing acrylic copolymer is dried, Protekta EJR should be applied not more than 6mm.
7. Protekta EJR should be applied in thin layers and the total depth should not exceed 1/2 inch. In other words you will have to apply about 3-4 layers.
8. The duration between two layers should be 70 minutes.
9. Next day it is advisable that you cover Protekta EJR and joints by using any other waterproofing acrylic copolymer , It is important that the sides are coated with 400 mortar to ensure smooth finish.
Depth of Sealant: Ideal: Maximum of 1/2 inch; Iviinimum of 1/8 inch.

Comparison with other products

Property Acrylic Butyl Latex Polysulfide Polyurethane Silicone Protekta EJR
Maximum
joint
movement
capability,
% 7 5 7 25 25 60 70
Weathering resistance Good Excellent Fair Good Excellent Excellent Excellent
Adhesion Good Excellent Fair Good Good Excellent Excellent
Shrinkage 12 18 20 10 5 3 0
Tack-free
time
(hours) 72 24 1 72 72 3 0
Water immersion No No No Yes ' Some No Yes
Elongation % Low Low 450 1000 700 1600 2000
Horizontal Joints No No No Yes Yes No Yes
Modulus of
elasticity,
Ib/in^ 40 25 18 30 35 30 45
The figures for other products are taken from literature.

Use or area of use for each product EP PUR Polyester MMA Protekta EJR
Structural bonding XXX X X XXX XXX
Corrosion protection XXX XXX XXX XXX XX
Sealing moving cracks 0 XX 0 0 XXX
Dampness XXX XXX XX XXX XXX
Water under pressure XXX XXX XXX XXX XXX
Acids XXX XX XXX XXX XXX
Alkali's XXX XX XX XX XXX
EP =Epoxy resin
PUR =Polyurethane
Polyester MMA =Methyl Methacrylate
O = not suitable
X = under certain conditions usable
XX = suitable
XXX = highly suitable
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Example 1: Component A
Take a clean and dry 50 Itr reactor fitted with stirrer , Take 35 to 55% of Aqueous plasticizer free anionic acrylic / styrene copolymer dispersion, 0,2 to 8% hydroxy propyl cellulose, culminal, starch cellulos are taken and a radical chain polymerization is conducted. The initiator generation of reactive radical is generated by 0.1 to 5% of amines like triethanolamine, triethylamine or any other ethanols are used for initiating radical chain polymerization and 0.5 to 5% of bxidizing agent used are persulphate or peroxides. The polymerization is conducted under control conditions and .1 to 6% cross linkers like NN Bisacrylamide / methacrylamide and other cross linkers are used by utilizing controlled amount of initiators and oxidizing agents. 5 to 15% of bisphenol added to give hardness to the products.
Component B
Take a clean and dry 50 Itr reactor fitted with stirrer , Take 25 to 60% of Aqueous plasticizer free anionic acrylic / styrene copolymer dispersion, 2 to 18% hydroxy propyl cellulose, culminal, starch cellulos are taken and a radical chain polymerization is conducted. The initiator generation of reactive radical is generated by 1 to 15% of amines like triethanolamine, triethylamine or any other ethanols are used for initiating radical chain polymerization and 5 to 15% of oxidizing agent used are persulphate or peroxides. The polymerization is conducted under control conditions and 1 to 16% cross linkers like NN Bisacrylamide / methacrylamide and other cross linkers are used by utilizing controlled amount of initiators and oxidizing agents,
Protekta EJR (H) is produced by mixing Component A & Component B, Acrylic resin, and after the reaction is over some hardeners like bisphenol, IPD amines were added. The properties of both the inventions were studied both in-house and test houses like Civil Aid,
Example 2: Component A

lake a clean and dry 50 Itr reactor fitted with stirrer , Take 25 to 50% of Aqueous plasticizer free anionic acrylic / styrene copolymer dispersion, 0.5 to 8.5% hydroxy propyl cellulose, culminal, starch cellulos are taken and a radical chain polymerization is conducted. The initiator generation of reactive radical is generated by 0.1 to 5% of amines like triethanolamine, triethylamine or afty other ethanols are used for initiating radical chain polymerization and 0.5 to 5% of oxidizing agent used are persulphate or peroxides. The polymerization is conducted under control conditions and .1 to 8% cross linkers like NN Bisacrylamide / methacrylamide and other cross linkers are used by utilizing controlled amount of initiators and oxidizing agents. 10 to 20% of bisphenol added to give hardness to the products.
Component B
Take a clean and dry 50 Itr reactor fitted with stirrer , Take 30 to 65% of Aqueous plasticizer free anionic acrylic / styrene copolymer dispersion, 2 to 15% hydroxy propyl cellulose, culminal, starch cellulos are taken and a radical chain polymerization is conducted. The initiator generation of reactive radical is generated by 5 to 20% of amines like triethanolamine, triethylamine or any other ethanols are used for initiating radical chain polymerization and 5 to 15% of oxidizing agent used are persulphate or peroxides. The polymerization is conducted under control conditions and 1 to 16% cross linkers like NN Bisacrylamide / methacrylamide and other cross linkers are used by utilizing controlled amount of initiators and oxidizing agents.
Protekta EJR (H) is produced by mixing Component A & Component B, Acrylic resin, and after the reaction is over some hardeners like bisphenol, IPD amines are added.

We Claim:
1. A process for the preparation of cross linked acrylic co-polymer comprising the following steps:-
A) Preparing the component A prepared by means of the following steps:
a. Carrying out the radical chain polymerization in a reactor filled with a stirrer of 35% to
55% of aqueous plasticizer free anionic acrylic / styrene co-polymer, 0.2% to 8%
hydroxyl propyl cellulose, cuneal, starch cellulose.
b. initiating radical chain polymerization of 0.1% to 5% of amines and 0.5% to 5% of
oxidizing agents under control conditions with 1% to 6% cross linkers and other cross-
linkers and adding 5 to 15% of bisphenol to provide required hardness to the product thus
obtaining the Component A.
B) Preparing the component B, prepared by means of the following steps:
a. Conducting radical chain polymerization in a reaction vessel fitted with a stirrer of
25% to 60% aqueous plasticizer free anionic acrylic / styrene polymer dispersion, 2 to
18% hydroxyl propyl cellulose and culminating starch cellulose.
b. Generating reactive radical by initiating the generation by means of 1 to 15% as
amines of any other ethanol and 5 to 15% and oxidizing element.
c. Conducting polymerization under controlled condition and adding 1 to 16% cross
linkers, and/or other cross linkers to obtain the component B.
d. Mixing component A, and component B and acrylic resin and after the reaction was
over, adding some hardeners and amines to obtain the desired product.


3. A process for the manufacturing of cross linked acrylic co-polymer wherein the
oxidizing agents used are persulphate or peroxide.
4. A process for the manufacturing of cross linked acrylic co-polymer wherein the cross-
linkers are Bisacrylamide and/or methacrylamide.
5. A process for the manufacturing of cross linked acrylic co-polymer wherein the cross
linkers used are NN Bisacrylamide and methyl amines.
6. A cross linked acrylic co-polymer comprising component A, component B acrylic resin and after the reaction is over some hardeners like bisphenol and IPD amines are added to it.
7. A cross linked co-polymer as claimed in claim 6, wherein the component A, is a product obtained by radical chain polymerization of 30 to 55% of aqueous plasticizer 0.2 to 8% hydroxy] propyl cellulose, culminal starch cellulose and a initiator 0,5% to 1% of amines and 1 to 6% cross linkers and the oxidizing agent.
8. A process for the preparation of cross linked acrylic co-polymer substantially as hereinbefore described with reference to the accompany drawings.
9. A cross linked acrylic co-polymer substantially as hereinbefore described with
reference to the accompanying drawings.