Method of making an asphalt coating

Abstract

The present invention involves the recycling of asphalt based roofing materials by comminuting the roofing material and subsequently separating a rock component from an asphalt component of the roofing material. The asphaltic component is separated into a feed stream having a mesh size of less than about 50 mesh while the rock component is separated into a feed stream having rocks in the size of 10 mesh or larger. A portion of the comminuted material may be recycled back for additional comminuting. The separated asphaltic component is placed in contact with the solvent to dissolve the asphalt in the asphaltic component providing a mixture of filler, fiber and dissolved asphalt. The liquid may then be applied to a surface of a wall to form a substantially continuous solidified film on the wall to provide waterproofing and an air barrier.

1 . A method of applying an asphalt coating:
 a) comminuting roofing material containing asphalt and rock particles;   b) separating rock from the comminuted roofing material to provide an asphaltic component containing less than about 20% by weight rock larger than about 10 mesh in size;   c) forming said asphaltic component into a liquid material; and   d) applying the liquid material to a surface to form a substantially continuous water resistant coating.   
   
   
       2 . The method of  claim 1  wherein the asphaltic component containing less than about 10% by weight of rock larger than about 10 mesh in size and said asphaltic component containing fibrous filler. 
   
   
       3 . The method of  claim 2  wherein the asphaltic component being in particulate form with at least about 80% by weight being of a mesh size of less than about 50 mesh prior to forming the liquid material therewith. 
   
   
       4 . The method of  claim 3  wherein the liquid is formed by dissolving an asphalt portion of the asphaltic component with solvent. 
   
   
       5 . The method of  claim 4  wherein the solvent including at least one of kerosene, biodiesel and naptha. 
   
   
       6 . The method of  claim 4  wherein the applying of the liquid material being by at least one of spraying, rolling or brushing. 
   
   
       7 . The method of  claim 1  wherein the comminuting is done at least partially by grinding with a hammermill. 
   
   
       8 . The method of  claim 7  wherein the hammermill having a plurality of output streams including first and second output streams, at least one of the output streams being separated into an asphalt component stream and a rock component stream. 
   
   
       9 . The method of  claim 8  wherein the first output stream being a return stream and the method further including returning the first output stream to the comminuting step. 
   
   
       10 . The method of  claim 9  wherein the second stream including asphaltic component and rock, and the method further including separating the rock from the asphaltic component with the separated asphalt component having a mesh size of less than about 50. 
   
   
       11 . The method of  claim 10  wherein the plurality of output streams including a third output stream including asphaltic component fines removed by an air stream. 
   
   
       12 . The method of  claim 11  wherein the asphaltic component after the separating step including fibers, mineral filler and asphalt. 
   
   
       13 . The method of  claim 12  wherein the liquid being applied to a concrete wall surface. 
   
   
       14 . The method of  claim 12  wherein the liquid being applied to a polymeric foam/concrete composite wall surface. 
   
   
       15 . The method of  claim 14  wherein liquid contacting the polymeric foam. 
   
   
       16 . The method of  claim 15  wherein the composite wall being a building wall above grade. 
   
   
       17 . The method of  claim 3  wherein the liquid is formed by heating the asphaltic component. 
   
   
       18 . The method of  claim 17  wherein the liquid asphaltic component is applied to a roof to form the coating. 
   
   
       19 . The method of  claim 18  wherein at least a portion of the separated rock is applied to the coating for adhesion to the coating. 
   
   
       20 . A method of building a structural exterior wall, said method comprising:
 forming a wall at least partially of cast concrete, said wall having an exterior surface;   forming a liquid of ground asphaltic roofing material by comminuting shingle material and separating a rock component from an asphaltic component, said asphaltic component having less than about 20% by weight rock component, and dissolving the asphaltic component in an organic solvent to form the liquid;   applying a coating of the liquid to an exterior surface of the wall; and   allowing the coating to solidify on the surface as a substantially continuous film.   
   
   
       21 . A liquid coating material comprising:
 asphalt derived from comminuted roofing material;   an organic solvent in an amount sufficient to make a liquid of the asphalt and solvent wherein substantially all of the asphalt is in solution, said solution having viscosity adequate for applying a coating to a surface that when solidified forms a water impermeable substantially continuous film; and   fibers derived from the comminuted roofing material.