Blast mitigation coating systems

Abstract

The present invention relates to methods of providing a blast mitigation coating system to a building structure and kits of the system. The method comprises the steps of: mixing and applying a water-based flexible polymer, a micro-fiber material, a mineral filler material, and other additives to the building structure to form a layer of coating; embedding one layer of glass-fiber reinforcing meshes into the coating; applying the second layer of coating; and embedding a second layer of meshes. The water-based flexible polymer comprises acrylic resin, styrene-acrylic, and vinyl-acetate ethylene. The micro-fiber material comprises polypropylene. The mineral filler material comprises ground silica and/or mica. The kit of the blast mitigation coating system comprises the water-based flexible polymer, the micro-fiber material, the mineral filler material and glass-fiber reinforcing meshes. Additional components may include a blend of Portland cement and dry additives, or a pigment, preservatives and rheology modifiers.

1 : A method of providing a blast mitigation coating system to a building structure, said method comprises the steps of:
 mixing a first component with a second component to form a mixture, wherein the first component comprises an organic polymer compound comprising a water-based flexible polymer, a micro-fiber material, and a mineral filler material, and the second component comprises a blend of Portland cement and dry additives;   applying the mixture directly to a surface of the building structure to form a first layer of coating;   placing and embedding at least a first piece of glass-fiber reinforcing mesh into the first layer of coating before the first layer of coating begins to dry;   applying the mixture onto the first piece of mesh that is embedded in the first layer of coating to form a second layer of coating; and   placing and embedding at least a second piece of glass-fiber reinforcing mesh into the second layer of coating before the second layer of coating begins to dry.   
   
   
       2 : The method according to  claim 1  comprising a further step of applying the mixture to the second piece of mesh embedded in the second layer of coating to form a third thin layer of coating and smoothing localized surface irregularities. 
   
   
       3 : The method according to  claim 1 , wherein the water-based flexible polymer of the mixture comprises 10-15% by weight of acrylic resin, 30-35% by weight of styrene-acrylic, and 5-10% by weight of vinyl-acetate ethylene. 
   
   
       4 : The method according to  claim 1 , wherein the micro-fiber material of the mixture comprises 3-5% by weight of polypropylene. 
   
   
       5 : The method according to  claim 1 , wherein the mineral filler material of the mixture comprises 45-50% by weight of ground silica. 
   
   
       6 : The method according to  claim 1 , wherein the mixture has a working time of about 1 hour at about 70° F. and about 50% relative humidity before application. 
   
   
       7 : The method according to  claim 1 , wherein the glass-fiber reinforcing mesh is a leno weave mesh with warp and weft strands approximately 8 strands per inch and having a density of about 20 oz/yd 2 . 
   
   
       8 : The method according to  claim 1 , wherein, when multiple meshes are placed and embedded into the coating, adjacent meshes are overlapped by a minimum of 2.5 inches along edges of the meshes. 
   
   
       9 : The method according to  claim 1 , wherein the second piece of mesh is embedded with its long dimension perpendicular to the long dimension of the first piece of mesh. 
   
   
       10 : A method of providing a blast mitigation coating system to a building structure, said method comprises the steps of:
 mixing a water-based flexible polymer, a micro-fiber material, and mineral fillers;   applying the mixture directly to a surface of the building structure to form a first layer of coating;   placing and embedding at least a first piece of glass-fiber reinforcing mesh into the first layer of coating before the first layer of coating begins to dry;   applying the mixture onto the first piece of mesh that is embedded in the first layer of coating to form a second layer of coating; and   placing and embedding at least a second piece of glass-fiber reinforcing mesh into the second layer of coating before the second layer of coating begins to dry.   
   
   
       11 : The method according to  claim 10 , wherein a pigment, preservatives and rheology modifiers are added in the mixing step. 
   
   
       12 : The method according to  claim 10  comprising a further step of applying a the mixture to the second piece of mesh embedded in the second layer of coating to form a third thin layer of coating and smoothing localized surface irregularities. 
   
   
       13 : The method according to  claim 10 , wherein the water-based flexible polymer of the mixture comprises 10-15% by weight of acrylic resin, 20-25% by weight of styrene-acrylic, and 10-15% by weight of vinyl-acetate ethylene. 
   
   
       14 : The method according to  claim 10 , wherein the micro-fiber material of the mixture comprises 3-5% by weight of polypropylene. 
   
   
       15 : The method according to  claim 10 , wherein the mineral fillers of the mixture comprise 20-25% by weight of ground silica. 
   
   
       16 : The method according to  claim 10 , wherein the mineral fillers of the mixture comprise 10-15% by weight of mica. 
   
   
       17 : The method according to  claim 10 , wherein the glass-fiber reinforcing mesh is a leno weave mesh with warp and weft strands approximately 8 strands per inch, and having a density of about 20 oz/yd 2 . 
   
   
       18 : The method according to  claim 10 , wherein, when multiple meshes are placed and embedded into the coating, adjacent meshes are overlapped by a minimum of 2.5 inches along edges of the meshes. 
   
   
       19 : The method according to  claim 10 , wherein the second layer of mesh is embedded with its long dimension perpendicular to the long dimension of the first layer of mesh. 
   
   
       20 : A kit of a blast mitigation coating system for a building structure, said kit comprises:
 a first component comprising a water-based flexible polymer, a micro-fiber material, and a mineral filler material;   a second component comprising a blend of Portland cement and dry additives; and   at least two pieces of glass-fiber reinforcing meshes.   
   
   
       21 : The kit according to  claim 20 , wherein the water-based flexible polymer comprises 10-15% by weight of acrylic resin, 30-35% by weight of styrene-acrylic, and 5-10% by weight of vinyl-acetate ethylene. 
   
   
       22 : The kit according to  claim 20 , wherein the micro-fiber material comprises 3-5% by weight of polypropylene. 
   
   
       23 : The kit according to  claim 20 , wherein the mineral filler material comprises 45-50% by weight of ground silica. 
   
   
       24 : The kit according to  claim 20 , wherein the glass-fiber reinforcing mesh is a leno weave mesh with warp and weft strands approximately 8 strands per inch and having a density of about 20 oz/yd 2 . 
   
   
       25 : A kit of a blast mitigation coating system for a building structure, said kit comprises:
 a first component comprising a water-based flexible polymer, a micro-fiber material, mineral fillers, a pigment, preservatives and rheology modifiers; and   at least two pieces of glass-fiber reinforcing mesh.   
   
   
       26 : The kit according to  claim 25 , wherein the water-based flexible polymer comprises 10-15% by weight of acrylic resin, 20-25% by weight of styrene-acrylic, and 10-15% by weight of vinyl-acetate ethylene. 
   
   
       27 : The kit according to  claim 25 , wherein the micro-fiber material comprises 3-5% by weight of polypropylene. 
   
   
       28 : The kit according to  claim 25 , wherein mineral fillers comprise 20-25% by weight of ground silica. 
   
   
       29 : The kit according to  claim 25 , wherein mineral fillers comprises 10-15% by weight of mica. 
   
   
       30 : The kit according to  claim 25 , wherein the glass-fiber reinforcing mesh is a leno weave mesh with warp and weft strands approximately 8 strands per inch, and having a density of about 20 oz/yd 2 .