Compositions and methods for coating surfaces

Abstract

An exterior building cladding system and methods of applying the building cladding system are described. The system is a weather resistive barrier and decorative system that is particularly effective as a covering system for buildings having an exterior wood substrate. The system includes a flexible waterproof base layer of acrylic and rubber that is adhered directly to a wood substrate, a mesh embedded in the flexible waterproof base layer and an acrylic stucco outer layer adhering directly to the flexible waterproof base layer. The system eliminates the need for building wrap while providing a moisture resistant and vapour permeable layer.

1 . An exterior building cladding system for application to a building substrate comprising:
 a flexible waterproof and water vapor permeable base layer composition of acrylic and rubber for adhering directly to the building substrate;   a reinforcement mesh for embedding in the flexible waterproof and water vapor permeable base layer composition prior to curing of the flexible waterproof and water vapor permeable base layer composition; and   an acrylic stucco outer composition for adhering directly to the flexible waterproof and water vapor permeable base layer composition.   
     
     
         2 . A system as in  claim 1  further comprising a joint sealing system for sealing joints in the building substrate, the joint sealing system comprising:
 a curable acrylic and cementitious joint sealing composition for adhering directly to joints within the building substrate; and 
 a joint reinforcement mesh for embedding in the joint sealing layer prior to curing. 
 
     
     
         3 . A system as in  claim 1  wherein the reinforcement mesh is a fiberglass mesh. 
     
     
         4 . A system as in  claim 2  wherein the joint reinforcement mesh is a fiberglass mesh. 
     
     
         5 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition includes rubber crumb. 
     
     
         6 . A system as in  claim 5  wherein the rubber crumb is from recycled tires. 
     
     
         7 . A system as in  claim 5  wherein the rubber crumb size is about 40 mesh. 
     
     
         8 . A system as in  claim 5  wherein the rubber crumb is 18-23% by weight of the flexible waterproof and water vapor permeable base layer composition. 
     
     
         9 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition has a water vapor permeability rate of greater than 60 ng/Pa.s.m 2 . 
     
     
         10 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition is impermeable to liquid water for up to 1.75 hr exposure to liquid water. 
     
     
         11 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition includes 55-65% solids by weight. 
     
     
         12 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition includes 1-2% by weight TiO 2 . 
     
     
         13 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition includes 2-3% by weight hard resin acrylic solids. 
     
     
         14 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition includes 12-13% by weight soft resin acrylic solids. 
     
     
         15 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition includes 25-30% by weight CaCO 3 . 
     
     
         16 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition includes 35-45% by weight volatile compounds. 
     
     
         17 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition has a density of 1.25-1.35 kg/Litre. 
     
     
         18 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition includes about 17.1 g/Litre of volatile organic compounds before curing. 
     
     
         19 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition has a viscosity of 350-600 KcP before curing. 
     
     
         20 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition is applied to a building substrate with a film thickness of about 2 millimeters. 
     
     
         21 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition has a bond strength to plywood and oriented strand board (OSB) of greater than 5 psi after 2000 hours of weathering. 
     
     
         22 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition has a tensile strength of greater than 20 lbs/inch. 
     
     
         23 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition is fire resistant. 
     
     
         24 . A system as in  claim 1  wherein the flexible waterproof and water vapor permeable base layer composition has a smoke developed classification of less than 20. 
     
     
         25 . A system as in  claim 2  wherein the joint sealing layer composition includes acrylic and Portland cement at about a 1:1 by weight ratio. 
     
     
         26 . A system as in  claim 2  wherein a cured joint sealing layer composition has an air leakage value of less than 0.01 L/sec/m 2 . 
     
     
         27 . A system as in  claim 2  wherein a cured joint sealing layer composition has a coefficient of water absorption of less than 0.0009. 
     
     
         28 . A system as in  claim 2  wherein a cured joint sealing layer composition has a bond strength to concrete of greater than 0.1 MPa after 2 hours and greater than 0.3 MPa after 7 hours. 
     
     
         29 . A system as in  claim 2  wherein a cured joint sealing layer has a bond strength to oriented strand board (OSB) of greater than 0.1 MPa after 2 hours and greater than 0.3 MPa after 7 hours. 
     
     
         30 . A system as in  claim 2  wherein a cured joint sealing layer composition has a bond strength to a cured flexible waterproof and water vapor permeable base layer composition of greater than 0.1 MPa after 2 hours and greater than 0.3 MPa after 7 hours. 
     
     
         31 . An exterior building cladding system for application to a building substrate comprising:
 a flexible waterproof and water vapor permeable base layer composition of acrylic and rubber for adhering directly to the building substrate, comprising by weight 18-23% rubber crumb of about size 40 mesh from recycled tires;   a fiberglass reinforcement mesh for embedding in the flexible waterproof and water vapor permeable base layer composition prior to curing of the flexible waterproof and water vapor permeable base layer composition; and   an acrylic stucco outer composition for adhering directly to the flexible waterproof and water vapor permeable base layer composition;   wherein the base layer has a water vapor permeability rate of greater than 60 ng/Pa.s.m 2 .   
     
     
         32 . A system as in  claim 31  further comprising a joint sealing system for sealing joints in the building substrate, the joint sealing system comprising:
 a curable acrylic and cementitious joint sealing composition for adhering directly to joints within the building substrate, including acrylic and Portland cement at about a 1:1 by weight ratio; and 
 a fiberglass joint reinforcement mesh for embedding in the joint sealing layer prior to curing; 
 wherein a cured joint sealing layer composition has an air leakage value of less than 0.01 L/sec/m 2 , a coefficient of water absorption of less than 0.0009 and a bond strength to concrete, oriented strand board (OSB) and a cured flexible waterproof and water vapor permeable base layer composition of greater than 0.1 MPa after 2 hours and greater than 0.3 MPa after 7 hours. 
 
     
     
         33 . A method of cladding a building having an exterior surface comprising the steps of:
 a) applying a flexible waterproof and water vapor permeable base layer to the exterior surface;   b) embedding a reinforcement mesh in the flexible waterproof and water vapor permeable base layer;   c) allowing the flexible waterproof and water vapor permeable base layer to cure to form a cured base layer; and   d) applying an acrylic stucco outer layer to the cured base layer.   
     
     
         34 . A method as in  claim 33  further comprising applying a joint sealing layer embedded with a joint reinforcement mesh to joints in the exterior surface prior to step a). 
     
     
         35 . A method as in  claim 33  wherein the base layer in step a) has a composition comprising by weight 18-23% rubber crumb of about size 40 mesh from recycled tires, the reinforcement mesh in step b) is fiberglass and the cured base layer in step c) has a water vapor permeability rate of greater than 60 ng/Pa.s.m 2 . 
     
     
         36 . A method as in  claim 35  wherein the joint sealing layer is curable and includes acrylic and Portland cement at about a 1:1 by weight ratio, the joint reinforcement mesh is fiberglass and the cured joint sealing layer has an air leakage value of less than 0.01 L/sec/m 2 , a coefficient of water absorption of less than 0.0009 and a bond strength to concrete, oriented strand board (OSB) and the cured base layer of greater than 0.1 MPa after 2 hours and greater than 0.3 MPa after 7 hours.