Waterproofing system for exposed rock surfaces

Abstract

Polymer Rubber Gel is heated to an elevated temperature and sprayed against the exposed rock to form a generally uniform surface. The Polymer Rubber Gel can be sprayed on the rock surface using a heated want coupled to a heated kettle. Then, a layer of I polyethylene is formed against the polymer rubber gel layer. Finally, a finish layer such as concrete, tile, brick or segmental wall block is placed against the outer side of the polyethylene layer.

What is claimed is: 
     
         1 . A method of providing a waterproofing and vapor barrier to an exposed rock surface, the method comprising:
 heating a non-curing polymer rubber gel to a temperature to allow the non-curing polymer rubber gel to be sprayed with a spray wand applicator;   spraying the polymer rubber gel onto the exposed rock surface until a continuous layer of the polymer rubber gel material is formed over the exposed rock surface;   disposing a layer of polyethylene sheet against the layer of polymer rubber gel, the polyethylene sheet having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and   forming a concrete layer adjacent the polyethylene sheet such that the concrete layer contacts the second side of the polyethylene sheet.   
     
     
         2 . The method of  claim 1 , wherein the second side of the polyethylene sheet comprises fleece material. 
     
     
         3 . The method of  claim 1 , wherein the polyethylene sheet comprises High-density polyethylene (HDPE). 
     
     
         4 . The method of  claim 1 , wherein the polyethylene sheet comprises Linear low-density polyethylene (LLDPE). 
     
     
         5 . The method of  claim 1 , further comprising:
 disposing as second polyethylene sheet against the layer of polymer rubber gel such that the second sheet partially overlaps the first sheet to define a seam; and   sealing the seam of the overlapped first and second polyethylene sheets to form a continuous polyethylene layer.   
     
     
         6 . The method of  claim 5 , further comprising sealing the seam by applying bitumen tape to the seam. 
     
     
         7 . The method of  claim 5 , further comprising sealing the seam by heat welding the seam. 
     
     
         8 . The method of  claim 1 , wherein the polymer rubber gel comprises 99% solids. 
     
     
         9 . The method of  claim 1 , further comprising heating the polymer rubber gel to a temperature in the range of 150-200 degrees Fahrenheit before spraying the polymer rubber gel onto the exposed rock surface. 
     
     
         10 . The method of  claim 1 , further comprising:
 loading the polymer rubber gel into an oil jacketed kettle, the kettle including a pump coupled to the spray wand applicator, wherein the spray want applicator is heated to at least the same temperature as the polymer rubber gel;   elevating the temperature of the polymer rubber gel inside of the kettle to liquefy the polymer rubber gel; and   delivering the liquefied polymer rubber gel to the heated spray wand applicator under pressure.   
     
     
         11 . A method of providing a waterproofing barrier to an exposed natural rock surface, the method comprising:
 heating a non-curing polymer rubber gel comprising 99% solids to a temperature sufficient to allow the non-curing polymer rubber gel to be sprayed onto the exposed natural rock surface with a spray wand applicator;   spraying the polymer rubber gel onto the exposed natural rock surface until a continuous layer of the polymer rubber gel material is formed over the exposed natural rock surface;   disposing a layer of polyethylene sheet against the layer of polymer rubber gel, the polyethylene sheet having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and   forming a finish layer adjacent the polyethylene sheet such that the finish layer contacts the second side of the polyethylene sheet.   
     
     
         12 . The method of  claim 11 , wherein the finish layer comprises a layer of concrete. 
     
     
         13 . The method of  claim 11 , wherein the finish layer comprises tiles. 
     
     
         14 . The method of  claim 11 , wherein the finish layer comprises bricks. 
     
     
         15 . The method of  claim 11 , wherein the second side of the polyethylene sheet comprises fleece material. 
     
     
         16 . The method of  claim 11 , further comprising:
 disposing as second polyethylene sheet against the layer of polymer rubber gel such that the second sheet partially overlaps the first sheet to define a seam; and   sealing the seam of the overlapped first and second polyethylene sheets to form a continuous polyethylene layer.   
     
     
         17 . The method of  claim 11 , further comprising heating the polymer rubber gel to a temperature above 150 degrees Fahrenheit before spraying the polymer rubber gel onto the exposed natural rock surface. 
     
     
         18 . The method of  claim 11 , further comprising:
 loading the polymer rubber gel into an oil jacketed kettle, the kettle including a pump coupled to the spray wand applicator, wherein the spray want applicator is heated to at least the same temperature as the polymer rubber gel;   elevating the temperature of the polymer rubber gel inside of the kettle to liquefy the polymer rubber gel; and   delivering the liquefied polymer rubber gel to the heated spray wand applicator under pressure.   
     
     
         19 . A method of waterproofing a tunnel formed through rock to define an exposed rock surface, the method comprising:
 heating a non-curing polymer rubber gel to a temperature sufficient to allow the non-curing polymer rubber gel to be sprayed onto the exposed rock surface of the tunnel with a spray wand applicator;   spraying the polymer rubber gel onto the exposed rock surface of the tunnel until a continuous layer of the polymer rubber gel material is formed over the exposed rock surface of the tunnel;   forming a continuous layer of polyethylene over the layer of polymer rubber gel, the polyethylene layer having a first side and an opposing second side, wherein the first side is in contact with the continuous layer of the polymer rubber gel; and   forming a finish layer adjacent the polyethylene layer such that the finish layer contacts the second side of the polyethylene layer.   
     
     
         20 . The method of  claim 19 , wherein the finish layer consists of one or more of the following materials: concrete, tile, brick and segmental wall block.