Ultra-low voc compositions and methods

Abstract

The present technology relates to ultra-low VOC compositions comprising asphalt, a softener, clay, a surfactant and one or more polymeric adhesives. The compositions may optionally include functional fibers, fillers and other additives. The present technology also includes methods of manufacturing such compositions and methods for using such compositions in coating, sealing, waterproofing and other applications.

What is claimed: 
     
         1 . A method of preparing an ultra-low VOC asphalt composition substantially free of aggregate, the method comprising the steps of:
 (a) mixing asphalt, a softener, and a polymeric adhesive to form a cutback;   (b) combining the cutback with a gelling surfactant and a clay to form a gel; and   (c) adding fibers to form the composition.   
     
     
         2 . The method of  claim 1 , wherein the cutback of step (a) has a viscosity in the range of about 110 cps to about 300 cps. 
     
     
         3 . The method of  claim 1 , wherein step (a) comprises adding about 18% to about 40% softener. 
     
     
         4 . The method of  claim 3 , wherein the softener comprises a bio-oil or biodiesel. 
     
     
         5 . The method of  claim 1 , wherein the polymeric adhesive is a synthetic polymer having the formula (C 4 H 6 O 2 ) n . 
     
     
         6 . The method of  claim 1 , wherein the polymeric adhesive comprises a plurality of polymeric adhesives. 
     
     
         7 . The method of  claim 1 , wherein step (a) comprises adding about 1% to about 10% polymeric adhesive. 
     
     
         8 . The method of  claim 1 , wherein step (c) comprises adding coarse fibers, fine fibers or a combination of coarse fibers and fine fibers to the composition. 
     
     
         9 . The method of  claim 8 , wherein step (c) comprises adding about 0.5% to about 10% fine fibers and about 0.5% to about 10% coarse fibers. 
     
     
         10 . The method of  claim 1 , wherein step (a) comprises adding about 41% to about 65% asphalt. 
     
     
         11 . The method of  claim 10 , wherein the asphalt is AC-20 (Performance Grade 64-22). 
     
     
         12 . The method of  claim 1 , wherein step (b) comprises adding about 9% to about 15% clay. 
     
     
         13 . The method of  claim 1 , wherein step (b) comprises adding about 1% to about 2.5% gelling surfactant. 
     
     
         14 . The method of  claim 1 , further comprising the step of:
 (d) adding a functional filler.   
     
     
         15 . The method of  claim 1 , further comprising the step of:
 (d) adding a wet surface adhesion additive.   
     
     
         16 . A method of preparing an ultra-low VOC asphalt composition, the method comprising combining the following:
 (a) about 30% to about 70% asphalt;   (b) about 15% to about 42% of a softener;   (c) about 8% to about 16% clay;   (d) about 1% to about 3% of a gelling surfactant; and   (e) about 1% to about 20% of a polymeric adhesive.   
     
     
         17 . The method of  claim 16 , wherein the composition meets the following requirements of ASTM D4586 when measured 4 weeks after manufacture: (i) Workability (ASTM D4586, section 6.2); (ii) Behavior at 60° C. (ASTM D4586, section 6.3)); and (iii) Pliability at 0° C. (ASTM D4586, section 6.4). 
     
     
         18 . The method of  claim 16 , wherein the resultant composition meets the following requirement of ASTM D4586: no more than about 3% moisture, measured in accordance with ASTM D6511, section 10. 
     
     
         19 . A method of preparing an ultra-low VOC asphalt composition comprising the steps of:
 (a) mixing asphalt, a softener, and a polymeric adhesive to form a cutback;   (b) combining the cutback with a gelling surfactant and a clay to form a gel; and   (c) adding fibers to form the composition;   wherein the resultant composition meets the following requirements of ASTM D4586 when measured 4 weeks after manufacture: Workability (ASTM D4586, section 6.2); and Behavior at 60° C. (ASTM D4586, section 6.3).   
     
     
         20 . The method of  claim 19 , wherein the resultant composition meets the following requirement of ASTM D4586: no more than about 3% moisture, measured in accordance with ASTM D6511, section 10.