NON-SOLVENT, SILICONE COATING/SEALANT INCORPORATING RECYCLED EPDM
A one-component, moisture-curing silicone rubber roof coating or sealant is manufactured using approximately 5-30% recycled EPDM rubber fill. The coating can be incorporated with a polyurethane foam insulation layer to form a roof assembly. Preferably, the EPDM roofing material is removed from an existing structure. It is processed forming powder on the order 50-200 mesh particle size and incorporated into a solvent-free silicone polymer to form a coating or sealant.
1 . A method of forming a silicone coating or sealant comprising:
forming a powder from EPDM roofing material; and
mixing the recycled EPDM powder with solvent-free silicone polymer to form one of a coating and sealant.
2 . The method of claim 1 further comprising recycling the EPDM roofing material by removing an EPDM roofing material from an existing structure.
3 . The method of claim 2 wherein the recycling step includes chopping the removed EPDM roofing into pieces.
4 . The method of claim 3 wherein the recycling step includes washing the chopped EPDM pieces.
5 . The method of claim 4 includes removing metal from the washed EPDM pieces with a magnet.
6 . The method of claim 5 wherein the recycling step includes freezing the removed EPDM roofing material.
7 . The method of claim 6 wherein the recycling step includes grinding the frozen roofing material.
8 . The method of claim 1 wherein the mixing step includes combining of a silicone polymer with approximately 15% of a non-reactive silicone plasticizer.
9 . The method of claim 8 further comprising adding on the order of 35% of a reactive silicone polymer.
10 . The method of claim 9 further comprising adding approximately 2% fused silica.
11 . The method of claim 10 further comprising adding approximately 2.5% of a slow cross-linking material.
12 . The method of claim 11 further comprising adding on the order of 43% powder.
13 . The method of claim 12 wherein the powder includes recycled EPDM and at least one of TiO2, calcium carbonate, quartz, and other solid fillers.
14 . The method of claim 12 further comprising adding a fast cross-linking material.
15 . The method of claim 14 further comprising adding an adhesion promoter.
16 . The method of claim 15 further comprising adding a catalyst.
17 . A one-component, moisture-curing silicone rubber roof coating or sealant comprising approximately 5%-30% recycled EPDM rubber fill.
18 . A roof assembly comprising:
a roof deck; and
spray applied SPF with a solvent-free recycled EPDM rubber layer received over the SPF.
19 . The roof assembly of claim 18 further comprising a solvent-based, abrasion resistant top coat received over the recycled EPDM rubber layer.
20 . The roof assembly of claim 18 wherein the recycled EPDM rubber layer includes approximately 5-30% recycled EPDM.
21 . The roof assembly of claim 20 wherein the recycled EPDM rubber layer includes EPDM particles ranging in size from approximately 50-400 mesh.
22 . The roof assembly of claim 18 further comprising a polyurethane foam insulation layer on the roof deck and the solvent-free recycled EPDM rubber layer is received over the insulation layer.
23 . A solvent free silicone/EPDM applied directly over an existing roof, such as SPF, single ply, built up, or metal as a restoration or maintenance membrane.