Rubber flooring and method for producing rubber flooring for heavy animal maintenance and care facilities

Abstract

A encapsulation system incorporating a polymer repair mixture with quartz sand that enables an underlying monolithic membrane to fully encapsulate an entire mat into a concrete surface allowing for resilient bond which holds up to the weight and force of Rhinoceros, Hippopotamus, Giraffe and Elephants. Use of such durable flooring of the present invention may be suitable to a diverse array of situations requiring a hard-wearing material, such as zoos, veterinary hospitals, animal transport trailers, quality stall systems, healthcare, arena footing, supermarkets, gymnasiums and schools, as well as other commercial, institutional and sporting uses.

Claims

1. Rubber flooring system comprising: a concrete base; a protective and elastic membrane; a mat structure; an elastomeric polyurethane membrane coat sand mixture; and encapsulating elastomeric polyurethane membrane mixture.

2. The rubber flooring system of claim 1 wherein said protective and elastic membrane is an elastomeric polyurethane membrane.

3. The rubber flooring system of claim 2 wherein said mat structure is a precut rubber mat.

4. The rubber flooring system of claim 3 wherein said concrete base has cured.

5. The rubber flooring system of claim 4 wherein said concrete base is depressed and drains are elevated with slope.

6. The rubber flooring system of claim 5 wherein said concrete base is primed with a coat of epoxy.

7. The rubber flooring system of claim 3 wherein said concrete base is an existing concrete slab.

8. The rubber flooring system of claim 7 wherein said existing concrete slab is prepared by shot blasting or diamond grinding the concrete surface.

9. The rubber flooring system of claim 3 wherein said elastomeric polyurethane membrane is applied with a serrated squeegee or serrate trowel.

10. The rubber flooring system of claim 3 wherein said precut rubber mats are placed over the said elastomeric polyurethane membrane layer while said elastomeric polyurethane membrane layer is still wet.

11. The rubber flooring system of claim 10 wherein said precut rubber mats are placed at a distance between 1/16″ and ⅛″ to the next rubber mat.

12. The rubber flooring system of claim 11 wherein said precut rubber mats are rolled with a turf roller.

13. The rubber flooring system of claim 3 wherein said elastomeric polyurethane membrane coat sand mixture comprising: elastomeric polyurethane membrane solvent free base and water; and equal volume of sand.

14. The rubber flooring system of claim 13 wherein said elastomeric polyurethane membrane solvent free base and water comprising: 4 parts elastomeric polyurethane membrane base; and 1 part water by volume.

15. The rubber flooring system of claim 13 wherein said elastomeric polyurethane membrane coat sand mixture is poured between the gaps of the said precut rubber mats.

16. The rubber flooring system of claim 15 wherein the top surface of the precut rubber mats are primed with an epoxy mixture.

17. The rubber flooring system of claim 3 wherein said encapsulating elastomeric polyurethane membrane mixture comprising: 4 parts elastomeric polyurethane membrane; and 1 part water by volume.

18. The rubber flooring system of claim 17 wherein said encapsulating elastomeric polyurethane membrane mixture is applied over the said precut rubber mats.

19. The rubber flooring system of claim 18 wherein a layer of ground rubber particles is applied to top surface of said encapsulating elastomeric polyurethane membrane mixture.

20. The rubber flooring system of claim 19 wherein one or more coats of sealer is applied to the top surface of said layer of ground rubber particles.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0028] FIG. 1 Cross section of the preferred embodiment for new construction.

[0029] FIG. 2 Cross section of the preferred embodiment for existing concrete slabs.

[0030] FIG. 3 Cross section of the layers in the rubber flooring. Thickness for the layers is not true to scale. The respective thickness of the preferred embodiment are approximately: 2 ml of primer epoxy (layer 14 and 17), 1/16″ for the monolithic base coat (layer 13 and 16), ¾″ for the preformed rubber mat (layer 15), 0.05 to 1.5 mm for the rubber granules (layer 12), and 12 ml for the top coat (layers 10 and 11).

DETAILED DESCRIPTION OF AN EMBODIMENT FOR NEW CONSTRUCTION

[0031] The rubber flooring system should not be installed over new concrete until the concrete has cured to allow no more than 80% relative humidity over 72 hours. The concrete sub floor is depressed ¾″ and drains are elevated ¾″ with adequate slope to the drain to accommodate the flooring system. The concrete subfloor should be clean, dry, free from sealer, drying agents, curing or parting compounds. The slab should be finished with an 80 grit (light broom) Finish. A ⅛″ pre-molded membrane should be installed below the concrete slab.

[0032] A primer coat of epoxy is then rolled over the concrete. After the epoxy cures (approximately 3-5 hours) apply an elastomeric polyurethane membrane with either a ¼″ serrated squeegee or a ¼″ serrated trowel to a settling level of 1/16″ to ⅛″ in thickness. (c). Place the precut rubber mats are over the wet elastomeric polyurethane membrane coat at a distance between 1/16″ and ⅛″ to the next mat and then roll with a turf roller.

[0033] Next, prepare an elastomeric polyurethane membrane coat sand mixture, which, for the present application, is a mixture of: (1) elastomeric polyurethane membrane solvent free base and water (elastomeric polyurethane membrane base 4 parts and water 1 part by volume); and (2) equal volume of sand.

[0034] Pour this elastomeric polyurethane membrane base and sand between the gaps of the mats.

[0035] Prime the top surface of the mats with an epoxy mixture of resin and cure until it sets up to a tacky point.

[0036] Next, float an encapsulating elastomeric polyurethane membrane mixture (without sand) over the mats to within a thickness of 1/16″ to ⅛″ thickness. This encapsulating elastomeric polyurethane membrane mixture is comprised of four parts elastomeric polyurethane membrane to one-part water. After the encapsulating mixture is applied While still wet, one applies a thin layer of finely ground rubber particles sufficient to cover the surface. After this step, cure out takes 6 to 8 hours naturally, or approximately twice as fast using an accelerator. After cure out of the elastomeric polyurethane membrane base, remove by any means all loose, unbonded ground rubber. At this point, two coats of Aliphatic Urethane Sealer are applied, the second coat being applied after the first has dried.

Description of an Embodiment for Existing Concrete Slabs

[0037] Prepare the concrete by shot blasting or diamond grinding the concrete surface to clean and profile the concrete surface.

[0038] A primer coat of epoxy is then rolled over the concrete. After it cures apply an elastomeric polyurethane membrane with either a ¼″ serrated squeegee or a ¼″ serrated trowel to a settling level of 1/16″ to ⅛″ in thickness. Leave a 3″ gap around outer edges of concrete slab. Place the precut rubber mats over the wet elastomeric polyurethane membrane coat at a distance between 1/16″ and ⅛″ to the next mat and then roll with a turf roller.

[0039] Next, prepare an elastomeric polyurethane membrane coat sand mixture, which, for the present application, is a mixture of: (1) elastomeric polyurethane membrane solvent free base and water (elastomeric polyurethane membrane base 4 parts and water 1 part by volume); (2) equal volume of sand; and (3) Then pour sand mixture between gaps in mats.

[0040] One-part polymer repair mortar+four parts Quartz Sand, pour mortar mixture around the 3″ outer edges of the mats and cove it an angle up to the top edge of the mat.

[0041] Prime the top surface of the mats, including the 3″ covered edges, with a mixture of resin and cure until it sets up to a tacky point.

[0042] Next, float an encapsulating elastomeric polyurethane membrane mixture (without sand) over the mats to within a thickness of 1/16″ to ⅛″ thickness. This encapsulating elastomeric polyurethane membrane mixture is comprised of four parts elastomeric polyurethane membrane to one-part water. After the encapsulating mixture is applied, one applies a thin layer of finely ground rubber particles sufficient to cover the surface. After this step, cure out takes 6 to 8 hours naturally, or approximately twice as fast using an accelerator. After cure out of the elastomeric polyurethane membrane base, remove by any means all loose, unbonded ground rubber. At this point, two coats of Aliphatic Urethane Sealer are applied, the second coat being applied after the first has dried.