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What are the applications of nonwoven fabrics in the construction industry?
Release date:
2022/05/19
The applications of nonwoven fabrics in the construction sector can be broadly categorized into three types: architectural waterproof nonwovens, architectural covering nonwovens, and other building structural materials.
Waterproof non-woven fabric
Flexible waterproof materials primarily refer to waterproof membrane materials applied to building surfaces, forming one or more layers of polymers or synthetic polymer materials with a certain degree of deformability. These materials can be categorized into two types: “roll-on waterproofing” and “coating waterproofing.” Nonwoven fabrics are mainly used for wrapping flexible waterproof materials.
Modified Asphalt Waterproof Membrane
As the primary raw material for waterproofing membranes, asphalt represents the first application of organic, flexible waterproofing materials. It is currently the most widely used, most extensively applied, and largest-produced waterproofing material worldwide. Historical evidence indicates that, to date, no product has been found that offers a better cost-performance ratio. Particularly in roofing and underground engineering projects, modified asphalt-based rolled materials, self-adhesive rolled materials, and composite waterproofing systems—combined with puncture-resistant and salt-alkali-resistant rolled materials—can achieve comprehensive functions such as waterproofing, root penetration prevention, and resistance to salt-alkali corrosion.
Nonwoven fabric serves as the reinforcing material in modified bitumen waterproofing membranes, imparting excellent tensile properties to these membranes and thereby extending their service life. Typically, bitumen-based waterproofing membranes are actually nonwoven-fabric-reinforced composites with a sandwich structure: the middle layer consists of nonwoven fabric, while the outer layers are made of modified bitumen.
There are three main types of nonwoven fabrics used in modified bitumen waterproofing membranes: polyester spunbond needle-punched nonwoven fabric, polyester staple fiber needle-punched nonwoven fabric, and wet-laid glass fiber mat. Although glass fiber mats are low-cost, synthetic fiber nonwovens can impart superior flexibility to modified bitumen waterproofing membranes, enabling them to better accommodate thermal expansion and contraction. This significantly reduces the likelihood of leaks and thereby extends the service life of the waterproofing membranes.
With the exception of a small number of unmodified asphalt waterproofing membranes, each square meter of modified asphalt waterproofing membrane must include at least the same area of nonwoven fabric as the reinforcing material. To meet market demand, polyester spunbond nonwoven fabrics are increasingly being used in modified asphalt waterproofing membranes.
Nonwoven fabrics for architectural cladding
On the premise of rational energy use, building energy conservation aims to maximize energy efficiency and enhance the comfort level of buildings. For most buildings, energy consumption by heating and cooling systems accounts for more than half of the total energy use. By implementing effective thermal insulation, we can reduce energy consumption and electricity demand, thereby lowering carbon dioxide emissions and other pollutants.
The key to effective thermal insulation lies in enhancing the airtightness and watertightness of buildings. In Europe and the U.S., the construction industry has begun widely adopting a layer of air barrier film, which is laid over the insulation layer and completely encloses the building, thereby significantly improving its airtightness and watertightness. However, due to the impermeability of this barrier film, moisture condensation on the building’s exterior walls and roof can severely compromise the performance of the insulation materials and the durability of the building envelope.
Therefore, people have developed a high-performance waterproof and breathable membrane. Its key functions include: 1) Breathability—allowing water vapor to escape from the building envelope, thereby addressing issues such as condensation and dew formation, protecting insulation layers, and preventing moisture intrusion. 2) Air tightness—used to seal structures and enclose buildings, enhancing their air-tightness and reducing heat loss caused by air leakage and convection. 3) Water resistance—providing a certain degree of auxiliary waterproofing capability.
The National Institute of Standards and Technology in the United States studied the impact of building airtightness on energy consumption in commercial buildings. The results showed that buildings equipped with waterproof and breathable membranes to enhance airtightness can save up to 40% on heating and cooling costs compared to buildings without such membranes.
Isolation air film
An air-barrier membrane is a material used to enhance the airtightness and watertightness of buildings, reducing the rate of water vapor diffusion through concrete structures and preventing indoor moisture from migrating into insulation layers. This helps to avoid condensation, preserve the thermal performance and structural integrity of insulation materials, and lower building energy consumption. The air-barrier membrane is installed on the foundation to improve the building’s watertightness, preventing indoor moisture from seeping into the insulation layer and ensuring it remains free from corrosion. It can be used in conjunction with a waterproof and breathable membrane above the insulation layer, enabling outstanding moisture resistance on walls or roofs. Moreover, any moisture trapped inside the building envelope can be smoothly discharged through the waterproof and breathable membrane, thereby protecting the envelope’s thermal performance and achieving energy-saving goals.
The air separation membrane, serving as an air separation layer, is installed on the inner side of the composite outer wall and can be used either in combination with a waterproof and breathable membrane or independently. This membrane is suitable for heating buildings with air separation requirements, as well as industrial equipment in the textile and food processing industries.
In the United States, a typical approach involves using both an air-barrier film and a waterproof-breathable film simultaneously: the air-barrier film is applied as the inner insulation layer, while the waterproof-breathable film is positioned on the exterior of the insulation layer. Membranes are also widely used in Germany; according to statistics, over 80% of buildings there utilize such membranes. In China, however, the use of wall membranes is relatively limited, primarily confined to two main types of buildings:
Roof: A gas separation membrane is installed between the two steel layers of the steel-structure workshop; alternatively, a steel wall with an insulation layer is installed in the middle of the membrane.
The temperature difference in buildings is significant, such as in refrigerated spaces.
The simplest windproof membrane is made by sandwiching a polypropylene spunbonded thermally bonded nonwoven fabric between two layers of waterproof film composite material. The outer nonwoven fabric must be UV-resistant.
Waterproof and breathable film
In most parts of North America and Europe, waterproof breathable membranes have already been widely adopted—and are now mandatory. A waterproof breathable membrane is a breathable barrier material installed between the wall and the exterior cladding. It prevents rainwater and other liquid water from passing through while allowing water vapor and air to permeate. It offers functions such as waterproofing, moisture resistance, mold prevention, sound insulation, and pest control.
Nonwoven fabrics used for breathable films mainly include spunbond thermally bonded nonwovens, cast-coated spunbond fabrics, film-composite materials, and spunbond fabrics combined with microporous films. The primary functions of these nonwovens are tear resistance, abrasion resistance, and puncture resistance. Additionally, they typically require UV resistance and a non-slip surface.
Synthetic polymer waterproofing membrane
Synthetic polymer rolled materials are a new type of flexible sheet waterproofing material. They are based on synthetic resins, synthetic rubbers, or mixtures thereof, to which a certain amount of chemical reagents and additives are added, followed by processing techniques involving both rubber and plastic technologies. These polymeric waterproofing membranes exhibit superior properties, including high tensile strength, high elongation at break, excellent heat resistance, good low-temperature flexibility, corrosion resistance, and the ability to be applied using cold-application methods.
Currently, polymer roll materials in China are showing a trend toward diversification and high-end development, and are widely used in building roofs, municipal engineering projects, underground spaces, environmental protection facilities, water conservancy projects, and the defense and military industries, among others.
In the U.S. market, polymer waterproof membranes dominate the flat-roofing segment, while in Europe, modified bitumen waterproof membranes still hold the largest share. In the Japanese market, the waterproofing market is evenly divided among bitumen membranes, polymer membranes, and waterproof coatings. In the Chinese market, bitumen waterproof membranes remain dominant, but the market for polymer membranes is gradually expanding.
Similar to its application in modified bitumen waterproofing membranes, nonwoven fabrics are used as reinforcing materials in polymer waterproofing membranes. Nonwoven fabrics can serve as the intermediate layer or backing substrate in polymer coils. The primary nonwoven fabric used in polymer waterproofing membranes is polyester staple fiber thermally bonded nonwoven fabric. It can be made from recycled polyester materials and boasts recyclability, environmental friendliness, as well as stable sound-absorbing and thermal-insulating properties.
As a rolled material with a nonwoven fabric backing polymer, its primary function is to facilitate construction by enabling the polymer rolled material to bond tightly to the concrete substrate under the action of an adhesive.
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John Han
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