MATERIALS USED AS WEATHERING COURSE

Materials for a weathering course include Materials for a weathering course include a base layer of brick jelly concrete (lime, surkhi, sand), a top layer of clay tiles, or alternatively, a lime terracing or a thermal insulation composite using materials like light-weight aggregates or Aerocon blocks.
 The specific materials and their composition vary, with common components being cement, sand, water, and tiles, while innovative courses may also incorporate waterproofing chemicals like epoxy or polyurethane. 
Common materials
Base Layer (Brick Jelly Concrete):
Lime: A traditional binder, often used with surkhi (brick powder) and sand. 
Surkhi: Powdered brick, which acts as a filler and binder in the mortar. 
Sand: Fine aggregate used to make the concrete mix. 
Brick Jelly: A mix of brick pieces in a concrete or mortar. 
Top Layer (Finishing and Protection):
Clay Tiles: Specifically, flat or Madras tiles are often used and laid over the base layer. 
Terracotta Tiles: Another common option for the finishing layer. 
Waterproofing Chemicals: Modern systems may incorporate chemicals like epoxy resins or polyurethane to enhance durability and water resistance. 
Alternative materials and methods
Thermal Insulation Composites:
Light-weight aggregates: Materials like Aerocon aggregates or other lightweight materials are used to create an insulating layer. 
Broken aerocon blocks: Another option for an insulating weathering course. 
Polymers: Acrylic polymers or styrene acrylate co-polymers can be added to the composite to improve waterproofing and durability. 
Other materials:
Bitumen sheets: Sometimes used, often in conjunction with other waterproofing materials. 
Cooling tiles: These are often used in conjunction with other materials like tiles to improve the thermal performance of the roof. 
 The specific materials and their composition vary, with common components being cement, sand, water, and tiles, while innovative courses may also incorporate waterproofing chemicals like epoxy or polyurethane. 
Common materials
  • Base Layer (Brick Jelly Concrete):
    • Lime: A traditional binder, often used with surkhi (brick powder) and sand. 
    • Surkhi: Powdered brick, which acts as a filler and binder in the mortar. 
    • Sand: Fine aggregate used to make the concrete mix. 
    • Brick Jelly: A mix of brick pieces in a concrete or mortar. 
  • Top Layer (Finishing and Protection):
    • Clay Tiles: Specifically, flat or Madras tiles are often used and laid over the base layer. 
    • Terracotta Tiles: Another common option for the finishing layer. 
    • Waterproofing Chemicals: Modern systems may incorporate chemicals like epoxy resins or polyurethane to enhance durability and water resistance. 
Alternative materials and methods
  • Thermal Insulation Composites:
    • Light-weight aggregates: Materials like Aerocon aggregates or other lightweight materials are used to create an insulating layer. 
    • Broken aerocon blocks: Another option for an insulating weathering course. 
    • Polymers: Acrylic polymers or styrene acrylate co-polymers can be added to the composite to improve waterproofing and durability. 
  • Other materials:
    • Bitumen sheets: Sometimes used, often in conjunction with other waterproofing materials. 
    • Cooling tiles: These are often used in conjunction with other materials like tiles to improve the thermal performance of the roof. 

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