ARCHITECTURAL PROTECTIVE COATINGS FEVE RESIN TECHNOLOGY

Transcription

1 Presented by: AGC 55 E. Uwchlan Ave., Ste. 201 Exton, PA ARCHITECTURAL PROTECTIVE COATINGS FEVE RESIN TECHNOLOGY Course Number: AGC09A Provider: AGC Chemicals Americas, Inc. Credit: 1 AIA HSW CE Hour Ron Blank & Associates, Inc. 2011

2 An American Institute of Architects (AIA) Continuing Education Program Approved Promotional Statement: Ron Blank & Associates, Inc. is a registered provider with The American Institute of Architects Continuing Education System. Credit earned upon completion of this program will be reported to CES Records for AIA members. Certificates of Completion are available for all course participants upon completion of the course conclusion quiz with +80%. Please view the following slide for more information on Certificates of Completion through RBA. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA or Ron Blank & Associates, Inc. of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

3 An American Institute of Architects (AIA) Continuing Education Program Course Format: This is a structured, web-based, self study course with a final exam. Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour Completion Certificate: A confirmation is sent to you by and you can print one upon successful completion of a course or from your RonBlank.com transcript. If you have any difficulties printing or receiving your Certificate please send requests to certificate@ronblank.com Design professionals, please remember to print or save your certificate of completion after successfully completing a course conclusion quiz. confirmations will be sent to the address you have provided in your RonBlank.com account.

4 Course Description Protective coatings fight deterioration caused by environmental elements, while also reducing maintenance costs and increasing the life of the finish. The design professional will explore different architectural coatings, specifically fluoropolymers, and their benefits. Through this one hour online course, we will also learn how next-generation fluoropolymer coating technology exhibits excellent weatherability and environmental advantages. This course will conclude with a brief 10 question quiz.

5 Learning Objectives By completing this course, the design professional will be able to: 1. Compare and contrast polyvinylidene fluoride (PVdF) and fluoroethylene vinyl ether (FEVE) architectural coatings in terms of application and performance. 2. Knowledgably determine which FEVE coating type to apply based on field or shop application and substrate (solvent-based, solid resins, water-borne, powder). 3. Discuss the low-voc/haps-free attributes of FEVE coatings and the importance of meeting South Coast Air Quality (SCAQMD) standards. 4. Discuss the attributes and benefits of FEVE technology when applied to a project exterior, including long-lasting protection from the elements (UV rays, wind, rain, corrosion) and reducing the use of resources and costs associated with maintenance/repair.

6 Architectural Coatings A N I N T R O D U C T I O N

7 The Role of Protective Coatings A picture in the mind or a conceptual sketch of a perfect architectural design can diminish once built in the real world, where it is subject to the elements, corrosion, abrasion, etc. Without protection from UV rays, wind, rain, and other impacts, a beautifully constructed project can quickly lose its luster. These factors can result in deterioration and render aesthetics awash of their former brilliance, leading to extensive costs to repair, correct and restore.

8 The Role of Protective Coatings The architectural and construction industry have been specifying and utilizing protective coatings for generations. These coatings work to prevent deterioration caused by impact and environmental factors to maintain durability and aesthetics while greatly reducing maintenance costs and increasing the life of the finish. archiexpo.com

9 Application Substrates Original metal applications, such as curtain wall applications, have grown to include many other surface types, such as glass, plastic, and concrete, in a diverse spectrum of projects. Evolving coating technology has brought about variations of coating types as well, including liquid, powder, etc., to support optimal applications in various settings. corporate.heraeus.com

10 Considerations When Selecting a Coating Specifying coatings with high performing characteristics ensures a finish will endure through time while still exhibiting that initial luster. Varying attributes to consider include ease of application, curing time/method, ability to maintain color/gloss, mechanical strength, weatherability and durability. Among protective coatings, fluoropolymer resins are commonly used for their superior performance. These coatings are known for their durability and ability to maintain initial performance over long time periods.

11 Fluoropolymers A C O M PA R I S O N

12 Properties of Fluoropolymers Fluoropolymer Resins have been used in coatings for over 40 years. These coating systems show superior UV protection, excellent chalking resistance, good mechanical properties and therefore are primarily used for exterior applications. Their advantages include: Low surface energy Excellent weatherability Corrosion, abrasion, temperature and chemical resistance Their main disadvantage: Difficult to apply Require heat to soften or melt, then apply to substrate

13 Properties of Fluoropolymers Examples of Fluoropolymers used in coating applications include: PTFE or Teflon FEP ETFE PVdF PVF PVF and PVdF are the most commonly used.

14 PVF resins PVF and PVdF Characteristics Limited use in coatings (melting and decomposition temperatures too close) PVFs require additives PVdF Resins Better processing characteristics than PVF Tendency to form pinholes Poor adhesion Blended with acrylic resin (70/30) to improve adhesion Commonly referred to as Kynar/Hylar Form pinhole-free coating with good adhesion at 250 C Between these two, PVdF coatings possess more durable and flexible characteristics.

15 PVdF Coatings PVdF coatings exhibit the following advantages: Over 20 year durability Good gloss & color retention over the life of the coating Good chemical resistance Flexibility required to fabricate pre-coated construction components PVdF coatings exhibit the following disadvantages: Coating is applied to substrate at high temperatures which leads to limited field applications. Limited gloss range Pigment compatibility also limited -- Limits amount and type of colors available

16 FEVE Resins T H E N E X T G E N E R AT I O N O F F L U O R O P O LY M E R C O AT I N G T E C H N O L O G Y

17 FEVE Technology FEVE resins were developed in the 80 s as solvent-soluble fluoropolymers that could be cured at room temperature conditions, so they could be used on-site for field applications such as heavy-duty architectural and aerospace coatings, as well as for oven-baked coatings. Over the past 25 years, fluoropolymer coatings based on FEVE technology have been produced by many coating manufacturers worldwide. Coated with FEVE Technology

18 FEVE Technology FEVE coatings were designed not only to overcome the limitations of PVdF resins, but also to possess the same weatherability as PVdF coatings. This strength is derived from a unique alternating polymer chemical structure discussed later in the Life Cycle Cost section of this course. Known for their high performance properties: Exceptional resistance to UV degradation Superior Chemical Resistance Excellent Thermal Resistance Good corrosion resistance Known for their unique formulation properties: Solvent soluble Can be cured at room temperature Can be cured at elevated temperatures Can achieve high gloss coatings

19 Advantages of FEVE Resins These coatings exhibit excellent pigment compatibility, enabling a broad range of colors. FEVE resins are solution polymers, offering brighter, more vivid colors. They also offer a broad range of gloss possibilities, from completely flat to high gloss. Because FEVE coatings can be field applied, they are ideal for recoating applications.

20 FEVE Resin Application Advantages Because FEVE resins exhibit characteristics of both fluoropolymers and urethanes, FEVE based coatings offer excellent bonding to substrates ranging from aluminum and steel to fiberglass. FEVE coatings also bond well with primers and undercoats such as epoxies and polyurethanes. FEVE coatings can be recoated and can also be used to repair and refinish other fluoropolymer coatings.

21 Ideal FEVE Resin Substrates FEVE based coatings are available for multiple substrate applications including: Steel, aluminum, copper, zinc, and other metals Concrete Construction Plastics (FRP, polycarbonate, PET) Recycled Plastics (polyethylene, polypropylene, PET) Glass Wood

22 Summary of Attributes Broader gloss range Brighter colors Field, shop or factory application Excellent corrosion resistance Excellent hardness and mar resistance Water based, solid resins, and powder coating resins for low/zero Volatile Organic Compound (VOC) coatings FEVE coatings pass the most stringent air quality standards (better for human health and the environment)

23 FEVE Coating Types A N D T H E I R AP P L I C AT I O N S

24 FEVE Coating Types Currently, there are four types of FEVE based coatings available for different applications: Solvent Based Used in most of the U.S. Field or shop application Water-Borne Low odor requirements Field or shop application Solid Resins Low/Zero VOC coatings Field or shop application Powder Coatings Factory applied

25 Solvent Based For ambient cured coatings based on FEVE resins, xylene is the solvent currently used. Xylene is used because of its physical properties and low cost. Xylene content of FEVE resins range from 40-67%. The coil coating industry uses FEVE resins blended with alternative solvents.

26 Solid FEVE Resins Due to more stringent environmental air pollution standards, solid FEVE resins have been developed as an alternative. These solid resins can be used to produce low-voc. Meet strictest standards: South Coast Air Quality Management District (SCAQMD) 100 g/l VOC Used in ambient or field applied coatings

27 Water-Based FEVE water-based resins were developed to meet air quality standards and with limited odor. Single component FEVE water-based resins can also be used to product coatings. Single component FEVE emulsions can also be used to produce coatings.

28 Powder Coatings FEVE resins can be made in a powder version that offers all of the weatherability and properties of their liquid counterpart along with other advantages: The powder versions offer the benefits of being solvent-free and little to no waste in application. Powder versions can be as much as 95% usage efficient. Unlike PVdF, the powder version of FEVE does not require a substrate primer.

29 FEVE Coating Versatility in Application Factory or Shop Application: Field Application: Coil coatings (metal composite materials) Powder coatings New construction Repainting existing structures Coil or powder coating repair Field color match to shop applied coatings

30 FEVE Resins for Field Applied Coatings Uses: To recoat existing structures previously coated with PVdF Ideal for structures that are difficult to repaint, e.g. tall buildings, water towers, bridges, etc. To repaint other coatings, e.g. urethane Surface Preparation: Sandblasting Removal of loose materials Prepare and prime substrate Advantages of FEVE: Use standard paint application equipment Water based, solvent based and solid grades can be used

31 FEVE Resins for Shop or Factory Application Uses: Exterior cladding applications including metal extrusions and metal composite Automotive exteriors Solar cells Coil Coatings Surface Preparation: Use substrates that have been properly treated Apply coatings directed to metal surface, no primer required Advantages of FEVE: FEVE offers application cost savings since PVdF s require a primed substrate Can be used on multiple metallic surfaces including ACM, Steel, etc. Can be used on surfaces such as construction plastics/polycarbonate

32 Powder Coatings Example: Aluminum extrusions for windows Curtain walls Architectural accessories Surface Preparation: No primer required Use substrates that have been properly treated Advantages of FEVE: Excellent stain and mar resistance Excellent corrosion resistance of properly treated metal substrates

33 Life Cycle Cost C O N T R I B U T I N G FA C T O R S

34 Life Cycle Cost Advantages Repainting and maintenance work on buildings, bridges, and other structures can cause both financial and operating disruptions. There are also significant environmental costs associated with repainting operations. FEVE resins minimize these costs. In addition to low VOC content, low life cycle costs make FEVE technology a more environmentally friendly choice. In a typical scenario, FEVE based coatings are more expensive than polyurethane coatings on a $/gallon basis. However, due to FEVE s superior weatherability, they will last at least twice as long as most coatings before recoating is necessary.

35 Life Cycle Cost Advantages Initial applied cost of FEVE-based topcoat: 5-10% higher than standard polyurethane topcoat FEVE-based topcoat life expectation: years Expected maintenance of standard polyurethane topcoat in this time frame: 2-3 repainting cycles Additional costs of repainting: Asset downtime Staging costs Environmental costs Emissions and CO 2 from equipment Relevant life cycle cost is dollars/sq.ft./year

36 Life Cycle Cost Analysis In this chart, the relative applied cost encompasses the cost of each portion of the coating system (for FEVE system it is around 85, for the initial polyurethane it is about 76). The total cost for each coating system is divided into the applied cost for each coat-that includes the cost of the coating and the cost of applying the coating. The initial applied cost of the urethane is somewhat lower than that of the FEVE coating. After 10 years, the urethane must be replaced because it has degraded over that time. So the life cycle cost of the FEVE coating (85) is lower than that of the polyurethane (around 123).

37 Weathering Properties The outstanding weatherability of FEVE resins is due to the unique high bond energy of the carbon-fluorine bond, and to their unique polymer structure. FEVE resins successfully prevent UV degradation thus maximizing gloss retention. Comprehensive testing has been achieved for real-time and accelerated weathering.

38 Accelerated Weathering: EMMAQUA Test EMMAQUA (Equatorial Mount with Mirrors for Acceleration with Water) is the most widely used outdoor accelerated weathering test method in the world today. The diagram below compares the weatherability of FEVE vs. PVdF and Polyurethane.

39 Natural Weathering: Okinawa The chart below displays weatherability over a 12 year period, confirming FEVE s comparability to PVdF in durability. FEVE PVdF

40 Corrosion Resistance of FEVE Coatings Fluorourethanes made with FEVE resins can perform effectively for several years in the presence of such corrosion initiators as chloride ions, water and oxygen. This advantage is due to the fluorine atom making the FEVE Coating tight and its inherent low levels of coating degradation. When applied at adequate thickness, FEVE based topcoats can be expected to last up to 60 years. The following slide shows the improved corrosion resistance of FEVE coatings compared to others. The flatter the line, the better the corrosion resistance of the topcoat.

41 Corrosion Resistance This accelerated corrosion test shows the superior performance of the FEVE coating. The horizontal line indicates no change in the corrosion protection of the FEVE coating. Competitive coatings suffer a loss of corrosion protection as they age, indicated by the sloping lines.

42 Corrosion Resistance of FEVE Coatings The ASTM B-117 Salt Fog Corrosion Test exposes scribed coated panels to a 5% salt solution over a period of time, in this case 2,000 hours. Corrosion is measured by the amount of rust in the scribe and under the coating adjacent to the scribe as well as by blisters formed by corrosion products. In the test below, both topcoats were applied over a 3 mil epoxy primer. Can be expected to last up to 60 years. Left Panel: Polyurethane Topcoat Right Panel: FEVE Topcoat

43 Sustainability

44 Sustainability of FEVE Coatings The weatherability, longevity and low VOC coatings of FEVE resins are all features that contribute to its sustainability FEVE coatings can last up to 30 years without fading, reducing life cycle costs related to the maintenance, re-application and/or replacement of underlying surfaces. Possible LEED v4 credits: Materials and Resources credit Building Life-Cycle Impact Reduction Sustainable Sites Credit Rainwater Management Sustainable Sites Credit Heat Island Reduction Energy and Atmosphere Prerequisite Minimum Energy Performance

45 Case Studies and Project Applications

46 Eerie on the Park Location: Chicago, IL 10 years of exposure Recoated with a zinc primer and FEVE resin-based coating

47 The Mohegan Sun Casino Location: Wilkes-Barre, PA Construction damage to ACM Affected panels repaired with a zinc primer and FEVE resin-based coating which matched the factory color of the metallic panels. Zero metallic flop.

48 Corporate Office Building Location: Washington, DC Installation damage to curtain wall Affected areas repaired with a zinc primer and FEVE resinbased coating which matched the original color of the metallic curtain wall. Zero metallic flop.

49 Projects Ferrari World, Abu Dhabi U.A.E Substrate: Aluminum Coss Y Leon Building, Mexico Substrate: Aluminum Composite

50 Projects Winnie Palmer Hospital, USA Substrate: Aluminum Composite Burj Al Arab Hotel, Dubai U.A.E Substrate: Aluminum Composite

51 Projects Windmill Substrate: Fiberglass NTT Sekimoku Network Center Substrate: Steel

52 Projects Rosemont Water Tower, USA Substrate: Steel Kiyosu Bridge, Japan Substrate: Steel

53 Conclusion

54 In Summary FEVE is the next-generation architectural coating technology. Its chemical make up produces un-matched weatherability and long service life. It also allows versatility in terms of substrate (adhesion) and field or shop application (able to cure at room temp.). It achieves brighter and wider array of colors. Last but not least, FEVE coatings can protect and maintain the initial luster and aesthetics of a project for 20+ years.

55 Course Summary Now, the design professional will be able to: 1. Compare and contrast polyvinylidene fluoride (PVdF) and fluoroethylene vinyl ether (FEVE) architectural coatings in terms of application and performance. 2. Knowledgably determine which FEVE coating type to apply based on field or shop application and substrate (solvent-based, solid resins, water-borne, powder). 3. Discuss the low-voc/haps-free attributes of FEVE coatings and the importance of meeting South Coast Air Quality (SCAQMD) standards. 4. Discuss the attributes and benefits of FEVE technology when applied to a project exterior, including long-lasting protection from the elements (UV rays, wind, rain, corrosion) and reducing the use of resources and costs associated with maintenance/repair.

56 Presented by: AGC 55 E. Uwchlan Ave., Ste. 201 Exton, PA ARCHITECTURAL PROTECTIVE COATINGS FEVE RESIN TECHNOLOGY Course Number: AGC09A Provider: AGC Chemicals Americas, Inc. Credit: 1 AIA HSW CE Hour Ron Blank & Associates, Inc. 2011