Extending Infrastructure Life Using FEVE Bridge Coatings

Transcription

1 Course Sponsor: AGC Chemicals Americas, Inc 55 East Uwchlan Ave, Ste 201 Exton, PA Please note: you must take the quiz online at RonBlank.com to receive credit. Extending Infrastructure Life Using FEVE Bridge Coatings AGC09B Credit for this course is 1 AIA HSW CE Hour 2014 Ron Blank & Associates

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 ; you can print one upon successfully completing a course, or from your RonBlank.com transcript. If you have any difficulties printing or receiving your Certificate please send request 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 In this one hour course, we will discover the strengths and advantages of FEVE fluoropolymer topcoats for both new bridges and maintenance re-coating of existing bridges. We will review the decades-long history of real-time and accelerated testing of FEVE fluoropolymer coatings in Japan due to their extensive use on bridge infrastructure. We will also assess the life-cycle cost advantage of FEVE topcoat despite its higher initial cost compared to other topcoat formulations. 4

5 Learning Objectives Upon completion of this course, the design professional will be able to: Identify FEVE fluoropolymer resin bridge coatings List incentives for specifying FEVE industrial maintenance coatings for bridges in terms of performance, application, and maintenance Discuss real-time and accelerated testing history of FEVE coatings that demonstrate its proven performance Quantify life-cycle benefits of FEVE coating for bridges 5

6 FLUOROPOLYMER AND CONVENTIONAL TOPCOAT OVERVIEW

7 Overview Conventional Coating Systems Zinc rich primer, epoxy, and polyurethane topcoat Offer good corrosion protection Topcoat begins to chalk and change appearance quickly Fluoropolymer Coating Systems Zinc rich primer, epoxy, and fluorinated urethane Developed in the early 1980 s; wide use by the 1990 s FEVE withstands UV exposure 2-3 times longer than conventional coating resins. 7

8 FEVE Fluoropolymer Advantages Excellent weatherability (30+ year topcoat life) Shop or field applied (new construction and maintenance) Uses standard painting equipment & application methods Formulated to meet all air quality regulations Superior gloss and color retention Superior resistance to chalking Resistant to airborne chemicals and acid rain Resistant to cleaning solvents used to remove graffiti 8

9 Review #1 The advantages of FEVE Fluoropolymer bridge topcoat systems are: a) Excellent weatherability (30+ year topcoat life) b) Can be field applied using standard painting equipment c) Excellent gloss and color retention and chalking resistance d) Resistant to airborne chemicals, acid rain, and cleaning solvents e) All of the above 9

10 Review #1 The advantages of FEVE Fluoropolymer bridge topcoat systems are: a) Excellent weatherability (30+ year topcoat life) b) Can be field applied using standard painting equipment c) Excellent gloss and color retention and chalking resistance d) Resistant to airborne chemicals, acid rain, and cleaning solvents e) All of the above 10

11 FEVE FLUOROPOLYMER STRUCTURE

12 Fluoroethylene Vinyl Ether (FEVE) Resins The high weatherability of FEVE coatings derives from its distinctive alternating polymer structure. Because the chemical bond between carbon and fluorine atoms is too strong to be broken by sunlight, the polymer is not degraded by UV radiation. The alternating structure also increases the strength of other bonds in the polymer, protecting against degradation. 12

13 Fluoroethylene Vinyl Ether (FEVE) Resins The fluoroethylene segments impart durability, whereas the vinyl ether gives a range of positive attributes to the FEVE resin including gloss, hardness, flexibility and the ability to crosslink. (Durability) (R1, R2, R3, R4) Transparency Gloss Hardness Flexibility Cross-Linkability Pigment Compatibility Adhesion 13

14 Review #2 FEVE is an acronym for: a) Fully Enveloped Vinyl Ethylene b) Fluoroethylene Vinyl Ether c) Fluoroethylene Vinyl Ester d) Fluorescent Vinyl Epoxy 14

15 Review #2 FEVE is an acronym for: a) Fully Enveloped Vinyl Ethylene b) Fluoroethylene Vinyl Ether c) Fluoroethylene Vinyl Ester d) Fluorescent Vinyl Epoxy 15

16 TEST RESULTS 16

17 Weather Resistance Tests for Coatings Accelerated Weathering Tests Short time frame for results Limited in accurately simulating real environment Used as screening tool and comparing coatings Real Time Weathering Tests Accurate results Very time consuming: up to 20 years to complete Often done in harsh conditions, e.g. South Florida 17

18 Accelerated Weathering: QUV Weatherometer Exposure Testing FEVE topcoat demonstrated vastly superior gloss retention in QUV Weatherometer testing. 18

19 Accelerated Weathering: Sunshine Weatherometer (SWOM) Test Carbon Arc SWOM Exposure Testing again showed FEVE with vastly superior gloss retention over acrylic, while PVDF at 4,000 hours exhibited 78% gloss retention compared to FEVE at 92%. FEVE coating PVDF coating Acrylic Urethane coating 19

20 Accelerated Testing: Photomicrographs after SWOM Test The hazy white areas in the photos are polymer structures; sharp white areas are pigment. After 2,000 hours in the SWOM chamber, chlorinated rubber and alkyd coatings both degraded and exhibited throughholes; polyurethane degraded and only pigment remained; FEVE remained intact. Initial appearance before exposure in SWOM SEM photomicrographs after 2,000 hours of exposure in SWOM chamber Fluorourethane Polyurethane Chlorinated Rubber Alkyd 20

21 Gloss retention (%) Real Time Weathering: South Florida Exposure FEVE Yellow Coating FEVE Clearcoat Years of Exposure 21

22 Gloss Retention, % Real Time Weathering: Okinawa, Japan The graph below compares the performance of PVDF and FEVE coatings after 12 years of weathering on Okinawa. FEVE vs. PVdF: Okinawa Weathering Years of Okinawa Exposure FEVE PVdF 22

23 Real-Time Weathering Test: Testing on Offshore Platform At Suruga Bay Marine Test Station (offshore), two samples were tested for 16 years. Both samples had 3 mils zinc-rich primer, 6 mils midcoat, and a 25 micron (1 mil) topcoat. After 13 years, the acrylic urethane topcoat was gone; at 16 years, the FEVE topcoat still measured 21 microns thickness. 23

24 Real-Time Weathering Test: Testing on Tokyo Rooftop Fluorinated Urethane Light sealed tape Std. Polyurethane Film consumption: 0~1.1μm / 15 yrs Film consumption: 22~28μm / 15 yrs In another real-time (15 year) test, a polyurethane topcoat lost µm thickness per year, while a fluoropolymer lost only.07 µm thickness per year over the period. This yields a theoretical topcoat life of 100+ years. 24

25 Real-Time Weathering Test: Chalking Test In the chalking test, topcoat properties are monitored over time. Chalking (coating degradation by UV light and corrosives) is rated from 0-10, with 10 being no chalking and 0 being severe chalking over the entire coating surface. The performance of FEVE fluoropolymer compared to polyurethane is striking. 25

26 Review #3 In a 16-year real-time weathering test, FEVE Fluoropolymer resin topcoat yielded results suggesting a potential topcoat life of: a) years b) years c) 65 years d) 100+ years 26

27 Review #3 In a 16-year real-time weathering test, FEVE Fluoropolymer resin topcoat yielded results suggesting a potential topcoat life of: a) years b) years c) 65 years d) 100+ years 27

28 Corrosion Resistance While resistance to weathering is important for bridge coatings, corrosion resistance is the primary reason for using coatings 1) Primary corrosion resistance is provided by zinc primer which corrodes before steel after coating damage 2) The topcoat serves to keep corrosion initiators like chloride, water and oxygen from reaching the metal surface 3) Because of their long term durability, FEVE topcoats offer superior corrosion protection 28

29 Impedance, 100Mohms/Sq. Cm. Corrosion Resistance of FEVE Coatings: Electrochemical Impedance Spectroscopy Electrochemical impedance spectroscopy (EIS) involves setting up a corrosion cell, measuring the movement of corrosion initiator chloride through coating systems. In this version of the test, the coatings are first weathered in the SWOM test, then placed in the salt fog corrosion test. The change in impedance in 100 ohms/cm ² is measured for each coating system. The smaller the change in initial impedance, the better the corrosion resistance of the coating system SWOM, 1000 hrs. Salt Spray, 500 hrs. Salt Spray, 1000 hrs. FEVE Polyurethane Chlorinated Rubber Alkyd 29

30 SPECIFICATIONS 30

31 Surface Preparation Standards The Society for Protective Coatings (SSPC) has prepared a series of standards detailing surface preparation required prior to abrasive blasting of steel substrates. 1) Surface imperfections such as weld splatter, sharp edges, crevices, and laminations shall be removed prior to cleaning 2) SSPC-SP-1: Solvent Cleaning: Describes cleaning of oil, grease, and other organic material from steel substrates 3) SSPC-Guide 15: Deals with measuring soluble salts on metal surfaces that require removal prior to coating 4) SSPC-SP-12: Describes surface cleaning by water-jetting prior to recoating steel surfaces 31

32 Surface Preparation Standards The Society for Protective Coatings (SSPC) has prepared a series of standards detailing surface preparation requirements for steel substrates. 1) SSPC-SP-5: White Metal Blast Cleaning: Strictest standard, requires removal of all coating, mill scale, rust, and stains 2) SSPC-SP-10: Near White Metal Blast Cleaning: Removal of coating, mill scale, rust, but small stains allowed 3) SSPC-SP-6: Commercial Blast Cleaning: Remove coating, mill scale, and rust but allow up to 33% surface staining 4) SSPC-SP-14: Industrial Blast Cleaning: Allows coating, mill scale, and rust on 10% of area, and allows surface staining 5) SSPC-SP-Brush Off Blast Cleaning: Allows well adhered coating to remain 32

33 Bridge Topcoat Specification This was the 1990 Japanese National Specification for Bridge Topcoats. FEVE topcoats were required for use only in the most severe environments 33

34 Bridge Topcoat Specification The Japanese National Specification was changed to focus on preventive maintenance and to yield lower life-cycle cost. Fluoropolymer topcoats are now required for all environments. Japanese National Specification for Bridge Topcoats (Version 2),

35 Bridge Coating Specification This is the Japanese specification for shop application of fluoropolymer highperformance coating systems 35

36 Bridge Coating Specification This is the field application process for fluoropolymer high-performance coating systems in Japan. The ability to field-apply is a major advantage for FEVE coatings. 36

37 LIFE CYCLE COST ANALYSIS 37

38 Cost Analysis When assessing bridge coatings, if only considering the cost of the protective topcoat system, FEVE coatings appear quite expensive; why are FEVE topcoats being used on so many bridge projects? 38

39 Life-Cycle Cost Comparison Total cost of applying the coating system should be the basis for life cycle cost analysis. Factoring in longer life of FEVE and the topcoat systems small portion of total application cost, FEVE yields an annual total system cost as low as 1/3 that of polyurethane and 1/6 the annual cost of an alkyd. 39

40 Review #4 In terms of cost comparison between bridge painting topcoat systems: a) FEVE Fluoropolymer topcoat component is more expensive than Alkyd or Polyurethane topcoats b) Topcoat component is a very small percentage of total painting project cost c) FEVE yields an annual painting cost only 1/3 that of polyurethane and 1/6 the annual cost of alkyd d) All of the above 40

41 Review #4 In terms of cost comparison between bridge painting topcoat systems: a) FEVE Fluoropolymer topcoat component is more expensive than Alkyd or Polyurethane topcoats b) Topcoat component is a very small percentage of total painting project cost c) FEVE yields an annual painting cost only 1/3 that of polyurethane and 1/6 the annual cost of alkyd d) All of the above 41

42 ENVIRONMENTAL 42

43 FEVE Fluoropolymer- Environmental Considerations Of the four types of FEVE resins, three solid, powder, and emulsion grades contain either zero volatile organic compounds (VOCs) or can be formulated to less than 50 g/l of VOCs, meeting the most stringent U.S. criteria. Due to its longevity, FEVE resin reduces environmental impact associated with production, transportation (energy consumed, greenhouse gas emission) and VOCs off-gassed during the repainting or recoating process. 43

44 CASE STUDIES 44

45 I-235 Pedestrian Bridge In 2003, this Des Moines, IA pedestrian bridge was constructed and spans 230 ft. across the interstate. This project features a zinc rich primer, an epoxy middle coat and an FEVE fluoropolymer topcoat. 45

46 Skydance Pedestrian Bridge This 197 ft. steel bird sits atop a pedestrian bridge in Oklahoma City, OK. This project was coated in 2012 with a 3-coat system with an FEVE fluoropolymer topcoat. 46

47 Shelby Street Bridge This Nashville, TN project was coated in 2004 with a 3-coat system of zinc-rich primer, epoxy midcoat, and FEVE fluoropolymer topcoat. 47

48 Gateway Bridge The red girder portion of this Nashville, TN project was coated in 2004 with a 3-coat system with FEVE fluoropolymer topcoat. 48

49 Akashi-Kaikyo Bridge This road-and-train bridge was coated in Constructed as a 100-year bridge, the expectation with the FEVE topcoat is for only one recoat during the service life of the bridge. 49

50 Tokiwa Bridge On the Tokiwa Bridge, the original coating scheme consisted of a coat of leadbased primer and two coats of chlorinated rubber. In 1986, the surface was prepared to SSPC SP2/SP3 and it was repainted with two coats of Epoxy primer and two coats of FEVE Fluoropolymer. 50

51 Tokiwa Bridge (cont d.) After 19 years, the FEVE fluoropolymer topcoat exhibits superior gloss retention and color stability not attainable with any other coating system. October 1988 April 1993 April

52 Learning Objectives Having completed this course, the design professional will now be able to: Identify FEVE fluoropolymer resin bridge coatings List incentives for specifying FEVE industrial maintenance coatings for bridges Discuss real-time and accelerated testing history of FEVE coatings that demonstrate its proven performance Quantify life-cycle benefits of FEVE coating for bridges 52

53 Course Sponsor: AGC Chemicals Americas, Inc 55 East Uwchlan Ave, Ste 201 Exton, PA Extending Infrastructure Life Using FEVE Bridge Coatings AGC09B Credit for this course is 1 AIA HSW CE Hour 2014 Ron Blank & Associates