advanced elastomeric cool roof coatings for highly ......2016/07/08 · requiring a solvent based...
TRANSCRIPT
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Encor® Flex and Kynar Aquatec®
Advanced Elastomeric Cool Roof coatings for
highly weatherable stay-clean roof coatings
Rick MinerArkema Coating Resins
Kurt WoodArkema Inc.
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Outline of talk
Basics of cool-roof coatings
“System” options for cool-roof coatings
High adhesion acrylic resin with excellent dirt resistance
PVDF technology for coatings with highly durable stay clean properties
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Green Movement
Core Values• Conservation
• Sustainable
• Environmentally Friendly
• Reducing Carbon Foot Print
Roofing?• 90% of Roofs in the US are dark colors
• Absorb Heat (150-190°F)
• Contribute to “Urban Heat Island Effect”
• Result in higher utility bills
• Accelerate deterioration of roofing materials which are sent to landfills
• Higher electricity demand leading to blackouts
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The Energy Balance on Roofs
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Roof Surface Layer
Convection
Reflected Radiation R
Re-emitted Energy E
Absorbed Energy
Net Heat Flux into Building
Solar Reflectance () is a ratio indicating the amount of solar energy reflected by a surface
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Reflective Cool White Roofing
Add R-value of roofs • EPA estimates up to R19 value
Reduce building heat-gain
15-30% HVAC savings
Increase HVAC and roof membrane longevity
Resulting in lower greenhouse gas emissions
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System approaches to cool roofing-example of after-market roof coating
Substrate
Substrate
Elastomeric primer-10-20 mils dft
Elastomeric primer-10-20 mils dft
Elastomeric topcoat-10-20 mils dft
High performance topcoat*~ 3 mils dft
• Choice of primer binder will depend on numerous factors such as substrate (asphalt? TPO? etc.), location (do I need low temperature flexibility?), etc.
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Degraded membranes can be replaced or repaired
Hail damage
Crazing Seam splittingUV deterioration
Dirt pick up and mildew growth
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High Adhesion AcrylicElastomeric Latex for Superior Adhesion and Durability
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High Adhesion binder can be employed to repair
various membrane types
Lowers the cost to building owners and improves theprofitability of roofing contractors
• Refurbishing existing membranes cheaper than replacing
• Eliminating the primer lowers the cost of materials and labor
Features
● Meets ASTM D6083-05 specification
● Excellent adhesion to various membrane types
● Excellent dirt pickup resistance
● Resistant to water ponding
● Ambient cross-linking functionality for increased toughness
● High solids for greater formulating latitude
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Surface Wetting vs. Gel Fraction
High gel content; poor flow
Low to moderate gel; good flow
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0
0.5
1
1.5
2
2.5
3
High Adhesion
Polymer
Standard Acrylic
New TPO
Aged TPO
High Adhesion Polymer BasecoatW
et
Peel (p
li)
ASTM minimum
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Passes ASTM D6083 wet peel adhesion requirement, even over difficult to adhere to membranes such as aged TPO, without
requiring a solvent based primer
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0
50
100
150
200
250
High Adhesion Polymer Standard Acrylic
Elongation
Tensile
Tear
ASTM minimums
psi
% Elongation
% Elongation
psi
lbf/inch
lbf/inch
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High Adhesion Polymer Basecoat provides
superior elastomeric properties
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0
5
10
15
20
25
30
35
40
45
High Adhesion
Polymer
Standard Acrylic
Iron Oxide
Coal Ash
Iron OxideIron Oxide
Coal AshCoal Ash
Dirt added as a slurry and allowed to dry overnight
% W
hiteness R
eduction
Photo of cleaned coating Photo of cleaned coating
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High Adhesion Polymer helps keep a cool roof
“white”
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High Adhesion Polymer demonstrates excellent exterior durability
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Sprayed Polyurethane Foam Substrate
Thermoplastic Polyolefin Substrate
High Adhesion Polymer High Adhesion PolymerCommercial 1 Commercial 2 Commercial 3
High Adhesion Polymer High Adhesion PolymerCommercial 1 Commercial 2 Commercial 3
4 years at South 5° Exposure
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High Adhesion Acrylic has very good dirt pick-up resistance
At two years South 5ͦ exposure in Cary, NC
High Adhesion Acrylic
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High Adhesion Acrylic
High Adhesion Acrylic
Commercial products
Coating failure - cracking
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WaterbornePolyvinylidene Fluoride Resin
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The Basis for Weathering Properties
Resistance
to Dirt Pick-
up
Resistance
to Film
Erosion
Resistance
to Mildew &
Fungi
Resistance
to Rain and
Chemicals
Retention of
Color and
Gloss
C-F Bond
PVDF
Polyvinylidene Fluoride
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Waterborne PVDF coatings for “stay-clean” surfaces
At least three mechanisms contribute to the “stay-clean” advantages of PVDF-based coatings:
• PVDF crystallinity and barrier properties
• Fluoropolymer surface properties
• Inhospitality to fungal growth
C
C
C
C
C
CH H H
F F FF F F
H H H
Poly(vinylidene fluoride)
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Key properties of coatings based on Waterborne PVDF resins
Highly resistant to UV degradation• Long term color retention• Long term gloss retention• Highly chalk resistant
Resistant to chemicals & corrosive environments
Very abrasion resistant
Highly flexible
Low dirt pickup
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Benefits of Waterborne PVDF based Coatings
Coatings formulated with Waterborne PVDF latex exhibit the following benefits for building and structure owners:
• Reduced Maintenance
Fewer recoats
Better dirt pick up performance
Improved mold and mildew
resistance
• Environmentally friendly
Aqueous
Low VOC’s
Waterborne PVDF resins are designed for high performance exterior applications
Broadway CTRFP
Washington, USA
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Waterborne Latex Technology-Polymerization & Film Formation
Stage 1: PVDF Polymerization to produce “seed” (>60% fluorine by weight)
Stage 2: Acrylic Emulsion Polymerization:
+ Acrylic
Fluoropolymer
“seed”
Polymerization:
Fluoropolymer
Acrylic
Blend
Film Formation:
CONSOLIDATION INTERDIFFUSIONCOMPACTIONDEFORMATION
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Why high PVDF resin based coatings don’t chalk
Color code:
Acrylic
Blend
PVDF
Pigment
How high PVDF resin levels lead to reduced
chalking and improved color retention
Differential
weathering
leads to
surface
enrichment
of PVDF
fraction
For high PVDF resin
levels, the pigment
stays covered by
PVDF resin even after
all the surface acrylic
is gone
Pigment stays
encapsulated:
minimal chalk
and color
fade!!
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Waterborne PVDF Emulsions vs. Acrylics
Waterborne coatings on Al
Appearance after 7.5 years
South 45º Florida exposure
• Cobalt blue pigment allows
penetration of UV inside the
coating: a very severe test
• Color fade comes only
from resin (polymer)
degradation and chalking
effects
• No chalking or cracking for
Waterborne PVDF coatings;
no progression of color fade
• Acrylics have completely
faded in 5-10 years
Waterborne
PVDF
Waterborne
PVDF
Waterborne acrylics
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Paints on primed fiber cement, 50 months South Florida 45 South exposure, January 2014
Commercial Commercial Commercial Waterborne PVDF
paint 1 paint 2 paint 3
Under flap
Unwashed
Washed
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Paints on primed fiber cement58 months South Florida 45 South exposure, January 2014
Under flap
Unwashed
Washed
Commercial Commercial Commercial Waterborne PVDF
paint 1 paint 2 paint 3
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Acrylic and PVDF Roof System Exposure
|
Commercial Standard Acrylics Acrylic BasecoatPVDF Topcoat
2 years exposure South 5°
Modified Bitumen
Asphalt Emulsion
Granulated Asphalt
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Acrylic and PVDF Roof System Exposure
Commercial Standard Acrylics Acrylic BasecoatPVDF Topcoat
EPDM
Galvanized Steel
Aluminum
2 years exposure South 5°
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Excellent Dirt Pick-Up Resistance
Resistance
to Dirt Pick-
up
Acrylic Resin
Based Coating
Waterborne
PVDF Based
Coating
PVDF resin based coatings have excellent dirt pick up resistance.
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Stain blocking of asphalt species
Commercial elastomeric acrylic paint- 10 mils dry-film thickness
Single coat, paint based on Fluoropolymer2 mils dry-film thickness
Paints applied on SBS asphalt substrate; air-dried then baked at 60 C for one week
Acrylic basecoat –10 mils dry-film thickness and Fluoropolymer topcoat - 2 mils dry-film thickness
Original paint colors
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Inherent Mold, Mildew and Fungal Resistance
Acrylic Resin
Based Coating
Waterborne
PVDF Based
Coating
18 months, South Florida
Neither paint contains biocide.Resistance
to Mildew &
Fungi
Coating Water Pick Up
Performance Comparison
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PVDF Resin Outdoor Exposure History
• TSR > 75% after 13 years
•Formulations based on Kynar Aquatec® ARC
• Photo taken January, 2014
• Panels put out for exposure in January, 2000
• Florida, south facing, 45º
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Waterborne PVDF coating on PVC Membrane 1.5 Years of Exposure in Southern Georgia
Fluoropolymer Coating
PVC Membrane on Peanut Dome
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System Approach for Metal RestorationHigh Performancetopcoat* based on
Waterborne PVDF latex~2-6 mils dft*
Waterborne acrylic primer~2-10 mils dft*
Metal
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Field Application of Waterborne PVDF based Coatings
Surface Preparation
• metal must be in sound, clean, and dry condition, free of contamination (mildew, dirt, grease, oils, etc.)
Priming
• apply appropriate primer
• application equipment
• conventional airless spray
• medium nap roller
• high quality nylon/polyester bristle brush
Top Coat Application
• same application equipment as primer
Dry/Cure Time for each Coating
• touch: ~ 2 hours
• hardness: ~ 24 hours
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Waterborne PVDF vs. commercial coatings
Waterborne PVDF vs. waterborne acrylic urethane hybrid
● Superior weatherability: color retention and chalk resistance
● Higher falling sand erosion resistance
● Meets AAMA 2605 requirements
3000 hours
QUVB
Accelerated Weathering
Urethane acrylic hybrid based coating
Waterborne PVDF based coating
Urethane acrylic hybrid based coating
Waterbonre PVDF based coating
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Commercial Applications ofWaterborne PVDF Coatings
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Summary
Water-based chemistry; allows formulators to meet stringent VOC requirements
Manufactured without fluorosurfactants and alkylphenol ethoxylate (APEO) surfactants
Roofing systems based on acrylic basecoat and PVDF topcoat have performance benefits
● High adhesion to difficult substrates
● Excellent dirt pick-up resistance for stay clean properties
● Excellent color fade resistance in tinted coatings