arkema coating resins welcome to the 2014 acr webinar series!! 5 elastomeric... · arkema coating...

Arkema Coating Resins

Welcome to the 2014 ACR Webinar Series!!

June 20, 2014

Invest one hour with us and we’ll help you grow your business with products and technology from Arkema Coating Resins

2014 ACR Webinar Series

Today’s Topic: Elastomeric Coatings

Speaker: John Dockery

Title: Technical Service Chemist

3

Our training goal

Give you the knowledge necessary to answer your customer’s questions concerning elastomeric coatings with confidence • Outline the basics of formulating

• Describe the ASTM testing protocols

• Outline the characteristics of the different product classifications

• Highlight several Arkema products and describe their performance benefits

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Today’s Agenda

What is a Elastomeric Coating?

Elastomeric Coatings Market Opportunity ● Market Size and Value ● US Siding and Roofing Market

Formulating and Testing Elastomeric Coatings

ACR Product Overview and Alternatives to Competitive Products

Product Spotlight ● ENCOR® Flex 192 ● ENCOR® Flex 187 ● ENCOR® Flex 3186

Recap

What is an elastomeric coating?

5

Elastomeric coatings are highly flexible, liquid applied, waterproof membranes

Flexible even at low temperatures

Adhere to a variety of substrates

Dry film is waterproof

6

http://www.ashrae.org/publications/detail/16396

Elastomeric coatings differ from standard architectural paints

Elastomeric Coatings Formulation have: ● Higher binder levels (< 45PVC) ● Based on lower Tg binders ● Higher solids 60% versus 35% ● Higher viscosity 100-130 versus 90 KU

Elastomeric Coatings are applied at a much lower spread rate (50 ft2/gallon) ● 2 coats with a dry film thickness of

approximately 40 mils

Elastomeric Coatings Performance ● Elongation greater than 100% ● Tensile strength greater than 200 PSI ● Low water permeability (< 50PERMS)

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Liquid

Binder

Pigment

Liquid

Binder

Pigment

Typical architectural paint composition

Elastomeric coating composition

Uses for Elastomeric Coatings

Floor ● Applied to parking decks, driveways, walkways and

other concrete floors to provide waterproofing, slip resistance and high traffic bearing

Wall ● Applied to exterior masonry, concrete and stucco they

have the ability to bridge cracks, protect the substrate from wind driven rain and provide a decorative finish

Roof ● Applied to numerous roofing types to waterproof and

extend service life

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Elastomeric Coatings Market Opportunity

9

10

Opportunity for latex is split evenly between Wall and Roof Coatings

Wall, $500,063,700

Floor, $171,554,700

Roof, $545,081,600

Wall, 25,003,185

Floor, 5,718,490

Roof, 32,063,624

Wall, 110,264,046

Floor, 1,401,030

Roof, 125,689,404

Elastomeric Coatings Sales by Segment Elastomeric Coatings Volume by Segment

Latex Volume by Segment

US Elastomeric Coatings Market, Frost & Sullivan Research

The U.S. Siding Market

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U.S. Siding Market Summary

11.7 billion ft2, $12.1 billion market by 2015

Projected annual growth rate of 7.2 %

Market is split 76/24 between residential/nonresidential

Market is split 44/56 between renovation/new construction

World Siding (Cladding), Industry Study #2834, The Freedonia Group, 2011

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Product Types – Masonry & Concrete

Stucco & EIFS

Concrete & Stone Fiber Cement

Brick & Tile

13

Product Types – Others

Vinyl

Wood

Metal

14

15

Masonry and concrete is the largest segment

15

U.S. Siding Market, 2015P Total = 11.7 billion ft2

Residential = 8.9 billion ft2

Nonresidential = 2.8 billion ft2

Brick & Tile24%

Stucco & EIFS40%

Concrete & Stone12%

Fiber Cement24%Masonry & Concrete

46%

Metal7%

Vinyl36%

Wood10%

Other1%

World Siding (Cladding), Industry Study #2834, The Freedonia Group, 2011

3.9% AGR

6.7% AGR

3.3% AGR

9.1% AGR

10.8% AGR

11.6% AGR 7.5% AGR

6.5% AGR

The U.S. Roofing Market

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U.S. Roofing Market Summary

26.3 billion ft2, $24.4 billion market by 2015

Projected annual growth rate of 5.7%

Market is split 63/37 between residential/nonresidential

Market is split 77/23 between reroofing/new construction

Environmentally friendly and energy savings are key themes in both the residential and nonresidential market ● Cool roofing ● Waste reduction and recycled content ● Integrated Photovoltaic

Roofing, Industry Study #2814, The Freedonia Group, 2011

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Product Categories

ROOFING SYSTEMS

CATEGORY FLAT SLOPED

SHINGLES

METAL

TILE

MEMBRANE

GREEN/LIVING

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Product Types – Sloped Roofs

Asphalt shingles Wood shingles

Tile

Metal

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Product Types – Flat Roofs

Green/Living

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Product Types – Flat Roofs

Ethylene Propylene Diene Monomer (EPDM) Modified Bitumen (Mod Bit)

Spray Polyurethane Foam (SPF) Thermoplastic polyolefin (TPO) Polyvinyl Chloride (PVC)

Elastomeric membrane Bituminous

Plastic membrane

Hot Built-Up Roofing System (Felt and hot tar)

21

22

Residential is the larger segment in the U.S. Roofing Market

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Asphalt shinglesBituminous low-slopeMetalElastomeric membraneTilePlastic membraneWood shinglesOther

ResidentialNonresidential

63%

37%

Residential = 16.5 billion ft2

Nonresidential = 9.8 billion ft2

Sloped = 19.9 billion ft2

Flat = 6.4 billion ft2

U.S. Roofing Market, 2015P Total = 26.3 billion ft2

60%

13%

8%

7%

5%

5%

1%

1%

2015

83%

2%

2%

1%

8% 1%

2%

1%

24%

76%

23

Residential structures predominately employ asphalt shingles

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New = 4.0 billion ft2

Reroofing = 12.5 billion ft2



U.S. Residential Market, 2015P Total = 16.5 billion ft2

NewReroofing


18%

31%

19%

17%

1%

11%

0%

3%

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Nonresidential structures utilize a range of products

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New = 2.1 billion ft2

Reroofing = 7.7 billion ft2



U.S. Nonresidential Market, 2015P Total = 9.8 billion ft2

NewReroofing

21%

79%


TPO share is growing at the expense of other technologies in the low slope roofing market

25

Low slope roofing market, 2015P Total = 6.4 billion ft2

0%

20%

40%

60%

80%

100%

2000 2005 2010 2015 2020

Ma

rkets

ha

re

Bituminous

EPDM

Elastomeric Other

TPO

PVC

Plastic Other

SPF

All Other


3.35

1.630.22

0.68

0.37

0.05

0.04

0.08

Popularity of roofing types can be correlated to cost

26

Total Installed Cost ($/100ft2)


Plastic Membranes

Elastomeric Membranes

Elastomeric Coatings Market Summary

Existing opportunity for latex is split evenly between Wall and Roof Coatings ● >$1 billion worth of coatings consuming 225 million lbs of latex ● Wall coatings are applied over masonry and concrete substrates ● Roof coatings are almost exclusively applied to rehab, commercial low

slope roofs

Large potential market opportunity for elastomeric coatings ● 2.9 billion ft2 of masonry substrate for elastomeric wall ● 6.4 billion ft2 of low slope roofing

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Formulating and Testing

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Elastomeric coatings utilize a pallet of raw materials similar to architectural paints

Latexes are softer (lower Tg) than those employed in architectural coatings ● Tg (midpoint) range from -30 to -5oC ● Ideally Dirt pick up resistance is built into the binder

Pigments ● Titanium Dioxide utilized as prime hiding pigment at lower levels than seen with architectural

paints ● Extenders

– Multiple types employed, should be limited to low oil absorption and particle sizes above 10um – Calcium carbonates typically employed in roof coatings but should be avoided in deeper colored wall paints

due to “frosting” – Zinc oxide can help build tensile strength but can interfere with bonding chemistry when used on TPO

Dispersants ● Ammonium salts give the best balance of tensile strength and elongation.

Solvents ● Due to softer binders only low levels of coalescing solvent required ● Glycols utilized to extend open time and for freeze-thaw protection

Thickeners ● HEUR, HEC, HASE and ASE all employed ● Minimize the use of associative thickeners due to water sensitivity 29

Keep pigment volume concentration to a minimum(< 45%), higher PVC can lower adhesion and promote a tendency to form cracks

Historically elastomeric coatings were available only in light colors, deeper colors for wall coatings is the latest trend. This can be challenging for water resistance and color retention.

Field testing is always recommended to ensure adhesion

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For optimal performance follow formulating guidelines

What is ASTM?

ASTM is an abbreviation for American Society for Testing and Materials

Organization dedicated to the development and delivery of international voluntary consensus standards

Standards benchmark performance

ASTM performance standards are accepted by the elastomeric and waterproof coatings industry

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ASTM D6083 is the specification standard for elastomeric coatings

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Test Requirements ASTM test

method Elongation > 100% D2370 Tensile Strength > 200 psi D2370 Tear Strength > 60 lbf/in D624 Peel Adhesion > 2 pli C794 Permeance < 50 perms D1653 Water Swelling < 20% D471 Low Temperature Flex no cracking (pass/fail) D522 Fungi Resistance Rating of 0 G21

Accelerated Testing (1000 hours) Elongation > 100% D2370 Low Temperature Flex no cracking (pass/fail) D522

The standard is commonly referenced in elastomeric coating performance across the country.

Only approximately 25% of roof coatings meet ASTM D6083

ASTM D6083 is required only in certain areas most notably Miami-Dade county, FL

Elastomeric coatings do not have to conform to D6083

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Dade County

Tensile and Elongation Testing ASTM D2370

Draw down a coating for a thickness of 20-40 mil dry

Dry for 14 days at 70°F and 50% RH

Pull ½ inch wide sample on an Instron

34 Goal: Greater than 100% elongation and 200PSI minimum tensile strength

Tear Strength ASTM D624



Pull a stamped sample that initiates tearing on an Instron

35 Goal: Greater than 60 lbf/in

Low Temperature Flex ASTM D522

Subject a dry film on an aluminum panel to -26°C/-15°F

Bend the panel on a ½ mandrel and observe for cracking on the bend.

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Goal: No through crack or adhesion loss

Permeance Testing ASTM D1653



Cut a circular film, place over cup opening and seal edges with screw on cap

Record weight loss over a 10 day period

Water

Dry Film

Atmosphere

Testing Cup

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Goal: Less than 50 PERMS

H2O H2O

0

5

10

15

20

25

30

35

40

0 1 2 3 4 5 6 7 8 9 10

Time (days)

Wei

ght L

oss

Permeance Testing ASTM D1653

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weight loss time x area WVT =

Adhesion in Peel ASTM C794

Peel Adhesion Video

Goal: Minimum peel adhesion of 2 lbs per linear inch

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White Reflective Roofing

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Why Reflective Roofs?

90% of Roofs in the U.S. 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

Satellite Image

Visible

Infra red

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Cool roofing is a growing market segment

● Add R-value of roofs – EPA estimates up to R19 value

● Reduce building heat-gain – Increased Solar Reflectance – Increased Thermal Emissivity (heat shedding)

● 15-30% HVAC savings ● Increase HVAC and roof membrane longevity ● Resulting in lower greenhouse gas emissions

178°F

93°F

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HVAC represents a significant portion of total annual energy demand

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Roofing Gov. agencies and independent organizations for cool white roofing

ASHRAE standards ● American Society of Heating, Refrigerating and Air-

Conditioning Engineers

Title 24 ● CA’s ASHRAE

Homestar

LEED ● Leadership in Energy and Environmental Design ● CA all new 10K sq/ft building LEED silver

BEES ● Building for Environment and Economic Solutions

DSIREUSA.org ● Sponsored by NC State, keeps up with the ever changing

property tax incentives / rebates for new construction and remodeling state by state

*RRCI ● Reflective Roof Coatings Institute

RCI ● Roofing Consultants Institute

*CRRC ● Cool Roof Rating Council

ANSI ● American National Standards Institute

SPRI ● Single Ply Roofing Industry

IGCC ● International Green Construction code

CEIR ● Center for Environmental Innovation in Roofing ● Roofpoints.wikispaces.com

EPA Energy Star

Chicago Energy Efficient Rating System

*NRCA ● National Roofing Contractors Association

ICC-ES and ICBO ● Roofing Evaluation Service

*RCMA ● Roof Coating Manufacturer Association

* Denotes that ACR is a member of these organizations 44



ACR Product Overview and Competitive Offsets

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ACR offers a range of products to cover the entire spectrum of performance and cost

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Product Chemistry Total solids

Tg (oC) Features

ENCOR® 123 Styrene Acrylic 60 -17 High solids, high adhesion and film toughness. Can be formulated to meet ASTM D-6083

ENCOR® 9176 Styrene Acrylic 61 -21

High solids, ambient temperature crosslinking for excellent adhesion and film toughness. Can be formulated to meet ASTM D-6083

ENCOR® 3176A Styrene Acrylic 50 -7 Designed for cost effective elastomeric coatings

ENCOR® Flex 3186 Styrene Acrylic 50 -7 Designed for cost-effective roof and wall coatings with enhanced dirt pick up resistance

ENCOR® Flex 187 Acrylic 60 -18 High solids for roof and wall coatings with enhanced dirt pick up resistance. Can be formulated to meet ASTM D-6083

ENCOR® Flex 192 Styrene Acrylic 60 -21 High solids with high adhesion to aged TPO membranes. Can be formulated to meet ASTM D-6083

Latex Performance

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Latex

Elon

gatio

n

Tens

ile

Stre

ngth

Tear

St

reng

th

Low

Tem

p Fl

ex

Alu

min

um

Stee

l

Bitm

us R

oll

TPO

EPDM

Asp

halt

Dirt

Pick

up

Resis

tanc

e

ENCOR 123 ENCOR 9176 ENCOR 3176A ENCOR Flex 3186 ENCOR Flex 187 ENCOR Flex 192

ASTM Adhesion

Competitive products and suggested ACR alternatives

48

Competitive Product ACR Alternative The Dow Chemical Company

Rhoplex EC-1791 ENCOR® Flex 187

Lipacryl MB-3640 ENCOR® Flex 192

Rhoplex EC-2848 ENCOR® Flex 187, ENCOR® Flex 3186

Rhoplex 2438C (wall only) ENCOR® Flex 187, ENCOR® 3176A, ENCOR® 123

Rhoplex 2019RX ENCOR® Flex 3186, ENCOR® 3176A, ENCOR® 123

BASF

Acronal DS 6257 ENCOR® Flex 187

Acronal NS 567 ENCOR® Flex 3186

Acronal NS 562 ENCOR® 9176

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Product Spotlight

More detailed information available in product literature

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ENCOR® Flex 192 Elastomeric Latex for Adhesion to Weathered TPO Roofing Membranes

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ENCOR® Flex 192 delivers excellent adhesion to aged TPO

Value Proposition

Offers our customers the ability to formulate an elastomeric coating with excellent adhesion to aged TPO eliminating the need for a solvent borne primer

Product Overview

Typical end use ● Elastomeric roof coatings

Features ● Excellent dirt pickup resistance ● Excellent adhesion to aged TPO membranes ● Ambient cross-linking functionality for increased toughness ● High solids for greater formulating latitude ● Resistant to water ponding ● Meets ASTM D-6083

52

What is TPO?

Thermoplastic polyolefin (TPO) is a blend of polypropylene and ethylene-propylene rubber utilized as roofing membrane

Originated in Europe and started gaining U.S. market share in the mid-1990s

European TPO is considered high quality material and higher cost

U.S. TPO low cost and many concerns about durability

Low surface energy substrate making adhesion difficult

53

http://www.nmcexteriors.com/tpo-pvc-commercial-roofing-systems.asp/attachment/507001/

http://www.nmcexteriors.com/tpo-pvc-commercial-roofing-systems.asp/tpo_roofing/

Many installed TPO membranes are reaching the end of their service life

Hail damage

Crazing Seam splitting UV deterioration

Dirt pick up and mildew growth

54

Repairing is cheaper than replacing

55

New Membrane Elastomeric Coating

0

50

100

150

200

250To

tal C

ost (

$/10

0 ft

2 )InstallationRemoval/Surface PrepMaterial

0

0.5

1

1.5

2

2.5

3

ENCOR® Flex 192 Competitive

New TPOAged TPO

ENCOR® Flex 192 provides superior adhesion W

et P

eel (

pli)

ASTM minimum

56

Passes ASTM D6083 minimum wet peel adhesion requirement, over aged TPO, without requiring a solvent based primer

0

50

100

150

200

250


Elongation

Tensile

Tear

ASTM minimums

psi

% Elongation

% Elongation

psi

lbf/inch

lbf/inch

57

ENCOR® Flex 192 provides superior elastomeric properties

05

1015202530354045


Iron OxideCoal Ash

Iron Oxide Iron Oxide Coal Ash Coal Ash

Dirt added as a slurry and allowed to dry overnight

% W

hite

ness

Red

uctio

n

Photo of cleaned coating Photo of cleaned coating

58

ENCOR® Flex 192 provides superior DPR

ENCOR® Flex 187 All-Acrylic Latex for Elastomeric Coatings

59

ENCOR® Flex 187 delivers superior performance

Value Proposition

Offers our customers the ability to formulate a high performance elastomeric coating

Product Overview

Typical end use ● Elastomeric wall and roof coatings

Features ● Excellent dirt pickup resistance ● Passes Wind Driven Rain test ● Meets CRRC product rating requirements for reflectance and emittance at

VOC < 50g/L ● Meets ASTM D-6083

60

0

50

100

150

200

250

300


Elongation

Tensile

Tear

ASTM minimums

psi

% Elongation

% Elongation

psi

lbf/inch lbf/inch

61

ENCOR® Flex 187 provides excellent elastomeric properties

0

10

20

30

40

50

60


Iron Oxide

Dirt added as a slurry and allowed to dry overnight

% W

hite

ness

Red

uctio

n

62

ENCOR® Flex 187 provides superior DPR

ENCOR® Flex 187 has superior dirt pick up resistance

At two years exposure in Cary, NC

ENCOR®Flex 187

63

ENCOR®Flex 187

ENCOR®Flex 187

Competitive products

Coating failure - cracking

ENCOR® Flex 3186 Styrene-Acrylic Latex for Elastomeric Coatings

64

ENCOR® Flex 3186 delivers superior cost/ performance

Value Proposition

Offers our customers the ability to formulate an extremely cost effective elastomeric coating

Product Overview

Typical end use ● Elastomeric wall and roof coatings

Features ● Excellent elongation ● Excellent dirt pickup resistance ● Good water ponding resistance ● Outstanding adhesion to metal ● Meets CRRC product rating requirements for reflectance and emittance at

VOC < 50g/L

65

ENCOR® Flex 3186 has excellent elongation

ENCOR Flex 3186 has excellent elongation when compared to competition.

0

200

400

600

800

1000

30 40 50

3186Competitive

66

ZnO can be used to build Tensile Strength

ZnO can help build in tensile strength even at low levels and have the added benefit of a mildewcide.

0

50

100

150

200

250

300

0 5 10 15 20 25#/100 gallons of ZnO

Tens

ile (p

si)

67

ENCOR® Flex 3186 has excellent ZnO stability

ENCOR Flex 3186 exhibits very good heat age stability after 4 weeks with ZnO.

0

1

2

3

4

5

6

3186 Commercial

Del

ta K

U

68

ENCOR® Flex 3186 has excellent wet peel adhesion on Aluminum and Steel

0

1

2

3

4

5

6

3186 Commercial

AluminumSteel

Wet

Pee

l Adh

esio

n (p

li)

69

ENCOR® Flex 3186 delivers excellent DPR

70

ENCOR® Flex 3186 Competitive Acrylic

More detailed information available in product literature

71

Highlights of Today’s Webinar Summary

72

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Recap

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Today’s session was intended to provide you with a technical grounding in Elastomeric coatings formulation and product selection Latex use is evenly split between elastomeric roof and wall coatings

Wall coatings are applied over masonry and concrete substrates

Roof coatings are almost exclusively applied to rehab, commercial low slope roofs

ACR offers a broad range of chemistries to the elastomeric coatings market to meet a range of cost/performance requirements

ENCOR® Flex 192 has excellent adhesion to aged TPO eliminating the need for a solvent borne primer

ENCOR® Flex 187 has good dirt pick-up resistance, tensile-elongation and low temperature flex

ENCOR® Flex 3186 is extremely cost effective

74

Questions? Please contact the Account Team

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Mary Chervenak [email protected]

Marlene Hernandez [email protected]

Mark Piggott [email protected]

Commercial Questions

Latin America

Commercial Questions

USA & Canada

Technical Questions

2014 ACR Webinar Series

Friday July 18, 2014 @ 2:00pm ET 75

Next Month’s Topic: Exterior Insulating Finishing Systems

Speaker: Ron Grieb

Title: Application Development Leader - Americas

Arkema Coating Resins

Thank You for Joining Us!!

See you in July!!

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arkema coating resins welcome to the 2014 acr webinar series!! 5 elastomeric... · arkema coating...

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