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CREATING TOMORROW'S SOLUTIONS
VINNAPAS® SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES
Saulat Khan, Wacker Chemie India P.L, 13.11.2010
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 1
VINNAPAS®
Wacker Chemie AG
WACKER Group (2009)
OVER 90 YEARS OF SUCCESS
• Founded in 1914 by Dr. Alexander Wacker • Headquartered in Munich
• Sales: €3.72 billion
• EBITDA: €607 million
• R&D: €164 million
• Investments: €740 million
• Employees: 15,618
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 2
VINNAPAS®
AGENDA
• WACKER
• Why to Insulate and current situation of cold stores in India
• Insulating Materials
• Recommended thickness of Insulating Materials IS-661:2000
• VINNAPAS®, its working and advantages
• Insulation boards application
• Technical requirement, Role of VINNAPAS® and Required Tests
• Summary
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 3
VINNAPAS®
WHY TO INSULATE AND CURRENT SITUATION OF INSULATION IN COLD STORAGES IN INDIA
• Conserve energy and save money
• Increase profitability
• 90% of existing cold storages are using inappropriate insulationmaterial (as per NHB expert committee report 1.1.1)
• level of insulation are very low (as per NHB expert committee report 1.1.1)
• 13 bil$ of fruits and vegetable get wasted annually (as per ISHS)
NHB= National Horticulture Board
ISHS= International Society for Horticultural Science
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 4
VINNAPAS®
PU, MINERAL WOOL & PF BOARD AS INSULATING MATERIALS
PU Boards:
Insulation effect much better than with conventional EPS boards
Thermal conductivity 0,022W/mK
brittle material - low impact strength
low flammability but highly toxic gases in case of fire
Phenol Formaldehyde Boards:
Thermal conductivity 0,022 W/mK
Insulation effect much better than with conventional EPS boards
comparable to PU boards
brittle material – low impact strength
severe shrinkage – very sensitive against water!
Mineral Wool
Mineral wool has a extremely open structure,
high water vapor permeability
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 5
VINNAPAS®
RECOMMENDED THICKNESS OF INSULATION FOR WALLSIS-661:2000 (As reaffirmed in year March 2008)
5507510012515017532Bonded glasswool
5507510012515017548Bonded Slagwool
5507510012515017548Bonded Rockwool
5507510012515017518Expanded Polystyrene
30304560759011050Rigid Phenolic Foam
30304560759011036Rigid Polyurethane foam
>1610 to 162 to 10-4 to +2-15 to -4-20 to -15-30to -20
Insulation Thickness in mm,
Temperature Range in °C
Minimum
Density kg/ cu.
m
Name of Material
(For Different Storage Temperatures with Design Ambient Temperature of 40 Degree Celsius and 50 % Relative Humidity)
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 6
VINNAPAS®
FILM FORMATION PROCESS OF VINNAPAS®
Filmformation
Evaporation of water
Particle deformation
Coalescence of
particles
and
filmformation
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 7
VINNAPAS®
POLYMER FILMS OF A VINNAPAS® IN A CEMENT MORTAR MATRIX
Polymer films based on Vac/E VINNAPAS® within a cement mortar matrix and at the interface
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 8
VINNAPAS®
SEM PICTURES OF INSULATION BOARD – MORTAR INTERFACE
(1) (1)(2)
(3)(2) (3)
1= INSULATION BOARD
2= cement mortar
3= polymer film
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 9
VINNAPAS®
WITH VINNAPAS®, YOU SET THE STANDARD!FOUR STRONG PERFORMANCE FEATURES
1.Improved adhesion to all substrates (polystyrene boards, mineral wool, concrete, bricks, old renders/coatings…)
2.Increased flexibility and improved impact resistance
3.Excellent hydrophobicity
4.Durability and long-term performance
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 10
VINNAPAS®
RequirementsAdhesive
Base Coat / Embedding
MortarMineral Top Coat
dispersible polymer powder 2-4% 2- 4% 0.5-3.0%
VINNAPAS® DP
5044 N
5046 T
7037 T
5044 N
5046 T
7037 T
7031 H
8031 H
8034 H
LL 3030 H
5044 N
7031 H
8031 H
8034 H
LL 3030 H
VINNAPAS® GRADES FACILITATE COMPLIANCEWITH ETAG 004 GUIDELINES.
Formulation basics for cementitious thermal insulation adhesion components with requirements according to ETAG 004 guideline
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 11
VINNAPAS®
Fixing the insulation panels with a polymer modified cement mortarPictures: Lugato manual
INSTALLATION (FIXING OF THE INSULATION PANELS)
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 12
VINNAPAS®
Application of the base coat (polymer modified cement mortar) + glass fiber meshPictures: Lugato manual
INSTALLATION (APPLICATION OF THE BASE COAT AND FIBER MESH)
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 13
VINNAPAS®
TECHNICAL REQUIREMENTS FOR THE MORTARS (MOST IMPORTANT)
� Adhesive mortar: good adhesion (high tensile adhesion strength) on various substrates
� Base coat mortar: high impact resistance, high flexibility and good
adhesion on various substrate)
� Finishing coat mortar:low water absorption and high impact resistance, good adhesion to the base coat
The technical performance depends on dosage (amount) and type of polymer used in
combination with cement
Exposure of system under practical conditions: from - 40°C up to +70°C
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 14
VINNAPAS®
Substrate: insulation panel 1 Substrate: insulation panel 2
TENSILE ADHESION STRENGTH [N/MM²] OF ADHESIVE MORTARS WITH DIFFERENT AMOUNTS OF VINNAPAS® ON DIFFERENT TYPES OF INSULATION PANELS
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 15
VINNAPAS®
TENSILE ADHESION STRENGTH [N/MM²] OF BASE COAT MORTARS ON INSULATION BOARD) BY PULL-OFF TEST
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 16
VINNAPAS®
base coat mortar with 4% dispersible polymer powder
base coat mortar without dispersible polymer powder
HARD BODY IMPACT TEST FOR BASE COAT
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 17
VINNAPAS®
Test at 23°C Test at 23°C Test at 23°C Test at 0°C
IMPACT RESISTANCE [J] WITH 1 KG STEEL BALL OF A CEMENT BASED MORTAR DEPENDING ON THE VINNAPAS®
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 18
VINNAPAS®
Substrate
Base coat
Water
T e s t p ro c e d u re a c c o rd in g to G e rm a n s ta n d a rd D IN 5 2 7 1 6
Determination of the water absorption
DETERMINATION OF THE WATER ABSORPTION OF INSULATION SYSTEM BASE COATS AND TOP COATS
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 19
VINNAPAS®TENSILE ADHESION STRENGTH, FLEXURAL STRENGTH AND WATER ABSORPTION OF A CEMENT BASED FINISHING MORTAR
0,040,060,082,002,102,252,50Coefficient of water absorption [kg/m²h0,5; 24 h]
2,302,302,202,302,302,251,50Flexural strength [N/mm²] (storage 28 days sc)
0,580,520,340,570,490,380,22Tensile adhesion strength [N/mm²] on concrete slab (storage 28 days sc)
3213210Dispersible polymer powder dosage [%]
VC/E/VL
(Tg 0°C)
VAc/E
(Tg 12°C)
Polymer used:
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 20
VINNAPAS®
TECHNICAL REQUIREMENTS ACCORDING TO EOTAREGULATIONS (ETAG 004)
< 3 J / 3-10 J / > 10 J
Hard body impact resistance [J]; three classes
> 0,08 N/mm²Bond strength (tensile adhesive strength [N/mm²])
After hygrothermal wall test according to EOTA (ETAG 004), composite system on the test rig (6x2,5x2 m)
> 0,08 N/mm²Storage 28 d sc + 2 d in water + 7 d sc
> 0,03 N/mm²Storage 28 d sc + 2 d in water + 2 hours sc
> 0,08 N/mm²Storage 28 d sc (sc = 23°C/50% R.H.; d = days)
Bond strength adhesive on insulation board (tensile adhesive strength [N/mm²])
> 0,25 N/mm²Storage 28 d sc + 2 d in water + 7 d sc
> 0,08 N/mm²Storage 28 d sc + 2 d in water + 2 hours sc
> 0,25 N/mm²Storage 28 d sc (sc = 23°C/50% R.H.; d = days)
Bond strength adhesive on substrate (tensile adhesive strength [N/mm²])
Laboratory tests:
Requirements
EOTA (ETAG 004) requirements for EIFS - tests
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 21
VINNAPAS®ARTIFICIAL WEATHERING TESTING ACCORDING TO EOTATEST CONDITIONS (HYGROTHERMAL WALL TEST; TEST RIG 6X2,5X2 M)
Test conditions hygrothermal wall test for the whole EIFS:
Heat – rain cycles:
80 cycles 70°C (rise for 1 h, maintaining for 2 h at 70°C and 10-15% R.H.) + spraying 1 h water (temperature 15°C; 1 l/m² min) + leave for 2 h at normal conditions
Heat cold cycles:
5 cycles of 24 h 50°C (rise for 1 h, maintaining for 7 h at 50°C and 10% R.H.) + exposure to -20°C (fall for 2 h, maintaining -20°C for 14 h)
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 22
VINNAPAS®
with EIFS, west wall temperatureno EIFS, west wall temperatureoutdoor air temperature
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31-10
-8
-6
-4
-2
0
2
4
6
8
10
12
14
16
18
20
time/d
Tem
pera
ture
[d
egr.
C]
During coldest month
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 3118
20
22
24
26
28
30
32
time/d
During the hottest month
TEMPERATURE VARIATIONS INSIDE THE MODEL HOUSES WITH AND WITHOUT INSULATION DURING THE COLD AND THE HOT SEASON IN CHINA
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 23
VINNAPAS®
COMPOSITION OF VINNAPAS® MODIFIED DRY-MIX MORTARS FOR THE ADHESIVES, BASE COAT, TOP COAT
sand cement
Polymer binder = dispersible powder
Just add water
Additives
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 24
VINNAPAS®
- VINNAPAS® SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES
-The use of dispersible polymer powder in the cement based mortars on suitable insulation material in order to achieve the following features even under extreme conditions
- Good adhesion on substrate and polystyrene panels
- High deformability and flexibility
- High impact resistance
- low water absorption
SUMMARY
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 25
VINNAPAS®
THANK YOU
FOR YOUR
ATTENTION…..
VINNAPAS SAVES COST IN THERMAL INSULATION FOR COLD CHAINS/STORAGES Saulat Khan, Wacker Chemie India P.L, 13.11.10, Slide 26
VINNAPAS®
XPS and EPS AS INSULATING MATERIAL
1.8 --- 1< 1Moisture absorption (%)
Self extinguishB2 classFlammability
0.034 ---- 0.0300.028Thermal conductivity
(W/m.K)
48 --- 320.4 -- 0.6Water vapour permeability
(per inch)
72.58 --- 103.96300Compressive strength at
10 % deformation (kPa)
16 -- 2432Density(Kgs/m3)
Characteristic
(EPS)(XPS)Name of the sample