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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
4
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
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
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)
7
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
8
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
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
12
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
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
17
Product Categories
ROOFING SYSTEMS
CATEGORY FLAT SLOPED
SHINGLES
METAL
TILE
MEMBRANE
GREEN/LIVING
18
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
22
Roofing, Industry Study #2814, The Freedonia Group, 2011
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
23
Roofing, Industry Study #2814, The Freedonia Group, 2011
New = 4.0 billion ft2
Reroofing = 12.5 billion ft2
Sloped = 15.8 billion ft2
Flat = 0.7 billion ft2
U.S. Residential Market, 2015P Total = 16.5 billion ft2
NewReroofing
Asphalt shinglesBituminous low-slopeMetalElastomeric membraneTilePlastic membraneWood shinglesOther
18%
31%
19%
17%
1%
11%
0%
3%
24
Nonresidential structures utilize a range of products
24
Roofing, Industry Study #2814, The Freedonia Group, 2011
New = 2.1 billion ft2
Reroofing = 7.7 billion ft2
Sloped = 4.1 billion ft2
Flat = 5.7 billion ft2
U.S. Nonresidential Market, 2015P Total = 9.8 billion ft2
NewReroofing
21%
79%
Asphalt shinglesBituminous low-slopeMetalElastomeric membraneTilePlastic membraneWood shinglesOther
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
Roofing, Industry Study #2814, The Freedonia Group, 2011
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)
Roofing, Industry Study #2814, The Freedonia Group, 2011
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
27
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
30
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
31
ASTM D6083 is the specification standard for elastomeric coatings
32
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
33
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
Draw down a coating for a thickness of 20-40 mil dry
Dry for 14 days at 70°F and 50% RH
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.
36
Goal: No through crack or adhesion loss
Permeance Testing ASTM D1653
Draw down a coating for a thickness of 20-40 mil dry
Dry for 14 days at 70°F and 50% RH
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
37
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
38
weight loss time x area WVT =
Adhesion in Peel ASTM C794
Peel Adhesion Video
Goal: Minimum peel adhesion of 2 lbs per linear inch
39
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
41
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
42
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 offers a range of products to cover the entire spectrum of performance and cost
46
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
47
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
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
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
ENCOR® Flex 192 Competitive
Elongation
Tensile
Tear
ASTM minimums
psi
% Elongation
% Elongation
psi
lbf/inch
lbf/inch
57
ENCOR® Flex 192 provides superior elastomeric properties
05
1015202530354045
ENCOR® Flex 192 Competitive
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 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
ENCOR® Flex 187 Competitive
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
ENCOR® Flex 187 Competitive
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 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
73
Recap
73
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
74
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