�Developments in Fluoropolymer Resins For Marine & Offshore ... - PowerPoint by J7xG8T

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									“Life Cycle Cost Considerations in
Selecting Fluoropolymer Coatings”



                  Webinar for Durability
                  and Design Magazine
                     May 18th, 2012
FEVE Fluoropolymer Resins for High-Performance Coatings




            What is an FEVE Fluoropolymer???
       1) A hybrid fluoropolymer resin with the ability to be
        used in standard coatings formulations like any other
                       conventional coating resin
      2) A high performance resin that can withstand severe
           ultraviolet light exposure 2-3 times longer than
                     conventional coatings resins




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FEVE Fluoropolymer Resins for High-Performance Coatings

      Fluoroethylene Vinyl Ether (FEVE) Resins




     FLUORINATED SEGMENTS: Weatherability, chemical resistance
     VINYL ETHER SEGMENTS: Gloss, solubility, crosslinking



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FEVE Fluoropolymer Resins for High-Performance Coatings


        Advantages of FEVE Fluoropolymer Resins:
    •   Ambient Cure
         – Field application

    •   OH Functional   - Crosslinkable with isocyanates

    •   Solvent Soluble
         – Conventional application techniques (airless spray)
         – Wide range of gloss (90 @ 60º)

    •   Fluoropolymer Segments
         – UV Resistance
         – Corrosion resistance



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FEVE Fluoropolymer Resins for High-Performance Coatings


    Markets for FEVE resin-containing coatings:

     1) Architectural Coatings for commercial buildings
    2) Industrial Maintenance Coatings for water towers,
      bridges, and assorted metal and concrete structures
                   3) Aerospace coatings
           4) Applications in Marine environments




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FEVE Fluoropolymer Resins for High-Performance Coatings


                                     QUV Weatherometer Exposure Testing

                           110
                           100
     Gloss Retention (%)



                            90
                            80
                            70
                            60
                                                                                   FEVE Coating
                            50
                                                                                   Polysiloxane Coating
                            40
                                                                                   Acrylic Urethane Coating
                            30
                            20
                            10
                             0
                                 0      2000       4000    6000    8000    10000       12000        14000


                                               Hours of QUV Exposure (UVA-340 Bulbs)




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FEVE Fluoropolymer Resins for High-Performance Coatings


                                 QUV Weatherometer Exposure Testing

                               110
                               100
                                90
         Gloss Retention (%)


                                80
                                70
                                60
                                                                       FEVE Coating
                                50
                                                                       Polysiloxane Coating
                                40
                                                                       Acrylic Urethane Coating
                                30
                                20
                                10
                                 0
                                     0   1000       2000    3000     4000           5000          6000


                                                Hours of QUV Exposure (UVB-313 Bulbs)




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FEVE Fluoropolymer Resins for High-Performance Coatings

    Sunshine Weatherometer Exposure Testing (Carbon Arc)


                              110
                              100
        Gloss retention (%)




                               90
                               80
                               70
                               60
                                                                                 LF200 coating
                               50
                                                                                 PVDF coating
                               40
                                                                                 Acrylic Urethane coating
                               30
                               20
                               10
                                0
                                    0   500   1000   1500   2000   2500   3000        3500        4000      4500



                                                     SWOM Exposure (hours)




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FEVE Fluoropolymer Resins for High-Performance Coatings

    EMMAQUA Testing (Outside Test Fence – Arizona)
                            110

                            100

                             90
      Gloss retention (%)



                             80

                             70
                                                                           FEVE coating
                             60

                             50                                            PVDF coating

                             40                                            Acrylic Urethane coating
                             30

                             20

                             10

                              0
                                  0   400   800     1200    1600   2000       2400          2800      3200

                                                  Radiant Energy (Mj/m²)




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FEVE Fluoropolymer Resins for High-Performance Coatings


                                         South Florida Test Fence Exposure

                               110
                               100
                                90
         Gloss retention (%)


                                80
                                70
                                60
                                50
                                40
                                                                  FEVE Yellow Coating
                                30
                                20                                FEVE Clearcoat

                                10
                                 0
                                     0     1   2   3     4    5        6       7        8   9   10   11


                                                       Years of Exposure




9
 FEVE Fluoropolymer Resins for High-Performance Coatings


     Corrosion Resistance Test of FEVE Coatings:
     LOCATION: Suruga Bay Marine Test Station (offshore)
     LENGTH OF TEST: 16 years
     COATINGS SYSTEMS ON TEST:
       1) Zinc-rich primer / Epoxy Midcoat / Acrylic Urethane Topcoat
       2) Zinc-rich primer / Epoxy Midcoat / Fluorourethane Topcoat

     THICKNESS OF COATING:
       PRIMER = 3 mils / MIDCOAT = 6 mils / TOPCOAT = 1 mil(25 microns)




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 FEVE Fluoropolymer Resins for High-Performance Coatings



           Measurement of Total Erosion of the Topcoat


                           ACRYLIC URETHANE     FLUOROURETHANE
                               TOPCOAT              TOPCOAT

     INITIAL MEASUREMENT
             (microns)
                                  25                  25

     FINAL MEASUREMENT
           (microns)
                           0 (after 13 years)         21




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 FEVE Fluoropolymer Resins for High-Performance Coatings

                  Life Cycle Cost Advantages
     Initial Cost of FEVE-based Topcoat:
           5 -10% higher than standard polyurethane topcoat
     FEVE-based Topcoat Life Expectation:
           30 - 60 years
     Expected Repaints of Std. Polyurethane Topcoat
     in this Time Frame:
           2 to 3 (based on topcoat erosion data from offshore test)
     Additional Costs of Repaints:
           facility downtime




12
 FEVE Fluoropolymer Resins for High-Performance Coatings


                   Breakdown of Total Cost of Recoating a Bridge*

                                 3 Coat Epoxy, 2 Coat   3 Coat Epoxy, 2 Coat FEVE
                                 Polyurethane System        Urethane System

            Staging Costs            $38.96/ m²                $38.96/ m²

         Surface Preparation          $8.44 / m²               $8.44 / m²
         Labor Cost For Paint
             Application             $26.22 / m²              $26.22 / m²

        Total Cost of Coatings       $12.03 / m²               $15.96 /m²

        Total Repainting Cost        $85.65 / m²              $89.58 / m²


            * “Prices of Construction Materials and Wages” October 2006
             (Published in Japan)




13
 FEVE Fluoropolymer Resins for High-Performance Coatings



                Estimation of Total Applied Cost Per Year (Coating System)

                                                   Estimated Life of Coating Total Applied Cost per
       Coating System        Total Repainting Cost         System               year of Service
      Polyurethane Topcoat
             System               $85.65 / m²                 18                   $4.76 / m²
     FEVE Urethane Topcoat
            System                $89.58 / m²                 30                   $3.00 / m²
     FEVE Urethane Topcoat
            System                $89.58 / m²                 60                   $1.50 / m²
     FEVE Urethane Topcoat
            System         $94.21 / m² (estimated)            30                   $3.14 / m²
     FEVE Urethane Topcoat
            System         $94.21 / m² (estimated)            60                   $1.57 / m²




14
 FEVE Fluoropolymer Resins for High-Performance Coatings


                       Some things to consider:
      1) FEVE polyols can be blended with other polyols to formulate
                      coatings to specific life cycle targets.
        2) Lower percentages of FEVE polyols in the formulation will
           reduce raw material costs compared to 100% FEVE polyol
                                  formulations.
     3) Coatings formulated for longer life durability will hold their gloss
         and color better than conventional polyurethane topcoats. This
        may be an important factor when the appearance of the coating
                            needs to be superior 24/7.




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 FEVE Fluoropolymer Resins for High-Performance Coatings



     Shelby Street Bridge
      (Nashville, TN)

     --- coated in 2004

--- 3 coat system on steel
       1) zinc-rich primer
       2) epoxy midcoat
       3) fluororurethane topcoat




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 FEVE Fluoropolymer Resins for High-Performance Coatings




                                            Gateway Bridge
                                            (Nashville, TN)

                                      --- opened in 2004

                                      ---    Red Support Girder
                                            coated with FEVE-
                                            containing coating




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 FEVE Fluoropolymer Resins for High-Performance Coatings


         Akashi-Kaikyo Ohashi road & train bridge (1997)




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FEVE Fluoropolymer Resins for High-Performance Coatings


                  Mercedes-Benz Museum,
                  Stuttgart , Germany
                  Coated 2004-2005
                  VERNICRON® FP
FEVE Fluoropolymer Resins for High-Performance Coatings




                                                   Clinton
                                                  Presidential
                                                     Library
                                                 Little Rock,
                                                 Arkansas, USA
FEVE Fluoropolymer Resins for High-Performance Coatings




                                                      Birmingham
                                                    Airport Car Park
                                                     Birmingham,
                                                          U.K.
                                                       ALPOLIC®
 FEVE Fluoropolymer Resins for High-Performance Coatings



         Project Update: Katsushika Harp Bridge

        Construction Completed in 1986
           Shop coating begun 1982

        Three Coat System

        Concrete Bridge Piers
           Elastomeric Primer
           2 Fluorourethane Topcoats

        Steel Encasement for Earthquakes in 2007



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FEVE Fluoropolymer Resins for High-Performance Coatings




  New Steel Encasement: Original Concrete Foot
     Coated 2007              Coated 1987
 FEVE Fluoropolymer Resins for High-Performance Coatings



                         Conclusion:
        For 30 years, FEVE resins have been included in
               exterior coatings for multiple end uses.
     Their excellent weatherability and corrosion resistance
       make them attractive for inclusion in topcoats for steel
                        and concrete surfaces.
     In the long run they can reduce the cost of maintaining
          both a decorative and a protective finish on many
                         exterior substrates.



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 FEVE Fluoropolymer Resins for High-Performance Coatings




                   Acknowledgements:
                       Takasi Takayanagi
                          Sho Masuda
                          Isao Kimura
                       Takuma Yamamoto




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