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AMI European Single Ply Roofing Membranes

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AMI European Single Ply Roofing Membranes Powered By Docstoc
					                     Versatility of Polyolefins in
                 Waterproofing and Roofing Systems
                                   Stefan Ultsch – Dow Europe GmbH


•   Waterproofing applications
•   State-of-the-art in polyolefins
•   Additives and formulations
•   Production technologies
•   Proven formulations
•   Designing future waterproofing solutions




                                                                     Page 1
 Applications of flexible waterproofing membranes
                                                              Unballasted roofing




                                                    Geomembranes, water liners

Ballasted/Green roof
                        Tunneling
                                                                          Page 2
Polyolefin-based waterproofing in civil engineering
                      Adhered roofing   Ballasted or green roof

Mechanically fixed roofing

                                                                    Breathable
                                                                    pitched roof

Facade sealants
                                                                    Vapor barriers

Parapet sealants
                                                                    Bitumen
                                                                    compatibility and
                                                                    modification
Expansion joints




       Pool- and tankliners                            Subsoil waterproofing
                                                                               Page 3
Unmet needs and development drivers




           Design           Manufacturing         Installation        Service-Life

  – Simple            – Fast product change – Flexible          – Longevity
  – Multipurpose      – Low scrap, economics – Reliable welding – Energy saving
  – Material usage    – Existing lines       – Material usage
  – Fire resistance




                                                             Optimized economics




                                                                                     Page 4
Design options for waterproofing membranes


   Coextruded top layer, coating, laminated film...
                                                      Top layer




                                                              Glasfleece




                                                                  Scrim, fabric


                                                      Bottom layer compound

 Fleece backing, substrate for adhesion

                                                                                  Page 5
 The Dow Polymer Portfolio

                                                               PP
                                                                          Al(OH)3
                                                         RCP
                HDPE                   INSPIRE™                           Mg(OH)2
                            DOWLEX™                      ICP
                                                                          CaCO3
                LLDPE
                                                                              TiO2
                  LDPE
                                                                              AO
Modulus




                             ATTANE™
                  ULDPE                                                       …...
                                             PBE
                                                        VERSIFY™
                                POE
               ENGAGE™                     AMPLIFY™
               INFUSE™          OBC          -MAH
               NORDEL IP™      EPDM               -EA

          PE                                                        PP   PP
                                                                                   Page 6
 Dow Elastomers manufacturing sites




                  Plaquemine   Tarragona
                  ENGAGE™      AFFINITY™
Seadrift          NORDEL™      ENGAGE™     Thailand (2011)
VLDPE                          VERSIFY™    AFFINITY™
                                           ENGAGE™
   Freeport
   AFFINITY™
   AFFINITY GA™
   INFUSE™




                                                   Page 7
                              ™
                                        ethylene-based olefin block-copolymers




                                                                                    Interlinking soft blocks
                    Crystalline hard-blocks



      Advantages:           Flexibility (Modulus 2 to 4 MPa, Shore A = 55 to 70 º)
                            Temperature resistance (TM = 120 ºC)
                            Filler take up
                            Welding......


* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                              Page 8
 INFUSETM Block Copolymers: Heat resistance and Flexibility

                         DSC Melting Temperature [ºC]
              140


              120


              100             INFUSE™ Block Copolymers

                80


                60

                                                                                    Random Copolymers
                40


                20
                     1                                            10
                                                                            Flexural Modulus [MPa]      100



  • Heat resistance and flexibility in highly-filled formulations
  • Ideal polymer for flexible B+C-formulations

* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                             Page 9
                            ™           random ethylene copolymers




                                                                       Octene-, Butene- or Propylene side chains


   Advantages:            Flexibility (Modulus 2 to 100 MPa, Shore A = 55 to 90 º)
                          Cold temperature impact
                          High melt strength ....

  • NEW XLT-grades offer significantly improved temperature resistance
  • Flexibility and low temperature impact in highly-filled and easy-to-process compounds


* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                             Page 10
   DOWLEX ™                       octene-based linear low-density polyethylene




                                                                                    Octene-side chains



     Major Advantages:               Mechanical strength, tear strength
                                     Excellent chemical resistance


  • Stand-alone LLDPE in geomembranes with broadest approvals and listings
  • Component for PE-based membrane formulations

* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                        Page 11
                                  ™


     Plastomes and Elastomers
                                              propylene-based elastomers


                                                                                    isotactic polypropylene backbone



    ethylene blocks



    Advantages:            Flexibility (Modulus 2 to 120 MPa, Shore A = 70 to 90 º)
                           Outstanding welding...


   • Excellent blending with PP and PE: the linking polymer
   • Highly flexible, propylene-based TPOs
   • Specific grades for building and construction membranes

* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                                 Page 12
     INSPIRE ™
     Performance Polymers           flexible impact Polypropylene

                     functional additives
                                                                                    isotactic polypropylene backbone




    Advantages:             Flexible PP (Modulus 700 to 1000 MPa)
                            Heat resistance
                            Cold temperature impact



   • Excellent blending, alloying with VERSIFY™

* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                                 Page 13
     AMPLIFY,™ PRIMACOR ™                                        polymers with added functionalities


      ethylene acrylic acid                           ethylene ethyl acrylate        Maleic anhydride




      Tailored performance in combination with Dow olefins


      Compatibilizers to              fillers and additives
                                      scrims and fabrics
                                      coatings, metal, substrates…..


* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                  Page 14
    Tailored and tight tolerance of DOW polymers

           Differential molecular
          1.2
           weight distribution                                           Representative molecular structure
                                                                         Representative
                                                                         Molecular Build-up
          1.0                                                            DOW Elastomers

          0.8

          0.6

       0.4
                 no oligomers or low
                 molecular weight fraction
                       no low-molecular
          0.2
                       fraction

            2               3              4               5                  6            7   Log [Mw]


      •         INSITE™-catalyst technology                               •       Excellent and lasting heat welding
      •         State-of-the-art reactor technologies                     •       High degrees of filling
      •         No vis-break processes...                                 •       Easy processing and excellent properties

* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                                  Page 15
Flame retardants
 •   Halogen-free flame retardants
 •   Purity, particle size distribution, surface coating are decisive parameters

 •   Processing and degradation characteristics are critical
                   100


                                                                        Magnesium-hydroxide
                    Weight loss [%]


                    90
                                                                        Mg(OH)2
                    80


                    70
                                          Aluminum-trihydrate
                                          Al(OH)3
                    60
                                      0        100       200    300   Temperature [ºC]
                                                                       400          500   600




 Dow Elastomer formulations:
 • Low melt temperatures allow high production rates with Al(OH)3
 • Passing stringent norms (ENV 1187 t3) with very flexible membranes

                                                                                                Page 16
Stabilizers and longevity

 •                               Phenolics and hindered amines                                processing and longterm
 •                               Titanium dioxide (TiO2) and carbon black                     UV-stabilizers and colorants
 •                               Flame retardants and fillers                                 purity affects longevity

                                       ISO 4892-2 (0.5 W/m²) weatherometer testing
                                 120
 Retained break elongation [%]




                                 100

                                  80

                                  60
                                            EN 12956: no cracks...
                                                                                     Customer reference
                                  40
                                                                                     Reference with DOW
                                                                                     DOW standard TPO
                                  20
                                                                                     DOW TPO without flame retardant
                                   0
                                       0        2000          4000   6000     8000         Exposure time [h]
                                                                                           10000       12000           14000




                DOW olefins: high stabilizer additions without plate-out or impact on welding
                                                                                                                               Page 17
Reinforcements
 Scrims           Fabrics          Inserted knits    Fleeces          Combinations




 • Tailored to manufacturing process, application- and norm-requirements.
 • Mostly PETP- and glas-fibers. Occaionally PP-fibers.


 Dow formulations
 • high adhesion with standard fiber-coatings (no oligomers)
 • for all type of reinforcements



                                                                                     Page 18
Formulation component strategy

DOWLEX™
                       LLDPE                                                                                   PP

                          LDPE                                                                           RCP

  ATTANE™                  ULDPE                                                                         ICP
                                                                                                                    INSPIRE™
                                                                                         PBE
    ENGAGE™                    POE
                                                                                                            VERSIFY™
    INFUSE™                    OBC
    NORDEL™                  EPDM                                                   Roofing (ballasted and unballasted)
                                                                                    Geomembranes, water liners
                                                                                    Tunnel liners
                                                                                    ..... Expansion joints, flexibility

  PE- or PP-based formulations matching various applications

* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                                     Page 19
Multi-generation development


 • European standards
 • North American standards
 • Unmet needs

                                                    Generation 1: TPO systems

               Formulations for waterproofing and
                    membrane applications            Generation 2: highly fire
                                                    resistant, flexible systems


                                                     Generation 3: specialty
                                                      elastomer systems




                                                                           Page 20
Compounding

 Co-rotating,                       Counter-rotating,                       Reciprocating
 intermeshing                       non-intermeshing                        co-kneaders




 Dow Elastomers
 • Formulation and compounding know-how and for all type systems
 • Favorable process conditions and output rates up to 85 % filler levels
 • Masterbatch- and pre-compound formulation know-how




                                                                                            Page 21
Direct extrusion on co-rotating twin-screw extruders

  Polymer 1                                   Fillers
  Polymer 2                 individual
                                              Flame retardant
  Additive MB              gravimetric
                             feeders

                                                                                                  Gear pump
                                                                                                  Flat-slit die
                       M             M
                                                                                                  Calander




                melting              filler feed, homogenisation, dispersion     homogenisation




    Dow Elastomers:        •   Formulation component strategy
                           •   Formulation- and process-know-how
                           •   High throughput rates, low torque and die pressure
                           •   Mass temperatures below 200 ºC enable use of ATH flame retardant

Diagram: courtesy of Krauss Maffei Berstorff, Hanover Germany                                           Page 22
Single-screw and counter-rotating systems

 Counter-rotating, intermeshing twin-screws


                                • Usually PVC-lines run from dry-blend
                                • Low mixing performance, limited filler take-up
                                • TPO from pre-compound with temperature stable MgOH



  Single-screw extruders

                               • Standard for low-filled formulations: geomembranes, liners
                               • Usually run from base materials and additive
                                 masterbatches




 • Start formulations and process know-how


                                                                                       Page 23
Calendering

                                                     Extrusion of bottom layer
Extrusion through flat slit die                      Fleece backing
Banbury, stock blender....                           Lamination of signal layers....



Supply of homogenuous melt

                                            Formulation requirements:
                                              • melt strength
                                              • homogenuous banking
                                              • reinforcement wetting
                                              • adhesion to reinforcement
                                              • no calander sticking
         Supply of reinforcement              • dimensional stability after calandering



• Start formulations and process know-how
                                                                                       Page 24
   Start Formulations for PP-membranes
                                                            Roofing                          Geomembranes
                                                standard                    generation 2                    flexible
                                      unballasted          ballasted         unballasted      PP
                                      top bottom         top bottom         top     bottom           PE
  INSPIRE™             ic-PP           20     35          35       40        10        15     35
  VERSIFY™              PBE            75     65          65       60        60        55     65                50
  ENGAGE™               POE             5                                                            50
  INFUSE™               OBC                                                  30      30                         50
  ATTANE™             ULDPE                                                                          50


  Flame ret.      ATH or MgOH          60                                    90      60                         60
  Filler            CaCO3              10       35        30      30         10      20       20     20         10
  UV, color          TiO2               6        1         6       1          6       1                          6
  UV, color       Carbonblack         0.05       1       0.05      1        0.05      1        1      1        0.05
  Stabilizer     Phenolic, HALS         1       0.6       0.6     0.6         1      0.6      0.6    0.6         1
                                                                                                            [phr]

   Formulation database to adress:                    • manufacturing technology
                                                      • filler and reinforcement properties
                                                      • end use and norm requirements

* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow                                   Page 25
   Benchmarking

                                                  COMMERCIAL TPO¹                    ¹ technical datasheets          DOW
EN 13956                                 1        2     3      4²             5      ² ballasted roof          Start    Gen. 2
Tensile strength [N]
                   [MPa]                > 12     >12      > 13      >5       > 15                               17           12
Break elongation [%]                   > 15 ³   > 13 ³   > 19 ³   > 150     > 15 ³   ³ reinforced              >600       > 1000
Peel resistance of joint [N/50mm]      > 200    > 300    > 300              > 150                              >500        >500
Shear resistance of joint [N/50mm]     > 500    > 500    > 500                                                >1300       >1300
Tear resistance [N]                    > 250    > 300    > 320    > 150     > 300                              >500        >500
Foldability at low temperature [ºC]    < - 30   < - 30    < -30   < - 40    < -40                              < -40       < -40
Fire resistance                        broof t1 broof t1 broof t1                                             broof t1   broof t1/t3
Artificial ageing [h]                 > 5000 4 > 5000 4 > 5000 4 > 3000 4            4
                                                                                         minimum requirem.    >13000
Root resistance                                  FLL      FLL               pass                               pass        pass
ASTM D6878-03
Heat ageing 670 h at 116 ºC            pass     pass     pass               pass                               pass        pass
Brittleness point                      pass     pass      fail    pass                                         pass        pass


   DOW start:                 easy to process
                              passing EN and ASTM standards
                              excellent welding

   Generation 2:              excellent fire resistance (ENV 1187 t3) in combination with flexibility
                                                                                                                         Page 26
Flexibility study




                    Page 27
Generation 2: testing of ENV 1187 bROOFt3




                     A high margin pass



 • 130 phr (65 wt%) flame retardant
 • Flexibility modulus < 30 MPa
 • Tensile strength > 9 MPa, Break elongation > 1500 %

                                                         Page 28
Economic evaluation

 Costs scheme of a TPO roofing membrane
                     Scrap rate                                  Aspects for Optimization
                        3%
      Manufacturing                                    Polymer            Component stategy
          9%                                                              High filler loading
                                                       Flame retardant    Synergisms with fillers
Reinforcement
     13%
                                                       Fillers            Balance with polymer
                                          Polymer      Colorant           Use as co-stabilizer
                                            45%
                                                       Stabilizer         Top layers
   Stabilizer                 Costs/m2
      3%                                               Scrim              Mesh width
                                                       Manufacturing      Capacity usage
      Colorant
                                                                          Scrap rate
        10%
                                                                          Component stategy
                Filler
                                                                          Material usage
                 1%
           Flame retardant
                16%


 • Database to optimize performance and system costs
                                                                                            Page 29
Market Solutions & Application Versatility
DOW



  • The broadest product mix of polyethylenes, olefin elastomers and polypropylene
  • Unique polymers and process technology
  • Global presence

  • Formulation know-how for any waterproofing application and production process
  • Technical support from polymer to end-use
  • Development of future solutions in cooperation with technology leaders


       www.dowelastomers.com




                                                                                     Page 30
Appendix: Dow Tradename Products

          •   AFFINITY™ Polyolefin Plastomers
          •   AMPLIFY™ Functional Polymers
          •   ATTANE™ Ultra Low Density Polyethylene Resins
          •   DOWLEX™ Linear Low Density Polyethylene Resins
          •   ELITE™ Enhanced Polyethylene Resins
          •   ENGAGE™ Polyolefin Elastomers
          •   INFUSE™ Olefin Block Copolymers
          •   INSPIRE™ Performance Polymers
          •   NORDEL™ IP Hydrocarbon Rubber
          •   VERSIFY™ Plastomers and Elastomers




* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow   Page 31

				
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