Fire Retardant Resins for Mass Transit and Building

Transcription

1 1 Fire Retardant Resins for Mass Transit and Building II International conference «Composites without borders» October 14-16, 2014 Open Innovation Expo, Technopolis Moscow 2014, Ashland Dr Tim Pepper Registered trademark, Ashland or its subsidiaries, registered in various countries Trademark, Ashland or its subsidiaries, registered in various countries With good chemistry great things happen.

2 Why a flame retardant industry? 2 The flame retardant industry is the result of National and International Fire Protection Regulations and tests Procedures which have been implemented during the last 50 years. Regulations cover 4 main industries: Building Rolling stock Aircraft Cruise boats

3 FRP in Architectural Applications 3 Barriers to FRP use Building and construction industry heavily dependent on building codes, most codes do not address use of composite materials. More difficult for engineers and architects to specify, can complicate design and approval process

4 Some National fire safety regulations for rail vehicles 4 Europe NFF : France BS 6853 : UK DIN 5510 : Germany UNI CEI : Italy Russia GOST UIC 564.2

5 Fire safety codes worldwide for building 5 US ASTM E 84 : Tunnel test ASTM E 162 : Radiant panel test ASTM E 662 : Smoke density Europe NFP : France BS 476 : UK DIN 4102 : Germany UNI CEI : Italy International UL 94 : Vertical flame test LOI : Limit Oxygen index test

6 European fire safety regulations 6 EN Fire Classification of construction products and building elements This first version of this Fire Classification has been implemented in EN Fire protection on Railway vehicles The European standard was given the status of National standard in 2013, and conflicting with national standards will be withdrawn at latest by march 2016.

7 FRP in Architectural Applications 7 Barriers can be overcome Case histories being used to help satisfy clients and authorities that composites are suitable

8 EN Material requirement sets 8 R1 : Surface products (wall, ceiling) Apparatus Parameter and Unit Requirements HL1 HL2 HL3 radiant panel CFE kw/m2 Minimum cone calorimeter MARHE kw/m2 Maximum smoke chamber Ds(4) dimensionless Maximum smoke chamber VOF4 Minutes Maximum smoke chamber CITg dimensionless Maximum 1,2 0,9 0,75

9 EN Classes of reaction to fire performance for construction products 9 (excluding flooring and linear pipe products) Apparatus Parameter and Unit Requirements A1 A2 B C D E Bomb calorimeter PCS - MJ/kg Maximum 2,0 3,0 Non combustibility furnace DT - C Maximum Dm - % Maximum tf - s Maximum 0 20 Single burning item FIGRA - W/s Maximum THR600s - MJ Maximum 7,5 15 Small burner Fs - mm Maximum Apparatus Parameter and Unit Requirements s1 s2 s3 Single burning item SMOGRA - m2/s2 Maximum not s1 or s2 TSP 600s - m2 Maximum not s1 or s2 Apparatus Parameter and Unit Requirements d0 d1 d2 Single burning item No flaming droplets - s Maximum 0 10 not d0 or d1

10 FRP in Architectural Applications 10 FRP provides unique properties Aesthetic appeal Excellent mechanical, physical and thermal properties Can be molded into complex shapes Excellent corrosion, flame, and weathering resistance Resistant to rot and insect attack Easy to assemble and install Lightweight

11 FRP in Architectural Applications 11 Wood, steel, aluminum, concrete used most often due to years of experience Wood - rots, not resistant to insects, moisture and fire Steel - very heavy, hard to form, rusts Aluminum - more costly, less strength and stiffness Concrete - heavy, requires reinforcement, sensitive to moisture and salt degradation

12 FRP in Architectural Applications 12 Architectural applications Building panels Columns Domes Facades Fascia panels HVAC ducting Doors, window frames Bridge structures and enclosures Polymer concrete

13 FRP Benefits in Architectural Applications 13 Architectural applications Lightweight & Versatile Cost Effective Corrosion Resistant Excellent Weathering Maintenance Free Before After

14 Architectural FRP Restorations 14

15 Commercial Building Exterior Applications 15

16 Columns, Facades & Cornices 16

17 Custom Shapes 17

18 Interior Applications 18

19 Industrial Building Structures 19 Structural Beams Doors Ducting Cable Tray Grating & Platforms Roofing & Siding Translucent or Opaque

20 FRP Panel 20

21 Day-Lighting Panels 21

22 Ducting 22

23 Cable Tray 23

24 Grating, Stairs & Handrails 24

25 Composite Bridges 25

26 A solution for builders, by builders 26 A clean, engineered solution for the replacement of concrete walls that combines strenght, integrated stud cavities for mechanicals, insulation top plate and damp proofing in a single step.

27 Current Cast in Place Concrete Foundation Technology 27 Extensive use of forms, rebar and concrete Labor Intensive and time consuming to set up and tear down (7-10 days) Guaranteed to crack and leak humid damp living environment High carbon footprint. Poor energy conservation.

28 Value Proposition 28 Builders deliver a higher value, more energy efficient home, faster Integrated studs ready to finish R 16.5 (3-4X R-Value of concrete) Installed in 90 min rather than 7-10 days Uses builder s own crew rather than another subcontractor Home buyers receive a warmer, drier, more energy efficient, ready-to-finish basement Cost competitive to poured concrete

29 Key Builder Benefits 29 Fast construction time with multiple benefits - House enclosed from weather faster - Builder gets money faster on each home - More homes per season with same crew Simple installation on site - High quality construction in controlled fabrication shop ready to use - Few connection points designed with the builder in mind - Fewer steps, no subcontractors. More predictable construction timeline. Less potential for delays Builder can use same crew for all facets of home construction Extended construction season - installation in cold climates

30 Key Homeowner Benefits 30 Energy savings / green - Estimated 15% reduction in energy costs - Smaller carbon footprint compared to concrete High quality living space - Warm, dry, comfortable living space w/o added expense of finished basement Larger interior floor plan - free 10 x 10 room No maintenance Greatly improved flexibility to modify / finish basement space

31 Why Use FRP Composites in Mass Transit Applications 31 Light Weight High Strength to Weight Ratio Low Maintenance Excellent Thermal Insulation Properties

32 Where Can FRP be Used in Mass Transit Applications? 32 Interior/Exterior Panels Doors Interior Components Roofs/Floors Seating Sleeper Compartments

33 Where Can FRP be Used in Mass Transit Applications? 33 Lavatory Compartments Third Rail Covers Maintenance Gratings Cable Trays Consoles

34 FRP Applications 34 Panels for Railway Rolling Stock FR Railway Seat Shell

35 FRP Applications 35 FRP Seats and wall panels

36 FRP Applications 36 Engineers Console

37 FRP Applications 37 Cable Trays for the Channel Tunnel

38 FRP Applications 38 Lavatories

39 Ashland s Value to FRP Fabricators 39 Largest global supplier of Fire Resistant Resins >50 years of successful applications experience Unmatched product portfolio FR solutions tailored to application needs - Fabrication processes - FR requirements (Low flame spread low smoke) - Mechanical performance targets Secondary selling into focus market segments Strong ongoing commitment to technology development and customer support

40 Ashland FR non filled resins 40 Aropol F 207 TPB Lloyds for survival craft material Class A-UTAC, Aropol F 195 LN Sweden: NT Fire 006 B2 DIN 4102, BS 476: Class 2, NF16101: M3 Hetron F 830 TE 95/28/CEE, BS 476: Class 2, NF16101: M2

41 Ashland FR filled resins 41 Hetron F 805 TF M1F2 / S4SR2ST2 / Class 1/ Bs3d0 / V-0 / Class A / GOST Hetron F 240 TF Hetron F 250 TF M2F2 / S4SR1ST2 / Class1 / Cs3d0 / V-0 / Class A M2F2

42 Ashland gelcoat line card 42 Enguard AE Maxguard FR M1 F3 with Hetron F 804 TF M2F2 Class 2 with Hetron F 240 TF / M2F1 S4 SR2 ST2 with Hetron F 640 TF

43 Case histories 43 Aropol F 195 LN

44 Case histories 44 Aropol F 207 TPB

45 Case histories 45 Hetron F 240 TF

46 Case histories 46 Hetron F 660 TFE

47 EHS impact on raw materials usage 47 Common Fire Retardant raw materials today; Decabromo phenylether: defined as a substance of very high concern (SVHC) Antimony trioxide: - classified in the EU with risk phrase R40 (DPD) - limited evidence of a carcinogenic effect - classified in the EU as a category 2 carcinogen (CLP CARC 2) - suspected of causing cancer

48 Ashland new generation resins 48 To meet the more demanding standards and to minimize the impact to human health and the environment. Ashland offers right now a new product range of flame retardant UP resins which complies with the highest standards: HETRON F 235 HETRON F 640 TF HETRON F 645 TF HETRON F 660 TF

49 Ashland new generation resins 49 Hetron F 640 TF HETRON F 640 TF filled resin is a performing new generation resin which meets: B s2 d0 according EN HL2 according EN HETRON F 640 TF key features: Low viscosity Easy processing Recommended for hand lay up, spray up and RTM

50 Ashland new generation resins 50 Hetron F 235 HETRON F 235 unfilled resin is a new halogen free and antimony free UP which can meet the highest standards when filled with Aluminium hydrate. Its very low viscosity allows it to be loaded with ATH from 50phr to 200phr. HETRON F 235 resin is recommended for RTM, infusion, pultrusion.

51 Ashland next generation resins 51 Our Targets: Designed for lower impact to human health and the environment (halogen-free, antimony free, very low styrene content) Meeting the highest standards (ASTM E84, EN 45545, EN 13501) Outstanding processability (pultrusion, RTM, spray and hand lay-up) Versatility and easyness of use (filled and unfilled versions)

52 Ashland next generation resins 52 What we design: New patented technology Highly improved processability with vast majority of ATH grinds 1500 Standard FR polyester resin Viscosity cp 20rpm Ashland new generation resin 0 ATH # 1 ATH # 2 ATH # 3 ATH # 4 ATH # 5 ATH # 6

53 Ashland next generation resins 53 What we design: Upon customer needs, our new generation resins will be delivered unfilled prefilled with ATH (100phr) End user can still add up to 200phr of ATH Applications: Pultrusion RTM Spray Hand lay-up

54 Ashland next generation resins 54 What we design: Into details: Low viscosity resins ( cps) Very low styrene content (15%) Halogen free, antimony free High mechanical properties: HDT>90 C, high elongation >2.5% Outstanding storage stability compared to standard filled polyester resins: No significant fillers settlement after 4 months

55 Ashland next generation resins 55 What we design: Fire certifications targets: ASTM E162 Class 1 ASTM E662 Class 1 EN HL3 EN Bs1d0

56 56 For more information, please contact our sales/technical representatives Registered trademark, Ashland or its subsidiaries, registered in various countries Trademark, Ashland or its subsidiaries, registered in various countries

57 With good chemistry great things happen.