Welcome to the 2014 ACR Webinar Series!!

Transcription

1 Arkema Coating Resins Welcome to the 2014 ACR Webinar Series!! Invest one hour with us and we ll help you grow your business with products and technology from Arkema Coating Resins April 25, 2014

2 2014 ACR Webinar Series Today s Topic: Caulks and Sealants: Test methods, Product Classes, Competitive products and ACR Technology Speaker: Rick Miner Title: Senior Technical Account Coordinator

3 Our training goal Give you the knowledge necessary to answer your customer s questions concerning caulks 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 Understand the cost structure of caulk formulations 3

4 Today s Agenda What is a caulk? ASTM Testing Methodology The economics of a tube of caulk Arkema Coating Resins Product Overview and competitive offsets Product Spotlight ENCOR 182, Vinyl Acetate-Ethylene Latex for Pigmented Caulks ENCOR 9192, All-Acrylic Latex for True Clear Sealant Applications ENCOR 9176, For Ambient Crosslinking Sealants Recap 4

5 What is a caulk? 5

6 Caulks are viscous materials which span gaps and fill voids High solids; low shrinkage formulations Low surface tack but flexible even at low temperatures Adhesion to a variety of substrates hydrophobic or resistant to water when dry 6

7 Caulks are comprised of various ingredients Latex binder Pigments Plasticizers Thickeners Additives 7

8 The binder is a key component of a caulk Binder holds pigment together Binder provides mechanical properties and adhesion Binder s performance is dictated by recipe choices Monomer and surfactant type and level Type and level of adhesion promoters or other functional materials Process conditions such as reaction temperature and monomer addition policy EXAMPLES 8

9 Polymer properties can impact performance Composition durability water resistance self thickening functionality Glass Transition Temperature (T g ) hardness dirt pick up resistance Tensile/Elongation Minimum Filming Temperature (MFT) softness film forming ability co-solvent/plasticizer demand Molecular weight Exterior Durability Toughness 9

10 Latex properties can also impact performance Particle size /Distribution/Morphology Thickener efficiency Rheology Freeze/thaw stability Binding efficiency Adhesion Surfactant package Stability 10

11 Pigments function primarily as filler Calcium Carbonate is the primary pigment used as a filler Will impart hardness, tensile strength and elongation properties 5 um or larger is typical Titanium dioxide provides whiteness Used at much lower levels than architectural paints Fumed silica imparts shear thinning rheology to the caulk EXAMPLES 11

12 Plasticizers enhance the flexibility of the caulk Lowers the T g of the polymer aiding flexibility of the caulk Need to ensure that plasticizer selection is compatible with latex binder to achieve desired properties Plasticizer can also improve the skrinkage of a caulk during drying Many caulk manufacturers are moving towards nonphthalate plasticizers for environmental reasons EXAMPLES 12

13 Thickeners impart the proper flow characteristics Consist of water soluble polymer, alkali swellable latexes, and fumed silica that impart suspension and stability Type and level impact extrusion rate and slump resistance EXAMPLES 13

14 Additives enhance key properties Glycols impart freeze/thaw resistance and increase open time Dispersants and surfactants provide stabilization to the pigment particles and long term caulk viscosity stability Silanes at low levels provide enhanced wet adhesion to glass Defoamers reduce the surface tension of the formulation to minimize foaming of the caulk Preservatives and mildewcides provide protection to bacteria and mildew growth EXAMPLES 14

15 Pigment to binder ratio is a critical formulation parameter Pigment to Binder Ratio (P/B) : P/B = Total P/B = Mass of Pigment (dry lbs) Mass of binder (dry lbs) Mass of Pigment (dry lbs) Mass of binder + plasticizer (dry lbs) % Plasticizer % Plasticizer = Mass of Plasticizer (dry lbs) Mass of binder (dry lbs) 15

16 Increasing the P/B ratio in a caulk will: Increase volume solids Increase tensile strength Reduce dirt pick-up Increase surface hardness Aid paintability Reduce Shrinkage Lower elongation Reduce crack resistance Lower cost Reduce adhesion Reduce tack Lower gunnability 16

17 Caulk Classification 17

18 Caulks can be classified by appearance Clear or True Clear - can see through; appears like glass Translucent can see through but has a haze Pigmented opaque; cannot see through 18

19 These categories must be formulated differently Caulk Type Clear Translucent Pigmented Binder Solids, wt% to to 22 Binder Tg, o C -10 to to to 0 Pigment/Binder ratio to to 5.0 Solids Content, wt% to to 85 Solids Content, vol% to to 75 Density, lbs/gal 8.7 to to to

20 Anatomy of a caulk Clear (P/B=0:1) Pigmented (P/B=5:1) Additives Pigment Plasticizer Binder Water 20

21 Quality Levels Non-spec ASTM classifies caulks and sealants based on performance Products used to seal or repair cracks in interior millwork ASTM C 834 Typically marketed with a 15 to 40 year warranty Middle of the road caulk (good performance) ASTM C 834 testing Specification includes testing typically conducted for non-spec caulk plus: - Artificial weathering - Low temperature flex - Extension recovery 21 ASTM C 920 Typically marketed with a 40-year to lifetime warranty ASTM C 920 testing Specification includes testing conducted for C 834 plus: - Hardness - Cyclic movement - Adhesion/peel - Accelerated weathering

22 Higher performing caulks have lower P/B ASTM C-920 Ingredients Class 25 Class 12.5 ASTM C834 Plasticizer Propylene Glycol Hydroxyethyl cellulose thickener Nonionic Surfactant Dispersant Preservative % solids water Calcium carbonate, 6 micron Titanium dioxide Organofunctional silane Ammonium hydroxide, 28% Rheotech Mineral spirits Caulk Properties P/B Total P/B % Plasticizer

23 ASTM Specifications and Methodology 23

24 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 caulk and sealant industry 24

25 Non-Spec Caulk 15 year or less warranty Pigment to binder ratio of > 4:1 Tested for the basic properties viscosity, ph, slump (< 0.20 ) and extrudability (> 2 grams/sec) 25

26 ASTM C834 Sealant 15 to 40 year warranty Good quality sealant typically used for interior applications Pigment to binder ratio typically between 2:1 and 4:1 Testing more demanding than for non-spec viscosity, ph, slump (< 0.20 ) and extrudability (> 2 grams/sec) artificial weathering, low temperature flex and extension recovery 26

27 Summary of ASTM C834 Tests C-731 Extrudability after package aging (20 days) C-732 Aging effects artificial weathering (28 days) C-733 Volume Shrinkage (29 days) C-734 Low Temperature Flexibility (25 days) Grades NF, 0 C, and -17 C C-736 Extension Recovery (16 days) D-2202 Slump Of Sealants (1 day) D-2203 Staining of Sealants (4 days) D-2377 Tack Free Time (4 days) 27

28 ASTM C834 Performance Requirements Test Requirements ASTM Test Method Extrudability 2 g/s, minimum C1183 Artificial Weathering 500 h C732 Wash-out none, after weathering Slump none, after weathering Cracking none, after weathering Discoloration as acceptable to purchaser Adhesion loss 25% maximum Volume Shrinkage Type OP Type C Low-temperature flexibility Grades -18 C and 0 C Grade NF 30% maximum 50% maximum no cracking through to substrate or adhesion loss none C1241 C734 Recovery Adhesion loss 75% minimum recovery, 25% maximum adhesion loss C736 Slump 4 mm maximum D2202 Stain index 3 maximum D2203 Tack-free time no material adhering to plastic strip D2377 Color as acceptable to purchaser

29 ASTM C920 Sealant High performance caulk 40 year to a lifetime warranty Pigment to binder ratio < 2:1 Testing even more demanding than for ASTM C834 viscosity, ph, slump (< 0.20 ) and extrudability (> 2 grams/sec) artificial weathering, low temperature flex and extension recovery cyclic movement, wet peel adhesion and accelerated weathering 29

30 ASTM C920 Tests C-510 Staining and Color change. (16 days) C-603 Extrusion Rate (can use c-731) (1 day) C-661 Indentation Hardness (21 days) C-679 Tack free time (up to 21 days) C-719 Adhesion & Cohesion under cyclic movement (approximately 55 days): Class 25 and Class 12.5 C-792 Heat Aging (weight loss, cracking, & chalking) (29 days) C-793 Low temp flex ( -26 degrees C) (16 days) C-794 Adhesion in Peel (30 days) 30

31 ASTM C920 Performance Requirements Test Requirements ASTM Test Method Rheological Flow Properties 4.8 mm maximum C639 Extrusion Rate 10 ml/min minimum C1183 proc. A Hardness 60 maximum C661 Adhesion and Cohesion Under Cyclic Movement Glass, aluminum, mortar Adhesion in Peel Glass, aluminum, mortar 9 cm 2 maximum adhesion loss for each substrate 5 pli minimum average, 25% maximum adhesive failure C719 C794 Effects of Accelerated Weathering -26 C after 250 h weatherometer C793 no cracking greater than pictorial control Effects of Heat Aging 7% maximum weight loss C1246 Stain and Color Change no visible stain C510 Color as acceptable to purchaser

32 32 Sealant Specs are typically printed on tube

33 33 Artificial Weathering ASTM C732

34 34 ASTM C719 Cyclic Tester

35 35 ASTM C719 Cyclic Tester Chamber

36 Slump Resistance ASTM D2202 Slump Video 36

37 Effects of Accelerated Weathering ASTM C793 Passing LTF Video Failing LTF Video 37

38 Adhesion in Peel ASTM C794 Peel Adhesion Video 38

39 Burrell Extrusion Rate Test Extrusion Video 39

40 The economics of a tube of caulk 40

41 Pricing varies dramatically across grades 41 ASTM C-920 Clear Ingredients Quantity Price Cost Plasticizer 33.1 $1.25 $41.38 Propylene Glycol 37.6 $0.65 $24.44 Hydroxyethyl cellulose thickener $3.00 $0.00 Nonionic Surfactant 5.1 $1.50 $7.65 Dispersant 0.0 $1.00 $0.00 Preservative 1.1 $4.00 $ % solids $1.75 $1, water 0.0 $0.00 $0.00 Calcium carbonate, 6 micron 0.0 $0.10 $0.00 Titanium dioxide 0.0 $1.50 $0.00 Organofunctional silane 1.8 $6.00 $10.80 Ammonium hydroxide, 28% 1.5 $0.25 $0.38 Thickener 9.4 $1.00 $9.40 Mineral spirits 21.5 $1.00 $21.50 Raw Materials $1, Unit RMC ($/10 oz tube) $1.16 Packaging $0.18 TOTAL ($/10 oz tube) $1.34 Selling Price ($/10 oz tube) $8.00 ASTM C-834 Ingredients Quantity Price Cost Plasticizer 92.6 $1.25 $ Propylene Glycol 13.0 $0.65 $8.45 Hydroxyethyl cellulose thickener 2.0 $3.00 $6.00 Nonionic Surfactant 13.0 $1.50 $19.50 Dispersant 3.0 $1.00 $3.00 Preservative 1.3 $4.00 $ % solids $1.50 $ water 45.6 $0.00 $0.00 Calcium carbonate, 6 micron $0.10 $92.59 Titanium dioxide 0.0 $1.50 $0.00 Organofunctional silane 1.5 $6.00 $9.00 Ammonium hydroxide, 28% 1.0 $0.25 $0.25 Thickener 10.0 $1.00 $10.00 Mineral spirits 15.0 $1.00 $15.00 Raw Materials $ Unit RMC ($/10 oz tube) $0.58 Packaging $0.18 TOTAL ($/10 oz tube) $0.76 Selling Price ($/10 oz tube) $1.59 ASTM C-920 Class 25 Pigmented Ingredients Quantity Price Cost Plasticizer $1.25 $ Propylene Glycol 10.5 $0.65 $6.83 Hydroxyethyl cellulose thickener 2.0 $3.00 $6.00 Nonionic Surfactant 3.9 $1.50 $5.85 Dispersant 1.5 $1.00 $1.50 Preservative 2.0 $4.00 $ % solids $1.75 $ water 17.7 $0.00 $0.00 Calcium carbonate, 6 micron $0.10 $45.36 Titanium dioxide 7.5 $1.50 $11.25 Organofunctional silane 1.2 $6.00 $7.20 Ammonium hydroxide, 28% 2.4 $0.25 $0.60 Thickener 10.0 $1.00 $10.00 Mineral spirits 15.0 $1.00 $15.00 Raw Materials $1, Unit RMC ($/10 oz tube) $0.91 Packaging $0.18 TOTAL ($/10 oz tube) $1.09 Selling Price ($/10 oz tube) $4.33 Non-spec Ingredients Quantity Price Cost Plasticizer 78.1 $1.25 $97.63 Propylene Glycol 12.4 $0.65 $8.06 Hydroxyethyl cellulose thickener 1.9 $3.00 $5.70 Nonionic Surfactant 11.2 $1.50 $16.80 Dispersant 2.8 $1.00 $2.80 Preservative 1.2 $4.00 $ % solids $0.75 $ water $0.00 $0.00 Calcium carbonate, 6 micron $0.10 $86.28 Titanium dioxide 5.3 $1.50 $7.95 Organofunctional silane 1.0 $6.00 $6.00 Ammonium hydroxide, 28% 1.5 $0.25 $0.38 Thickener 9.3 $1.00 $9.30 Mineral spirits 9.6 $1.00 $9.60 Raw Materials $ Unit RMC ($/10 oz tube) $0.37 Packaging $0.18 TOTAL ($/10 oz tube) $0.55 Selling Price ($/10 oz tube) $1.45

42 C920 caulks deliver disproportionate value Volume Revenue Non-spec 40% C920 Clear 10% C920 Pigmented 20% Non-spec 21% C920 Clear 29% C834 18% C834 30% C920 Pigmented 32% 42

43 Product Overview 43

44 ACR is the market leader to this segment with our Tool Box of Polymers Broadest technology platform NEOCAR Acrylic polymers Acrylic polymers Styrene acrylic polymers NEOCAR polymers Vinyl acrylic polymers Vinyl acetate ethylene polymers Styrene-butadiene polymers 44

45 Diverse product range to provide options to our customers Waterborne Chemistry Arkema BASF Dow Acrylic Alkyd Dispersions Styrene acrylic Styrene butadiene Vinyl acetateethylene Vinyl-acrylic Vinyl versatateacrylic Vinyl versatatevinyl acetate Opacifier 45

46 A range of products to cover the entire spectrum of performance and cost Product Chemistry Total solids (%) T g ( o C) Features CONTRACTOR CAULKS/SEALANTS ENCOR 162 Vinyl acrylic 55 7 Contractor/DIY caulk ASTM C 834 CAULK ENCOR 154S Acrylic 60-4 Pigmented caulk ENCOR 182 Vinyl acetate ethylene Pigmented caulk, can be formulated without modification to meet 0 o C flexibility requirement, must be blend with ENCOR 169S to pass -17 o C flexibility ENCOR 9192 Acrylic 66 0 True clear caulk ASTM C 920 CAULK ENCOR 163S Acrylic Pigmented caulk ENCOR 169S Styrene acrylic Translucent/pigmented caulk ENCOR 9176 Styrene acrylic Pigmented caulk; crosslinking; adhesion to low energy substrates 46

47 47 Products attributed are summarized in our Construction products selection guide

48 48 More details are available in our enhanced technical data sheets

49 ENCOR 182 Ethylene Vinyl Acetate Copolymer for Caulk Applications 49

50 ENCOR 182 Properties Total Solids : 56% Glass Transition Temperature : 5 o C Particle Size : 0.42 micron Brookfield Viscosity : 90 cp ENVIA compliant No added formaldehyde APEO free Latex VOC < 5 g/l Low residual monomer : total < 500 ppm Below regulatory reporting limits for carcinogens, reproductive toxins and ozone depleting compounds 50

51 ENCOR 182 Vinyl Acetate-Ethylene Latex for Pigmented Caulks Vinyl Acetate-Ethylene based polymer designed for cost effective sealants meeting ASTM C834 specification Passes ASTM C834 Grade 0 o C specification Can be formulated with higher performing acrylic polymers such as ENCOR 169S to meet ASTM C834 Grade -18 o C Compatible with many new nonphthalate type plasticizers 51

52 ENCOR 9192 Acrylic polymer for true clear caulks and sealants 52

53 ENCOR 9192 Properties A 100% acrylic latex with: Very high solids Low color in dry film Rapid dry to clear Low surface tack The ability to self-thicken to formulated viscosity without addition of additional thickener Formulation latitude allowing a variety of different desirable properties to be achieved 53

54 Comparison of Formulated U9192 with Commercial Clear Sealants % Clarity day 14 day 10 0 U9192 A B C D E F G H I 54

55 ENCOR 9176 Ambient cure crosslinking sealants 55

56 ENCOR 9176 Properties Total Solids : 61% Glass Transition Temperature : -21 o C Particle Size : 0.35 micron Brookfield Viscosity : 500 cp 56

57 ENCOR 9176 For Ambient Crosslinking Sealants Unique waterborne polymer with ambient cure crosslinking technology providing elastomeric properties High gel content; poor flow High adhesive bonding to architectural substrates Very good pigment binding capabilities for higher P/B formulations Can be formulated into translucent and pigmented sealants meeting ASTM C920 Class 35 Wet Peel Adhesion, pli Low to moderate gel; good flow ENCOR 9176 GE W&D Pine Wet Pine Semigloss Mortar Wet Mortar Lexan Plexiglass Formica 57

58 Competitive Products and Suggested Offsets Product Technology Solids, % Tg, C Arkema Offset Dow Chemical Rovace 86 Vinyl Acrylic 55 5 ENCOR 162 ENCOR 182 Rhoplex 3805 Acrylic ENCOR 163S Rhoplex A-920 Acrylic 62 2 ENCOR 163S ENCOR 169S Rhoplex 928 Acrylic copolymer ENCOR 9192 Rhoplex 2620 Acrylic ENCOR 169S Momentive Synthebond AC111 Acrylic ENCOR 163S Synthebond E6016 Acrylic copolymer ENCOR 163S ENCOR 169S Synthebond E6022 Acrylic copolymer ENCOR 169S Synthebond E6260 Acrylic copolymer ENCOR 169S Wacker Vinnapas EF575 Vinyl acetate-ethylene Copolymer 55 0 ENCOR

59 Summary Highlights of Today s Webinar 59

60 Recap Today s session was intended to provide you with a technical grounding in caulk formulation and product selection Caulks can be classified base on their appearance or by ASTM performance category ACR is the segment leader in caulks and sealants ACR offers the broadest range of chemistries to the caulks and sealants market to meet a range of cost/performance requirements 60

61 Questions? Please contact the Account Team Commercial Questions Latin America Commercial Questions USA & Canada Technical Questions Marlene Hernandez Mark Piggott Mary Chervenak 61

62 2014 ACR Webinar Series Next Month s Topic: Cementious Coatings Speaker: Mike Kaufman Title: Sr. Applications Development Leader Friday May 16, 2:00pm ET 62

63 Arkema Coating Resins Thank You for Joining Us!! See you in May!! 63