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 October 17, 2014

2 2014 ACR Webinar Series Today s Topic: Waterborne Coatings for Metal Speaker: Jeffrey Arendt Title: Technical Account Coordinator

3 Our training goal Give you the knowledge necessary to answer your customer s questions, concerning metal coatings, with confidence Outline the maintenance coatings market Review corrosion chemistry Discuss formulating of maintenance paints Describe testing protocols Highlight several Arkema products and describe their performance benefits 3

4 Agenda Maintenance Coatings Market Common types of metals Corrosion Fundamentals Describing Topcoats, Primers and Direct to Metal (DTM) needs Maintenance Coatings formulating and testing ACR product overview and product spotlight Recap 4

5 Maintenance Coating Market 5

6 6 Maintenance coatings for metal represent ~5% of total paint sales

7 7 Maintenance coatings for metal is growing

8 8 The price for maintenance coatings has been flat

9 9 Maintenance coating market is highly consolidated

10 10 Maintenance coating market is highly profitable

11 11 67% of all maintenance coatings sold are for rehab

12 12 Metal coatings market is 25% water borne

13 Key takeaways Volume for the segment is projected to grow at 1.3% annually. Due to anticipated price increases, the value of the segment will grow at a faster rate of 5.4%. All segments with the exception of highway and bridges are projected to grow. Spending for industrial maintenance coatings are influenced by the overall economy, public and private construction, the price of oil and public spending on infrastructure. Water-based acrylic and alkyd will grow at the expense of solvent borne. 13

14 Common Metal Types 14

15 Steel is the most abundant metal used in construction Types of steel and its alloys Mild steel (carbon steel) Cold rolled steel Phosphated Prepainted Stainless (200, 300-series) Steel is a ferrous metal, if exposed to moisture and oxygen it will rust 15

16 Types Aluminum is inherently more corrosion resistant than steel, but. Many Alloys Untreated Treated (chromated) Prepainted Corrosion resistance is due to the formation of a low permeability oxide layer 16

17 Galvanized coating provides a sacrificial protective layer Some common types include Hot dipped galvanize (HDG) Electrogalvanized 17

18 18 Galvanized metal will eventually corrode

19 Corrosion Fundamentals 19

20 20 Corrosion requires water and oxygen, and is accelerated by water soluble salts

21 Rust convertors consolidate the corrosion layer but do not prevent future deterioration Rust convertors are sometimes used by consumers to paint over rust with minimal surface preparation These products are based on tannic and/or phosphoric acid and function by attempting to passivate the pre-corroded surface by converting the iron (III) oxide to iron phosphate and iron tannate These products produce a hard surface that can be painted over. Long term effects are debatable. A US military study in the mid-1980 s showed these products can actually accelerated corrosion after a period of time. 21

22 Topcoats, Primers and DTM systems 22

23 Primers ensure proper adhesion to the substrate Primers must adhere well to the intended metal substrate Primers often contain anti-corrosive pigments to provide maximum protection Since UV resistance is not needed a wider range of primer compositions are available Topcoat Primer Metal Substrate 23

24 Topcoats provide an aesthetically pleasing finish Topcoat Primer Metal Substrate The primary functions of the topcoat is to enhance aesthetics and to protect primer from environment For exterior environments weatherability is needed Gloss Retention Color Retention Water Resistance Resistance to specific environmental degradants (i.e. chemicals, dirt, etc.) Excellent compatibility and adhesion to primer is required 24

25 DTM Must perform both primer and topcoat functions Shipping Containers Protective Coatings 25

26 Maintenance Coating Formulating 26

27 Paints are complex mixtures of raw materials Component Polymer Coalescent Primary Pigments Extender Pigments Anticorrosive Pigments Flash Rust Inhibitors Dispersants & Surf. Defoamer Preservative/Mildewcide Thickener/Rheo. Mod. Misc. Additives Function Film Former Plasticizer Hiding Power Control Gloss Inhibit Corrosion Alleviate Flash Rust Wetting Eliminate Foam Prevent Microbials Application Anti-Mar, etc. 27

28 Binder holds the pigment together Water-borne latex Acrylic Styrene acrylic Alkyd Emulsions Formulates like a latex but requires a metal drier (ex. cobalt naphthenate) 28

29 Pigments provide color and hiding Prime Hiding and color Titanium dioxide, Iron oxides, Organic pigments Functional imparts specific properties Corrosion Inhibitive Pigment Zinc Phosphate: Corrosion control Zinc oxide: Corrosion resistance mildew resistance Extender flatness, sheen control, cost Calcium Carbonate: Used in both interior and exterior paints, a general purpose, low cost, low hide pigment. Silica: Provides enhanced durability in exterior paints as well as scrub and abrasion resistance. Talc: A soft, general purpose extender pigment. 29

30 Pigment volume concentration is a key formulation parameter Pigment Volume Concentration (PVC): PVC = x 100% volume of pigment volume of pigment + volume of binder solids 30

31 PVC tells us about the nature of the paint film Critical Pigment Volume Concentration (CPVC) CPVC marks the transition from a system in which the pigment is dispersed in a continuous binder matrix to one where there is insufficient binder to completely encapsulate all the pigments. paint film pigment substrate Low PVC Film (< CPVC) CPVC Film High PVC Film (> CPVC) 31

32 Coatings properties change dramatically at CPVC blistering gloss CPVC film tensile adhesion permeability rusting PVC 32

33 Formulating paints for metal substrates have many similarities to other coatings Coatings used on metal substrates: Vary in sheen from Gloss to Flat Covers the PVC range but usually below CPVC Vary in VOC content coalescence and freeze/thaw additives will impact Solvent release is critical to achieve good early water resistance Can be applied either by brush, roller or spray gun Rheology modifiers impacted 33

34 Film formation is critical! Poor coalescence can lead to channels for water to migrate through the film Latex particles must fuse tightly together. Application temperature is important 34

35 Film thickness will impact coating performance Higher film thickness = better barrier = better corrosion Multiple thin coats are theoretically preferred to achieve the target film thickness as this will correct for missed or thin spots DTM coatings typically are applied in fewer coats (often one coat) to save labor and time. 2 mils 4 mils 18 mils 20 mils 6 mils 22 mils 8 mils 24 mils 10 mils 26 mils 35

36 Primers must exhibit good adhesion and low porosity Primers must have adhesion to the target metals To make the path of water ingress more tortuous platy talcs are often used to lengthen the path from the surface to the metal. The inclusions of talc and anti-corrosive pigment increases the PVC. Stay safely below the CPVC. surface water molecule talc particle metal substrate 36

37 Anti-corrosive pigments react with metal surface to yield a protective layer Courtesy of ICL (Halox) 37

38 38 Anti-corrosive pigments enhance coating performance

39 Flash rust is a challenge particular to coating metal Flash Rust can occur immediately after application of water based coatings on ferrous metals Additives of various chemistries are used in water based systems to eliminate this problem Sodium Nitrite salt is one of the the most commonly used add additives. Can be exacerbated by high humidity or other conditions that slow the dry time of the coating Courtesy of Raybo Chemical 39 Handbook of Coating Additives 2 nd Edition, Florio and Miller

40 Additive type and quantity affects performance The photo shows the results from two different dispersants. Surfactants should be minimized Surfactants migrate to metal interface Reduce adhesion Affect water resistance Affect corrosion resistance All hydrophilic ingredients should be scrutinized Hydrophilic solvents Rheology modifiers ph control additives Avoid cellulosic thickeners Dispersant A Dispersant B ASTM B hours 40

41 Maintenance Coating Testing 41

42 Cross hatch tape pull is the industry standard for assessing adhesion ASTM D 3359 Wet and Dry 42

43 Cleveland Humidity Cabinet is used to assess blistering and gloss loss ASTM D 2247 Blistering Gloss loss 43

44 Salt Fog is the industry standard for assessing corrosion resistance, but ASTM B 117 A Static Condition Test 5% NaCl salt fog atmosphere 35 ºC Results Blistering Corrosion Scribe Creep Undercut 44

45 Cyclic Prohesion is believed to be a better predictor of real world performance ASTM G 85 Test cycles between wet and dry phases Wet phase subjects samples to salt spray 0.35% wt Ammonium sulfate and 0.5wt% NaCl salt fog atmosphere 35 ºC 45

46 Chemical Resistance is another important performance characteristic ASTM D4752- MEK Double Rub Test Count number of rubs to failure Chemical Spot testing Monitor film for deterioration 46

47 ACR Products for Metal Coatings 47

48 ACR s broad toolbox offers the most options for solving customer problems Broadest technology platform NEOCAR Acrylic polymers Acrylic polymers Styrene acrylic polymers NEOCAR polymers Vinyl acrylic polymers Vinyl acetate ethylene polymers Styrene-butadiene polymers 48

49 Resins for Metal Primers Product Chemistry Solids (%) T g ( o C) Steel Aluminum Galvanized Features ENCOR DM 166 Styrene Acrylic General metal; 150 g/l VOC potential, gloss ENCOR DM 99 Styrene Acrylic Increased adhesion vs. DM 166. Highest pendulum hardness DM resin ENCOR DM 109 Styrene Acrylic General metal primers; corrosion, chemical resistance, flash rust Synaqua 4804 Alkyd Emulsion 50 NA Near zero VOC, excellent adhesion, water based alkyd ENCOR DT-250 Styrene Acrylic Fast dry, good adhesion, strong ammonia odor ENCOR 481 Styrene Acrylic 47-3 Zero VOC, good adhesion, interior only ENCOR DL 215 Styrene Butadiene Very hydrophobic, occasionally requested, low MVTR ENCOR CL 36 Styrene Acrylic Very hydrophobic, good adhesion to metal ENCOR 627 Acrylic Light duty primers with good adhesion for architectural metal 49

50 Resins for Metal Topcoats over a Primer Product Chemistry solids (%) MFT ( o C) ENCOR DM 166 ENCOR DM 99 Styrene Acrylic Styrene Acrylic T g ( o C) Features General metal; lowest VOC DM resin, highest gloss DM resin, best DM for gloss retention Increased adhesion, and block resistance vs. DM 166. Highest pendulum hardness DM resin ENCOR DM 109 Styrene Acrylic Suitable as a topcoat, DM 166 and DM 99 are cost preferred. Synaqua 4804 ENCOR 2721 Alkyd Emulsion Styrene Acrylic 50 0 NA W/B alkyd, highest gloss, near zero VOC 43 <5 NA Hardest film, fast dry, interior topcoat only, less than 100 g/l SNAP 720 Acrylic 49 0 NA SNAP 728 Acrylic 49 0 NA ENCOR 481 Styrene Acrylic Zero VOC topcoats, with good hardness, Envia Zero VOC topcoats, with good hardness, Envia Zero VOC, high gloss, recommended interior only, can be epoxy crosslinked in 2k system 50

51 Resins for DTM Coatings Product Chemistry Solids (%) T g ( o C) Steel Aluminum Galvanized Features ENCOR DM 166 Styrene Acrylic General metal; 150 g/l VOC potential, gloss ENCOR DM 99 Styrene Acrylic Increased adhesion, and block resistance vs. DM 166. Highest pendulum hardness DM resin ENCOR DM 109 Styrene Acrylic General metal primers; corrosion, chemical resistance, flash rust Synaqua 4804 ENCOR 481 Alkyd Emulsion 50% NA * Styrene Acrylic 47-3 Near zero VOC, excellent adhesion, high gloss, water based alkyd Light duty zero VOC DTM coatings when strong adhesion is needed and corrosion resistance is secondary 51

52 Competitive Products Acrylic and Styrene Acrylic Emulsion Product Supplier Arkema Suggestion Acronol Optive 760 BASF Encor DM 109 Maincote HG-54 Dow Encor DM 99 Maincote HG-56 Dow Encor DM 109 Avanse MV-100 Dow No recommendation Maincote 4950 Dow No recommendation Alkyd Emulsions Product Supplier Arkema Suggestion Becksol AQ 210 Reichhold Synaqua 4804 Becksol AQ 510 Reichhold Synaqua

53 ENCOR DM 166 Styrene Acrylic Binder for Topcoats, Primers and DTM systems 53

54 ENCOR DM 166 delivers excellent costperformance Product Description An acrylic latex binder for general purpose industrial maintenance coatings Performance Benefits Suitable for use in topcoats, primer and DTM coatings Good block resistance Good gloss retention Excellent pigment binding Low coalescent demand, lower VOC Good corrosion resistance Good adhesion to steel, aluminum and galvanized Best economics of the DM Series 54

55 ENCOR DM 166 is your starting point for cost effective DTM systems ENCOR DM 166 Application requires better adhesion or block -Highest initial gloss -Best gloss retention -Good adhesion -Lowest VOC -Best economics Application requires better corrosion resistance ENCOR DM 99 ENCOR DM 109 -Increased adhesion -Hardest DM latex in series -Best block resistance -Best corrosion resistance -Best adhesion -Best flash rust resistance -Fastest early water resistance 55

56 56 ENCOR DM 166 delivers good performance

57 SYNAQUA 4804 Waterborne Alkyd for High Gloss Coatings 57

58 SYNAQUA 4804 offers solvent borne performance in a water borne system Product Description An APEO and ammonia free short oil alkyd water borne emulsion with performance similar to solvent based alkyds. Performance benefits High gloss potential and excellent gloss retention Very good hardness Quick dry time Low yellowing Good stability with anticorrosive pigments Good application characteristics Outstanding resin for blending with other technologies, including styrene acrylics, acrylics and polyurethane dispersions 58

59 Why do alkyds continue to be interesting? Low molecular weight application followed by self-crosslinking offers. Excellent substrate wetting and adhesion Excellent gloss and flow Excellent corrosion protection Low glass transition temperature (Tg) Good film formation Excellent corrosion protection Bio-renewable Alkyd is naturally hydrophobic Very good intrinsic water resistance Soybeans and Soybean Oil 59

60 Alkyds emulsion and Acrylic latexes have many things in common Acrylic Emulsion Fair 20 o and good 60º gloss Acrylic latex dispersed in water and surfactant stabilized Very good UV resistance High Molecular Weight Faster property development Needs some solvent for optimum film formation Does not need a drier Long Shelf Life Water clean-up Particle size nm Alkyd Emulsions Highest 20º and 60º gloss Alkyd resin emulsified in water and surfactant stabilized Alkyd is contained in a discrete latexlike domain Acceptable UV resistance Low Molecular weight Slower property development Higher crosslink density when cured Better substrate penetration Forms films with no solvent Drier needed to cure film Long Shelf Life Water clean-up Particle size nm 60

61 Chemical drying via oxidative crosslinking H O 2 Autoxidation Metal Drier ( M( n+1)+ ) OOH Metal Drier ( M n+ ) OO. O. Molecular Weight Time O O + O 2 O O 61

62 Alkyd Technology, Film Formation Diffusion Wave Spectroscopy of film formation of a Solventborne Alkyd 62

63 Alkyd Technology, Film Formation Diffusion Wave Spectroscopy of film formation of a Waterborne Alkyd 63

64 Alkyd VOC Challenges and Evolution Converting From Solvent to Water Water Reducible Alkyd (Short Shelf life) Alkyd Emulsions (Long shelf Life) Exempt Solvent Alkyd Conventional Alkyd High Solids Alkyd Water-Reducible Alkyd Alkyd Emulsion Acrylic Modified Alkyd Dispersion 480 g/l (4.0 lbs/gal) 360 g/l (3.0 lbs/gal) 240 g/l (2.0 lbs/gal) 120 g/l (1.0 lbs/gal) 0 g/l (0 lbs/gal) 64

65 Synaqua 4804 can yield a formulation with very low VOC content and. LBS Gallons LBS/gal Solids WATER DISPERBYK TEGO FOAMEX 815 N AMP TIONA Heucophos ZCP-Plus (P) Heucorin FR Disperse at high speed during 15 min. (check grind) Stop the mixer and set aside In a new container mix - SYNAQUA DriCat In a new container mix - --mix 5 minutes-- Slowly add the millbase from above while mixing AQUAFLOW NHS COAPUR 830 W FOAMSTAR A ACTICIDE MBS WATER % solids 54.3%

66 Synaqua 4804 delivers outstanding performance Anti-Corrosive Primer, 3 mils DFT (no topcoat) Gloss DTM 3 mils DFT (no primer) 66

67 Recap Give you the knowledge necessary to answer your customer s questions, concerning metal coatings, with confidence ACR offers products for use in primers, topcoats and direct to metal (DTM) formulations ENCOR DM 166 delivers excellent cost performance in general purpose industrial maintenance coatings Synaqua 4804 offers solvent borne performance in a water borne system 67

68 Questions? Please contact the Account Team Commercial Questions Latin America Commercial Questions USA & Canada Technical Questions Marlene Hernandez Mark Piggott Mary Chervenak 68

69 2014 ACR Webinar Series Next Month s Topic: Taking the Fear out of Wood Coatings - Understanding Wood for Better Coatings Choices Speaker: Doug Mall Title: Senior Technical Service Chemist 69

70 Arkema Coating Resins Thank You for Joining Us!! See you in November!! 70