Charmor for intumescent coatings- Protecting People & Property Henrik Bernquist Perstorp AB

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1 Charmor for intumescent coatings- Protecting People & Property Henrik Bernquist Perstorp AB

2 Charmor - Protecting people and property Outline Architectural steel and the need of fire protection Different ways of steel protection Intumescent technology how does it work Formulation of intumescent paints Perstorp s offer for intumescent paints Summary

3 Structural steel During a fire, the temperature of steel can rapidly reach more than 1000 C if not protected properly Steel is itself not combustible but loses it strength and structural integrity in fire unless protected. Already at reaches 500 C it loses it s strength and the building risk collapsing To prevent the buildings collapsing upon fire the steel needs to be protected With new trends of using more visible exposed steal the need of protection is even more critical!

4 Different methods of passive fire protecting to protect steel Passive fire protection systems Gypsum boards Spray Applied Fire Resistant Materials (SFRMs) such as concrete Plaster-poured concrete Sprayed concrete Intumescent fire protective coatings Increasingly being used due to the combination of high performance and aesthetical appearance Used mainly for cellulosic and hydrocarbon fires

5 What is an intumescent paint? Mostly physical drying, thermoplastic paint systems High PVC Three main active ingredients 1. Acid donor (Ammonium polyphosphates, APP) 2. Blowing agent (Melamine) 3. Carbon donor Charmor High layer thickness (~1000 μm) Applied by brush or spraying Heat activated ( C) insulating paint Swelling times Intumescent system is usually made up of Primer for adhesion and corrosion resistance The intumescent coating Top coat for protection and appearance

6 Mechanism of Intumescence 1. The binder melts, facilitating chemical reactions in a soft matrix 2. The acid donor decomposes to form polyphosphoric acid 3. The polyphosphoric acid reacts with the carbon donor to form polyphosphoric acid esters 4. The blowing agent releases gases that cause the carbon matrix to create foam that expands to form a tough insulating char barrier that adheres to the substrate. 5. The esters decompose to form a foaming carbon matrix

7 What influences the foam? A firm, stable and well insulating foam is required for optimal steel protection Resin the choice of binder is important The thermoplastic resin should have a suitable melt viscosity to provide a good matrix for the intumescent reaction and facilitate the foam formation TiO 2 place an active part in the foaming process and helps to re-inforce the char Key raw materials: Acid donor (Ammonium polyphosphates, APP) Blowing agent (Melamine) Carbon donor Charmor The particle size and particle size distribution is crucial to ensure an efficient and reproducible intumescent reaction The composition and purity of the raw materials are important for a consistent foam formation

8 Different categories of passive fire protecting coatings Coatings are categorized according to severity of the fire they are intended to protect against: Cellulosic fire of natural carbonaceous-type materials such as wood and paper, these fires have relatively slow heat rise and peak temperatures of 950 C Hydrocarbon - intended to represent fires fuelled by oil spills or gas clouds, characterized by higher heat fluxes and faster time to a maximum temperature of 1100 C Jet Fires - a unique type of hydrocarbon fire caused by pressurized gases or fuels that are released through an orifice and then ignited. These produce even higher heat fluxes: peak temperatures can exceed 1200 C and generate highly erosive forces

9 Intumescent Coatings - cellulosic Type of Technology Solvent-based Intumescent Coatings Typically used in exterior applications and, to some extent, in interior applications. Solvent-based IC dry faster than the water-based IC. More robust coating performance, minimum mechanical damage to them during transportation and erection in the job site. Can be used for on-site exterior applications throughout the year, unlike the water-based coatings where drying is affected by humidity or frost in the winter seasons. Water-based Intumescent Coatings These coatings are relatively new as compared to the solvent-based IC. The low odor benefit of these coatings often makes them to be preferred over the solventbased alternatives for applications in occupied buildings. The majority of these coatings find applications in the interiors of commercial and light industrial buildings to protect steel, wood, and other combustible substrates against the cellulosic fire.

10 Intumescent Coatings - hydrocarbon Type of Technology Epoxy-based Intumescent Coatings These coatings are 100 % solids coatings offer high durability and mechanical properties but requires a topcoat for UVresistance are used in harsh environments where accessibility for maintenance is difficult and long-term durability is a primary concern Onshore oil and gas markets Refineries Petrochemicals, and chemical processing plants

11 Example of Intumescent paint Waterborne formulation for Cellulosic fire Part one: Gridning part Active components APP:Charmor :Melamine ~ 3:1:1 Materials Charmor Charmor Part I, Grinding part PM40 PM15 Water Disperbyk Kronos 2063 (TiO2) Charmor PM40 (carbon donor) Charmor PM15 (carbon donor) Aerosil Melafine (blowing agent) Exolit APP 422 (acid donor) Byk Natrosol Hr 250, 2 % water solution Part two: Let down Part II, Let down Mowilith DM 230 (PvAc disp) PvAc resin NX Sodium Polyphosphate, 10% water solution Water Total PVC, % 68±2 68±2 Viscosity, mpas

12 Fire test result Waterborne paint formulation Critical temp unprotected steel Additional time for evacuation

13 Charmor Product data summary Property Charmor PM Charmor PT Charmor DP Melting point 260 C 250 C 222 C Water solubility (% at RT) Typical hydroxyl number (mg KOH/g) Density (g/ml) Heat of melting (kj/kg) 2770 N/A 7740 Improved water resistance Choice of grade affects: 1. Water resistance 2. Melting behaviour (initiation temperature) 3. Paint formulation (difference in OH-number)

14 Charmor Importance of particle size Grade Particle size Expansion factor Foam characteristics PM40 <40 µm ~20 Homogenous, soft, compact, more stable PM15 <15 µm ~30 Homogenous, soft, fluffier, better isolation Conclusion: Particle size matter Consistency and reliability is important

15 Quality of Charmor Consistent high purity products Non-toxic Non-hygroscopic Small and well defined particle size Narrow particle size distribution No coarse particles Responsible for the entire production process from formaldehyde to milling Charmor PM40 Charmor PM15

16 Out latest invention Charmor PM40 Care Same specification and performance as Charmor PM40 grade but with a sharpened sustainability profile Charmor PM40 Care is partly based on renewable raw material and produced using renewable energy It reduces carbon footprint (cradle to grave) by up to 75% A simple way to reduce the carbon foot print and achieve an intumescent formulation with improved sustainability profile

17 Perstorp as a supplier to Intumescent paints Long history in the polyol business Own production facilities with dedicated line no risk for cross-contamination Consistent quality and supply Responsible for the entire production process from formaldehyde to final product Our own R&D resources and lab facilities Installed fire test equipment for coating Technical service and customer support Global sales and distribution network

18 Conclusions Intumescent coatings Increased demand for architectural steel in buildings and higher awareness of safety and fire protection Growing technology due to the combination of high performance and an aesthetically appealing look which gives esthetic freedom to designer/architect without compromising on safety Required three critical components: The carbon source, Charmor, ammonium polyphosphate and a blowing agent where the particle size and particle size distribution are very important to ensure an efficient and stable protective foam Our highly trusted Charmor range offers three distinct grades with different water solubility and particle sizes which will allow formulation of intumescent coatings with high and consistent performance.