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 June 20, 2014

2 2014 ACR Webinar Series Today s Topic: Elastomeric Coatings Speaker: John Dockery Title: Technical Service Chemist

3 Our training goal Give you the knowledge necessary to answer your customer s questions concerning elastomeric coatings 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 3

4 Today s Agenda What is a Elastomeric Coating? Elastomeric Coatings Market Opportunity Market Size and Value US Siding and Roofing Market Formulating and Testing Elastomeric Coatings ACR Product Overview and Alternatives to Competitive Products Product Spotlight ENCOR Flex 192 ENCOR Flex 187 ENCOR Flex 3186 Recap 4

5 5 What is an elastomeric coating?

6 Elastomeric coatings are highly flexible, liquid applied, waterproof membranes Flexible even at low temperatures Adhere to a variety of substrates Dry film is waterproof 6

7 Elastomeric coatings differ from standard architectural paints Elastomeric Coatings Formulation have: Higher binder levels (< 45PVC) Based on lower T g binders Higher solids 60% versus 35% Higher viscosity versus 90 KU Elastomeric Coatings are applied at a much lower spread rate (50 ft 2 /gallon) 2 coats with a dry film thickness of approximately 40 mils Typical architectural paint composition Liquid Binder Pigment Elastomeric coating composition Liquid 7 Elastomeric Coatings Performance Elongation greater than 100% Tensile strength greater than 200 PSI Low water permeability (< 50PERMS) Binder Pigment

8 Uses for Elastomeric Coatings Floor Applied to parking decks, driveways, walkways and other concrete floors to provide waterproofing, slip resistance and high traffic bearing Wall Applied to exterior masonry, concrete and stucco they have the ability to bridge cracks, protect the substrate from wind driven rain and provide a decorative finish Roof Applied to numerous roofing types to waterproof and extend service life 8

9 9 Elastomeric Coatings Market Opportunity

10 Opportunity for latex is split evenly between Wall and Roof Coatings Elastomeric Coatings Sales by Segment Floor, $171,554,700 Elastomeric Coatings Volume by Segment Floor, 5,718,490 Wall, $500,063,700 Wall, 25,003,185 Roof, $545,081,600 Roof, 32,063,624 Latex Volume by Segment Floor, 1,401,030 Wall, 110,264,046 Roof, 125,689, US Elastomeric Coatings Market, Frost & Sullivan Research

11 11 The U.S. Siding Market

12 U.S. Siding Market Summary 11.7 billion ft 2, $12.1 billion market by 2015 Projected annual growth rate of 7.2 % Market is split 76/24 between residential/nonresidential Market is split 44/56 between renovation/new construction 12 World Siding (Cladding), Industry Study #2834, The Freedonia Group, 2011

13 Product Types Masonry & Concrete Brick & Tile Stucco & EIFS 13 Concrete & Stone Fiber Cement

14 Product Types Others Metal Vinyl 14 Wood

15 Masonry and concrete is the largest segment U.S. Siding Market, 2015P Total = 11.7 billion ft 2 Wood 10% Other 1% Brick & Tile 24% 3.3% AGR 11.6% AGR 7.5% AGR Stucco & EIFS 40% Vinyl 36% 6.7% AGR 9.1% AGR Masonry & Concrete 46% Fiber Cement 24% 10.8% AGR 6.5% AGR Concrete & Stone 12% Metal 7% 3.9% AGR Residential = 8.9 billion ft 2 Nonresidential = 2.8 billion ft 2 15 World Siding (Cladding), Industry Study #2834, The Freedonia Group, 2011

16 16 The U.S. Roofing Market

17 U.S. Roofing Market Summary 26.3 billion ft 2, $24.4 billion market by 2015 Projected annual growth rate of 5.7% Market is split 63/37 between residential/nonresidential Market is split 77/23 between reroofing/new construction Environmentally friendly and energy savings are key themes in both the residential and nonresidential market Cool roofing Waste reduction and recycled content Integrated Photovoltaic 17 Roofing, Industry Study #2814, The Freedonia Group, 2011

18 Product Categories ROOFING SYSTEMS CATEGORY FLAT SLOPED SHINGLES METAL TILE MEMBRANE GREEN/LIVING 18

19 Product Types Sloped Roofs Metal Asphalt shingles Wood shingles 19 Tile

20 Product Types Flat Roofs Green/Living 20

21 Product Types Flat Roofs Bituminous Elastomeric membrane Hot Built-Up Roofing System (Felt and hot tar) Modified Bitumen (Mod Bit) Ethylene Propylene Diene Monomer (EPDM) Plastic membrane Thermoplastic polyolefin (TPO) Polyvinyl Chloride (PVC) Spray Polyurethane Foam (SPF) 21

22 Residential is the larger segment in the U.S. Roofing Market U.S. Roofing Market, 2015P Total = 26.3 billion ft 2 13% 37% Residential Nonresidential 8% Asphalt shingles Bituminous low-slope Metal 7% Elastomeric membrane Tile 63% 60% 5% Plastic membrane Wood shingles 5% Other 1% Residential = 16.5 billion ft 2 Nonresidential = 9.8 billion ft 2 Sloped = 19.9 billion ft 2 Flat = 6.4 billion ft 2 1% 22 Roofing, Industry Study #2814, The Freedonia Group, 2011

23 Residential structures predominately employ asphalt shingles U.S. Residential Market, 2015P Total = 16.5 billion ft 2 2% % 1% 24% 8% 1% 2% 76% New Reroofing New = 4.0 billion ft 2 Reroofing = 12.5 billion ft 2 Sloped = 15.8 billion ft 2 Flat = 0.7 billion ft 2 83% 1% Asphalt shingles Bituminous low-slope Metal Elastomeric membrane Tile Plastic membrane Wood shingles Other 23 Roofing, Industry Study #2814, The Freedonia Group, 2011

24 Nonresidential structures utilize a range of products U.S. Nonresidential Market, 2015P Total = 9.8 billion ft 2 3% 0% 21% New Reroofing 17% 1% 11% 18% 31% Asphalt shingles Bituminous low-slope Metal Elastomeric membrane Tile Plastic membrane Wood shingles Other 79% New = 2.1 billion ft 2 Reroofing = 7.7 billion ft 2 Sloped = 4.1 billion ft 2 Flat = 5.7 billion ft 2 19% 24 Roofing, Industry Study #2814, The Freedonia Group, 2011

25 TPO share is growing at the expense of other technologies in the low slope roofing market Low slope roofing market, 2015P Total = 6.4 billion ft Bituminous EPDM Elastomeric Other TPO 100% 80% PVC Plastic Other SPF All Other Marketshare 60% 40% 20% % Roofing, Industry Study #2814, The Freedonia Group, 2011

26 Popularity of roofing types can be correlated to cost Plastic Membranes Elastomeric Membranes Total Installed Cost ($/100ft 2 ) 26 Roofing, Industry Study #2814, The Freedonia Group, 2011

27 Elastomeric Coatings Market Summary Existing opportunity for latex is split evenly between Wall and Roof Coatings >$1 billion worth of coatings consuming 225 million lbs of latex Wall coatings are applied over masonry and concrete substrates Roof coatings are almost exclusively applied to rehab, commercial low slope roofs Large potential market opportunity for elastomeric coatings 2.9 billion ft 2 of masonry substrate for elastomeric wall 6.4 billion ft 2 of low slope roofing 27

28 28 Formulating and Testing

29 Elastomeric coatings utilize a pallet of raw materials similar to architectural paints Latexes are softer (lower T g ) than those employed in architectural coatings T g (midpoint) range from -30 to -5 o C Ideally Dirt pick up resistance is built into the binder Pigments Titanium Dioxide utilized as prime hiding pigment at lower levels than seen with architectural paints Extenders Multiple types employed, should be limited to low oil absorption and particle sizes above 10um Calcium carbonates typically employed in roof coatings but should be avoided in deeper colored wall paints due to frosting Zinc oxide can help build tensile strength but can interfere with bonding chemistry when used on TPO Dispersants Ammonium salts give the best balance of tensile strength and elongation. Solvents Due to softer binders only low levels of coalescing solvent required Glycols utilized to extend open time and for freeze-thaw protection 29 Thickeners HEUR, HEC, HASE and ASE all employed Minimize the use of associative thickeners due to water sensitivity

30 For optimal performance follow formulating guidelines Keep pigment volume concentration to a minimum(< 45%), higher PVC can lower adhesion and promote a tendency to form cracks Historically elastomeric coatings were available only in light colors, deeper colors for wall coatings is the latest trend. This can be challenging for water resistance and color retention. Field testing is always recommended to ensure adhesion 30

31 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 elastomeric and waterproof coatings industry 31

32 ASTM D6083 is the specification standard for elastomeric coatings Test Requirements ASTM test method Elongation > 100% D2370 Tensile Strength > 200 psi D2370 Tear Strength > 60 lbf/in D624 Peel Adhesion > 2 pli C794 Permeance < 50 perms D1653 Water Swelling < 20% D471 Low Temperature Flex no cracking (pass/fail) D522 Fungi Resistance Rating of 0 G21 Accelerated Testing (1000 hours) Elongation > 100% D2370 Low Temperature Flex no cracking (pass/fail) D522 32

33 Elastomeric coatings do not have to conform to D6083 The standard is commonly referenced in elastomeric coating performance across the country. Only approximately 25% of roof coatings meet ASTM D6083 ASTM D6083 is required only in certain areas most notably Miami- Dade county, FL Dade County 33

34 Tensile and Elongation Testing ASTM D2370 Draw down a coating for a thickness of mil dry Dry for 14 days at 70 F and 50% RH Pull ½ inch wide sample on an Instron 34 Goal: Greater than 100% elongation and 200PSI minimum tensile strength

35 Tear Strength ASTM D624 Draw down a coating for a thickness of mil dry Dry for 14 days at 70 F and 50% RH Pull a stamped sample that initiates tearing on an Instron 35 Goal: Greater than 60 lbf/in

36 Low Temperature Flex ASTM D522 Subject a dry film on an aluminum panel to -26 C/-15 F Bend the panel on a ½ mandrel and observe for cracking on the bend. Goal: No through crack or adhesion loss 36

37 Permeance Testing ASTM D1653 Draw down a coating for a thickness of mil dry Dry for 14 days at 70 F and 50% RH Cut a circular film, place over cup opening and seal edges with screw on cap Record weight loss over a 10 day period Atmosphere Dry Film H 2 O H 2 O Water Testing Cup Goal: Less than 50 PERMS 37

38 Permeance Testing ASTM D WVT = weight loss time x area Weight Loss Time (days) 38

39 Adhesion in Peel ASTM C794 Peel Adhesion Video Goal: Minimum peel adhesion of 2 lbs per linear inch 39

40 40 White Reflective Roofing

41 Why Reflective Roofs? Satellite Image 90% of Roofs in the U.S. are dark colors Absorb Heat ( F) Contribute to Urban Heat Island Effect Result in higher utility bills Accelerate deterioration of roofing materials which are sent to landfills Higher electricity demand leading to blackouts Visible Infra red 41

42 Cool roofing is a growing market segment Add R-value of roofs EPA estimates up to R19 value Reduce building heat-gain Increased Solar Reflectance Increased Thermal Emissivity (heat shedding) 15-30% HVAC savings Increase HVAC and roof membrane longevity Resulting in lower greenhouse gas emissions 178 F 93 F 42

43 43 HVAC represents a significant portion of total annual energy demand

44 Roofing Gov. agencies and independent organizations for cool white roofing ASHRAE standards American Society of Heating, Refrigerating and Air- Conditioning Engineers Title 24 CA s ASHRAE Homestar LEED Leadership in Energy and Environmental Design CA all new 10K sq/ft building LEED silver BEES Building for Environment and Economic Solutions DSIREUSA.org Sponsored by NC State, keeps up with the ever changing property tax incentives / rebates for new construction and remodeling state by state *RRCI Reflective Roof Coatings Institute RCI Roofing Consultants Institute ANSI American National Standards Institute SPRI Single Ply Roofing Industry IGCC International Green Construction code CEIR Center for Environmental Innovation in Roofing Roofpoints.wikispaces.com EPA Energy Star Chicago Energy Efficient Rating System *NRCA National Roofing Contractors Association ICC-ES and ICBO Roofing Evaluation Service *RCMA Roof Coating Manufacturer Association *CRRC Cool Roof Rating Council 44 * Denotes that ACR is a member of these organizations

45 45 ACR Product Overview and Competitive Offsets

46 ACR offers a range of products to cover the entire spectrum of performance and cost Product Chemistry Total solids T g ( o C) ENCOR 123 Styrene Acrylic ENCOR 9176 Styrene Acrylic ENCOR 3176A Styrene Acrylic 50-7 ENCOR Flex 3186 Styrene Acrylic 50-7 ENCOR Flex 187 Acrylic ENCOR Flex 192 Styrene Acrylic Features High solids, high adhesion and film toughness. Can be formulated to meet ASTM D-6083 High solids, ambient temperature crosslinking for excellent adhesion and film toughness. Can be formulated to meet ASTM D-6083 Designed for cost effective elastomeric coatings Designed for cost-effective roof and wall coatings with enhanced dirt pick up resistance High solids for roof and wall coatings with enhanced dirt pick up resistance. Can be formulated to meet ASTM D-6083 High solids with high adhesion to aged TPO membranes. Can be formulated to meet ASTM D

47 Latex Performance ASTM Adhesion Latex Elongation Tensile Strength Tear Strength Low Temp Flex ENCOR 123 ENCOR 9176 ENCOR 3176A ENCOR Flex 3186 ENCOR Flex 187 ENCOR Flex 192 Aluminum Steel Bitmus Roll TPO EPDM Asphalt Dirt Pick up Resistance 47

48 Competitive products and suggested ACR alternatives Competitive Product The Dow Chemical Company Rhoplex EC-1791 ENCOR Flex 187 Lipacryl MB-3640 ENCOR Flex 192 ACR Alternative Rhoplex EC-2848 ENCOR Flex 187, ENCOR Flex 3186 Rhoplex 2438C (wall only) ENCOR Flex 187, ENCOR 3176A, ENCOR 123 Rhoplex 2019RX ENCOR Flex 3186, ENCOR 3176A, ENCOR 123 BASF Acronal DS 6257 ENCOR Flex 187 Acronal NS 567 ENCOR Flex 3186 Acronal NS 562 ENCOR

49 Product Spotlight 49

50 50 More detailed information available in product literature

51 ENCOR Flex 192 Elastomeric Latex for Adhesion to Weathered TPO Roofing Membranes 51

52 ENCOR Flex 192 delivers excellent adhesion to aged TPO Value Proposition Offers our customers the ability to formulate an elastomeric coating with excellent adhesion to aged TPO eliminating the need for a solvent borne primer Product Overview Typical end use Elastomeric roof coatings 52 Features Excellent dirt pickup resistance Excellent adhesion to aged TPO membranes Ambient cross-linking functionality for increased toughness High solids for greater formulating latitude Resistant to water ponding Meets ASTM D-6083

53 What is TPO? Thermoplastic polyolefin (TPO) is a blend of polypropylene and ethylene-propylene rubber utilized as roofing membrane Originated in Europe and started gaining U.S. market share in the mid-1990s European TPO is considered high quality material and higher cost U.S. TPO low cost and many concerns about durability Low surface energy substrate making adhesion difficult 53

54 Many installed TPO membranes are reaching the end of their service life Crazing UV deterioration Seam splitting Hail damage Dirt pick up and mildew growth 54

55 Repairing is cheaper than replacing Installation Removal/Surface Prep Material Total Cost ($/100 ft 2 ) New Membrane Elastomeric Coating 55

56 ENCOR Flex 192 provides superior adhesion Passes ASTM D6083 minimum wet peel adhesion requirement, over aged TPO, without requiring a solvent based primer 3 Wet Peel (pli) ASTM minimum New TPO Aged TPO 56 0 ENCOR Flex 192 Competitive

57 ENCOR Flex 192 provides superior elastomeric properties 250 % Elongation Elongation 200 psi % Elongation Tensile Tear 150 psi ASTM minimums 100 lbf/inch lbf/inch 50 0 ENCOR Flex 192 Competitive 57

58 ENCOR Flex 192 provides superior DPR Dirt added as a slurry and allowed to dry overnight Iron Oxide Coal Ash % Whiteness Reduction Photo of cleaned coating Iron Oxide Coal Ash Photo of cleaned coating Iron Oxide Coal Ash 0 ENCOR Flex 192 Competitive 58

59 ENCOR Flex 187 All-Acrylic Latex for Elastomeric Coatings 59

60 ENCOR Flex 187 delivers superior performance Value Proposition Offers our customers the ability to formulate a high performance elastomeric coating Product Overview Typical end use Elastomeric wall and roof coatings Features Excellent dirt pickup resistance Passes Wind Driven Rain test Meets CRRC product rating requirements for reflectance and emittance at VOC < 50g/L Meets ASTM D

61 ENCOR Flex 187 provides excellent elastomeric properties 300 Elongation 250 psi % Elongation Tensile Tear 200 % Elongation 150 psi ASTM minimums lbf/inch lbf/inch 0 ENCOR Flex 187 Competitive 61

62 ENCOR Flex 187 provides superior DPR Dirt added as a slurry and allowed to dry overnight 60 Iron Oxide % Whiteness Reduction ENCOR Flex 187 Competitive 62

63 ENCOR Flex 187 has superior dirt pick up resistance Competitive products ENCOR Flex 187 ENCOR Flex 187 ENCOR Flex 187 At two years exposure in Cary, NC Coating failure - cracking 63

64 ENCOR Flex 3186 Styrene-Acrylic Latex for Elastomeric Coatings 64

65 ENCOR Flex 3186 delivers superior cost/ performance Value Proposition Offers our customers the ability to formulate an extremely cost effective elastomeric coating Product Overview Typical end use Elastomeric wall and roof coatings Features Excellent elongation Excellent dirt pickup resistance Good water ponding resistance Outstanding adhesion to metal Meets CRRC product rating requirements for reflectance and emittance at VOC < 50g/L 65

66 ENCOR Flex 3186 has excellent elongation Competitive ENCOR Flex 3186 has excellent elongation when compared to competition. 66

67 ZnO can be used to build Tensile Strength Tensile (psi) #/100 gallons of ZnO ZnO can help build in tensile strength even at low levels and have the added benefit of a mildewcide.

68 ENCOR Flex 3186 has excellent ZnO stability Delta KU Commercial ENCOR Flex 3186 exhibits very good heat age stability after 4 weeks with ZnO. 68

69 ENCOR Flex 3186 has excellent wet peel adhesion on Aluminum and Steel 6 Wet Peel Adhesion (pli) Aluminum Steel Commercial 69

70 ENCOR Flex 3186 delivers excellent DPR ENCOR Flex 3186 Competitive Acrylic 70

71 71 More detailed information available in product literature

72 Summary Highlights of Today s Webinar 72

73 Recap 73 Today s session was intended to provide you with a technical grounding in Elastomeric coatings formulation and product selection Latex use is evenly split between elastomeric roof and wall coatings Wall coatings are applied over masonry and concrete substrates Roof coatings are almost exclusively applied to rehab, commercial low slope roofs ACR offers a broad range of chemistries to the elastomeric coatings market to meet a range of cost/performance requirements ENCOR Flex 192 has excellent adhesion to aged TPO eliminating the need for a solvent borne primer ENCOR Flex 187 has good dirt pick-up resistance, tensile-elongation and low temperature flex ENCOR Flex 3186 is extremely cost effective

74 Questions? Please contact the Account Team Commercial Questions Latin America Commercial Questions USA & Canada Technical Questions Marlene Hernandez Mark Piggott Mary Chervenak 74

75 2014 ACR Webinar Series Next Month s Topic: Exterior Insulating Finishing Systems Speaker: Ron Grieb Title: Application Development Leader - Americas Friday July 18, 2:00pm ET 75

76 Arkema Coating Resins Thank You for Joining Us!! See you in July!! 76