Palle Gustafsson Vamdrup 20.05.2015 New systems for wind mill towers
Coating demands for Wind mill towers Excellent corrosion protection Excellent outdoor durability - Good gloss and color retention. Working conditions from 40 -> +45 C Excellent resistent to salt, water and ice. Chemical resistant (lubricants, hydraulic fluids and cleaners). Environmental friendly Expected lifetime >25 years.
The production process High output. Fast drying - preferebly at ambient temperature. Reliable Repainting is costly. Environmental friendly VOC compatible.
Traditional system for towers TEKNOS SPECIFIKATION STANDARD SYSTEM C5M-high Product name DFT (µm) Volume solids (%) Theo. Spreading (m2 / L) VOC (g / L) VOC (g / m2) Drying time (h) Paint volume (L/100m2) EPOXY ZINC 90 60 53 8,8 450 51 1 h 11,36 EPOXY PRIMER (high solid) 2*100 66 3,3 320 97 2*4 h 30,30 POLYURETHAN 60 56 9,3 430 46 6 h 10,75 Total 320 194 15 52,42 High amount of VOC High drying time
Polyaspartic system for towers TEKNOS SPECIFIKATION FAST DRYING HIGH SOLID SYSTEM C5M-high Product name DFT (µm) Volume solids (%) Theo. Spreading (m2 / L) VOC (g / L) VOC (g / m2) Drying time (h) Paint volume (L/100m2) EPOXY ZINC 90 60 53 8,8 450 51 2 h 11,36 POLYASPARTIC 240 77 3,2 240 75 1 h 31,25 Total 320 126 3 42,61
Pure polyaspartic system for towers TEKNOS SPECIFIKATION FAST DRYING HIGH SOLID SYSTEM C5M-high Product name DFT (µm) Volume solids (%) Theo. Spreading (m2 / L) VOC (g / L) VOC (g / m2) Drying time (h) Paint volume (L/100m2) TSM 60 100 16,6 0 0 6,02 POLYASPARTIC 240 77 3,2 240 75 1 h 31,25 Total 320 75 1 37,27
Overview 250 Traditionel vs polyaspartics 200 150 100 50 0 VOC (g / m2) Drying time (h) Paint volume (L/100m2) Traditionelt Zn(EP) polyaspartic polyaspartic
What s a Polyaspartic Polyaspartics are very low viscous The have a very high reaction speed with isocyanates No reaction gasses are being build The reaction of polyaspartics with isocyanates leeds to a polyurea coating
Idea to market
New but with 10 years experience Teknos was one of the first to introduce polyaspartic technology to the European market. Development started in 2003 and the first implemented products were used in 2005. TEKNODUR COMBI 3560 has been one of the most succesfull products in the TEKNOS group
Experiences Used in a range of system Solvent- and waterborne 1- and 2 component systems Used in several applikations General industry products Windmill towers Windmill wings Parts for towers ISO 12340 Norsok M-501 approved
TEKNODUR COMBI 3560 Technology Teknos Polyaspartics for metal are named: TEKNODUR COMBI 3560 This new polyurea chemistry which provide: High solids ( 75-100 ) % by volume Adjustable curing speed From standard cure speed to extremely fast. Low viscosity Spraying with standard eqiupment Adjustable pot life From 7 min to 2 hours. High filmthickness in one coat possible Hard and though paint film Excellent corrosion protection and weatherability.
Additional documentation C3 system 3560 (200µm) C5M System TSM (60µm) +3560 (240µm) Pinholes NACE SP0188 Low voltage 90V OK OK Pull-off ISO 4624 >15 Mpa >15 Mpa Continious condensation ISO 6270 part of ISO 12944 480 hours 720 hours Saltspray DS/EN ISO 9227 part of ISO 12944 720 hours Na (OK 1440) "NORSOK": DS/EN 20340 passes 25 weeks Thermal cycling NACE TM304-2004 Section 9 3 weeks 3 weeks Flexibility test NACE TM304-2004 Section 12= NACE RP0394 2 degrees R200 at 23 degrees C at -18 degrees C 2 degrees R200 at 23 degrees C at -18 degrees C NACE TM304-2004 Section 13=ASTM G14/ASTM D2794 Impact resistance test equal to DS/EN ISO 6272-1 >15 inp >15 inp Cold check Teknos internal specification 10 cycles 10 cycles Immersion test ISO 2812-2 Na 4200 h * Not part of ISO12944 however no blistering rust ect.
Example of test equipments
Proces window What will happend at deviation in mixing ratio 3560-73 system C3M
100 Drying time (drying recorder) 90 80 70 Minutes 60 50 40 Dust dry Dry to touch Dry to handle 30 20 10 0 TEKNODUR 3560-73 TEKNODUR 3560-73 TEKNODUR 3560-73 TEKNODUR 3560-73 TEKNODUR 3560-73 TEKNODUR 3560-73 TEKNODUR 3560-73 Udhærdningsgrad: Udhærdningsgrad: Udhærdningsgrad: Udhærdningsgrad: Udhærdningsgrad: Udhærdningsgrad: Udhærdningsgrad: 70% 80% 90% 100% 110% 120% 130%
Chemical resistanse spottest 6 5 4 Evaluation from 0-5 3 2 Spottest 24 h NaOH Spottest 1h formic acid Spottest 24 hours Xylene 1 0 TEKNODUR 3560-73 Udhærdningsgrad: 70% TEKNODUR 3560-73 Udhærdningsgrad: 80% TEKNODUR 3560-73 Udhærdningsgrad: 90% TEKNODUR 3560-73 Udhærdningsgrad: 100% TEKNODUR 3560-73 Udhærdningsgrad: 110% TEKNODUR 3560-73 Udhærdningsgrad: 120% TEKNODUR 3560-73 Udhærdningsgrad: 130%
140,0 König hardness Seconds 120,0 100,0 80,0 60,0 40,0 20,0 0,0 TEKNODUR 3560-TEKNODUR 3560-73 73 Udhærdningsgrad: Udhærdningsgrad: 70% 80% TEKNODUR 3560-73 Udhærdningsgrad: 90% TEKNODUR 3560-73 Udhærdningsgrad: 100% Mixing ratio TEKNODUR 3560-TEKNODUR 3560-73 73 Udhærdningsgrad: Udhærdningsgrad: 110% 120% TEKNODUR 3560-73 Udhærdningsgrad: 130% Hardness König 1 day Hardness König 2 day Hardness König 4 day Hardness König 1 week Hardness König 10 days Hardness König 2 weeks Hardness König 3 weeks Hardness König 4 weeks Hardness König 8 weeks
Conclusion for process window 3560 has the safety in production needed to assure a safe and full performing systems even at higher deviations in mixing ratio than would be accepted. Always use 2-component equipment when using polyaspartics Keep track on mixing ratio and pot-life. Fix the mixing ratio to stay between +/-5% of set-point
Documentation of repair system Repair system are based on Zn (EP) or 1-component 3560-53 (1 hour potlife) Tested on: Steel TSM Damage to both Primed surface Tested at standard conditions as well as extreme conditions
Conclusion on repair system Repair system are showing the same performance as the original system Painting can be done by roller, brush or spray Painting on cold substrates and early exposure is possible
Conclusion VOC Output Energy consumption Isocyanate Epoxy EP/PU Powder Polyaspartic
What s the cons Short pot-life 2-K equipment is needed. Clean and rough surface is needed. Teknos recommends gritblasting to a roughness medium to rough. Compared to powder coating this system contains isocyanate like other PU s If you want full control on drying time the condition needs to be controlled (Teknos recommends RH 40-60% and temp 20-25 degrees C).
Flexible range 3560-73 3560-83 3560-53 Describtion Full automatic lines Manual painting with 2-K equipment Manual painting Pot-life (25 degrees C) Mixing ratio volume 8 min 15 min. 1 hour 4,5:1 4,5:1 4:1 Volume solid 77% 77% 83% VOC content 240 g/l 240 g/l 170 g/l Dry to handle at 23 degrees C (240 µm DFT) 70 minutes 90 minutes 4 hours
Summary TEKNODUR COMBI 3560 is recommened for towers inside as well as outside C3 to C5 marine For C5 Marine conditions Zn-rich primer or TSM are approved and to be recommended For other parts several primers are tested for C5 TEKNODUR COMBI 3560 will help you Reduce amount of VOC needed for the painting process Reduce energy consumtiom needed for the drying process Reduce time of production
Palle Gustafsson Vamdrup 20.05.2015 New systems for wind mill blades
TEKNODUR COMBI 3572 Polyaspartics for windmill blades Developed for windmill blades with strong adhesion (>8 MPa pull-off) direct to reinforced polyester and epoxy as well as PU and EP fillers With improved rain erosion resistance With excellent fatique resistance
Rain erosion resistance of 3572 Tested in chopper test with windmill tip at Speed 135 m/s Rainfall 60mm/h Passes test at 120 min!
TEKNODUR COMBI 3572 for Windmills Blades: TEKNODUR COMBI 3572 1 x 160 µm Total dry film thickness 160 µm
System for windmill blades TEKNODUR 3572-02 has been tested and approved in accordance with customer specification. The full system is based on: Filler Intermediate filler polyaspartic possible -> 3574 sanding after 1h Topcoat: TEKNODUR 3572 dry to touch after 1 hour.
Palle Gustafsson Vamdrup 20-05-2015 Thank you!