Transcript Developments in Fluoropolymer Resins For Marine & Offshore

“FEVE Fluoropolymer Technology for
High-Performance, Long-Life Coatings
on Steel and Concrete Bridges”
JPCL / SSPC Webinar
February 8th , 2012
FEVE Fluoropolymer Resins for High-Performance Coatings
What is an FEVE Fluoropolymer???
1) A hybrid fluoropolymer resin with the ability to be
used in standard coatings formulations like any other
conventional coating resin
2) A high performance resin that can withstand severe
ultraviolet light exposure 2-3 times longer than
conventional coatings resins
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FEVE Fluoropolymer Resins for High-Performance Coatings
Fluoroethylene Vinyl Ether (FEVE) Resins
FLUORINATED SEGMENTS: Weatherability, chemical resistance
VINYL ETHER SEGMENTS: Gloss, solubility, crosslinking
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FEVE Fluoropolymer Resins for High-Performance Coatings
Advantages of FEVE Fluoropolymer Resins:
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•
Ambient Cure
– Field application
•
OH Functional
•
Solvent Soluble
– Conventional application techniques (airless spray)
– Wide range of gloss (90 @ 60º)
•
Fluoropolymer Segments
– UV Resistance
– Corrosion resistance
- Crosslinkable with isocyanates
FEVE Fluoropolymer Resins for High-Performance Coatings
Markets for FEVE resin-containing coatings:
1) Architectural Coatings for commercial buildings
2) Industrial Maintenance Coatings for water towers,
bridges, and assorted metal and concrete structures
3) Aerospace coatings
4) Applications in Marine environments
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FEVE Fluoropolymer Resins for High-Performance Coatings
QUV Weatherometer Exposure Testing
110
Gloss Retention (%)
100
90
80
70
60
FEVE Coating
50
Polysiloxane Coating
40
Acrylic Urethane Coating
30
20
10
0
0
2000
4000
6000
8000
10000
Hours of QUV Exposure (UVA-340 Bulbs)
5
12000
14000
FEVE Fluoropolymer Resins for High-Performance Coatings
QUV Weatherometer Exposure Testing
110
Gloss Retention (%)
100
90
80
70
60
FEVE Coating
50
Polysiloxane Coating
40
Acrylic Urethane Coating
30
20
10
0
0
1000
2000
3000
4000
5000
Hours of QUV Exposure (UVB-313 Bulbs)
6
6000
FEVE Fluoropolymer Resins for High-Performance Coatings
Sunshine Weatherometer Exposure Testing (Carbon Arc)
110
Gloss retention (%)
100
90
80
70
60
LF200 coating
50
PVDF coating
40
Acrylic Urethane coating
30
20
10
0
0
500
1000
1500
2000
2500
3000
SWOM Exposure (hours)
7
3500
4000
4500
FEVE Fluoropolymer Resins for High-Performance Coatings
EMMAQUA Testing (Outside Test Fence – Arizona)
110
Gloss retention (%)
100
90
80
70
FEVE coating
60
50
PVDF coating
40
Acrylic Urethane coating
30
20
10
0
0
400
800
1200
1600
2000
Radiant Energy (Mj/m²)
8
2400
2800
3200
FEVE Fluoropolymer Resins for High-Performance Coatings
South Florida Test Fence Exposure
110
Gloss retention (%)
100
90
80
70
60
50
40
FEVE Yellow Coating
30
FEVE Clearcoat
20
10
0
0
1
2
3
4
5
6
Years of Exposure
9
7
8
9
10
11
FEVE Fluoropolymer Resins for High-Performance Coatings
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FEVE Fluoropolymer Resins for High-Performance Coatings
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FEVE Fluoropolymer Resins for High-Performance Coatings
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FEVE Fluoropolymer Resins for High-Performance Coatings
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FEVE Fluoropolymer Resins for High-Performance Coatings
Corrosion Resistance Test of FEVE Coatings:
LOCATION: Suruga Bay Marine Test Station (offshore)
LENGTH OF TEST: 16 years
COATINGS SYSTEMS ON TEST:
1) Zinc-rich primer / Epoxy Midcoat / Acrylic Urethane Topcoat
2) Zinc-rich primer / Epoxy Midcoat / Fluorourethane Topcoat
THICKNESS OF COATING:
PRIMER = 3 mils / MIDCOAT = 6 mils / TOPCOAT = 1 mil(25 microns)
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FEVE Fluoropolymer Resins for High-Performance Coatings
Measurement of Total Erosion of the Topcoat
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ACRYLIC URETHANE
TOPCOAT
FLUOROURETHANE
TOPCOAT
INITIAL MEASUREMENT
(microns)
25
25
FINAL MEASUREMENT
(microns)
0 (after 13 years)
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FEVE Fluoropolymer Resins for High-Performance Coatings
SEM Scan of cross section
Of Coating System
(after 16 year exposure)
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EDX (Energy Dispersive X-Ray
Microanalysis)
BLUE: Chloride
GREEN: Coating System
RED: Metal
FEVE Fluoropolymer Resins for High-Performance Coatings
INITIAL
AFTER 15 YEARS
SEM Scan of Zinc-rich Primer
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FEVE Fluoropolymer Resins for High-Performance Coatings
Electrochemical Impedance Spectroscopy Test Results
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Impedance (100 Mohms/cm²)
FEVE Coating
10
Polyurethane
8
Chlorinated Rubber
6
Alkyd
4
2
0
0
1
Initial
Reading
18
2
After 1000 hours
of SWOM
Exposure
3
SWOM Exposure +
500 hours in
Salt Spray cabinet
4
SWOM exposure +
1000 hours in
Salt Spray Cabinet
5
FEVE Fluoropolymer Resins for High-Performance Coatings
Life Cycle Cost Advantages
Initial Cost of FEVE-based Topcoat (includes Application cost):
5 -10% higher than standard polyurethane topcoat
FEVE-based Topcoat Life Expectation:
30 - 60 years
Expected Repaints of Std. Polyurethane Topcoat
in this Time Frame:
2 to 3 (based on topcoat erosion data from offshore test)
Additional Costs of Repaints:
facility downtime
lodging of paint crew on offshore platform
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FEVE Fluoropolymer Resins for High-Performance Coatings
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FEVE Fluoropolymer Resins for High-Performance Coatings
Shelby Street Bridge
(Nashville, TN)
--- coated in 2004
--- 3 coat system on steel
1) zinc-rich primer
2) epoxy midcoat
3) fluororurethane topcoat
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FEVE Fluoropolymer Resins for High-Performance Coatings
Gateway Bridge
(Nashville, TN)
--- opened in 2004
---
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Red Support Girder
coated with FEVEcontaining coating
FEVE Fluoropolymer Resins for High-Performance Coatings
Can water-based one component acrylic
bridge coatings incorporate FEVE
technology to improve their weatherability?
YES
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FEVE Fluoropolymer Resins for High-Performance Coatings
Project: Incorporate an FEVE emulsion into an “established”
water-based acrylic bridge coating formulation to access
it’s ability to increase the weatherability of the coating.
Details: 1) Replace a portion of the acrylic binder in the
formulation with an FEVE emulsion (30% and 45%)
2) Run accelerated exposure tests in the QUV
Weatherometer (UV340 light source) and chart the
change in 60° Gloss property and the change in
color
during the exposure period.
3) Color is a Federal Standard 595 Dark Green –
FS14090; 60° Gloss Range is 21-25
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FEVE Fluoropolymer Resins for High-Performance Coatings
60° Gloss Measurement of Dark Green Formulations 100% Acrylic and FE emulsion blends
35
60° Gloss Measurement
30
25
20
15
10
5
0
0
500
1000
1500
2000
2500
3000
3500
4000
4700
5000
Hours in QUV Weatherometer
100% Acrylic
25
70% Acrylic/30% FE4300
55% Acrylic/45% FE4300
5500
6000
6500
7000
FEVE Fluoropolymer Resins for High-Performance Coatings
Color Change (ΔE) of Dark Green Formulations 100% Acrylic and FE emulsion blends
10
9
Color Change (ΔE)
8
7
6
5
4
3
2
1
0
500
1000
1500
2000
2500
3000
3500
4000
4700
5000
5500
6000
6500
Hours in QUV Weatherometer
100% Acrylic
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70% Acrylic/30% FE4300
55% Acrylic/45% FE4300
7000
FEVE Fluoropolymer Resins for High-Performance Coatings
Conclusion:
For over 25 years, FEVE resins have been included in
exterior coatings for multiple end uses.
Their excellent weatherability and corrosion resistance
make them attractive for inclusion in topcoats for steel
and concrete surfaces.
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FEVE Fluoropolymer Resins for High-Performance Coatings
Acknowledgements:
Takasi Takayanagi
Sho Masuda
Isao Kimura
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