“Life Cycle Cost Considerations in Selecting Fluoropolymer Coatings”

Webinar for Durability and Design Magazine May 18 th , 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

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FLUORINATED SEGMENTS: Weatherability, chemical resistance VINYL ETHER SEGMENTS: Gloss, solubility, crosslinking

3 FEVE Fluoropolymer Resins for High-Performance Coatings

Advantages of FEVE Fluoropolymer Resins

: • Ambient Cure – Field application • OH Functional - Crosslinkable with isocyanates • Solvent Soluble – Conventional application techniques (airless spray) – Wide range of gloss (90 @ 60º) • Fluoropolymer Segments – UV Resistance – Corrosion resistance

4 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

5 FEVE Fluoropolymer Resins for High-Performance Coatings 110 100 90 80 70 60 50 40 30 20 10 0 0

QUV Weatherometer Exposure Testing

FEVE Coating Polysiloxane Coating Acrylic Urethane Coating 2000 4000 6000 8000 10000 12000

Hours of QUV Exposure (UVA-340 Bulbs)

14000

6 FEVE Fluoropolymer Resins for High-Performance Coatings

QUV Weatherometer Exposure Testing

110 100 90 80 70 60 50 40 30 20 10 0 0 FEVE Coating Polysiloxane Coating Acrylic Urethane Coating 1000 2000 3000 4000 5000

Hours of QUV Exposure (UVB-313 Bulbs)

6000

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Sunshine Weatherometer Exposure Testing (Carbon Arc)

110 100 90 80 70 60 50 40 30 20 10 0 0 LF200 coating PVDF coating Acrylic Urethane coating 500 1000 1500 2000 2500 3000

SWOM Exposure (hours)

3500 4000 4500

8 FEVE Fluoropolymer Resins for High-Performance Coatings

EMMAQUA Testing (Outside Test Fence – Arizona)

110 100 90 80 70 60 50 40 30 20 10 0 0 400 FEVE coating PVDF coating Acrylic Urethane coating 800 1200 1600 2000

Radiant Energy (Mj/m²)

2400 2800 3200

9 FEVE Fluoropolymer Resins for High-Performance Coatings

South Florida Test Fence Exposure

110 100 90 80 70 60 50 40 30 20 10 0 0 1 FEVE Yellow Coating FEVE Clearcoat 2 3 4 5 6

Years of Exposure

7 8 9 10 11

10 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

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MIDCOAT = 6 mils

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TOPCOAT = 1 mil(25 microns)

11 FEVE Fluoropolymer Resins for High-Performance Coatings Measurement of Total Erosion of the Topcoat INITIAL MEASUREMENT (microns) FINAL MEASUREMENT (microns)

ACRYLIC URETHANE TOPCOAT

25 0 (after 13 years)

FLUOROURETHANE TOPCOAT

25 21

12 FEVE Fluoropolymer Resins for High-Performance Coatings

Life Cycle Cost Advantages

Initial Cost of FEVE-based Topcoat:

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

13 FEVE Fluoropolymer Resins for High-Performance Coatings

Breakdown of Total Cost of Recoating a Bridge* Staging Costs Surface Preparation Labor Cost For Paint Application Total Cost of Coatings Total Repainting Cost

3 Coat Epoxy, 2 Coat Polyurethane System $38.96/ m² $8.44 / m² $26.22 / m² $12.03 / m² $85.65 / m² 3 Coat Epoxy, 2 Coat FEVE Urethane System $38.96/ m² $8.44 / m² $26.22 / m² $15.96 /m² $89.58 / m² * “Prices of Construction Materials and Wages” October 2006 (Published in Japan)

14 FEVE Fluoropolymer Resins for High-Performance Coatings

Estimation of Total Applied Cost Per Year (Coating System) Coating System Total Repainting Cost Estimated Life of Coating System Total Applied Cost per year of Service

Polyurethane Topcoat System FEVE Urethane Topcoat System

$85.65 / m² $89.58 / m²

FEVE Urethane Topcoat System

$89.58 / m²

FEVE Urethane Topcoat System

$94.21 / m² (estimated)

FEVE Urethane Topcoat System

$94.21 / m² (estimated) 18 30 60 30 60 $4.76 / m² $3.00 / m² $1.50 / m² $3.14 / m² $1.57 / m²

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Some things to consider:

1) FEVE polyols can be blended with other polyols to formulate coatings to specific life cycle targets.

2) Lower percentages of FEVE polyols in the formulation will reduce raw material costs compared to 100% FEVE polyol formulations.

3) Coatings formulated for longer life durability will hold their gloss and color better than conventional polyurethane topcoats. This may be an important factor when the appearance of the coating needs to be superior 24/7.

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 16

17 FEVE Fluoropolymer Resins for High-Performance Coatings

Gateway Bridge (Nashville, TN)

--- opened in 2004 -- Red Support Girder coated with FEVE containing coating

18 FEVE Fluoropolymer Resins for High-Performance Coatings Akashi-Kaikyo Ohashi road & train bridge (1997)

FEVE Fluoropolymer Resins for High-Performance Coatings

Mercedes-Benz Museum, Stuttgart , Germany Coated 2004-2005 VERNICRON® FP

FEVE Fluoropolymer Resins for High-Performance Coatings

Clinton Presidential Library Little Rock, Arkansas, USA

FEVE Fluoropolymer Resins for High-Performance Coatings

Birmingham Airport Car Park Birmingham, U.K. ALPOLIC®

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Project Update: Katsushika Harp Bridge

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Construction Completed in 1986 Shop coating begun 1982

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Three Coat System

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Concrete Bridge Piers Elastomeric Primer 2 Fluorourethane Topcoats

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Steel Encasement for Earthquakes in 2007

FEVE Fluoropolymer Resins for High-Performance Coatings

New Steel Encasement: Original Concrete Foot Coated 2007 Coated 1987

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Conclusion:

For 30 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.

In the long run they can reduce the cost of maintaining both a decorative and a protective finish on many exterior substrates.

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Acknowledgements:

Takasi Takayanagi Sho Masuda Isao Kimura Takuma Yamamoto