CREATING TOMORROW S SOLUTIONS

Transcription

1 CREATING TOMORROW S SOLUTIONS Construction I Hybrid polymers WaterProofing starts here: α-hybrids for Liquid membranes

2 Moisture damage in buildings is fairly common, even in advanced economies. In 2008, 14% of Germany s population lived in apartments or houses damaged by moisture [1]. This makes waterproofing a top issue. At the same time, new toxicological and environmental regulations have made it difficult to formulate high performance waterproofing membranes. The answer to these challenges are WACKER s new α-hybrid polymers GENIOSIL WP. 2

3 Discover the new Potential for Liquid Waterproofing Systems Cold applied, liquid waterproofing systems have become indispensable in the construction industry. With the new GENIOSIL WP α-hybrid polymers WACKER presents an innovative binder technology for formulations which combine the benefits of different liquid sealing systems, but avoid their drawbacks. Advantages of Liquid Systems Besides traditional single-ply rolled sealing membranes, liquid waterproofing systems have become popular, especially for surfaces with many joints and wall penetrations, as well as for more complex shapes. These types of liquid waterproofing systems cure after being applied to a solid material, forming a seamless waterproof membrane that adheres to the substrate. Typical Applications of Liquid Membranes Waterproofing of flat roofs Sealing of balconies and patios Waterproofing of interior and exterior basement walls Air barrier coatings Waterproofing of cracks in roofs and walls Sealing of indoor and outdoor connections, dome lights, guttering etc. Moisture barrier under floor screeds Under-tile waterproofing Existing Technologies and Their Drawbacks However, available liquid waterproofing systems have a number of drawbacks. Some are two-component systems and, therefore, have to be mixed directly at the construction site before application, entailing the risk of improper mixing, which may affect sealing properties. VOC vs. H 2 O Other systems contain significant quantities of volatile organic solvents (VOC), which are necessary to achieve the low viscosity required for their application. Water-based waterproofing systems, on the other hand, have poor drying characteristics in moist and cold surroundings. A few of the common systems even contain low-molecular weight isocyanates, which recently require special labeling for toxicity reasons. The Solution: α-hybrids With its patented α-technology, WACKER has developed new α-silane-terminated polyethers designed specifically for use as a binder for liquid waterproofing systems. They allow the formulation of systems which, after curing, form a well adhering membrane. Even ETAG 005 compliant formulations are feasible. [1] German Federal Statistics Office, Zahl der Woche No. 035, August 31, 2010 press release GENIOSIL is a registered trademark of Wacker Chemie AG. 3

4 innovation starts here: The α-technology Hybrids: Benefits at a Glance Silicones UV resistant high elasticity Hybrids + easy processing broad adhesion profile Polyurethanes paintable good mechanical properties Silane-modified polymers have been used since the 1980s as binders for adhesives & sealants. These binders, though innovative at that time, displayed certain disadvantages. Following extensive screening, α-silane chemistry could address many of the drawbacks. In recognition that this approach proved correct, WACKER was conferred with the Construction Sealants New Product Innovation Award in 2011, acknowledging this technology as truly ground-breaking. α-hybrids + fast & reliable curing tin-free formulations long shelf-life What are hybrids? Hybrids are silane-crosslinking organic polymers that combine properties typical of both silicones and polyurethanes. They are highly versatile yet easy and safe to use as they are isocyanate- & solvent-free and in case of the α-hybrids don t need tin-catalysts for curing. GENIOSIL α-hybrids: Building on the Performance of Existing Hybrids With the GENIOSIL α-technology WACKER introduced a new group of silane-terminated polyethers. Formulations based on this technology building on the performance of traditional systems. They encompass those characteristics attainable with established systems and take the formulator yet a step further by offering greater advantages: Fast & complete curing Tin-free formulations thus avoiding sidereactions leading to greater shelf-life Low viscosity for easy dosing and plasticizer-free formulations if desirable Straightforward & cost-efficient compounding Tack-free surfaces 1) The Construction Sealants New Product Innovation Award in 2011 is awarded by the prestigious consulting firm Frost & Sullivan 4

5 The Technology Silane-modified polymers generally contain silane components that are coupled to an organic polymer backbone and which can be used for curing through hydrolysis and subsequent condensation. The silane-terminated polyethers from Wacker, also belong to this group of hybrid polymers. These have a polyether chain as their organic polymer backbone, with di- or trialkoxysilyl groups at its ends (see graph 1). This structure is achieved through urethane coupling, with an aliphatic bridge positioned between the urethane group and the silane component. In commercially available grades, this aliphatic bridge is either a methylene or a propylene group. The methylene group leads to an α-silane-terminated polyether, the propylene group produces a γ-silane-terminated polyether. The Key to Differentiation: The α-effect The WACKER experts noticed that the condensation reaction proceeds particularly rapidly when the two silane components of the hybrid polymers are linked to the polymer backbone via a methylene group, which represents the shortest possible spacer. In this case, the nitrogen atom of the urethane group is located in the α-position relative to the silicon atom of the silane component, and accelerates the crosslinking condensation reaction as a result of the so-called α-effect. Because of their short methylene bridge, α-silane-terminated polyethers can crosslink without the aid of a tin catalyst (α-effect, see graph 2). The absence of tin provides a number of advantages: Elimination of toxicological risks in storage & handling Reduced tendency for transesterification less additional VOC Long shelf-life of formulated products State-Of-The-Art Applications Silane-terminated polymers have for years served as the binder of choice in a a variety of applications. These are typically transparent sealants, wood-flooring adhesives, universal assembly adhesives and industrial adhesives. However the hybrid technology was hardly found in waterproofing applications until recently. A New Dimension in Waterproofing The new hybrid polymers GENIOSIL WP now enable the use of α-silane technology for waterproofings. In terms of their mechanical properties, the cured formulations based on these polymers make advances into the previously ex - clusive domain of polyurethane-based, isocyanate curing systems whilst being one-component yet solvent-free. Consequently, these new hybrid polymers present a number of advantages to both formulators and end-users. Graph 1: Structure of a Silane-Terminated Polymer. R Independantly can be Alkyl or Alkoxy functional silane R R Si R functional polymer functional silane R Si R R Graph 2: Structure of an α-dimethoxysilane-terminated Polyether OCH 3 H 3 C Si CH 2 C O Polyether O C CH 2 Si CH 3 OCH 3 N H O O H N OCH 3 OCH 3 5

6 GENIOSIL WP: The first low viscous hybrid polymers for waterproofings With the newly developed GENIOSIL WP polymers formulators of liquid membranes can now use the unique α-technology for formulation of innovative waterproofings. These products combine the advantages of various liquid sealing systems currently available on the market whilst avoiding their drawbacks. Products will have the application viscosity, curing and post-cure properties of conventional one-component polyurethane-based products thus providing long-term reliability. Being solvent-, isocyanate- and tin-free formulated products meet all health, occupational safety, and environmental requirements, even if these become more stringent in the future. These developments were spurred by the new regulatory chemical classification for diphenylmethane diisocyanate (MDI), a commonly used isocyanate component in liquid polyurethane waterproofings, as well as by an increasing demand for solvent-free systems. A New Standard in Waterproofing GENIOSIL WP The polymers have been optimized to have the lowest possible viscosity. Especially GENIOSIL WP 1 was designed to have a higher density of silane groups than conventional silane terminated polymers. The greater degree of polymer functionally results in an enhanced three-dimensional network formed during curing. The network is significantly more tightly linked thus rendering good mechanical properties and high chemical resistance to the cured formulation. Comparison of Viscosities of Silane-Modified Polymers Viscosity mpa s GENIOSIL WP polymers Conventional silane terminated polymers Conventional silane terminated polyurethanes The new specialty polymers have a viscosity of less than 1000 mpa s at 25 C (Brookfield, Spindle 1, 2.5 rpm), which is far below the viscosity of conventional types of silane-terminated polyethers/polyurethanes. Such low-viscosity silane-crosslinking polymers have not been commercially available until now. 6

7 Reference Formulation for Preparing a Solvent-free, One-Component Waterproofing Based on GENIOSIL WP Mass fraction in % Component Product designation 50 Base polymer GENIOSIL WP Water scavenger GENIOSIL XL Stabilizer package e.g. UV absorber, antioxidant, HALS stabilizer Filler e.g. Aluminum trihydroxide trihydrat (ATH), untreated, Talcum, Calciumcarbonate Pyrogenic silica HDK H18 or H Catalyst/Adhesion promoter GENIOSIL GF 96 To produce a liquid waterproofing system, the polymer will be mixed with a water scavenger. Afterwards stabilizers for UVand weather resistance will be added. Fillers are contributing to the mechanical performance and a rheological additive is used to adjust workability properties. At the end the formulation will be activated by adding an aminosilane which acts as a catalyst and adhesion promoter. During the final production step air bubbles will be removed by using vacuum and the formulation will be filled into the packaging in the presence of a nitrogen blanket. 7

8 The corresponding finished products display a multitude of advantages One-Component Yet Solvent-free Plus Rapid Curing With the new GENIOSIL WP polymers it is now for the first time possible to formulate one-component liquid systems that are isocyanate- and tin-free and require no solvents for viscosity reduction. With their high crosslinking speed which is typical for α-silanes the specialty polymers contribute to rapid curing of the formulation. The cured end-products exhibit good mechanical properties and excellent crack-bridging which correspond to the performance of a one-component polyurethane-based waterproofing. Application with Standard Methods Forming a Reliable Sealing Liquid waterproofing systems based on GENIOSIL WP can be applied by roller, brush or airless sprayer, whichever method is preferred. Depending on the formulation the waterproofing has a workability of minutes, assures early rain resistance (~ 1 hour) and will fully cure to a tack-free membrane after ~ 2 3 hours. At Any Weather Condition Because the curing mechanism is largely independent of the weather, waterproofing products formulated with the new hybrid polymers can be applied under practically any weather conditions, even on cold, wet days, and on moist substrates the only exception is stagnant water. The tack-free sealing membrane which results from the curing is waterproof (hydrostatic pressure resistance > 6 bar) but vapor-permeable (sd value of ~ 1.0 m for a 1.5-mm layer thickness). Broad Adhesion Spectrum Formulations based on GENIOSIL WP adhere to most common substrates in the construction industry, even without priming, for example on: Concrete, even on fresh concrete Glass Glazed tile Steel, and stainless steel Aluminum Copper Zinc Wood Certain types of asphalt sheeting High Resistance to Chemicals and Solvents Laboratory tests have shown that the cured membranes offer very high resistance to chemicals and solvents. Pieces of 14 days cured membranes have been put into solvents and acids e.g. ethanol, isopropanol, ecetone or 5% citric, sulfuric or acetic acid. After 40 days of storage, none of the specimens were dissolved or turned crumbly, none disintegrated on slight finger pressure. Furthermore the 180 bending test was ok in any case. No turbidity of solvents was visible. Therefore this technology is also suitable for undertile-coatings in highly stressed wet areas like breweries or dairies, thus, offer an alternative to two-component epoxy systems. 8

9 Advantages at a Glance For the formulator: Based on a-technology Fast compounding Non-hazardous raw materials No tin catalysts Long shelf-life 100% reactive material Low viscosity for easy handling Formulation in standard dissolver No special packaging needed ETAG 005 compliant products feasible For the applicator: 1-component system, no mixing Solvent & NCO free Readily applied with roller or brush Processable under humid or cold conditions Short drying times fast working Excellent adhesion to many substrates without primer No shrinkage Product Overview GENIOSIL WP 1 GENIOSIL WP 2 Property Test method Value Value Density at 25 C 1013 hpa 0.95 g/cm³ 0.97 g/cm³ Flash point ISO C 140 C Viscosity, dynamic Brookfield 700 mpa.s 800 mpa.s at 25 C Autoignition temperature (liquids) EN C 370 C 9

10 With the new hybrid polymer GENIOSIL WP 1 it is now for the first time possible to formulate ETAG 005 compliant waterproofings based on α-silane technology. 10

11 The number 1 for standard compliant formulations: GENIOSIL WP 1 Setting New Standards Using this new hybrid polymer, building material and coatings manufacturers can formulate liquid waterproofing systems which have long-term reliability and which are suitable to meet the necessary standards of regulated construction projects for waterproofing of flat roofs. Formulations with GENIOSIL WP 1 comply with the European Technical Approval Guidelines for liquid applied roof waterproofing kits (ETAG 005) specifically, for all listed use categories, minimum thicknesses, load classes, and performance levels. Mechanical Properties of a GENIOSIL WP 1 Sample Formulation Density (ISO 1183-B) 1.3 g/cm³ Hardness Shore A (DIN A-87) 70 Elongation at break 250% Tensile strength (DIN /S1) 2.3 N/mm² Resistance to further tearing ASTM D 624 B N/mm Tensile adhesion strength in combination with tiles 1.4 N/mm² (DIN EN A.6.2) Skin-over time 40 min Water absorption (cured membrane 28 days stored in water) < 0.5% Viscosity at 25 C (Brookfield, Spindle 6, 50 rpm) 5,000 mpa s Crack bridging 2 mm Performance Comparable to PU In a benchmark test with a commercially available one-component PU waterproofing for professional use it has been proven that GENIOSIL WP 1 provides comparable performance plus additional benefits. Strength and Curing Time May be Varied By varying the formulation, it has also been possible to achieve strengths which surpass those of the benchmark product. In addition, the skin-over time may be set between 10 minutes and 2 hours by varying the formulation. The skin-over time depends primarily on the quantity of the aminosilane catalyst that is used, but is also affected by the fillers. Also Suitable for Applications with High Hydrostatic Pressure Liquid waterproofing systems based on GENIOSIL WP 1 are also suited for cases in which high hydrostatic pressure resistance needs to be achieved. Not only outstanding values of positive pressure resistance of minimum 6 bar but also negative pressure resistance of up to 4 bar can be achieved. This opens up further applications as e.g. sealing of an interior wall against external water pressure. Chemical Properties of Waterproofings Formulated with Geniosil WP 1 are Comparable to 1K PU Products Shore A hardness Tensile strength N/mm 2 0 Tear resistance N/mm Hybrid PU Additional benefits 1K but solvent-free, NCO-free, plasticizer-free, tin-free = No labeling required 11

12 The innovative GENIOSIL WP 2 hybrid polymer is the ideal choice for formulating general-purpose waterproofing and filling compounds for a host of applications ranging from basements to roofs. 12

13 THE PERFECT ALL-IN-ONE PRODUCT FOR POTTING & WATERPROOFING: GENIOSIL WP 2 An All-Rounder with a Unique Profile Its first-class properties come to the fore whenever different kinds of repair work require highly efficient and environmentally compatible sealing systems. Typical applications include: the reliable sealing of connecting parts and pipe penetrations; the repair of gutters; undertile coatings for balconies, patios and bathrooms; the dependable sealing of structural parts in contact with the ground (such as basement rooms); and sophisticated air barrier coatings. What s more, formulations based on GENIOSIL WP 2 are the ideal potting compound for horizontal expansion and movement joints. Simple, Yet Efficient Formulations The viscosity of the liquid sealant can be adjusted easily using fillers and rheology additives. This therefore enables the formulation of products used both in vertical (e.g. basement-wall sealing) and in horizontal applications (e.g. sealing underneath screed). Due to the low viscosity of GENIOSIL WP 2, no solvents are needed to lower viscosity. Highly Elastic and Able to Bridge Cracks A further advantage of formulations based on GENIOSIL WP 2 is their considerable elasticity. The cured membrane achieves elongation values of up to 600% and crack-bridging of approx. 5 mm. This is a reliable way to compensate for structural stresses. Meeting DIN Criteria The specific formulation will determine whether liquid sealants based on GENIOSIL WP 2 meet the requirements of DIN 18195, Table 9. Mechanical Properties of a GENIOSIL WP 2 Sample Formulation Density (ISO 1183-B) Hardness Shore A (DIN A-87) g/cm³ Elongation at break 400% Tensile strength (DIN /S1) Resistance to further tearing ASTM D 624 B - 91 Tensile adhesion strength in combination with tiles (DIN EN A.6.2) Skin-over time Viscosity at 25 C (Brookfield, Spindle 6, 50 rpm) Crack bridging 1.2 N/mm² 6.0 N/mm 0.7 N/mm² 40 min 5,500 mpa s 5 mm 13

14 ExpErtisE and service network on FivE continents Sales and production sites, plus 20 technical centers, ensure you a local presence worldwide. WACKER is one of the world s leading and most research-intensive chemical companies, with total sales of 4.91 billion. Products range from silicones, binders and polymer additives for diverse industrial sectors to bio-engineered pharmaceutical actives and hyperpure silicon for semiconductor and solar applications. As a technology leader focusing on sustainability, WACKER promotes products and ideas that offer a high value-added potential to ensure that current and future generations enjoy a better quality of life based on energy efficiency and protection of the climate and environment. Spanning the globe with five business divisions, operating 25 production sites, WACKER is currently active in over 100 countries. The Group maintains subsidiaries and sales offices in 29 countries across Europe, the Americas and Asia including a solidly established presence in China. With a workforce of 17,200, WACKER sees itself as a reliable innovation partner that develops trailblazing solutions for, and in collaboration with, its customers. WACKER also helps them boost their own success. Our technical centers employ local 14

15 specialists who assist customers worldwide in the development of products tailored to regional demands, supporting them during every stage of their complex production processes, if required. WACKER e-solutions are online services provided via our customer portal and as integrated process solutions. Our customers and business partners thus benefit from comprehensive information and reliable service to enable projects and orders to be handled fast, reliably and highly efficiently. Visit us anywhere, anytime around the world at: all figures are based on fiscal

16 The data presented in this brochure are in accordance with the present state of our knowledge but do not absolve the user from carefully checking all supplies immediately on receipt. We reserve the right to alter product constants within the scope of technical progress or new developments. The recommendations made in this brochure should be checked by preliminary trials because of conditions during processing over which we have no control, especially where other companies raw materials are also being used. The information provided by us does not absolve the user from the obligation of investigating the possibility of infringement of third parties rights and, if necessary, clarifying the position. Recommendations for use do not constitute a warranty, either express or implied, of the fitness or suitability of the product for a particular purpose. 6932e/09.12 Wacker Chemie AG Hanns-Seidel-Platz München, Germany Tel info.geniosil@wacker.com