TPO Waterproofing Systems using Novel Plastomers and Elastomers

Transcription

1 TPO Waterproofing Systems using Novel Plastomers and Elastomers Stefan Ultsch DOW Europe GmbH Global Waterproofing Markets Applications, Requirements, and Trends Norms and Testing VERSIFY TM Plastomers and Elastomers VERSIFY TM use in Waterproofing Systems /TM : Trademarks of The Dow Chemical Company

2 European and North American Single-Ply Roofing PVC TPO EPDM ECB CPE PIB CSPE EVA, CSM. LIQUID PVC TPO OXID BITUMEN APP BITUMEN APP BITUMEN EPDM SBS BITUMEN SBS BITUMEN LIQUID Europe = 340 mio m 2 /a North America = 320 mio m 2 /a /TM : Trademarks of The Dow Chemical Company

3 Global Waterproofing Markets European Olefinic Waterproofing Estimate Temporary Use Single-ply Roofing Relining Geo nets Tarps, P itched Roo f, Vapor Barriers Total = 160 k tons/a Geomembranes and Tunnel liners Drainage and Water Retentio n Waterproofing Tapes and Perimeter Sealants /TM : Trademarks of The Dow Chemical Company

4 Waterproofing Applications Unballasted (Naked) Roof /TM : Trademarks of The Dow Chemical Company

5 Waterproofing Applications Unballasted Roof, Mechanically Fixed Mechanical fixation Heat weld Fabric reinforced TPO roofing membrane No separation layer Thermal Insulation Vapor barrier Installation aid Base construction /TM : Trademarks of The Dow Chemical Company

6 Waterproofing Applications Adhered Roof Fleece backed reinforced TPO roofing membrane Fleece backing Adhesive Thermal Insulation Adhesive Bitumen Plywood/OCB Refurbishment Concrete /TM : Trademarks of The Dow Chemical Company

7 Waterproofing Applications Ballasted Roof /TM : Trademarks of The Dow Chemical Company

8 Waterproofing Applications Green Roof /TM : Trademarks of The Dow Chemical Company

9 Waterproofing Applications Ballasted Roof (TPO) Ballast (pebbles, stone chipping) Separation layer TPO, fleece reinforced roofing membrane No separation layer Thermal Insulation Bituminous vapor barrier Concrete /TM : Trademarks of The Dow Chemical Company

10 Waterproofing Applications Reversed Roof /TM : Trademarks of The Dow Chemical Company

11 Waterproofing Applications Reversed Roof Paving Filter/fleece layer Stone chipping Fleece layer (ROOFMATE TM MK) Thermal Insulation (STYROFOAM TM XPS) Adhered or loose laid waterproofing Substructure /TM : Trademarks of The Dow Chemical Company Trademark of The DOW Chemical Company

12 Waterproofing Applications Civil B&C Waterproofing Liquid roofing Insulation bonding Pitched roof Façade sealants Expansion joints Acrylics adhered roof Bitumen bonding PUR adhered refurbishment Wet room sealants Subsoil waterproofing /TM : Trademarks of The Dow Chemical Company

13 Waterproofing Applications Water Management /TM : Trademarks of The Dow Chemical Company

14 Waterproofing Applications Tunnel Liners /TM : Trademarks of The Dow Chemical Company

15 Waterproofing Applications Modern Architecture /TM : Trademarks of The Dow Chemical Company

16 Waterproofing Trends Converging but Growing Industries Price Driven Markets Broad Variety of Applications and Products 60 % Refurbishment, 40 % New Buildings Diversification: Roofing, Waterproofing, Water-Management, Tunnel liners Service and Quality Requirements are high Norms and Standards are manifold National Preferences TPO share is increasing at the expense of Bitumen, EPDM, PVC, Exotics Smart Accessories, Ease of Installation Environmental Friendly System Solutions One-Stop Shops /TM : Trademarks of The Dow Chemical Company

17 Roofing Application Requirements Dimensions Materials Property Requirements North America mils (1 1.5 mm) 12 ft width EPDM, Bitumen, TPO PVC = high quality TPO = Future EPDM = losing share Higher stiffness Mostly naked roofs Mostly for mechanical fixing White color, Energy Star Europe mm 2 m width Bitumen, PVC PVC = low quality TPO = On the rise Higher flexibility Many different roof types Mechanical, adhered, ballasted Extensive refurbishment Al(OH)3, MgOH 2 flame retardant for TPO Greyish 10 to 15 year warranties 25 year longevity /TM : Trademarks of The Dow Chemical Company

18 Roofing Standards: TPO NORTH AMERICA EUROPE ASTM D EN /2007 TPO Roofing Flexible Sheet for Waterproofing Property Test Requirement Test Requirement Common Overall sheet Thickness D 751 > 1 mm Effective Thickness EN MDV -5/+10 > 1.2 Mass per Unit Area EN > 80 g/m^2 > 1200 g/mm^2 Coating over Fabric or Scrim (Weathering Side) D 751 > Breaking Strength D N EN > MLV > 7 Mpa Elongation at D 751 > 15 % Reinforcement Break Elongation at Break EN ISO 527- > MLV > 500 % (Polymer) Tearing Strength D 751 > 245 N EN > MLV Resistance to Static Loading EN > MLV /TM : Trademarks of The Dow Chemical Company

19 Roofing Standards: TPO NORTH AMERICA EUROPE ASTM D EN /2007 TPO Roofing Flexible Sheet for Waterproofing Property Test Requirement Test Requirement Common Brittleness point D 2137, < - 40 ºC Foldability at Low Temperature EN > MLV -30 ºC, no cracks Ozone resistance (rubber only) D 1149 no cracks EN 1844 no cracks, pass Heat Aging D 573, 116 ºC Retained Break Elongation > 90 % Retained Elongation at > 90 % RTearing i f Strength t B k > 60 % Change of mass +/-1% Linear Dimensional Change +/-1% Water Tightness EN 1928, B Pass at 10 kpa (.1 Water Absorption / Exposure D471, < +/-3 mass% EN 1847 b BE ) > 200 % 70 ºC Change BE < 25 % Factory Seam Strength D 751, > 290 N EN Peel resist. > MLV Welding Window 25 mm Joint Strength EN Shear Resist. > MLV /TM : Trademarks of The Dow Chemical Company

20 Roofing Standards: TPO NORTH AMERICA EUROPE ASTM D EN /2007 TPO Roofing Flexible Sheet for Waterproofing Property Test Requirement Test Requirement Common Weather Resistance G 155 No cracks EN 1297 > 1000 h > 3000 h ballasted BS ret > 90 % > 1000 h > 5000 h naked roofs EB ret > 90 % 3 % Change of Mass Resitance to Impact EN , A > MLV pass > 700 mm fall h i ht Resistance to hail EN > MLV > 25 m/s Resistance to chaulk milk, acidic solutions, break elongation > MLV 200 % change of break Reaction l to Fire ti (for naked roofs) Flame retardancy Root resistance (green Bitumen Contact f(where l ) li bl ) EN ºC 28 d EN > MLV 25 % Class B, no dripping etc.. DIN EN 4102 System tests pren Pass, no root pren 1548 < 5 % t mass ti l EN Single Burning Item /TM : Trademarks of The Dow Chemical Company

21 Tunnel Liner/Geomembrane Standards International Standards Similar requirements and tests as roofing standards Some specialized tests & approvals required Environmental, drinking water approvals Special joint technology Specific water pressure Perforation testing Flexibility Specialty Plastics & Elastomers from DOW are the starting point for your waterproofing solutions /TM : Trademarks of The Dow Chemical Company

22 VERSIFY Plastomers and Elastomers Commodity PE & PP (with Conventional Catalyst) Modulus HDPE LLDPE ULDPE Et Elastomers Specialty PE & PP (with Metallocene & Post-Metallocene Catalyst ) EPDM Propylene based Plastomers/ Elastomers RCP ICP hpp 100% C 2 100% C 3 Comonomer Content /TM : Trademarks of The Dow Chemical Company

23 VERSIFY Plastomers & Elastomers Based on INSITE catalyst technolgy Propylene/Ethylene copolymer No reactor blends, no reactor cascades, no vis-breaking Tailored, narrow molecular weight structure No oligomers, no low-molecular weight fraction Excellent and lasting heat welding Excellent filler acceptance and properties /TM : Trademarks of The Dow Chemical Company

24 VERSIFY Plastomers and Elastomers Soft Compounds Injection Molding/Extrusion Coating 25 VERSIFY TM 4000 VERSIFY TM 4200 DE ºC 8 Film Sealants General Purpose VERSIFY TM 3000 VERSIFY TM 3200 VERSIFY TM 3300 Impact Modification VERSIFY TM 3401 Extrusion Grades 2 VERSIFY TM 2000 VERSIFY TM 2200 VERSIFY TM 2300 VERSIFY TM 2400 /TM : Trademarks of The Dow Chemical Company Density

25 VERSIFY Plastomers and Elastomers Product Designation MFR Density (g/cc) Shore A Flex Modulus (MPa) Typical Applications VERSIFY Food and Specialty Films, Blown Films VERSIFY Food and Specialty Films, Blown Films VERSIFY TPE, Calandering and Extrusion VERSIFY TPE, Calandering and Extrusion VERSIFY General Purpose, BOPP Sealant, Cast Films VERSIFY General Purpose, BOPP Sealant, Cast Films VERSIFY General Purpose, Elastic films, Cast Film VERSIFY Impact Modification,TPE/TPO, Cast Film VERSIFY Injection Molding VERSIFY Extrusion coating, Injection Molding DE Injection Molding /TM : Trademarks of The Dow Chemical Company

26 VERSIFY -based TPO Membranes VERSIFY Plastomers and Elastomers versus PVC No plasticizer migration, no separation layers Compatible with hot bitumen Lower density provides weight advantages Improved heat resistance Improved cold temperature impact Excellent root resistance Metal-free stabilizers, no biocides Advantages for drinking water applications No irritating fumes in heat welding /TM : Trademarks of The Dow Chemical Company

27 VERSIFY -based TPO Membranes VERSIFY Plastomers and Elastomers versus Bitumen One layer, installation cost savings No open torch required, no toxic fumes Easy to color Excellent root resistance, no biocides No environmental issues VERSIFY Plastomers and Elastomers versus EPDM No extender migration Heat weld possibility, no pre-confectioning Ease of installation Excellent root resistance /TM : Trademarks of The Dow Chemical Company

28 VERSIFY -based TPO Membranes VERSIFY Plastomers and Elastomers versus standard TPOs Broad heat welding window Long-term heat seal strength - No migration of Oligomers No pre-cleaning with solvent Long-term stable adhesion to fabrics Temperature resistance and flexibility design freedom Transparent / clarity Excellent filler acceptance, compatibility and morphology Excellent processing properties, higher production rates /TM : Trademarks of The Dow Chemical Company

29 VERSIFY -based TPO Membranes Processing Comparative Trials on Co-rotating Twin Screw Extruders Standard TPO Copolymer 30 wt% flame retardant 50 wt% flame retardant + Less die pressure = Potential for Faster Extrusion + Lower Mass Temperature = Faster Extrusion, less Stress on Flame Retardant + Excellent Appearance + Adjustable Flexibility + Excellent Scrim Adhesion /TM : Trademarks of The Dow Chemical Company

30 Lab-Scale Direct Extrusion Line Courtesy of BERSTORFF, Hanover Germany /TM : Trademarks of The Dow Chemical Company

31 Intake of polymers FR-TPO In-Line Compounding FR(40 50 wt%) M Pellets, flakes, powders Vacuum M M Atm. Vent Atm. Vent M Metering Degassing De-venting Dispersion Intake of powder De-venting Plasticizing Diagram with courtesy of BERSTORFF, Hanover Germany /TM : Trademarks of The Dow Chemical Company

32 VERSIFY -based TPO Membranes Starting formulations MATERIAL BALLASTED ROOFS GRADE AMOUNT (phr) ELASTOMER VERSIFY 2300, VERSIFY POLYPROPYLENE PP HOMOPOLYMER, INSPIRE STABILIZER BATCH VARIOUS, PROCESSING, THERMAL, UV COLORANT VARIOUS, WEATHERING RESISTANT 2-4 Often as pre-batch for ease of handling Up to 15% recycle can be fed into the lower membrane layer /TM : Trademarks of The Dow Chemical Company

33 VERSIFY -based TPO Membranes Starting formulations MATERIAL NAKED ROOFS GRADE AMOUNT [phr] ELASTOMER VERSIFY 2300, VERSIFY DE POLYPROPYLENE PP HOMOPOLYMER, INSPIRE FLAME RETARDANT MAGNESIUM OR ALUMINUM STABILIZER BATCH VARIOUS, PROCESSING, THERMAL, UV COLORANT VARIOUS, WEATHERING RESISTANT 2-4 Often as pre-batch for ease of handling Up to 15% recycle can be fed into the lower membrane layer /TM : Trademarks of The Dow Chemical Company

34 Summary Global Waterproofing Markets require different Solutions TPO Waterproofing is growing substantially TPO membranes provide improved properties Excellent heat-weld performance broad window, long-term stability Design freedom low-temperature flexibility, good fabric adhesion Processing advantages high filler acceptance, processability Let us assist you in solving your Waterproofing Needs Please visit us: /TM : Trademarks of The Dow Chemical Company