September EUROPEAN 2009 POLYURETHANE JOURNAL · 2017-09-05 · EUROPEAN POLYURETHANE JOURNAL KP...

EUROPEAN POLYURETHANE JOURNAL

KP VERLAGISSN 1867-3503

September2009

FACHMAGAZIN FÜR DIE POLYURETHANINDUSTRIE

German Issue Russian Issue

WORLD OF POLYUREA

10-1708-09-FAPU-EN-56-epj-b-fin.1 1 27.08.2009 17:22:33 Uhr

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Cover Photos: Hennecke, KraussMaffei, Elastogran


Countdown to a Fall Full of EventsThe way things are going nowadays it is getting harder and harder to keep track of the dates of all the events in our industry. The calendar in our website can help you stay on top of things.

The great number of upcoming trade shows and conventions would exceed the scope of our space limitations here. So we suggest having a look at our Event Calendar at www.fapu.de which is continu-ally updated. Should you be an exhibitor at any of the trade shows named below, we welcome your press releases. Please submit them well in advance and keep in mind that we can publish only articles relating to PU.

BONDEXPO, EUROCOAT, PUTECHEURASIA, FAKUMA, COMPOSITE EUROPE

… and, if after all these events you still feel like getting out and about – this time with your family – here are two suggestions:

1.The World’s First Oil Well – in the Lüneburg Heath The world’s first successful oil well was not drilled (as one might sus-pect) in Texas or Dubai; it was drilled in the Lüneburg Heath region of Germany. In 1859, prospecting in search of lignite in the village of Wietze, geologist Konrad Hunäus struck the „black gold“ at a depth of 35 m. In 1899 an oil rush broke out in Wietze when free-gushing oil was found in a well at a depth of 270 m. Within a few years, the oil boom transformed Wietze; its infrastructure was improved and a refinery was built. (See photo at right.)Drilling operations accelerated with tremendous speed. Wietze soon supplied some 80 % of the domestic oil demand in Germany. Up to 1963, when all operations were discontinued for economic reasons, a total of 2028 wells had been drilled in Wietze. Comparison of photos

from then and now reveals that the industrial “Little Texas” has since developed into a beautiful, tranquil town typical of the region.Today you can marvel at past technology, drilling rigs and history in Wietze’s Deutsches Erdölmuseum (German Petroleum Museum), which was opened in 1970 on part of the former oil field. You can learn about the different drilling and production techniques em-ployed and scrutinize an assortment of crude oil samples. The show-pieces of the collection are a number of oil well pumpjacks which are still in their original locations where they were operated up to 1963. For further information contact: Deutsches Erdölmuseum Wietze, www.erdoelmuseum.de

Birgit Harreither

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Event Calendar

Technical Articles PU-Directory

Events

World of Polyurea

Public Affairs

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BBG: World‘s first production plant for polyurethane window profiles

POLYURETHANE NEWS

The Chinese central govern-ment has approved the

Joint Feasibility Study Report submitted by BASF and SINO-PEC for the expansion of their joint venture, BASF-YPC Co., Ltd. (BYC), in Nanjing, China, as of July 1, 2009. BASF and Sinopec will jointly invest ap-proximately $1.4 billion in state-of-the-art technologies to produce downstream specialty chemicals for the Chinese mar-ket, serving multiple industries such as construction, electron-ics, pharmaceutical, automotive and chemical manufacturing. The investment, which includes

the expansion of the existing steam cracker, the construction of 10 new chemical plants, and the expansion of three exist-ing plants, will strengthen the market competitiveness of the joint venture by broadening the product scope and further leveraging the advantages of the integration.

The final approved project scope includes among other things the following:- The expansion of the exist-

ing steam cracker to a total of 740,000 metric tons per year of ethylene

- The development of an integrated ethylene oxide (EO) derivatives value chain, including:

- The expansion of the existing EO plant and the construction of a new EO purification unit

- The construction of EO deriva-tives plants, including a new butyl glycol ether plant, a new non-ionic surfactants plant, and a new amines complex for the production of etha-nolamines, ethyleneamines and dimethylethanolamine, and the construction of a new DMA3 plant

Engineering work for the expan-sion is in full swing. The routine cracker turnaround scheduled for 2010 will be used to tie in the expansion modules and integrate the production processes. The startup will take place in a stag-gered approach and the expan-sion will be operational from 2011 onwards. Simultaneously, Yangzi-BASF Styrenics Co., Ltd. (YBS), another joint venture in Nanjing between the two part-ners, is being merged into BYC to further increase synergies in Nan-jing operations. YBS produces styrene monomer, polystyrene and expandable polystyrene.

Chinese government approves expansion of Nanjing joint venture chemical

site by BASF and SINOPEC

BBG GmbH & Co. KG from Mindelheim in the German

region Unterallgäu have started negotiations with renowned window manufacturers on the construction of the world’s first plant for the series production of polyurethane (PU) window profiles with highly effective thermal insulation. The manu-facturer of molds, machinery

and plants, who is specialized in the processing of polyurethane, has developed concepts for two manufacturing lines for series production with varying output, following a research project that was completed over the past few months.

In addition to the fully au-tomatic manufacturing line

“ContiPart“ for capacities from 1.2 million linear profile meters as a continuously extruded profile, BBG has developed a “SinglePart“ line with smaller dimensions for an annual capac-ity from approximately 200,000 meters onwards. The window-producing industry is currently mainly interested in this line. The “SinglePart” manufacturing

line can be equipped with molds for profile lengths from four to six meters and can be operated semiautomatically with the profiles being fed and unloaded manually or with fully auto-matic feeding and loading. Eight encapsulation tools arranged in a carousel-shaped configura-tion on a rotating drum can be replaced independently of each

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More and more users benefit of the advantages of dos-

ing technology in comparison with traditional gasket systems. Dostech GmbH is specialised in processing of 1- and 2-compo-nents formed-in-place-gasket systems, adhesive and grouting materials and offers customised prototypes, small and middle lot sizes for many different in-dustries.

Whether fill in or sensor sys-tems, elements of telecommu-nications, operating systems in automotive interiors, navigation systems of aviation, indus-

try and mobile automation, pneumatic and electric drive technology, lighting systems or mobility aids, there are hardly any application limits.

The following example shows a problem and the recently prac-tised approach. In the electri-cal engineering an electrically conducting gasket should be batched on a base of only 1 mmbreadth. A mechanical stop cared for a gap of 1 mm between upper- and underpart in the assembled status. For a constant contacting and seal effect, the gap had to be filled in for sure.

Competent in solutions of dosing technology

other and can be fitted with molds for the production of dif-ferent profile types. Production consists of several steps. After the profile cores are encapsu-lated in the molds, which are mounted on a rotating drum, they are cut to length and pro-vided with spacers that maintain the right distance between core and sheath. The subsequent quality test is followed by the sheathing process. In the pro-cess, the rigid-foam inner cores are coated with a 2-mm layer of impact-proof compact foam in a second drum. After a short period of time, the profile cores can be processed further and can be painted, for example. Eight 6-m profiles can be produced in cycle times of 90 seconds each.

The target price is around 1.5 million Euros for the “Sin-glePart” manufacturing line and ca. 3.6 million Euros for the fully automatic manufacturing line “ContiPart”.

On the occasion of the Glasstec 2008 trade fair, BBG presented the high-performance heat-insulating „TopTherm 90” window, which is particularly slender on account of its width of 90 mm and was offered in a triple-glazing and in a vacuum-thermopane version, which met with great interest on the part

of the specialist audience. The standard window is the world’s first one with a polyurethane profile core and frame. It has been developed during the past two years by a company con-sortium within the framework of the “Hochwärmedämmende Fenster- und Fassadensysteme (HWFF, Highly-Insulating Windows and Facade Systems)” research project, which was headed by BBG. Mechanical test series on impact strength and rain permeability as well as thermal tests at the beginning

of 2009 have shown that PUR profiles are on a par with PVC profiles in terms of statics and

superior in terms of heat insula-tion.

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Whether it’s red mullet, South African strawberries,

Argentine steaks, French pous-sins, or prawns from Greenland – Elastogran’s PUR systems de-liver perfect insulation to ensure our much-loved delicacies arrive ice-cold through environmen-tally-friendly refrigeration that cuts expensive wastage.

The systems are designed to work effectively throughout all stages of the refrigeration chain – and they are suitable for much more than fine food. PU systems are also ideal for transporting sensitive items such as medica-tion, as the insulation provided is so efficient.

A vital link in the refrigeration chainThe refrigeration chain incor-porates the complete process of storage and transport from the producer to the consumer, and an effective chain guarantees the constant maintenance of the ideal storage temperature for the product transported. The more sensitive the commodity is (for example units of stored blood or perishable food), the faster the cool-boxes must connect to the terminal or onward transport.

The most crucial aspect for producers, hauliers, and con-sumers alike is a refrigeration system that is both efficient and protects resources. This can only

be achieved through perfect insulation of refrigeration con-tainers, whether they are boxes, hangars, cupboards or shelves. And it is in this field that the PUR systems of Elastopor® H, Elastopir®, and Elastocool® lead the way.

Welcome to the next generation of refrigeration technologyAs the need for high quality, cost-effective refrigeration trans-portation that cares for the en-vironment increases, so does the demand for high performance materials that really deliver at every step of the refrigeration chain. Elastogran’s Elastopor®, Elastopir®, and Elastocool® materials all combine greater insulation capacity with innova-tive technology to guarantee superior refrigeration.

16:1 – the factor you can count onOur intel-ligentpolyurethanehard foam

insulation systems offer greater sustainability, economy, and environmental protection. But how?

Saving energyWhen one euro pallet of deep frozen goods travels through the entire refrigeration chain – from

the manufacturer’s deep-freeze storage depot all the way to the consumer – 16 times more energy is saved (than was used during production) when PU insulation is used. That’s an energy conservation factor of 16:1*.

In other cases the saving can be greater still. In supermarket freezing, the energy conserva-tion is 25:1* and in refrigera-tion and freezing combination systems, the factor is 20:1*.

Cutting CO2 emissionsPU insulation reduces CO2

emissions by more than 13%*, as well as saving on resources by over 12%*

Green is goldBringing ecology and economy together under one roof is not that difficult when you already have the right people with the right ideas. Our people have de-veloped the most groundbreak-ing polyurethane hard foams – Elastopor®H, Elastopir®, and Elastocool® – for use in deep freeze halls, deep freeze transport, transport containers, refrigeration cells, supermarket freezers, refrigeration and freez-ing combination systems, and even the smallest of medical transportation boxes.

Leading the way in refrigeration insulation

The central issue was that the applied seal during the applica-tion was more wide than high at least by the factor 1.3.This would mean for a maximal sealing width of 1 mm, that only a sealing height of 0.7-0.8 mm could be reached – this would be too low for a custom-ised application.With the aid of a twincrawler the problem in principle could be solved. But this would im-plicate a high cycle time and a high material consumption.

The Dostech GmbH used in this case the conversion technology “TriShield” and brought the original dose increased seal from 0.8 mm height and 1,1 width to the required data of 1.3 mm in the height with a sealing width of only 0.7 mm.Because of the resulting over-hang of 0.3 mm, a swaging of 30% of the seal has been reached, what warranted an ideal sealing and conduction function. At the same time the seal also went a little more un-

stable and softer. This all led to less necessary forces of swaging processes. Thus also larger toler-ances can be caught.

In the meantime the product with this sealing system is on the verge of readiness for start of production. High reproducibility and high repeat accuracy by accurate measuring of the parts by the measuring system of the dosing system give the customer a high degree of process reli-ability.

The customers get a real added value by the experienced as-sistance at the construction of parts and selection of materials. If application-technological necessary the surfaces of the sealing elements also can be cleaned, activated, etched and sterilised with the aid of plasma-technology.

* The basis for these results is the current

conditions of PU insulation against the lowest

insulation strength available on the market

today.

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New Graco® XM Plural-ComponentSprayerThe new Graco® XM plural-

component sprayer provides precise ratio control, allows us-ers to download historical spray-ing data and handles a wide range of two-part materials.The Graco XM is engineered to proportion accurately, even at high flow rates; this allows cus-tomers to increase productivity and improve their profitability. At the heart of the precision ratio assurance is Graco‘s revolu-

tionary dosing technology. The main material component (res-in) flows constantly, while the minor component (hardener) is injected at higher pressures. Advanced sensing technology allows pumps to compensate for pressure fluctuations, resulting in accurate, on-ratio mixing for a better yield and less waste. The Graco XM is equipped with a USB drive that allows coat-ing contractors or equipment manufacturers to insert a flash

A fresh forecastAs consumers demand more, transport becomes faster and

more efficient, and saving money, energy and the envi-ronment become even more important, the future will allow only the very best refrigeration chain solutions and products. After all, it’s these products that will add value to companies and their customers.

Elastogran’s rigid foam systems are clearly the first choice for sustainability, efficiency and cost-effectiveness. They are the systems of the future.

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Hand-operated spraying instead of laminating by hand: Polyurethane as cost-effective and environmentally compatible GRP alternative

drive and download critical data. Downloadable data now includes parameters such as spray pressures, temperatures, actual ratio and total flow out-put. Users can save this data to a computer for analysis and future reference.

As coating standards evolve, stricter requirements are placed on how a material is applied. A perfect example are the Perfor-mance Standards for Protective Coatings adopted by the Inter-national Maritime Organization. With data downloads from

the Graco XM, operators can verify that they were spraying at the correct ratios and require-ments set by the coating’s manufacturer. It’s like having an onboard inspector. They have the confidence that the job was done right.

Each Graco XM is configurable. End-users start with a base unit, then select the accessories required for the specific applica-tion. Thanks to the dosing tech-nology (patent pending) and configurable options, the Graco XM can handle a wide range of

materials allowing customers to standardize equipment. The Graco XM base model includes a frame, mix manifold, Xtreme pumps, a flush pump, controls, dosing valves, a USB drive, two static mixers, one Graco XTR-7 gun, an Xtreme-Duty hose, choice of power supply, and a recirculation kit. Optional ac-cessories include: 26- or 76-liter material hoppers, hopper heat-ers, transfer pumps, agitators, hose rack kits and casters. Mate-rial hoppers can be mounted on the side or the rear of the XM unit.

Graco XM plural-component sprayers support multiple spray guns for added productivity and are ideal for corrosion-control applications, such as tank lining, secondary containment, marine ballast storage tank coatings, potable water tank coatings, shipbuilding and marine main-tenance, railcar maintenance, wind tower coatings, bridge and infrastructure projects, pipeline coatings, and for coating struc-tural steel.

For PU processors, the Poly-urethane-Composite-Spray-

Moulding (PUR-CSM) technol-ogy from Hennecke GmbH based in Sankt Augustin near Bonn is a set expression. For the very first time a new type of system allows hand-operated spray application, thus mak-ing the advanced polyurethanespray technology interesting for processors who laminate GRP in small series by hand. A novelty which offers the end consumer real added value and which can also convince in production as it uses neither solutions contain-ing solvents nor explosion pro-tection zones (ex zones).PUR-CSM enables glass-fibre reinforced components or composite mouldings to be made from PU systems in a PU spraying process. Due to the continuous further develop-ment of the spray technology and the associated identification of more and more fields of use, polyurethanes are now moving into typical GRP applications. The use of PUR-CSM fulfils the highest demands with regard to flexibility in production, repro-ducible component quality, and efficient material input.

Decisive for manual processing is a new 3-component spray mixing head with individually connectable glass fibre feed. In the hand-operated spraying process, the mixing head with its compact dimensions and its relatively low weight enables ergonomically correct handling for the machine operator. This means that longer operations, e.g. when manufacturing large components or great numbers, are no longer a problem. Thanks to the optional adaptation of spray lances which allow PU application at angular posi-tions of 45° or 70°, even the reinforcement of complex shape geometries or undercuts is con-siderably faster and simpler than is the case when processing glass fibre reinforced plastics. How-ever, the mixing head not only enables a targeted reinforcement with cut glass fibres. In combi-nation with state-of-the-art high pressure polyurethane metering machine technology and thanks to its 3-component design, the hand-operated PUR-CSM version is also suitable for direct applica-tion of various polyurethane foam layers (sandwich construc-tion). This ensures, optimal

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amongst other things, thermal insulation and improved acous-tic component properties in the form of clearly reduced acoustic emissions.Another plus for the operat-ing company is the excellent environmental balance of polyurethanes as, in contrast to traditional hand lamination, time and energy-consuming tempering processes can be eliminated. The fact that no

solvents are used also reduces the need for occupational safety measures, such as special ex-haust filter systems or safeguards for operators.This means that PUR-CSM spray technology considerably cuts production costs. Therefore, the use of CSM technology makes sense from both economic and ecological aspects. Moreover, the elimination of ex-zones is of major importance against the

background of existing hazard potentials for man and machine.In general, production by means of the hand-operated polyure-thane spray technology does not need any special requirements due to its conceivably simple system geometry. The PUR-CSM equipment demands little from the production location, but of-fers many options. For example, when using auxiliaries such as component positioners or

smooth running systems, which can be integrated at any time for production support without elaborate explosion protection measures. The sum total of the advantages makes CSM spray technology a convincing alter-native compared to traditional production methods, simply because the PUR-CSM technol-ogy of Hennecke GmbH adapts to the respective application and not the other way round.

Innovation for retrofittingWith its new constant pres-

sure injector, Hennecke offers its customers a patented innovation for fast and simple retrofitting. The low-main-tenance injector optimises a machine‘s performance effec-tively and brings further signifi-cant benefits to the production process. The patented high-tech

component also marks the start of a whole series of special offers for efficient upgrading as part of Hennecke GmbH‘s 360° spare parts service.

The newly developed constant pressure injector is much more than just a replacement, of-fering real added value in any

production process that uses Hennecke metering and mixing head technology. For example, there is a significant increase in production efficiency thanks to the flow-optimised injector geometry. And because gener-ally a lower operating pressure is needed, there is less wear and noise development in the meter-

ing pumps, and the energy con-sumption of the whole metering system is reduced. The constant pressure injector also offers the user more flexibility within the production process because

9


With the spin-off of the automotive business

division of Julius Heywinkel GmbH in August 2009 the legal and commercial requirements were met for the independent and clearly-defined launch of “Heyform Bramsche GmbH Systeme & Komponenten“ into the business sector of suppliers to the automobile industry. The unification of name and product had been secured. Heyform can now become a recognised brand name for all manufacturers of passenger cars, commercial and industrial vehicles.

Heyform provides panelling parts for vehicle interiors as well as parts for acoustic and thermal insulating. In addition, Hey-form’s development and produc-tion ranges from components and entire systems through to complete vehicle cabins for customers in the construction and agricultural sectors.

Klaus Pontius, Managing Director of Heywinkel Holding GmbH emphasises the brand values of the new company: “With Heyform, we are giving our customers an unmistakable brand, one on which they can rely.” “The new company of Heyform has given Heywinkel Holding’s automobile business both character and a name. Pontius continues: “I am satis-fied that in Heyform we have created a concern belonging to

the automobile supply industry able to perform independently and one which is recognisable as a stand-alone brand.”

With Heyform, the Heywin-kel-Group continues its course of independently developing special areas of technology. Julius Heywinkel GmbH was part of the Karmann group until 2007 when it was sold to the NORD Holding Unterneh-mensbeteiligungsgesellschaftmbH. The shareholders of the NORD Holding are the Lower Saxony Savings Banks, the VGH, and the NORD/LB. With their Evergreenfonds, the NORD Holding guarantees sustain-able concern development and provides stable customer rela-tions. Heyform’s most important customers are Volkswagen, Audi, Porsche, DAF together with Volvo, and John Deere in the commercial vehicle sector.

In spite of the current crises in both the financial and automo-bile worlds, Heyform anticipates a positive result in 2009. In 2008, 234 employees achieved a turnover of 44.8 million Euro. Pontius opines: “We have been

able to weather the effects of the crisis extremely well. And as far as 2010 is concerned, we con-fidently assume that this stable growth will be continued.“ During the course of Heyform’s jockeying for market position the company will concentrate solely on the automobile indus-try. Rainer Schönfeldt, Head of Sales and Development in Hey-form says: “We are the experts for special technologies in pro-cessing synthetic materials. We work with polyurethanes and almost every variation of natural fibre moulded materials.” In doing so, Heyform makes use of state-of-the-art technologies in the sectors of thermoforming, moulding, squeeze moulding, adhering and laminating pro-cesses including the associated cutting and joining processes.

One excellent example of the company philosophy of consis-tently risking something new is the innovative processing of natural fibre moulded materials.

Natural fibre moulded material is the ideal material for produc-ing panelling with decorative surfaces. A whole kilogramme

per square metre is saved when compared with injection-mould-ing. Higher safety requirements can also be met, which is particularly important for such crucial parts as door panelling. As a welcome side-effect one should not leave unmentioned the contribution to climate pro-tection. After all, not one drop of oil is needed when natural fibres are involved.

Heyform has already put these technologies into use and has been able to gain considerable experience. Just two examples are: cushioned arm rests with natural fibre supports and door panelling for vehicles from VW AG, at present in mass produc-tion.

The company has been certified by many OEMs, additionally fulfilling the highest qualitative demands that can be made on automobile interior panelling. From design through develop-ment and the construction of prototypes through to delivery of the complete sub-assemblies construction, Heyform covers the entire spectrum of a techni-cal expert.

Heyform: A new name for proven achievements

changes in output are possible from shot to shot without any further adjustments having to be made to the injector. Product changes can thus take place both rapidly and cost-effectively.

Moreover, the component also wins points in terms of operating safety. Thanks to the

automatic readjustment of the throttle gap, any dirt particles are very easily rinsed out.

Retrofitting is surprisingly easy and can be done in no time at all and without having to use special tools – just two screws have to be loosened. Not only is it very simple to install the

injector but it is also very easy to use. For adjusting the respective injection pressure, the adjusting nut simply has to be turned by hand.

The constant pressure injector, which offers an attractive price-performance ratio, is already available in different versions

for high-pressure mixing heads of the MX, MN and MT series. In future, the 360° spare parts service will be expanded by other innovative retrofitting measures that are tailored to customer needs and efficiency. More than just a replacement part – innovation for retrofit-ting.

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Sandwich panels with premium surface qualityWithin just a few months

of entering the market for double-band systems, Krauss-Maffei is reporting significant sales successes. A customer in Asia has placed an order – worth well over a million Euros – for a double-band system 36 metres long with a working width of 1300 mm. KraussMaffei cur-rently has on its books orders for double-band systems to the value of several million Euros.

The Asian system is due to go into operation in 2010 produc-ing premium quality PUR/PIR sandwich panels used in the construction of industrial build-ings. The steel surfaces of the panels are absolutely smooth – requiring careful and precise

manufacturing processes to avoid any visible surface defects.

The whole manufacturing process demands the highest precision. KraussMaffei devel-oped a special infeed geometry to minimize vertical movement and variations in feed rate. The result is highly uniform horizon-tal movement of the upper and lower bands. The two bands are supported in a high-precision and very stable frame, which guarantees maximum paral-lelism of the upper and lower band.

The high-spec slats were special-ly designed and made by Krauss-Maffei. Optimized welding and milling processes produce these

slats with minimal tolerances. The double-band system is fitted with a highly efficient tempera-

ture control system, capable of heating the bands up to 80 °C.

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CO2 cuts costs in PUR foaming

There is a steady trend to-wards using CO2 as the

physical blowing agent in flexible foam production. CO2

nucleation is already being used successfully in series production of back-foamed carpets. CO2

is also increasingly the option of choice in producing flexible foam seat elements for the auto-motive and furniture industries. KraussMaffei supplies reliable

and cost-effective systems for mass-flow regulated CO2 nucle-ation.

CO2 has a number of techni-cal and cost advantages as a physical blowing agent for PUR. Its high solubility means that it mixes very homogenously with the PUR components. As a nucleation agent, it improves the mixing quality. CO2 reduces urea formation, resulting in fewer hard segments in the flex-ible foam. Using CO2 produces low-density flexible foams with outstanding mechanical proper-ties. CO2 is a low-cost, environ-ment-friendly blowing agent and it’s available in virtually unlimited quantities.

Foaming systems that currently operate with conventional blowing agents can be easily ret-rofitted to use CO2 and deliver the same benefits. KraussMaffei CO2 nucleation units can be in-tegrated quickly and with mini-mal effort. The simplest solution – recommended for extremely low to medium CO2 concentra-tions – is a batch system that is linked directly to a day tank. For applications requiring very high CO2 concentrations, KraussMaf-fei offers batch systems where nucleation takes place in a buffer tank. The third approach is an online system where the CO2 is metered in at the mixing head. This variant allows CO2

concentrations to be varied from shot to shot.

In all three variants, CO2 meter-ing is mass-flow regulated, in other words, the concentration of CO2 in the PUR components is not affected by pressure or temperature. The process is en-gineered to ensure that the gas dissolves completely in the PUR component.

KraussMaffei expertise and trials in the company’s test lab will help to determine which variant is best-suited for a specific appli-cation. In addition, KraussMaffei makes loan equipment available, so that processors can try out the benefits of CO2 nucleation before coming to an investment decision.

Versatile spray system from KraussMaffei opens up new applications

Italian PUR processor Ruberti will soon be producing PUR

skins using new spray technol-ogy from KraussMaffei. The versatile process delivers very high surface quality even for parts with complex geometries. Further advantages are short cycle times and the significantly lower mould costs.

Ruberti specializes in production of PUR cladding and trim ele-ments used in a very wide range of products, from commercial vehicles and sports equipment to air conditioning systems, medical and other equipment. In all these applications, the parts must meet exacting me-chanical specifications. At the same time, customers expect surfaces that look good, have a pleasant feel and meet abrasion-resistance criteria.

These types of products provide a striking illustration of the process advantages of PUR skin spraying. The carefully con-trolled spray process delivers surfaces with a very high quality look & feel. Combining skin spraying with in-mould paint-ing (IMP) results in a one-step process capable of producing quality parts with high-gloss paint surfaces. IMP is far cheaper than a post-mould paint process. Mould costs are also significant-ly lower because the material is spayed into an open mould, so that only one mould half is needed and no sophisticated and expensive locking system is required.

KraussMaffei’s MK 2.0-2K-S-Lmixing head delivers the polyurethane without admix-ture of air, using a spray nozzle developed especially for this process. Important advantages

of this spraying method are the uniformity of the spray layer and minimal overspray. The mixing head is fitted with a lance to spray accurately even into awkward and inaccessible areas. This makes it possible to produce spray skins with complicated, three-dimensional geometries.

With precise temperature control all the way from the metering machine to the mixing

head, the system guarantees gentle, non-destructive process-ing of the material, and hence consistently excellent product quality. The flexibility and versatility of the new system will ensure that Ruberti is strongly positioned to meet escalating criteria for PUR products. This project once more illustrates the expertise and reliability of KraussMaffei as a supplier of solutions for PUR spraying.

12


Togetherfor climate protection

Polyurethane insulation an investment in the climate that pays off.

EXCELLENCE IN INSULATIONPu euRoPe

EXCELLENCE IN INSULATION

is the new name of the European polyurethane insulation association. While our name changes, our commitment remains the same :

Providing sustainable insulation solutions for low energy buildings40% of all energy is used to heat and cool buildings we live and work in. This is equivalent to 450 million tons of oil per year! Almost a third of this huge amount can be saved with no reduction in comfort. Even better, the investments required will pay off after only a few years so that they help citizens save money.

Reducing energy demand through high performance insulationOver the past years, Europe has taken major steps towards low and zero energy buildings and, by doing so, set an ambitious example to the whole world. The holistic building approach starts from a reduction of the

cient thermal insulation. Polyurethane insulation offers more than ever cost-effective solutions without major adjustments to the

In fact, no other insulant can offer the same level of thermal insulation combined with light weight, high compressive strength, moisture resistance and ease of handling, hence ensuring highest energy savings over the whole building life cycle. During its lifetime, polyurethane insulation will save as much as 80 times the amount of energy required for its production.

Learn more about the bene ts of high performance insulation at : www.pu-europe.eu and

www.excellence-in-insulation.eu or contact us directly at [email protected]

Pu euRRRRRRRRRRRRRR PPPPPPPEXCELLENCE INEXCELLENCE INN INNNNN INSUNSUNSUN UNS LATLATLATLA IONIONONNNNN INNNNN INSUNSUNSUN UNS LATLATATIONIONONNNN

will continue to provide positive contributions to the European legislative process and offer

its support to all initiatives promoting a holistic approach to the energy ef ciency and

sustainability of buildings.

Formerly known as


Premiere: Gravimetric Dosing of Liquid Colors

Liquid colors continue to be very popular as material

suppliers make full use of en-ergy and polymer cost savings potential. In addition to saving money, liquid colors offer the additional production benefits of high color consistency, low dosing amounts and rapid color changes. Novosystems says that due to these advantages, pro-ducer demand for liquid colors continues to rise for injection, molding, extrusion, and PU manufacture. Reason enough for Novosystems to radically rede-velop their whole program of mixing and dosing technology – resulting in a completely new system.

The basis of the new system is the WB4000 dosing device. This makes reliable and clean feed of liquid colors in a closed system possible. Easy calibration en-

ables color changes in seconds, not possible in the same way with Master batch. In addition to the use of a peristaltic pump, the WB4000 also features an eccentric screw head option, greatly extending dosing range. This allows for very large dos-ing volumes of up to 60 l/hr as required for extrusion processes. What’s more, the eccentric screw head makes technical opera-tion up to pressures of 40 bars possible. Material delivery via eccentric screw results in a very linear feed for the whole range of the feed volume and high-est dosing accuracy. A further benefit for special requirements of commercial operation is the delivery of color via pipes up to distances of 8 – 10 meters. This is useful when color contain-ers are not set up directly next to the manufacturing cell or where a steep incline has to be

overcome. Last but not least, a special quick-release system allows rapid changing of the ec-centric screw attachment.

The dosing device includes an injection molding and an extrusion mode with regranu-late management as well as monitoring of dosing volume and remaining material. Mixing and dosing data is logged by the WB4000 and backed up to data-bases. Additionally, the module can be integrated into existing IT infrastructure via LAN cable, Blue-Tooth, and WLAN. Users have the option of entering commands for the correct recipe via a PDA handheld device or a central PC or notebook. Novosystems also offers special software for these control op-tions, designed to handle up to 100 pumps.

Novosystems has developed two really innovative features: gravimetric management of liquid color dosing via software and scales. According to Novo-systems, gravimetric dosing of amounts up to 50 kg is possible. The system calibrates itself: gravimetric dosing also results in even more accurate dosing with minimal variation in compari-son with volumetric dosing with automatic adjustment. This new process means optimal consumption while maintaining

high color quality, especially with very small amounts of col-or. Secondly, optional integra-tion of the gravimetric technol-ogy via a handheld computer or WLAN – previously the standard for volumetric measurements is now possible.

To sum up: the different demands of plastic production processes and the whole issue of production volumes – from the deployment of liquid colors for laboratory extruders or micro injection molding through to high volume extrusion – Novo-systems has taken all of these requirements into account when designing the WB4000. High-tech dosing of liquid colors for increased potential and sig-nificantly more flexibility, when coloring plastics.

Everything under control: mobile control with

a PDA

High dosing accuracy in a closed system: dosing device WB4000 featuring an eccentric

screw resulting in a wider range of applications

Setting the standard for extrusion: eccentric screw attachment for production volumes up to

60 l/hr and up to 40 bar (quick-release attachment system)

Made to measure control options: stationary and mobile via PDA

14


Diepocell® MH 30 – An EngineeringMaterial for Vibration-Damping Pads with Good Dynamic Properties.This material developed by

P+S Polyurethan-Elastomere GmbH & Co. KG is used in a very broad range of applications in transport systems and lifting devices. When the machine or system supported vibrates at high frequencies, high energy absorption is required along

with good damping properties.These two properties are found in combination in Diepocell® MH 30. Increasing numbers of users in the application fields mentioned above demand a ma-terial providing good dynamic properties along with good damping performance.

Diepocell® MH 30 was spe-cifically developed to ensure minimum compression set even under high dynamic loads. This feature opens up new applica-tions in a wide variety of indus-trial sectors. Diepocell® MH 30 is a foamed MDI/polyester-based polyurethane. The compression

hardness of this material can be adjusted by changes in its apparent density. Densities are available in a range of 350 kg/m³ – 650 kg/m³. The table be-low summarizes its materials properties as well as the results of dynamic vibration-damping testing.

Test specimen D 56mm x 156mm Apparent density

Sample Original height = ho Cycles Frequency Deformation Height after dyn. Test Loss Loss No. ho [mm] Hz % h [mm] h [mm] h [%]1 156 400000 2 65 109,2 46,8 302 156 400000 1 65 140,4 15,6 103 156 400000 1 45 145,9 10,1 6,5

Dynamic Testing of Diepocell ® MH 30 - 50

approx. 0.50gr./cm³

Units Value409

% 55

MPa 5,9% 520

kN/m 15% 66

Tear resistance DIN ISO 34-1BOpen-cell content DIN EN ISO 4590

Tensile strength DIN EN ISO 1798Elongation at break DIN EN ISO 1798

Permanent set @ 80°C, 40% compression, 22h 80°C + 2h 23°C DIN EN ISO 1856 % 7,7

Permanent set @ 23°C, 40% compression ,72h 23°C DIN EN ISO 1856 % 6,6

Shore D hardness DIN 53505Impact resiliency DIN 53512

Mechanical PropertiesTest Method

Shore A hardness DIN 53505

15


Flexible foam is by far the single most important market for polyurethane

chemicals in South America, accounting for 65% of production in the region, whilst rigid foam accounts for almost 20%. These are two of the key findings in IAL Consultants’ new report, Polyurethane Chemicals and Products in South America. This is the third edition of this report, with the previous edi-tion being published in 2004.South America remains one of the most traditional regions of the world, the implica-tion being that long-established markets continue to hold sway, with innovative ap-plications and ideas tending to lag behind in terms of implementation in this region. In addition, the market is sensitive to a number of factors, including cost,and cheaper competing materials. However, on the back of a booming economic period for the region between 2003 and 2008, rising affordability has put the quality of polyure-thane goods such as mattresses and pillows in regional consumers’ rooms for the first time. However the global economic crisis has put this growth on hold somewhat.Brazil is the dominant producer of poly-urethane products, accounting for 378,500 tonnes of the total 558,480 tonnes output by the region in 2008 (about 67% in all).

Unsurprisingly Argentina is a distant second, barely accounting for 10% of the total.The collective CASE applications represent the third-largest end-use segment after flex-ible and rigid foams, with production total-ling 80,760 tonnes, as seen below:

South American Output of Polyurethane CASE Products, 2008 (Tonnes)Application Production, 2008 (Tonnes)

Cast Elastomers 1,500

Footwear 39,500

Synthetic Leather 1,500

Spandex 8,000

TPU 6,000

Coatings 10,200

Adhesives and Sealants 14,060

Total 80,760

Source: IAL Consultants

Once again, Brazil accounts for the vast majority of the output, accounting for 75% of the total.Although footwear is the largest subsegment of use, future projections suggest that this will find the slowest growth, up until 2013. Instead, the most rapid growth –albeit touching just 4% p.a. – will be in the coatings market.

From the market perspective:• Although Brazil is the third-largest pro-

ducer of footwear in the world, demand for polyurethane from the sector has been static in recent years. However, tightening health and safety regulations are expect to drive the demand for safety shoes, bring-ing some growth to the sector.

• Chile is witnessing rising demand for insulation products as the effects of global warming on climate are becoming more noticeable. This bodes well for all insula-tion types, including polyurethane types.

• In Colombia, as with many other countries in the region, a buoyant secondhand car market is boosting the automotive refinish sector. In general, environmental aware-ness in Colombia is higher than in many other countries, which is affecting the choice of paint formulations.

• Strong growth is expected in Peru, stem-ming from both the refrigeration and con-struction sectors. Rigid foams are therefore a key area of growth.

Polyurethane Chemicals and Products in South America is now available from IAL Consultants, priced 5 000 for a single hard copy edition. More information: www.ialconsultants.com

Polyurethane Chemicals and Products in South America

New Phono Spray S 904, S 907, and I 905 Thermo-Acoustic Polyurethane Systems

Synthesia Internacional S.L.U., Spain’s leading manufacturer of spraying polyurethane systems, Research, Quality, and Service

have always been and will always be their identity signs. Those three tools have led to the creation, development, and marketing of new products, such as PHONO SPRAY. PHONO SPRAY is the brand name of three current polyurethane systems, two for spraying – Phono Spray S 904 and Phono Spray S 907, and one for injection – Phono Spray I 905. The first two are for thermo-acoustic insulation against airborne noise and impact respectively. The third one is a thermo-acoustic polyurethane injection system for non-insulated cavities and restoration of existing building solutions.PHONO SPRAY S 904 is a low density, open cell polyurethane spray system for thermo acoustic insulation against airborne noise in different building elements. Due to its porosity and stretch, it is an absorbing material in intermediate cavities of double building solu-tions. Phono Spray S 904

16


Porosity, open cell

PHONO SPRAY S 907 is a high density, open cell polyurethane spray system for thermo acoustic insulation against airborne and impact noise in different building solutions. Due to its porosity and stretch, it is ideal for impact insulation in building floors or foundations.

Phono Spray S 907

Continuous system w/o thermo-acoustic bridges

PHONO SPRAY I 905 is a low density, open cell injection system for thermo-acoustic insulation in non-insulated building solutions under restoration. Also in dry wall partitioning, this system contributes to providing a robust plaster board, widely demanded by the final users.

Phono Spray I 905

Cavity filling with Phono Spray I 905

Spain has become the top European country in brand new building in the last few years, being polyurethane the most popular product in building, with over 500 million m2 insulated in Spain only. This is due to the excellent waterproofing, thermal and acoustic properties of the product, thanks to the new Phono Spray; adherence to any building material, quick fixation, over 500 m2 per day, equipment and continuous adaptability (without thermal or acoustic bridges) to all difficulties which come up every day during the building process are amongst the main features of this leading product.

And... how about the future? Energy saving, sustainable develop-ment and social welfare they all push for a better insulation quality. An excellent insulating material is understood as the one which com-bines waterproofing, insulation, and comfort. In the rest of Europe, restoration surpasses brand new building, this is the reason why Phono Spray I 905 injected material is ideal for renovation. No need for wall demolition, in a very easy and professional way, the product insulates both thermally and acoustically all those insulating mate-rial less existing cavities.

17


With sales of more than $ 1.3 bn, Hexcel (www.

hexcel.com) is the world’s lead-ing advanced structural materi-als company and is a global enterprise with over $ 1 billion in annual sales. With headquar-ters in the USA and 17 manu-facturing sites in Europe, USA, and China, it offers a breadth and depth of products and ser-vices that is unmatched in the industry. It manufactures a full spectrum of advanced material solutions – everything from car-bon fibre and reinforced fabrics to pre-impregnated materials (or prepregs) and honeycomb core, adhesives, tooling materials and finished aircraft structures, through to after-sales and sup-port.

The UK plant, in Duxford, Cam-bridge, is the European Centre for Research and Technology, and the main mechanical test-ing facility in Europe, and its laboratory is a critical facility for R&T, Qualification and QC operations.

Well equipped with fatigue, impact, tensile, flexure, and compression test equipment, it carries out research using more than 70 different testing specifi-

cations for its customers in the US and Europe. The laboratory is also heavily used by R&T in the development of new materials, whilst a significant amount of qualification testing is undertak-en for certification of materials for customers, including Airbus. In addition, most of the QC testing for Europe is carried out at Duxford.

20 years ago, Hexcel was the first company in the world to purchase commercial robotic testing systems for both tensile testing and flexure testing on composite specimens. The key objectives were to improve the consistency of test results especially the measurement of Elastic Modulus, and to speed up testing throughput. The robot system was used for both Research and Development work and routine QC tests.

More recently Hexcel purchased two more robotic testing sys-tems from Zwick Roell, this time with additional functionality as their markets now demand more extreme environmental testing, and the number of different specimen type and shapes has increased. For example, the lat-est systems carry out tensile and flexural tests inside a tempera-ture chamber operating between [-80 °C and +300 °C for tensile and 23 °C to 300 °C on flexure] using robots to handle the speci-mens between the user maga-zine and the testing machines.

“Testing using robotics removes many sources of error from the test. At the same time it allows

the operator more time to con-centrate on specimen prepara-tion,” comments John Rennick, Hexcel’s Laboratory Engineer. “After production the specimens are measured by an automatic measuring unit, and this helps us to guarantee high reproduc-ibility of test results from the very beginning.”

“Once the cross-sectional area is transmitted from the measur-ing unit, the optimum gripping pressure for the hydraulic tensile grips is set. This makes sure that the specimen is gripped correctly and avoids exces-sive forces which could cause specimen damage leading to premature failure of the speci-men. The main advantage of the automatic specimen measuring unit is the consistency of our specimen measurements which reduces errors in subsequent steps in the testing process. The specimen measuring unit also aligns the specimen so that each one can be inserted into the testing machine in precisely the right position and orientation. This is very difficult to achieve manually on a 24/7 operation,” he adds.

When testing above and below ambient temperature there are many challenges for testing laboratories. The test through-put is influenced heavily by the time taken for the temperature chamber, test fixtures, and specimen to reach the desired test temperature. All of this is handled automatically by Zwick’s latest roboTest® system which controls the tempera-

ture based on the pre-set test specification. The robot system inserts the specimens through a specially designed door in the temperature chamber and into the hydraulically controlled tensile grips or on to the flexure fixture. One of the robots’ main strengths is its ability to test a set of specimens with very little temperature variation between specimens.

The test is then carried out au-tomatically by the robot system, which takes over the complete process including the applica-tion of a digital extensometer, and allows operators to do other more important tasks. When carrying out flexure tests the span of the rig is motorised and is set by the software according to the test specification ensuring that specimens are always tested correctly. At the same time the testing system records the specimen temperature and logs it on the test report and in the data file together with all the mechanical test results.

Hexcel pioneers robotic testing of composites

These thermo-acoustic systems will fill those cavities which, whilst mixing with several common separating building elements, provide synergy value in their result.Values which, by the way, surpass the minimum requirements established in the Spanish Building Technical Code (CTE DBHR) of D2m,nT,Atr , between 30 and 51 dBA, RA over 33 dBA, DnTA over 50 dBA y L’nTw below 65 dB.

On-site spraying and injection, three materials (Phono Spray S 904,S 907 and I 905), plus a continuous result without thermal or acoustic bridges accomplish the airborne noise and impact insulation requirements of the CTE DB HR.Moreover, by combining Phono Spray S 904 with Poliuretan S Spray will obtain an on-site continuous thermo-acoustic waterproof solu-tion, absolutely unique in the marketplace.

18


NEWS

BASF specifies restructuring plansBASF has finalized its plans for the integration of Ciba Hold-ing AG, which it acquired in April 2009. Under the plans, former Ciba businesses are to be integrated into the operating divisions in BASF’s Performance Products segment where their potential can best be realized and developed. The integration will involve extensive restructur-ing measures that BASF expects to generate synergies of at least

400 million per year from 2012 onward. By the end of 2010, savings of approximately 300million are to be achieved. At the same time, the integration process is expected to entail cash costs totaling approximately

550 million, about 150million thereof in 2009. BASF will report details of non-cash integration costs as part of its second-quarter interim reporting on July 30, 2009.The restructuring plans include a reduction of approximately 3,700 positions by 2013, the majority of which will be elimi-nated by the end of 2010. BASF is reviewing strategic options – including restructuring, sale or closure – for 23 of the 55 former Ciba production sites world-wide. Decisions will be made about these sites by the end of the first quarter of 2010. The re-maining 32 production sites are to be optimized as part of BASF’s global production network or restructured. By the end of 2010, BASF also aims to consolidate 36 of the former Ciba’s 70 sales

and administrative offices and research sites with existing BASF activities.

Brand-Name Hoses on the InternetWhether sprinkler or drinking water hoses, hoses for the food, beverage, cosmetics or phar-maceutical industries, steam or cleaning hoses, compressed air hoses or autogenous hoses, construction or machine-feed hoses, large hoses, hydraulic hoses or multipurpose hoses – every hose must comply with certain material and construc-tion specifications in order to do the job it was designed for. End-users and sales partners can now get fast and comprehensive information via the Internet, including details of the techni-cal features, fields of application, and range of sizes for the most important brand-name hoses from ContiTech AG.Indeed, ContiTech has now added the Internet pages of five more brand-name hoses to its website (COLLECTOR®, PURPLE SNAKE®, TRIX AU-TOGEN®, TRIX BLAUSTRAHL®, and UNITRIX®), and has thoroughly revised the pages for three brand-name hoses (AQUAPAL®, LACTOPAL®, and TRIX ROT-STRAHL®) to give them a more user-friendly structure. Each hose is now accessible via its own domain (www.conti-collec-tor.de, www.purpurschlange.de, www.trix-blaustrahl, www.conti-unitrix.de, www.trix-autogen.de, www.aquapal.de, www.lactopal.de, and www.trix-rotstrahl.

de), as well as via ContiTech’s homepage www.contitech.de. All online product informa-tion is available in German and English.The same applies – but still in the old design – for the web pages of the GOLD SNAKE® high-grade water hose, CONTI FORMFLEX® water hose, and the BLAUDIECK® food and beverage industry hose.

UK Manufacturer Stiffens Up Competition With The Worlds Largest PU MachineCTM Equipment LTD, the UK agent for Cannon Polyurethane has successfully developed the world’s largest (PU) dispensing machine for use in the offshore industry. The equipment was specially designed to meet the requirements for Trelleborg Offshore’s bend stiffener produc-tion at their plant in Skelmers-dale, England for use in the Vega field in the North Sea. CTMs EL2000 dispensing machine produced its first record breaking bend stiffener in July ‘09 using a total PU volume of 5,360 litres/1,416 gallons. The 2,000 kg per minute machine incorporates a state-of-the-art control system designed to ef-fectively monitor and evaluate performance in-shot.Shane Wootton, Managing Director at CTM explains “with our integrated data capture sys-tem we enabled our customer to run extensive testing to ensure that the supply chain provides excellence right through to the end user”.CTM produce custom built machinery to suit applications including the offshore and sub-sea industries, with particular experience with filled syntactic foam and polyurethane elasto-

mers. In addition they act as the UK agent for Cannon Polyure-thane, and provide a range of solutions for all PU applications. To find out more about CTMs current projects including their revolutionary high-pressure low-output metering unit please visit: www.pu-technology.co.uk

Dow Plans to Shutdown its Ethylene Oxide and Glycol Plant at Wilton, UKThe Dow Chemical Company announced that it intends to close its ethylene oxide and glycol (EOEG) production facil-ity at Wilton, United Kingdom by the end of January 2010. The site employs 55 people. The actual number of jobs that could be impacted by the intended closure will be determined fol-lowing an employee consulta-tion period. „Decisions to shutdown a facil-ity are not taken lightly. A com-prehensive review of potential options was conducted, which included seeking a buyer for the site and engagement with indus-try leaders, regional and govern-ment groups to identify alterna-tives to a shutdown. A workable option was not identified“ said Malcolm Wilson, Site leader, Dow (Wilton) Ltd. „Without an economically viable alternative it is with great regret we have to announce our intention to stop production at the Wilton site by the end of January 2010.“ Several factors contribute to the intention to close the Dow Wilton EOEG plant, including the site‘s disadvantaged input costs. In addition, demand and profit margins for the site‘s out-puts, particularly monoethylene glycol (MEG), began to soften in early 2008. MEG economics have been significantly wors-ened by the global economic recession, further placing the Wilton site at a disadvantage. The ongoing recession is expected to prolong difficult global EOEG industry condi-tions for several years and has expedited the need for Dow to come to a decision regarding the Wilton facility.

19


PUR-NEWS NAFTA

ALTANA acquires Water Ink TechnologiesThe specialty chemicals Group ALTANA has entered into an agreement to acquire the busi-ness of the North American company Water Ink Technolo-gies, Inc. The company produces primarily water-based and UV inks, coatings and varnishes for narrow web applications at three sites in North Carolina (U.S.). Among others, these applica-tions are used for packaging printing and labels. In addition, Water Ink Technologies provides extensive customer service through several mixing stations in the U.S. and Canada. With consolidated sales of about $34 million ( 27 million) in 2008 and almost 150 employees, the company is one of the leading manufacturers of the mentioned products in North America. Within the Group, Water Ink Technologies will be integrated into the ACTEGA Coatings & Sealants division under the new name ACTEGA WIT. The existing Water Ink Technologies management team, under the leadership of Michael C. and Patrick S. Hague, will continue to run the operations also under the roof of ALTANA.

Bayer MaterialScience LLC to Close Resins Operations at New Martinsville, W.Va.As part of ongoing global restructuring initiatives, Bayer MaterialScience LLC has an-nounced the closure of its Coat-ings, Adhesives and Specialties (CAS) resins operations in New Martinsville. The New Martins-ville resins operations, which manufacture polyesters, polyure-thane dispersions and polyaspar-tic esters for use in the automo-bile, furniture and construction industries, are scheduled to cease production by the end of 2009. In the future, sourcing of these products will be consoli-dated into various world-scale Bayer MaterialScience facilities.The closure will affect ap-proximately 40 employees. These employees will have the opportunity to explore employ-

ment within other parts of the company. Bayer MaterialScience LLC‘s standard separation pay and benefit programs will apply to those who are displaced from the company.The New Martinsville site will continue to manufacture a range of polyurethanes raw materials used in the same industries, plus Texin® thermoplastic poly-urethane, which is used in the automobile, tool, sporting goods and medical industries. The site employs about 300.

BaySystems™ inks agreement with IDI Distributors Inc. BaySystems™ announces the selection of Eden Prairie, Minn.-based IDI Distributors Inc. as its premier U.S. distributor of spray polyurethane foam materials.IDI Distributors Inc., a lead-ing distributor of insulation products, is a privately owned business that maintains a cus-tomer-first policy. This custom-er-centric philosophy was one of the key factors in their selection by BaySystems™.IDI Distributors Inc. is able to supply its customers with spray foam products from BaySys-tems™ from its more than 25 locations. Customers are able to receive the products either same-day or within 24 hours. The spray polyurethane foam product families from BaySys-tems™ that IDI Distributors Inc. is distributing, effective immedi-ately, are:• Bayseal™ OC open-cell spray

polyurethane foam insulation is intended for wall insula-tion and sound attenuation in residential and commer-cial structures. Bayseal™ OC increases energy efficiency by filling open voids, cracks and crevices. Buildings insulated with Bayseal™ OC provide occupants with a quieter and more comfortable indoor space. Bayseal™ OC has an aged R-value of 3.9 per inch.

• Bayseal™ CC closed-cell spray polyurethane foam insulation seals the building envelope to create an optimal energy-ef-ficient environment, while

providing superior insula-tion, stopping air leakage and adding structural strength to the building. Bayseal™ CC is intended for perimeter wall application in residential and commercial structures. Bay-seal™ CC insulation is recom-mended for non-vented attics, ceilings, floors, foundations, piping and non-vented crawl spaces. It has an aged R-value of 6.9 per inch.

Dow Completes Specialty Polyols Capability Expansion at its Freeport, Texas, FacilityThe Dow Chemical Company (Dow) announced that it has further developed its specialty polyols manufacturing capabil-ity at the Company’s Freeport, Texas, plant to meet the demand for differentiated polyurethane products from customers in the automotive, coatings, adhesives, sealants and elastomers, and fur-niture and bedding industries. Polyols manufactured at the Freeport site support demand for specialty products and systems in North America.The completion of the project, which coincides with the clos-ing of Dow’s Sarnia, Ontario, polyols facility announced in August 2006, further strength-ens Dow’s competitiveness in today’s challenging economic environment.

Johns Manville Introduces JM Corbond IIITM, a Premium High-Yield Closed-Cell Spray Foam Building Insulation Johns Manville (JM) introduced JM Corbond IIITM, a premium high-yield closed-cell spray foam insulation product that comple-ments JM’s full line of Formalde-hyde-freeTM fiber glass building insulation. This is a result of JM acquiring Corbond Corporation, a 26-year-old manufacturer of advanced spray foam insulation. JM Corbond III, which is imme-diately available, is a spray-ap-plied, medium-density closed-cell polyurethane foam plastic insulation that can be used alone or in hybrid systems with JM fiber glass to create custom

insulation solutions for residen-tial, commercial and industrial applications. JM Corbond III offers the highest yield of any closed-cell foam building insula-tion, providing 5,000 to 5,200 board feet of coverage per set. It also provides superior thermal, moisture and cold-temperature performance and dimensional stability. It sprays at 3 inches per pass, allowing for maximum productivity. Corbond is now a wholly owned subsidiary of JM. Corbond em-ployees will continue operating out of the company’s Belgrade, Mont., manufacturing facility, where JM plans to build a prod-uct demonstration and training facility.

Lyondell to Restart PO/SM Unit at ChannelviewIn August, Lyondell Chemical Company announced that a pro-pylene oxide / styrene monomer (PO/SM) unit at Channelview, Texas, will return to service in September due to increased demand for propylene oxide and its derivatives. The unit was temporarily idled in December 2008 due to declining market and economic conditions.LyondellBasell, through its glob-al businesses and joint ventures, has the capacity to produce nearly 4.6 billion pounds per year of propylene oxide at facili-ties in the United States, Europe and Asia.

20


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From Pest Plants to PolyolInterview with Mr. Hans-Juergen Keil (CEO) and Ms. Jana Cavanagh (Sales & Marketing)

COMPANY PRESENTATION

As a globally operating business, Keil Anlagenbau

GmbH & Co. KG manufactures and services storage tank farms, production equipment, spe-cial devices and machinery as well as customized equipment, including supply equipment for solid and liquid chemicals that are both flammable and classified as harmful to water resources. Keil has been in the manufacturing business since 1973 and provides its customers with all-in solutions including licensing procedures and subse-quent maintenance and service inspection of the machinery / equipment and the electrical components. The philosophy’s emphasis is not only on estab-

lishing a variety of projects but also on guaranteeing the after service around the clock for seven days a week.

Which branches and markets do you operate in and how large is the proportion of the Polyurethane industry in these markets according to your estimation?H.-J. Keil: Our experience in the chemical industry, auto-mobile and foods processing industries makes us a competent partner for an extensive group of customers. Our staffers in the different departments in our company, engineering, pipeline and equipment construction, electrical engineering as well as automation, manage the work-ing processes together and effi-ciently on each common project and synchronize all individual project requirements, reaching an optimal implementation progress. The only field where we are less active is the field of structural and civil engineer-ing. Our markets comprise the PU industry in the first place, especially the elastomeric sector, but also cleantech develop-ments, process energy, block heat and power plants, biogas, ORC equipment, thermal oil equipment, biomass processing equipment for liquid biofuel production, and oil mills. The renewable resources sector is something I am personally in-terested in, and this goes also for the Polyurethane industry, mak-ing between 35 and 55 % of the Keil business volume depending on the size of the project com-missioned.

What does ‘cleantech’ mean?H.-J. Keil: ‘Cleantech’ stands for clean technology and it joins several industrial branches and

contains the following 11 seg-ments: production and storage of energy, energy infrastructure and efficiency, mobility, water and liquid waste, air and envi-ronment, materials, production, agriculture as well as recycling and waste.Cleantech’s emphasis is on integrated environment protec-tion. This means that the clean technologies try to get at the root of the evil, and to pre-vent any emissions in the first place. Great examples for clean technologies are such renewable energies as wind energy and hydro power, photovoltaics, solar heat and biomass. Also, the businesses in the Polyurethane industry should make a point of allowing zero emission in the production processes. It is our task to watch each produc-tion step very closely – exactly what remains do we have at the end of each production process and whether we can recycle the remains. This is for us the equip-ment engineering and construc-tion of the future.

On which significant exhibitions is the company Keil present and what sort of innovations have been shown to the general public this year?J. Cavanagh: The ACHEMA is a must for us. Of course we go

and visit other branch exhibi-tions such as UTECH, FAKUMA and K. On this year’s ACHEMA, we have been able to present the Big-Bag Unit BBU 2000. This is a new generation of Big-Bag discharge systems, developed by 3Defacto. It was a pleasure for us, as an exclusive sales partner, to be able to present this techni-cal innovation in May 2009. The improved BBU 2000 is definitely incomparable with the tradition-al Big-Bag discharge systems. By means of its new construction design without a crane, it meets the all the practical require-ments entirely. An intelligent swing device guarantees that the Big-Bag handling is determined by controlled movements – the time-consuming and laborious hanging-up of the Big-Bag and the handling with cranes can both be dismissed. In addition, the sack is straightened auto-matically, so there is no need for manpower during the discharge process.The qualities of the new BBU 2000 can also be seen at a commissioning procedure and during the maintenance and service inspection: the compact design, an electrical supply of mediums and the frame of the entire construction allow not only an easy installation but also an operation with simpli-fied maintenance and service inspection with clearly reduced cleaning costs.It is the variety that rounds up the performance of the BBU 2000: an extended version with equipment components such as conveying systems or dosing scales if required, or an optional design including stainless steel parts for solid bulk material make it a perfect discharge sys-tem for almost any purpose and application.

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Could you, please, tell us about a few projects that have been launched especially for the Polyurethane industry?J. Cavanagh: In the PU sec-tor, we take care of our German customers, those in the entire European market as well as of our international customers. If you have a look around, you will see Keil equipment on all continents today. Names such as BASF, Bayer, Elastogran, DOW, Faurecia, Johnson Controls and many others are well known to us and these companies belong to our long-time customers. The companies we have once launched a PU project for usually rely on us and recom-mend us to new prospective customers. For example, we have erected storage tank farms for liquid materials for our customer Kingspan Insulation at several European locations. We have engineered, delivered and set up a complete storage system for Polyol and Isocyanate in Hungary, the United Kingdom, and Belgium. Polyurethane insu-lation panels are manufactured on the basis of the said materials after mixing in some additives. The storage tank farms yield a volume of between 120 000 and 200 000 litres. Ireland and the UK are the places for the largest production locations of our customer King-span Insulation, and we supply and assemble aboveground and underground Pentane storage tank farms for the production facilities in Kingscourt (IR), Cas-tleblaney (IR), Holywell (UK), Sherburn (UK) and Pembridge (UK). The storage capacity is about 30 000 and 50 000 liters each.

We have been developing more projects in the Czech Republic and in the Netherlands. The storage capacity of Polyol, Iso-cyanate and additives is 280 000liters in the Czech Republic. Also, we have erected a 50 000liter Pentane tank there.

Another example is our cus-tomer in Basildon (UK), where we have set up a PU storage tank farms during a short construc-tion period of only 12 weeks. The storage tank farm supplies an equipment for the produc-tion of PU foam panels.

All in all, we have supplied and assembled

the following parts:

– 10 aboveground storage tanks with each

60 000 l capacity for Polyols, Isocyanates and

additives

– working platform with ladders

– filling platform with filling arm for

Isocyanate

– complete supply units for filling, discharge,

cooling and heating of the equipment

– complete prefabricated pipe bridge with a

span width of 16 meters. The complete pipe

bridge has been prefabricated and equipped

with pipelines, electrical heating and

insulation at our manufacturing plant.

– pipeline systems for all raw materials

– electrical switch boards and automation

– connecting an additional Pentane discharge

unit into an existing system. All of this has

been managed under hard conditions.

We started the constructing in mid-February and the 10 storage tanks were erected by mid-March. All filling/discharge pump units, switch cabinets and the pipe bridge had been assembled. During this time, the English weather truly lived up to its name. Our work was heavily impacted by rain and storm, but by virtue of superb coordination

of our well-rehearsed assembly team on-site, we were able to hand over the equipment on time and ready to be operated.

What are the projects that are getting started now?H.-J. Keil: There is one espe-cially interesting project that we are working on together with the University of Leipzig. As you may have already noticed, I have been very much involved with the renewable resources lately. As the use of sun flower and palm oil, along with rape and soy beans have been criticized in the recent times as being valuable foods used for purposes other than intended, the Jatropha plant, as a matter of fact known for many years, has become good news. To be more accurate, we are talking about the psychic nut (Jatropha curcus), a shrub growing eight meters in height. The capsule-formed fruits, up to 3 × 2 cm large, turn black when ripe and the seeds in the capsules contain oil up to 50%. With the cetane number of about 60 (rape has only 54), this oil is suitable for the production of biodiesel, a very successful application e.g. in India at this moment. The plant is able to grow even in sandy and saline soils and it can endure long periods of drought. The oil extracted from the nut has some chemical components that cause nausea, this is why the German name for the plant has originated ‘Brechnuss’ – ‘puke nut’ and it is not appro-priate as human food. Our research, which has been determined over a time scale of 2 ½ years, has the objective of developing equipment for the production of Polyol from this oil.

...and what exactly has the company Keil to do with this?H.-J. Keil: Well then, let’s start with the seed of this Jatropha plant. To be able to extract the seed from the nut, we have to handle the nut thermally and break the nutshell. Then we move on with our oil mills to press oil out of the extracted seed. The resulting waste is high-quality manure. At the end, the oil is cleaned and filtered.

During a biochemical process, the transformation of oil into Polyol takes place – this is the process we are working upon together with the University of Leipzig. The required equip-ment comprises bioreactors with a separating system next in line, to be able to separate “the good components“ from “the bad components“. The waste product can be recycled in a biogas equipment and used subsequently as energy source. The remains after this process can be used as manure – the perfect biogeochemical cycle that our business has developed the equipment for or already has on its program.

When would the information of the characteristics of the Polyols thus extracted be available and what kind of fields of application do you think there are?H.-J. Keil: I believe that we will be able to have some more accurate information in about 1 ½ years, and I am already looking forward to having the pleasure to present the upcom-ing project results in the FAPU magazine.

From Pest Plants to Polyol: the psychic nut

(Jatropha curcus)

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www.putecheurasia.com

Phone: +90 212 324 00 00 Fax: +90 212 324 37 57E-mail: [email protected]

www.artkim.com.tr

8-11October 2009Istanbul Expo Center

POLYURETHANE INDUSTRY EXHIBITION

Polyurethane is in every part of life...

PUBLIC AFFAIRS

Formerly BING is now PU EuropeEuropean polyurethane insulation industry adopts new name

PU Europe is the new name of the European association of polyurethane insulation – formerly known as BING. “With this move, we want to establish a closer link between the products we represent and

the name of our organisation,” the association’s secretary gen-eral Oliver Loebel said. “With the new European Parliament and Commission coming in, this change in name was very timely.”

There are indeed numerous challenges waiting for strong input from the polyurethane insulation industry. The revised energy performance of build-ings directive is in the legislative process and a number of parallel sustainability initiatives such as eco-design, energy label-ling, eco-labelling, green public procurement and a new basic works requirement of the future construction product regulation offer both risks and opportuni-ties. Other current priorities include the implementation of

REACH, the development of new EU rules for ozone deplet-ing substances and fluorinated greenhouse gases and the Euro-pean waste policy.

“With polyurethane, we have a fantastic thermal insulation product to meet the require-ments of low energy buildings,” says Loebel. “On the other hand, we see that a lot of awareness raising still needs to be done to show that with polyurethane, low energy buildings do not re-quire major design adjustments.

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Well-earned retirement for a driving force in the plastics sector

For several decades, Dr. Erwin Bürkle was a major force

for development and progress at KraussMaffei. He also played a key role in forging links be-tween science and industry for the whole plastics industry. In addition to being director of Predevelopment/New Tech-nologies and Future Technology Identification at KraussMaffei, Dr. Bürkle was also active on numerous advisory panels. He was always an innovator and an

expert with the interests of the whole plastics industry at heart. After he retires at the end of July 2009, Dr. Bürkle will continue to make his highly-valued expertise available to KraussMaffei as a consultant.

More than almost any other industry insider in recent years, Dr. Erwin Bürkle has shaped the development of injection moulding technology and driv-en forward acceptance of multi-technology solutions. As head of Predevelopment/New Tech-nologies and Future Technology Identification at KraussMaffei he drew together all the different strands of technological progress across the company. His endur-ing motivation was to facilitate productive partnerships between science and industry to the great advantage of both partners.

Dr. Dietmar Straub, CEO of KraussMaffei AG, commented: “Dr. Erwin Bürkle has become an institution for the entire

plastics processing industry. He has worked for KraussMaffei for over 48 years and has earned our highest respect and gratitude. Today we thank him from the bottom of our hearts for his tremendous commitment, his decisive innovations, the successful cooperations he has been instrumental in bringing about and his acute awareness of market and technology trends. I am delighted to report that Dr. Bürkle has agreed to continue his association with our com-pany by acting as a consultant.”

A remarkable careerAfter an apprenticeship as a toolmaker in Pforzheim, Dr. Er-win Bürkle joined KraussMaffei in the early 60s as a tooling de-signer in the Resource Engineer-ing department. “Even then I was impressed by KraussMaffei’s incredible power to innovate,” recalls Dr. Bürkle. He completed an apprenticeship as a mechani-cal engineering technician and then continued studying part-

time to qualify as an industrial master engineer. After a brief spell designing extrusion ma-chinery for another company, Dr. Erwin Bürkle moved back to KraussMaffei in 1968. In 1971, he completed his part-time qualification and immediately began working for a degree in mechanical engineering at the Technical University of Munich. After graduating Dr. Bürkle became a development engineer in the Application Engineering team for plastics machinery at KraussMaffei in 1978. During the 1980s, researching in paral-lel with his job, Dr. Erwin Bürkle obtained a Ph.D. from the Insti-tute of Plastics Processing (IKV) at the RWTH Aachen University under Prof. Georg Menges. The theme of his doctoral thesis was “Improved Understanding of the Plasticating System in Injection Moulding Machines”. Thereaf-ter, he concentrated on basic R&D into injection moulding processes at KraussMaffei.

This is an important competitive advantage for our products.” PU Europe has therefore launched a communication campaign and will have a joint exhibition stand with ISOPA at the world climate summit in Copenhagen (13-14 December 2009).

The organisation has its head office in Brussels and represents nine national trade associations and 20 supplier members. This makes PU Europe a unique plat-form which brings together the whole supply chain and allows for significant synergies in areas such as research and interest representation.

To mark the event, PU Europe has developed new websites for the association (www.pu-europe.eu) and for polyurethane insula-tion in general (www.excellence-in-insulation.eu).

EUROPEANPOLYURETHANE JOURNAL

F A P U - S U P E R - S U B S C R I P T I O NR E A D Y, S T E A D Y, G O !

© Foto: www.photocase.de

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NORRES Schlauchtechnik moves to new premisesNORRES, the Gelsenkirchen

based hose manufacturer, has taken up residence in its new home: the refurbished Plant II on the „Am Stadthafen 12-18 site“ in Gelsenkirchen was finally ready for occupancy on July 20. The full benefit of the significantly expanded manufac-turing capacities can now be lev-eraged as a result of the move to the new facility. The investment

in new plant during the last few months and years will make our production processes both faster and more efficient. NORRES‘ new headquarters boasts a series of modern energy saving tech-nologies that help protect the environment, such as centrally controlled air conditioningwith water chillers and produc-tion utilising heat recovery.

The new Plant II will also ben-efit for NORRES customers all over the world in a number of ways: The new, central ware-house covering approximately 25,000 m² of floor space with state-of-the-art logistics technol-ogy and nearly one million metres of hose and one million component parts and also 24 h delivery service. Owing to the extended warehouse capacity, the customers can profit from an even bigger stock and quicker availability of products in larger quantities. The investment in new production equipment and technologies has been simi-larly worthwhile. Our expanded manufacturing facility is more modern, more streamlined and above all faster, and our processes have been optimised still further. Our already high level of cost effectiveness is set to take another leap forward. In addition, more production lines

can be dedicated to custom-ised solutions. From now on, NORRES will be in a position to meet your needs even more flexibly – thanks not least to our in-house R&D and Engineering departments, which have been the source of many exciting in-novations in the past.

Numerous cutting-edge develop-ments in environmental protec-tion, energy saving technologies and efficiency improvements have been consistently imple-mented in all areas. To take just two examples, the centrally con-trolled air conditioning reduces energy consumption and creates a room climate that is generally more pleasant. Production lines utilising heat recovery lessen the environmental burden of our manufacturing processes while providing optimum insulation for the buildings.

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BASF’s eco-efficiency analysis wins international recognitionBASF’s eco-efficiency analysis has been awarded the inter-nationally recognized seal of approval of the National Sanita-tion Foundation (NSF). The U.S.-based NSF is an international non-profit organization that is active in the field of public health protection and consumer safety.The eco-efficiency analysis, which has already been evalu-ated by the German Association for Technical Inspection (TÜV), provides information on the relationship between the eco-nomic value of a product and

its impact on the environ-ment. This tool helps BASF and its customers to decide which products and processes are most suitable, both in economic and in environmental terms. The entire lifecycle of a product or production process is assessed, for example, in terms of resource and energy consumption, emis-sions to air, water and soil as well as risk potential.In collaboration with various stakeholders and product safety experts at BASF Corporation, the NFS has defined standard requirements for eco-efficiency analyses. The aim of NFS Proto-col 352 is to ensure conclusive-

ness, objectivity and transpar-ency for the different types of eco-efficiency analyses. BASF’s method has now been verified under the requirements of this protocol. “This NSF certificate is a big step forward and shows the increasing acceptance of our strategic ecoefficiency tool – also in the United States,” said Dr. Ulrich von Deessen, head of BASF’s Environment, Health & Safety Competence Center in Ludwigshafen.“NSF shares BASF’s commit-ment to the environment, and we applaud their leadership in helping to develop an intelligent methodology, which provides

solutions that improve the environment and the economy,” said Bob Ferguson, NSF Vice President.BASF’s eco-efficiency analysis is based on standards DIN EN ISO 14040 and 14044. Since the introduction of this tool in 1996, BASF has performed more than 400 analyses for BASF busi-ness units, as well as for external partners and customers. Eco-efficiency analyses have been conducted for major products in 90 percent of BASF’s product lines.For more information about the eco-efficiency analysis, visit www.basf.com/eco-efficiency

NEWS

In-House Symposium at Pestel PUR-Kunststofftechnik GmbH

On the 25th June Pestel PUR-Kunststofftechnik GmbH invited business partners, customers, suppliers and people or compa-nies with an interest in polyure-thane to a presentation on the company and its manufacturing capabilities. The information provided was impressive… In the last few years Pestel have developed into a market leader in large scale moulded parts with an injected weight up to 50 kg (up to 90 kg is possible with

their current machine), made in Polyurethane RIM Baydur 110. Such performance also im-pressed the judges at this years Automotive Plastics Awards where Pestel received 3rd place in the ‘Exterior’ section for the side panel of a harvester made by the company Claas. During the symposium Pestel demonstrated how the award winning side panel was pro-duced in addition to other com-ponents including the tailgate

and a bath frame. All visitors were impressed by the sheer size of the production equip-ment and by the commentary given by Mr. Pestel, managing partner, who explained how moulds made from aluminium and weighing up to 18 tons, together with presses that can handle up to 400 tons and the necessary mixing and dosing technology were all needed to produce these parts. Pestel’s real expertise is shown in how they make the individual pieces of equipment work together. All the moulds were designed and manufactured in the factory and engineered to meet the require-ments of the equipment (presses and dosing). By designing the large parts with ribs and undercuts Pestel is able to achieve economical manufacture with minimal manual intervention. Skills such as the positioning and type of injection point, methods of air release and the rib arrangement must be precisely mastered because there is no margin for error during the injection

of such large moulds. Further demonstration of the company’s innovation was found during the tour of the paint coating department where the design and build of the paint installa-tion and transportation equip-ment continued the efficient production line. State of the art CNC-tooling-machines are used in the mould manufacture. Here too the fact that large parts are a speciality of Pestel was vis-ible, with further moulds being manufactured from different kinds of polyurethane systems. Finishing and / or paint coating of the parts can be completed as and when it is needed.The presentation was rounded off with talks from, among oth-ers, Bayer Material Science on the uses and possibilities of Bay-dur products and Mankiewicz on paint coating applications.The combination of family and employee involvement, varied discussions with the owner, Mr. Pestel and professional discus-sion in a very pleasant atmo-sphere meant that the day was a success for all participants.

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Plastic Technologies - Made by FakumaThe World‘s Top Trade Fair for Injection Moulders

P.E. Schall GmbH & Co. KGGustav-Werner-Straße 6 · D - 72636 Frickenhausen Tel. +49 (0) 7025.9206 - 0 · Fax +49 (0) 7025.9206 - 620 [email protected] · www.schall-messen.de

Organizer:

Location:Messe Friedrichshafen GmbHNeue Messe 1 · D - 88046 FriedrichshafenMember of the associations:

13. – 17. Oct. 2009Exhibition Centre Friedrichshafen

w w w. f a k u m a - m e s s e . d e

20th FAKUMA – The International Trade Fair for Plastics Processing

• injection moulding machines• extruders and extrusion plants• Processing machines• machines and equipment for preprocessing• Machining centres and surface fi nishing machines

• blow moulding machines• presses• welding machines • Measuring machines and test instruments• recycling• auxiliary equipment

Exhibition Accents:

• Raw materials and auxiliaries• Semi-fi nished and fi nished goods• moulding tools parts and components• services


Faurecia joins Ford’s ABF network of key suppliersFaurecia’s addition to Ford’s Aligned Business Framework (ABF) to strengthen collabora-tion and drive mutual profit-ability and technology develop-ment Leading global tier one automotive supplier Faurecia was recently named by Ford Motor Company as a member of its Aligned Business Framework (ABF), the automaker’s network of key suppliers. Faurecia’s Inte-riors and Exhaust Systems prod-uct groups join ABF along with 15 other suppliers announced by Ford on June 24, 2009. Ford now has named 82 companies to its select group of component and service suppliers chosen for long-term relationships and closer collaboration.In 2008, Faurecia generated 10 percent of its global sales with Ford Motor Company and its affiliates. The Group supplies more than 35 Ford vehicles worldwide. Most recently Faurecia has partnered with Ford on the development and production of the instrument panel and door panels/modules for the Ford Fiesta, introduced in Europe last year, and the exhaust system (cold end) of the Ford Taurus.ABF companies enter into long-term relationships with Ford to strengthen collaboration and drive mutual profitability and technology development.

Another hat trick: three SPE awards for KraussMaffei Parts produced using KraussMaf-fei technology won three awards at the SPE Automotive Awards 2009. As in prior years, Krauss-Maffei convincingly demonstrat-

ed the strength of its innovative capability as worldwide the only manufacturer supplying machinery for three key plastics technologies – injection mould-ing, extrusion and reaction processing.KraussMaffei won first place in the category Body Exterior with a support element for the louvered grille of the CLS Coupe from Mercedes Benz. The metal-lic effect essential to the grille’s distinctive optics is produced during the injection mould-ing process without any extra painting process. In the same category, the jury, made up of members of the automotive industry, processors, mouldmak-ers, raw materials suppliers, engineering companies and plastics institutes, also selected another KraussMaffei develop-ment for an award. This award went to a bodywork component for a forage harvester manufac-tured using technology devel-oped by KraussMaffei’s Reaction Process machinery division. In the Powertrain category, a glassfibre reinforced roll restrictor for the popular Opel Insignia also won an award. The component is manufactured using a KraussMaffei system that controls the concentration of re-inforcing fibres to deliver high-est strength where required and minimum weight. Carrying off these three awards, the Munich plastics engineering company has repeated its success in the SPE Automotive Awards 2007 when it also won three awards.The Society of Plastics Engineers (SPE) aims to promote com-munication among scientists and engineers working in fields related to the development,

production and processing of plastics and plastics-based composites.

Momentive’s Ladislau Heisler Wins Foam Industry’s Herman Stone Technical Excellence AwardMomentive Performance Materi-als Inc. announced that Ladislau Heisler, Technology Leader, Ure-thane Additives, has been recog-nized as winner of the presti-gious Herman Stone Technical Excellence Award. The award, presented by the Polyurethane Foam Association (PFA), is given twice a year in conjunction with PFA technical programs, and is aimed at encouraging the shar-ing of technical innovations, the use of scientific methodology and professionalism in presenta-tion technique. “We would like to congratulate Ladislau and his team on this outstanding achievement,” said Tony Lanchak, Global Marketing Director, Urethane Additives, Momentive. “This award is testament to the dedication they put into developing new, high-performing products made from renewable materials that can help manufacturers lower the environmental impact of foam production.”Mr. Heisler’s winning paper, New Silicone Surfactant for Flex-ible Slabstock Foams Produced Using Natural Oil-Based Polyols, was presented at the Spring PFA meeting held in Baltimore, Maryland on May 20 and 21. The research focused on Niax sil-icone L-670, a new Momentive surfactant that is an excellent candidate to consider for flexible slabstock foams produced using natural oil-based polyols (NOP).

Consumer awareness of “green” issues and the depletion of non-renewable resources have heightened demand for the creation of foam products that leverage renewable content. The paper, which achieved one of the highest scores since the competiton’s inception, was co-authored by Gregory Pickrell. Momentive technicians Jolene Graham, Kevin Husk and Der-rick Johns performed the labora-tory work upon which the paper and presentation were based. Mr. Heisler’s team is based in Momentive’s Sistersville, West Virginia location.

SusChem Welcomes German CO2 ResearchSusChem welcomes a German government initiative to inject 100 million euro over five years into research into the use of car-bon dioxide as a raw material.This high-tech research pro-gramme offers opportunities for international cooperation and is expected to be an important contribution to SusChem, the EU Technology Platform for Sustainable Chemistry.The German ‘Technology for Sustainability and Climate Protection’ programme aims to put the positive into CO2 by researching its potential as a raw material and in the develop-ment of production processes which reduce the use of energy and resources and reduce carbon emissions. The German ministry recognises the key role the chemical industry has to play as it is at the start of so many value chains.The research programme is ex-pected to develop new processes using CO2 as a base chemical, for example for the develop-ment of high-value polymers which have a number of appli-cations including insulation.Gernot Klotz, Executive Direc-tor, Cefic Research & Innovation said: “As SusChem, we welcome any contributions to the sustain-able future of chemistry. This new initiative from the Ger-man government is particularly interesting as it turns the CO2

problem on its head and looks for a solution.”

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Trade Meeting – PU Elastomers16th – 17th September 2009Leipzig, GermanyOrganizer: KuZ, Kunststoff-Zentrum Leipzig gGmbHPO Box 31 07 32, 04211 Leipzig, GermanyPhone: +49-(0)341-4941500Fax: +49-(0)341-4941555e-mail: [email protected]

BONDEXPO21st – 24th September 2009 Neue Messe Stuttgart, GermanyOrganizer: P. E. Schall GmbH & Co. KGGustav-Werner-Straße 6, 72636 Frickenhausen, GermanyPhone: +49-(0)7025-9206-0Fax: +49-(0)7025-9206-620www.bondexpo-messe.de

24th European Photovoltaic Solar Energy Conference and Exhibition21st – 25th September 2009CCH – Conference Centre Hamburg, GermanyOrganizer: WIP Renewable EnergiesSylvensteinstr. 2, 81369 Munich, GermanyPhone: +49-(0)89-72012735Fax: +49-(0)89-72012791e-mail: heinz.ehmann@wip-munich.dewww.wip-munich.dewww.photovoltaic-conference.com

ABRAFATI 2009 23rd – 25th September 2009Transamerica Expo Center, São Paulo, BrasilOrganizer: ABRAFATI – Assoc. Brasil.dos Fabricantes de TintasDr. Cardoso de Mello, 1340 – 13º andar – CJ. 131 – Vila Olímpia, São Paulo – SP – CEP: 04548-004Tel.: +55 11-3766-9015Fax: +55 11-3766-9015e-mail: [email protected]; [email protected]

EUROCOAT 200929th Sept. – 1st October 2009Fira de Barcelona – Granvia/Barcelona, SpainOrganizer: Groupe ETAI – Eurocoat48-50, rue Benoît Malon, 94250 Gentilly, FrancePhone: +33-(0)1-419840-00Fax: +33-(0)1-419840-70 e-mail: [email protected]

Polyurethanes 2009 5th – 7th October 2009Gaylord National Resort & Convention Center On The Potomac, Fort Washington, MD (Wash., DC area)Organizer: Center for the Polyurethanes Industry (CPI), 1300 Wilson Blvd., Arlington, VA 22209, USA, Mrs. Neeva-Gayle CandeloriPhone: +1-703-741-5654, e-mail: [email protected]/polyurethane

PUTECHEURASIA Istanbul 20098th – 11th October 2009Istanbul Expo Center, TurkeyOrganizer: Artkim Fuarcılık Tic. Ltd. ti.nönü Caddesi Yıldırım Merkezi No:11, Kat:4

Çeliktepe/ STANBUL, TurkeyPhone: +90-(212)-324-0000Fax: +90-(212)-324-3757, e-mail: [email protected]; [email protected]

Understanding Polyurethanes – Seminar13th – 15th October 2009 Smithers Rapra, Shawbury, UKOrganizer: iSmithersShrewsbury, Shropshire, SY4 4NR, UKPhone: +44-(0)1939-250383 Fax: +44-(0)1939-252416 e-mail: [email protected]

MATERIALICA13th – 15th October 2009New Munich Trade Fair Centre, Munich, GermanyOrganizer: MunichExpo Veranstaltungs GmbHZamdorfer Straße 100, 81677 Munich, Germany Phone: +49-(0)89-322991-0 Fax: +49-(0)89-322991-19 e-mail: [email protected]

20. FAKUMA13th – 17th October 2009Expo Center Friedrichshafen, GermanyOrganizer: P. E. Schall GmbH & Co. KGGustav-Werner-Straße 6, 72636 Frickenhausen, GermanyPhone: +49-(0)7025-9206-0Fax: +49-(0)7025-9206-620www.fakuma-messe.de

testXpo – International Forum for Materials Testing 19th – 22nd October 2009Zwick premises, Ulm, GermanyOrganizer: Zwick GmbH & Co. KGAugust-Nagel-Str. 11, 89079 Ulm-Einsingen, GermanyPhone: +49-(0)7305-10-376Fax: +49-(0)7305-10-470e-mail: [email protected] / www.zwick.de

parts2clean 200920th – 22nd October 2009Stuttgart, GermanyOrganizer: fairXperts GmbHHauptstraße 7, 72639 Neuffen, GermanyPhone: +49-(0)7025-8434-15Fax: +49-(0)7025-8434-20e-mail: [email protected]

COMPOSITES EUROPE 27th – 29th October 2009New Stuttgart Exhibition Centre, GermanyOrganizer: Reed Exhibitions Deutschland GmbH, Project COMPOSITES EUROPEVölklinger Str. 4, 40219 Düsseldorf, GermanyPhone: +49-(0)211-90191-226Fax: +49-(0)211-90191-122e-mail: [email protected]

FSK – PUR-Conference10th – 11th Nov. 2009Würzburg, GermanyOrganizer: Fachverband Schaumkunststoffe und Polyurethane e. V.Am Hauptbahnhof 10, 60329 Frankfurt/M., GermanyPhone: +49-(0)69-299207-0Fax: +49-(0)69-299207-11 e-mail: [email protected]

PDA Europe 200916th – 18th November 2009Where: Phantasialand, Buehl / near CologneOrganizer: Polyurea Development Association Europe, AISBL142 Avenue Jules Bordet, 1140 Brussels, BelgiumPhone: +32-2-761-1611Fax: +32-2-761-1699e-mail: [email protected]

EuroMold 20092nd – 5th December 2009Trade Fair Centre Frankfurt/Main, GermanyOrganizer: DEMAT GmbHPostfach 110 611, 60041 Frankfurt, GermanyPhone: +49-(0)69-274003-0Fax: +49-(0)69-274003-40 e-mail: info@ demat.com www.euromold.com

Preview 2010

INTERPLASTICA 201026th – 29th January 2010ZAO EXPOCENTR Exhibition Center at Krasnaya Presnya, Moscow, Russia www.interplastica.de

POLYURETHANEX 201024th – 26th February 2010Pavilion 1, Hall 1, Crocus Expo, Moscow, Russiawww.mirexpo.ru/exhibitions

VDI: Plastics in Automotive Engineering 201017th – 18th March 2010Congress Center Rosengarten, Mannheim, Germanywww.kunststoffe-im-auto.de

EXPOCOATING – International Exhibition & Conference17th – 19th March 2010Olympiysky complex, Moscow, Russia,www.primexpo.ru

Blowing Agents & Foaming Processes 201019th – 20th May 2010Cologne, Germany www.polymerconferences.com

EVENT CALENDAR

31


MISCELLANEOUS EVENTS

American Coatings Show & Confer-ence 2010: Preparations underwayThe 2008 premiere of the American Coat-ings Show & Conference was a great success with 331 exhibitors, roughly 5,600 show visitors, and around 750 attendees at the conference. Now, in summer 2009, preparations are underway for the second edition of the leading trade show for the paint and coatings industry. The event will take place at the Charlotte Convention Center in Charlotte, NC. The trade show is scheduled for Tuesday, April 13th, through Thursday, April 15th,while the conference begins one day earlier and runs from Monday, April 12th, through Wednes-day, April 14th, 2010. The web site for the event at www.american-coatings-show.com provides an overview and will answer any questions that exhibitors and visitors may have. It contains infor-mation on many valuable topics, including details regarding travel and housing, important exhibitor information, product presentations and sponsor-ship opportunities. The show management team of the American Coatings Show will provide all necessary support to make your participation a success. For additional information please call +1. 7 70. 6 18-58 30 or send an e-mail to [email protected] who register before Oct. 10th, 2009, will receive an early booking discount for the exhibit space.

American Coatings Conference 2010: Call for papersThe 2010 conference will once again be the per-fect place for intensive networking at the highest level. A complete program covering the most cur-rent issues in the industry not only offers in-depth technical information, but plenty of opportunities for personal interaction with experts from around the world. Over the next few months, a team of experts from NPCA / FSCT and Vincentz Network will once again compile the list of presentations from all of the papers that are submitted. The call for papers is addressed both to innovative companies and to research institutions, and can now be viewed at www.american-coatings-show.com/en/conference. Abstracts can be submitted directly online through Sep. 15th, 2009.

Blowing Agents & Foaming Processes 2010 – Call for papers iSmithers is inviting papers for the twelfth inter-national Blowing Agents and Foaming Processes 2010 conference to be held in Cologne, Germany, 19th-20th May, 2010. If you would like to present a paper at the Blowing Agents & Foaming Processes conference please e-mail an outline of your pro-posed paper by 20th October 2009 to Gemma Da-vies ([email protected]). You will be allowed 30 minutes for the presentation at the conference which includes approximately 5 minutes for questions. Finished papers must be provided prior to the conference for inclusion in the pre-printed proceedings distributed free to all delegates at the event. The programme consultants will review abstracts submitted and authors will be notified of acceptance by 26th November 2009. Presenting authors at the conference will be entitled to free registration on both days including meals, refresh-ments and a copy of the proceedings.

COMPOSITES EUROPE 2009 with Prod-uct Demonstration Area From a three metre high windmill to a racing car, from a resin infusion to an intelligent surface: With its special Product Demonstration Area, COMPOSITES EUROPE will again create a special visitor attraction in the autumn in Stuttgart when it will open its doors for the fourth time. Together with the exhibitors, it will once again demonstrate the potential and the innovative character of composite materials from 27th to 29th October. The special display that is being created in cooperation with the Institute of Plastics Processing (IKV) at RWTH Aachen University and the Federation for Reinforced Plastics (AVK) is focusing this year on high performance composites. The main feature will consist of composites that contain continuous reinforcing fibres, such as glass, carbon or aramide fibres. Within the exhibition, the Product Dem-onstration Area offers visitors demonstrations of production processes, presentations of raw materi-als, intermediate and end products from various application industries as well as a variety of testing procedures for composite products. Access to the Product Demonstration Area is free-of-charge for the visitors to COMPOSITES EUROPE.

DEMAT und Gardner will organise the first-ever „amerimold” May 2010 in Cincinnati, USA With the premiere of “amerimold”, May 11th

– 13th, 2010, in Cincinnati, USA, DEMAT GmbH now launches its successful concept of EuroMold in America. “amerimold” is held in co-operation with Gardner Publications and aims to be the leading exhibition for Moldmaking and Tool-ing, Design and Application Development in North-America. The whole world of molds and tools as well as related technologies such as Rapid Prototyping and Rapid Manufacturing will be highlighted. The agreement of co-operation be-tween DEMAT GmbH and Gardner Publications, Inc., was announced by Dr. Eberhard Döring and Richard G. Kline at The NPE2009 in Chicago. “Having started successfully in Asia, we now are pleased to have the opportunity to bring the EuroMold concept and experience to the North American market,” said Dr. Döring. “Our target is to create the most important market-place for moldmaking and tooling and for product develop-ment in North-America. Furthermore we will link together all related areas of technologies, present state-of-the-art technique and thus support prod-uct development in America most efficiently.” Since 2006 DEMAT GmbH already has transferred the successful fair concept of EuroMold to foreign key markets. Promising EuroMold Pavilions have been established at RosMould (June 2th-4th, 2010 in Moscow) and at DieMold India (March 2010, 18-20 in Mumbai). DEMAT GmbH also organises the trade fair Asiamold in cooperation with Messe Frankfurt, Germany. It is the Asian sister event of EuroMold and will be held in Sep. 16th-18th,2009 in Guangzhou, China. Gardner Publications, Inc., established in 1928, is a leading producer of publications, websites and events. Richard G. Kline, CEO of Gardner, said: “The EuroMold show has become the premier European event. We will bring this experience and more to North America with the co-operation with DEMAT GmbH.”

From the 24th to 26th of February, 2010, the Exhibition Company “Mir Expo” holds the 2nd edition of the International Specialized Exhibition “Polyurethanex” which will take place in the International Exhibition Center “Crocus Expo”, Pavilion 1, Hall 1, Moscow, Russia.

The primary purpose of the Exhibition is to arrange the venue which will help exhibitors to establish new business contacts and partner relations, the event which will encourage the development and implementation of the polyurethane technologies and materials in various branches of industry.

The Exhibition’s Main Subjects: Raw Materials for Polyurethane Manufacturing; Polyurethane Producing and Processing Technologies; Foamex based Thermo Insulation; Polyurethane Use / ApplicationWithin the framework of the Exhibition there will take place the 2nd Re-search-&-Practice Conference „The Modern State and Prospects of Develop-ment of Polyurethane Materials Production and Use in Russia” as well as the presentation of the exhibiting firms. More Information: [email protected], www.mirexpo.ru/exhibitions/

32


WORLD OF POLYUREA

Event Calendar Polyurea

PDA 2009 Leadership Meeting14th – 15th September 2009Kansas City, MO (meeting location TBA)Organizer:Polyurea Development Association400 Admiral Blvd.; Kansas City, MO 64106Phone: +1-816-221.0777, Fax: +1-816-472.7765www.pda-online.org

Polyurea Applicator Spray Course6th – 9th October 2009Polyvers Facility, 9777 West Gulf Bank, Suite 15,Houston, TX 77040Organizer:Polyurea Development Association400 Admiral Blvd., Kansas City, MO 64106, USAPhone: +1-816-221-0777, Fax: +1-816-472-7765www.pda-online.org

PDA Europe 2nd Spray Course19th – 22th October 2009, in German languagePanadur GmbH, Am Sülzegraben 17, 38820 Halberstadt, GermanyOrganizer: Polyurea DevelopmentAssociation Europe, AISBL; 142 Avenue Jules Bordet, 1140 Brussels, BelgiumPhone: +32-2-761-1611, Fax: +32-2-761-1699e-mail: [email protected]

Annual Conference PDA Europe 200916th – 18th November 2009Phantasialand, Bruehl near Cologne, GermanyOrganizer: Polyurea Development Association Europe, AISBL142 Avenue Jules Bordet, 1140 Brussels, BelgiumPhone: +32-2-761-1611, Fax: +32-2-761-1699e-mail: [email protected]

PDA 2010 – Annual Conference13th – 15th April 2010Orlando, FL, USA (More information coming soon!)Organizer: Polyurea Development Association400 Admiral Blvd. Kansas City, MO 64106, USAPhone: 816.221.0777 Fax: 816.472.7765www.pda-online.org/

PDA’S 2010 Annual Conference ‘Call For Presentations’The Polyurea Development Association (PDA) is pleased to announce its ‘Call for Presentations’ for the 2010 Annual Confer-ence in Orlando, FL, April 13 – 15, 2010. The abstract submission deadline has been extended until September 30, 2009.

Suggested presentation topics include:• Coating projects that originated through a

government entity• Projects focusing on novelty of application,

uniqueness of design, or success where other coatings have failed

• Specifying coatings into Miami-Dade• Polyurea industry trends, new technologies,

case studies etc!

If you or your company has a topic you would like to submit for this year’s annual conference please contact Kelin Bower at 713.466.4988 or [email protected] or Erin Nied with PDA at 816.221.0777 or [email protected].

33

www.composites-europe.com

Register now and get your discount!

www.composites-europe.com/tickets


POLYUREA – TECHNICAL ARTICLES

Evaluation of applied film thickness for Polyurea thick-film elastomeric coating/lining systems over concrete substratesDudley J. Primeaux II, Primeaux Associates LLC, Elgin, Texas, USAKelin Bower, PolyVers, International, Houston, Texas, USA

Key learning points:

Learn about the importance of maintaining a minimum applied polyurea coating / lining film build and the resulting failures that can and will occur. Gain a basic understanding of the industry stan-dards and tools associated with evaluation of applied polyurea elasto-mer coating / lining film thickness. Learn how ultrasonic gauges can be used successfully to monitor applied film thickness for a polyurea coating / lining system over concrete substrates.

Abstract

In the application of coating / lining systems, applied film thickness is an important aspect in the execution of the project. Specifica-tions call for a required minimum film build, not to verify material use, but because it relates to the overall performance of the project. Knowing the applied film thickness of the coating / lining system as the job proceeds also helps determine if one has obtained sufficient material to successfully complete the application work as specified. Traditional wet film thickness measurements used in coating / lining work may not readily apply to the polyurea technology. This is due to the unique characteristics of the polyurea technology, primarily the fast cure / set of the system. Other forms of cured film thickness measurement are then required for polyurea elastomeric coating / lining systems. These methods may either be destructive or non-destructive to the continuous membrane. Destructive methods used will require repair of that area tested. Non-destructive methods may require the use of highly expensive and delicate test equipment. But either way, monitoring applied film thickness is a part of quality and can help insure a successful polyurea coating / lining project. This paper will take a look at the various applied film thickness measure-ment techniques and how they relate to the polyurea elastomer coat-ing / lining technology. Specifically, this paper will focus on ASTM D 6132 – 04: “Standard Test Method for Nondestructive Measurement of Dry Film Thickness of Applied Organic Coatings Using an Ultra-sonic Gage” and the new SSPC Paint Application Specification No. 9: Measurement of Dry Coating Thickness on Cementicious Substrates Using Ultrasonic Gages.

INTRODUCTION

In coating / lining work, it is essential to obtain the specified mini-mum or minimum average coating / lining thickness. In addition, that applied coating / lining must be uniform and void free to pre-vent potential premature failures that can and will occur. Film thick-ness can affect the color, gloss, surface profile, adhesion, flexibility, impact resistance and hardness of the coating. This is especially true for the fast set, plural component polyurea spray coating and lining systems (1). While these type systems do offer performance and in-

stallation advantages over other coating technologies in many appli-cation areas, they too are subject to proper installation methods and surface preparation. This is especially true for concrete substrates.

If the applied systems are too thin, or less than specified, and espe-cially if the application is one of corrosive chemicals and potential abrasion, the system can easily be breached, or worse yet, removed from the substrate. If the application is a lift station, as shown in Fig-ure 1, then the loosened lining can be caught up in the pump system and lead to expensive shutdowns.

Figure 1: Failed Polyurea Concrete Lining System

Lower than specified film thick-ness led to a weak polymer membrane that did not possess the reported elastomer properties as published on the product data sheet. The turbulence inside the lift station, compounded with the

downspout of the wastewater stream, resulted in tearing of the poly-mer film. The failure of this application required shutdown of the facility and complete removal and replacement of the lining system.

For outdoor applications with environmental exposure, thin, non-uniform applied systems will show significant degradation. The following Figure 2 was taken from a roofing application where poor application technique resulted in a non-uniform membrane.

Figure 2: Failed Polyurea Roofing System

The thin film application, cou-pled with the constant UV and environmental conditions lead to deterioration of the polymer film, thus exposing the exiting sub-strate. Failure occurred in the thin film portions of the coating sys-

tem where cracks and tears began to form. While the thicker areas, or those that met minimal film build required, although discolored, have held up well, the roof still leaked and the application did not perform as intended.

These failures, and many more, could have potentially been avoided with proper application training and attention paid to the specifica-tion requirements and minimal applied film thickness requirements (2). Requirements are not placed in specifications arbitrarily, but to insure the performance required for the application project.

34


Thickness Measurement Methods

So just how does one measure the applied film thickness of these types of polyurea coating / lining systems to concrete? The tradi-tional and easiest method recognized by the industry is the use of notched gages on the applied wet film (3, 4). While this is a fast, economical process, the applied coating systems must remain in a liquid state for a period of time to properly use the gauge. With fast set systems, like polyurea, a wet film gauge is woefully inadequate.

As the polyurea spray elastomer gels or sets very rapidly, usually within 15 seconds, there is no time to place the gauge in the “wet” material, remove and achieve accurate reading. Also, the gauge can become stuck / glued into the polymer system, or damage the mate-rial, leaving visible defects. See Figure 3.

Figure 3: Wet Mil Gauge in Fast Set Polyurea

Other methods, although destructive, would include the P.I.G. or Tooke gauge for the dry film thickness (5). While these are typically employed on thinner film coating systems, < 10 mils (254 μm), they can be used on the thicker applied coating systems. However, it has been shown in some cases that when using this technique on the thicker applied polyurea elastomeric systems, the resilient qualities of the film build do not allow for a clean cut and

inconsistent readings can be noted. Some may actually be “un-cut-able” or soft, gooey like and reading of the cut angle is useless for evaluation. In addition, repair to the test area must then be done.

Magnetic gauges could be employed with some creative work on the side of the contractor / applicator (6). By either driving large head metal nails in the concrete substrate, or by placing small metal panels on the surface, followed by application of the coating system, magnetic thickness gauges can be used. Figure 4 is a simple illustra-tion of that procedure.

Figure 4: Polyurea Applied Over Nail or Metal

Plate

While this procedure may seem simple, easy and ideal, it is not without problems. The “hu-

man factor” then comes into play. If the coating applicator knows the purpose of the nails or metal panels, he may tend to pay more attention to that specific area with application of the coating. This may lead to those areas being within the average minimum thick-ness requirements, while leaving areas outside that are thinner than required.

The use of the nails can also result in raised or higher levels in the coating application. This can result in both aesthetic issues and performance concerns if traffic or mechanical movement is present in the area, such as clarifier lining work. For the metal panels, unless these are permanently bonded to the substrate, areas of de-bond-ing can be noted especially if multiple locations are used for overall thickness measurements, such as that required in SSPC-PA 2 or SSPC-PA 9 (7, 8). This is not always such a good method.

Relatively new to the arsenal of the coatings applicator and inspec-tor is the ultrasonic gauges for use on concrete / cementicious sub-strates (9). These gauges work by sending a signal (ultrasound) pulse through the applied coating system and measure the time required for bounce back from the substrate of that signal. Using this data,

the gauge then calculates the coating thickness. It is thus essential that the proper transducer / detection probe be used for polyurea systems.

It has been discussed by some that the ultrasonic gauges do not work well for applied fast set polyurea spray elastomer systems (10). This is due, as is claimed, to the fact that the applied polyurea, due to the high pressure impingement mixing, is microcellular and this inter-feres with the signal. Also that it may be “deformable” under load of the test probe. While some of this might be true to a minor point, there are some other factors that come into play with polyurea sys-tems and knowing these polymer characteristics of polyurea systems can help overcome this situation.

One of the characteristics of the polyurea spray technology, aside from the possible microcellular nature, is the fact that the polymer builds higher molecular weight at the outer surfaces of the polymer cross section thickness (11, 12). This is unlike polyurethanes and epoxy systems that possess relative uniform polymer molecular weight distribution throughout a cross section of the polymer film. Since ultrasonic units work off changes in density, the unit “sees” the applied layers or spray passes. This is what often confuses ones using this method for thickness evaluations with applied polyurea spray systems.

As such is very important that verification of the calibration be conducted before the unit is used on the project, and that this be re-affirmed throughout the measurement process. Initial spot mea-surement should be made to give one an idea of the applied coating thickness range. Once this is confirmed, the gain can be adjusted on the unit to evaluate that thickness range thus overcoming “noise”. Furthermore, one can also get an idea of how many passes or layers have been applied. ASTM D 6132, Section 3.3.3 does note that non-uniform coating density can influence accuracy

Again, proper transducer probe use is essential for the polyurea systems. It has been found that the “D” probe is the optimum and suggested probe to use when evaluating applied film thickness for fast set polyurea spray elastomer systems.

Concrete Coating / Lining Measurement Testing

One of the largest uses for the polyurea spray elastomer technology is in coating / lining of concrete substrates (13). With that in mind, it is very important that proper applied film thickness be observed to insure performance in these application areas. To illustrate the use-fulness of the ultrasonic gauges, a series of experimental test panels were prepared.

A series of prepared concrete blocks, (8” x 16”, 20 cm x 40.6 cm) were used. These were prepared such that a profile of CSP 2 to CSP 3 was present (14). The top half of each block was primed with an epoxy primer system. In the center of each block, a metal coupon (3” x 5”, 7.6 cm x 12.7 cm) was used for thickness measurement using magnetic gauges. The top portion of the metal panel was taped off to allow for conventional micrometer testing of applied dry film thick-ness. The metal coupons had a surface profile of 3 to 4 mils, 76 to 101 μm. This is illustrated in Figure 5.

Figure 5: Concrete Test Samples

Using a fast set spray polyurea elastomer system, with a gel time of about 10 secs and tack free time of about 30 secs, the four blocks were coated using 1coat,

36


12th International Trade Fair for Materials Applications, Surface Technology and Product EngineeringOctober 13 - 15, 2009New Munich Trade Fair Centre

P R O D U C T E N G I N E E R I N G I N M O T I O N

w w w . m a t e r i a l i c a . c o m


2 coats, 3 coats and 4 coats respectively. Application of the polyurea system was done using a plural component, high temperature / high pressure proportioning unit, fitted with a mechanical purge impinge-ment mix spray gun. After 1 hour of application of the polyurea sys-tem, each sample was evaluated for system uniformity and applied film thickness.

In visual observation of the coated concrete panels, the 1 coat ap-plication provided for poor, incomplete coverage over the unprimed and primed concrete area, while the 2 coat showed incomplete coverage over only the unprimed concrete area. For each of the four metal samples, complete coverage was noted for the 1 to 4 coats ap-plied. See Figure 6.

Figure 6: Coated Concrete Test Samples, 1-coat to

4-coats, L to R

Read more in FAPU – EPJ – November 2009

www.bondexpo-messe.de

3rd Bondexpo –Trade Fair for IndustrialBonding Technology

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Raw materials for adhesives and sealants • Machinery, equipment and accessories for the adhesives manufac-turing industry • Adhesives and sealants • Machinery, equipment and accessories for the adhesives proces-sing industry • Measuring and test technology • Services

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Organizer:

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Location: New Trade Fair Centre Stuttgart · Messepiazza · 70629 Stuttgart

C O M P E T E N C E F O R Y O U R C L I E N T S

Reprints of Technical Articles for Your Customers!

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E-Mail: [email protected] tinsbruggstrasse 94CH-9016 St.GallenPhone +41 71 282 40 60 Fax +41 71 282 40 70E-Mail [email protected]

Hard chromium-plating

Electroless nickel plating

Cylindrical grinding

HartchromwerkBrunner AG

Hard chrome plating and electrolessnickel plating for workpieces inaluminium, non-ferrous metal and CFRP as follows:extrusion screw rollers flat diespiral mandrel blow molding headsall kind of molds

Homepage www.hcwb.com

Sonderhoff Engineering GmbH

Allgäustr. 3

6912 Hörbranz · Österreich

Tel. +43 5573 82991

Fax +43 5573 82946


PDA Europe142 Avenue Jules Bordet

1140 Brüssel, BelgienTel: +32 27 61 16 11Fax:+32 27 61 16 99

E-mail:[email protected]


PUMPS AND VOLUMETERS

for PU Productionwww.kral.at

KRACHT GmbH Gewerbestraße 20

58791 Werdohl, Germany

fon +49 (0) 2392.935 - 0fax +49 (0) 2392.935 - 209

mail [email protected] www.kracht.eu

PU-DIRECTORY


Presented by:Dr. James (Jim) M. O’Connor, SynUthane International Inc.

13th, 14th, 15th October 2009

Expert Seminar - 3 day modular programmeat Smithers Rapra, Shawbury, UK

Rapra training is organised by

www.rapra.net

www.rapratraining.comFor more information and to register online, please visit:

or telephone the iSmithers Conference Department tel +44 (0)1939 250383, fax +44 (0)1939 252416 or e-mail [email protected]


September EUROPEAN 2009 POLYURETHANE JOURNAL · 2017-09-05 · EUROPEAN POLYURETHANE JOURNAL KP...

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