Smart Formulating Journal - Coatings...
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Additives | Crosslinkers | Resin Components | Resins Issue 11 | March 2014 Smart Formulating Journal Editorial Novel silane resins tool box for ambient temperature curable and scratch resistant coatings page 11 Green solutions for safety road markings page 8 VISIOMER® Terra the new product family for methacrylate monomers based on renewable raw materials page 4 A well-developed and functioning infrastructure has always been an important factor for the success of an economy in global competition. Therefore, the development of roads, bridges, tunnels, etc. is of great importance. Of all the works of construction around the world, bridges are among the most demanding. B ridges ‒ M asterpieces of A rchitecture With some bridges reaching a life span of 100 years, it is crucial that these structures are constructed using only the highest quality materials. This why concrete as a building material plays such a crucial role. As bridges age, damage can become more frequent and preservation and rehabilitation become increasingly nec- essary to ensure their durability. Due to the limited finan- cial resources available to government agencies, bridge designers and authorities have found that the repair of bridges is a much more economical approach when com- pared to new bridge construction. The steady increase in road traffic, high axle loads of heavy traffic, extreme weather conditions, aggressive environmental influences and strong chloride exposure from road salt can all lead to concrete and steel corrosion. The structures will only withstand this stress if moisture or contaminants are kept from penetrating through cracks and gaps and if underground and surface elements remain stable. Evonik offers a wide variety of effective DEGADUR® systems that ensure the stability and structural safety of bridges, while also protecting the concrete against the ingress of contaminants and reinforcing the structure against corrosion. To ensure the durability of bridge structures, joints, expansion joints and cracks, the deck surface can be sealed with different DEGADUR® prod- ucts. These systems offer flexible, crack-bridging prop- erties, even at low temperatures, and are resistant to chemical attack. Their easy application and suitabil- ity for various configurations and surfaces allows for fast application and optimization of construction time. ▸▸▸ Dear Readers, Have you ever asked yourself – what is it that makes an effective team? And why do some teams manage to resolve major challenges with the greatest of ease? We at Evonik believe that a mixture of personalities, as well as a combi- nation of skills, experience and knowledge are important in order to create an effective team and establish it for the long term. We can offer you just such a team for finding solutions to your coating problems: with experience and knowledge of crosslinkers, matting agents, resin components, additives and resins. As you can see, we can offer you a broad-based team with strong personalities and crystal clear benefits: one partner, many experts! In order to survive in the highly competitive coatings sector, the Evonik team focuses on three essential pillars: resource efficiency, environmentally friendly solutions, as well as a growth-oriented overall strategy. Our aim is to give our customers a competitive edge through innovative solutions so as to become and your number one partner especially when new and sustainable coating solutions need to be developed in collaboration with our customer, or when existing formulations need to be improved. We achieve this, for example, by taking new, cost-effective solutions to problems into consideration, helping our customers to become even more efficient. The cover story in this journal, which deals with coatings for bridges based on DEGADUR®, is certainly a good example of this. The coatings market is one of Evonik’s core businesses. This can be seen in the commissioning of two major investment projects, namely, the fiſth isophorone chain in Shanghai (China) and the commencement of production of POLYVEST® HT, the so-called hydroxyl-terminated liquid polybutadienes in Marl (Germany). This, too, is part of our understanding of supporting the growth of our customers in this key industry. We hope you enjoy reading about it. Best regards, Dr. Ulrich Küsthardt President, Coatings & Additiv Business Unit
Transcript of Smart Formulating Journal - Coatings...
Additives | Crosslinkers | Resin Components | Resins Issue 11 | March 2014
Smart Formulating Journal
Editorial
Novel silane resins tool boxfor ambient temperature curable and scratch resistant coatingspage 11
Green solutions for safety road markings
page 8
VISIOMER® Terra the new product family for methacrylate monomers based on renewable raw materialspage 4
A well-developed and functioning infrastructure has always been an important factor for the success of an economy in global competition. Therefore, the development of roads, bridges, tunnels, etc. is of great importance. Of all the works of construction around the world, bridges are among the most demanding.
Bridges ‒ Masterpieces of Architecture
With some bridges reaching a life span of 100 years, it is crucial that these structures are constructed using only the highest quality materials. This why concrete as a building material plays such a crucial role.
As bridges age, damage can become more frequent and preservation and rehabilitation become increasingly nec-essary to ensure their durability. Due to the limited fi nan-cial resources available to government agencies, bridge designers and authorities have found that the repair of bridges is a much more economical approach when com-pared to new bridge construction.
The steady increase in road traffi c, high axle loads of heavy traffi c, extreme weather conditions, aggressive environmental infl uences and strong chloride exposure from road salt can all lead to concrete and steel corrosion. The structures will only withstand this stress if moisture
or contaminants are kept from penetrating through cracks and gaps and if underground and surface elements remain stable.
Evonik off ers a wide variety of eff ective DEGADUR® systems that ensure the stability and structural safety of bridges, while also protecting the concrete against the ingress of contaminants and reinforcing the structure against corrosion. To ensure the durability of bridge structures, joints, expansion joints and cracks, the deck surface can be sealed with diff erent DEGADUR® prod-ucts. These systems off er fl exible, crack-bridging prop-erties, even at low temperatures, and are resistant to chemical attack. Their easy application and suitabil-ity for various configurations and surfaces allows for fast application and optimization of construction time.
▸▸▸
Dear Readers,
Have you ever asked yourself – what is it that makes an eff ective team? And why do some teams manage to resolve major challenges with the greatest of ease? We at Evonik believe that a mixture of personalities, as well as a combi-nation of skills, experience and knowledge are important in order to create an eff ective team and establish it for the long term.
We can off er you just such a team for fi nding solutions to your coating problems: with experience and knowledge of crosslinkers, matting agents, resin components, additives and resins. As you can see, we can off er you a broad-based team with strong personalities and crystal clear benefi ts: one partner, many experts!
In order to survive in the highly competitive coatings sector, the Evonik team focuses on three essential pillars: resource effi ciency, environmentally friendly solutions, as well as a growth-oriented overall strategy. Our aim is to give our customers a competitive edge through innovative solutions so as to become and your number one partner especially when new and sustainable coating solutions need to be developed in collaboration with our customer, or when existing formulations need to be improved. We achieve this, for example, by taking new, cost-eff ective solutions to problems into consideration, helping our customers to become even more effi cient. The cover story in this journal, which deals with coatings for bridges based on DEGADUR®, is certainly a good example of this.
The coatings market is one of Evonik’s core businesses. This can be seen in the commissioning of two major investment projects, namely, the fi � h isophorone chain in Shanghai (China) and the commencement of production of POLYVEST® HT, the so-called hydroxyl-terminated liquid polybutadienes in Marl (Germany). This, too, is part of our understanding of supporting the growth of our customers in this key industry.
We hope you enjoy reading about it.Best regards,
Dr. Ulrich KüsthardtPresident, Coatings & Additives & Additives Business Unit
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Smart Formulating Journal | Issue 11 | March 2014
Fast Curing Methacrylate Resin SystemsToday, the prolonged closure of any travel route, particu-larly bridges, due to maintenance and repair is of increas-ing concern to those using and managing these routes. The need to keep these closures as short as possible has led to the development of the extremely accelerated meth-acrylate resin, DEGADUR® Bridge Primer.
State-of-the-art systems for repair and waterproof-ing of bridge decks require a reactive resin primer and a polymer bitumen waterproofi ng membrane. The resin must have reacted to the point that, during the applica-tion of bitumen sheets with a torch, no damage occurs. Depending on the product type and outside tempera-ture, many commonly used resin systems require wait-ing times between 8 and 72 hours. With DEGADUR® Bridge Primer, these waiting times are reduced to an hour. The application of DEGADUR® Bridge Primer and the polymer bitumen sheets can now be fi nished on the same day. In addition, DEGADUR® Bridge Primer even cures in freezing temperatures as low as –10 °C, while conventional epoxy resins are limited to temperatures above 8 °C.
Highly Reactive Liquid Membrane SystemsThe extensive product range from Evonik enables durable and reliable waterproofi ng solutions in the fi eld of sur-face sealing systems. DEGADUR® MDP, a highly reac-tive liquid membrane system, is an ideal product for bridge waterproofi ng applications. The sealing layer is a sprayable liquid membrane and off ers advantages in more complex geometries and connections. Used on reinforced concrete bridges under asphalt, a tack layer consisting of resin ensures that resultant thrust forces are transferred securely into the ground. The extremely fast cure time and the effi cient application speed allow for a short down-time and a quick return to traffi c.
The sprayable DEGADUR® MDP liquid membrane sys-tem can also be used in the coating of gravel troughs on railway bridges.
Durable Bridge Overlay SystemsWith Evonik’s DEGADUR® Bridge Deck Overlay system, the bridge surfaces which are being used by pedestrians and motorists are protected with a thin layer reactive res-in coating. This covering system consists of several layers, including a primer, scratch coat, wear layer and seal coat. These multiple layers provide a crack-bridging, mechani-cally strong surface that protects against increased traffi c wear and external contaminants from the environment.
On steel bridges, DEGADUR® Steel primer ensures superior corrosion protection, while the base coat and topcoat seal against the penetration of de-icing salts.
Versatile Casting SystemsIn the preservation and repair of bridge structures, there is usually a need for casting and fi lling of cavities, recesses or openings, or fi xing of bolts or anchors. Typical appli-cations include precision grouting of bridge bearings, shedding of expansion joints, drainage of gutters or other installed parts in the traffi c deck and anchoring of railing posts. For this work, the use of a casting reactive resin product is recommended.
In order to re-open the bridge as quickly as possible to normal traffi c, fast and versatile repair products are required. DEGADUR® PC Liquid, the two-component synthetic resin mortar made of polymethylmethacrylate (PMMA), meets these requirements. This 2-component resin system off ers high mechanical strength and low creep under constant load, resulting in low shrinkage and low cracking. The optimal fl ow characteristics and reactivity allow for applications even at low temperatures (< 10 ° C) and a quick re-opening to traffi c in as little as 1 hour.
SustainabilityIn addition to the need for a highly durable product, there is also an increasing demand for products that address sus-tainability and environmental
impact for bridge projects. This is important due to the size of such construction projects and their intervention in nature and habitat. By responsibly using our limited natural resources around the world, we are ensuring the survival of future generations.
Sustainable solutions for construction and repair play an important role at Evonik. Major eff orts are made to continuously optimize production processes, reduce ener-gy consumption, conserve natural resources and develop innovative, environmental friendly products. Awarded by Institut Bauen und Umwelt e. V., Evonik’s DEGADUR® products are certifi ed with an Environmental Product Declaration that can be transferred to the various envi-ronmental standards held in countries worldwide.
With the DEGADUR® product range, Evonik is not only protecting the future of bridge structures; we are also protecting the well-being of the environment.
ContactMichael Wolff
michael.wolff @evonik.com
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DEGADUR® Seal CoatTraffic Surface• Non-filled protective layer• Fixing of broadcast material• Provides chemical resistance
DEGADUR® Road CoatWaterproof barrier• Main layer with filler, broadcasted• Provides mechanical properties
DEGADUR® Primer• Seals the concrete surface• Provides adhesion between
concrete and coating
Concrete/Cement screed
Hot roll asphalt concrete• Traffic surface
Bitumen sheet• Waterproof barrier
DEGADUR® Bridge Primer• Seals the concrete surface• Provides adhesion between
concrete and coating
Concrete/Cement screedConcrete/Cement screed
Hot roll asphalt concrete• Traffic surface
MDP Tack resin• Provides adhesion between coating and asphalt
MDP Membrane Spray Grade • Waterproof barrier
MDP Primer Spray Grade
Bridge Deck OverlayBridge Primer under bitumen sheets Bridge waterproofing with membrane
DEGADUR® resins for Civil Engineering
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Smart Formulating Journal | Issue 11 | March 2014
There are many raw materials suppliers on the coatings market, but only a few all-round problem solvers. Evonik Industries is one of them. For the specialist chemicals company, fi rst and foremost, problems present an opportunity for innovation: Rather than letting tricky issues frustrate them, employees from Research & Development and Application Technol-ogy see them as a chance to explore new avenues.
How is it possible for Evonik to off er services to its cus-tomers that go beyond supplying top-quality raw materi-als? The answer is surprisingly simple: behind every con-tact partner at Evonik there is a whole team of experts.
These experts support their customers along the entire value chain, regardless of where they are located in the
global coatings industry. Evonik off ers a broad portfolio of products and solutions for paint components, span-ning resins, crosslinkers, binders, additives, and matting agents. This, in combination with decades of experi-ence in the coatings industry, enables the company to be actively involved and serve its customers as a partner and creative problem-solver. “The coatings industry is one of our most important growth markets. By making use of synergies within the Group we are able to off er tailored solutions,” explains Dr. Jürgen Lorösch, spokesperson for Evonik’s Paints & Coatings Industry Team. This team of experts is specialized in sales and marketing as well as research and development. In order to serve customers exactly where they are located and to understand their specifi c requirements, Evonik set up this internationally active industry team for coatings.
But that’s not all. Evonik works closely with strategic partners to ensure it stays at the forefront of research. Employees collectively study the needs of end custom-ers on a long-term basis and develop new technologies and products. These strategic partnerships are the key to achieving future profi table growth and to further devel-oping Evonik’s expertise for the coatings market.
Sustainable growth, however, can only happen on the basis of intensive dialog with customers. For this purpose the company holds regular customer days and provides information about the latest developments in established brands – such as VESTAMIN®, DEGALAN®, TEGO®, AEROSIL®, VISIOMER® and DYNAPOL® – in the Smart Formulating Journal.
To live up to the claim “One partner. Many experts.” the company now goes one step further by establishing comprehensive skills networks within the Group. “These networks cluster the expertise of our colleagues from the various business units,” says Dr. Jürgen Lorösch. “We then use this concentrated knowledge about application tech-nology and the market to support our customers’ growth projects.”
Evonik sets the bar high. The company is not only on an equal footing with its customers in the coatings market, it also always thinks one step ahead. Evonik’s expert teams off er interdisciplinary support worldwide – one partner, many experts.
We love your problems.
ContactAlexandra Schwarz
One Partner. Many Experts. We Love Your Problems.
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Smart Formulating Journal | Issue 11 | March 2014
VISIOMER® Terra ‒ the New Product Family for Meth-acrylate Monomers Based n Renewable Raw MaterialsSustainability is one of the core elements of Evonik Industries’ global activities. The Acrylic Monomers Business Line of Evonik not only strives to permanently improve the ecological footprint along the entire value chain, it also uses and develops manufacturing processes with utmost resource effi ciency. The use of renewable raw materials is an integral part of our new product development process, and we are also assessing possible options for producing existing products from bio-based raw materials in the future. Taking into account existing and future developments, we deliver sustainable solutions and provide a high level of specifi c value to our customers.
VISIOMER® Terra is Acrylic Monomer’s new product fam-ily for partially bio-based methacrylate monomers. We are launching this product family on the basis of existing products derived from bio-renewable raw material sourc-es and are therefore giving them a more prominent place in our product portfolio. To address future market needs, Acrylic Monomers is committed to further expanding the VISIOMER® Terra product family, focusing on the use of
sustainable bio-based resources for our future raw mate-rial basis. The table shows the VISIOMER® Terra products and their technical parameters.
VISIOMER® Terra IBOMA not only off ers a partially bio-based raw material source, it also brings value-added environmental benefi ts to end use applications. Its main raw material, camphene, is made from 100 % renewable feedstock. Camphene is produced primarily from pine
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tree resin, which can be harvested without harming the pine trees. VISIOMER® Terra IBOMA enables the formula-tion of environmentally-friendly paint resins that have a lower content of volatile organic compounds (VOC). Fur-thermore, it is used in high-solid clear coat formulations to reduce resin viscosity.
Isobornyl methacrylate contains a bulky side chain at the molecular level, which results in a resin with a high glass transition temperature (Tg). In coatings, a high Tg resin translates into good mechanical properties and, in addition, can improve the coating’s drying time. An important application of VISIOMER® Terra IBOMA is in automotive refi nishes to provide durable top coats for automobiles.
Viscosity-reducing properties of VISIOMER® Terra IBOMA in a clear coat resinSolvent-based resins were synthesized by convention-al free radical polymerization to illustrate the eff ect of VISIOMER® Terra IBOMA as a high-solid monomer. A control sample without a high-solid monomer was pre-pared, and the high-solid monomer content in the resin ranged from 20 – 30 wt %. Rotational viscometry was used to characterize the solution polymers. This method
clearly demonstrated the property changes that were induced by VISIOMER® Terra IBOMA. The comparison result of the viscosities of the 75 % resin solution depicts the viscosity-decreasing eff ects under the infl uence of a high-solid monomer, VISIOMER® Terra IBOMA.
VISIOMER® Terra C17.4-MA and Terra C13-MA improve the hydrophobicity of resins, which results in improved water repellency and resistance against polar solvents. These products are made from C17.4 and C13 based building blocks, which are derived from natural oil-based raw materials.
VISIOMER® Terra C17.4-MA and Terra C13-MA are long alkyl chain esters (LACE) with distinct diff erences. VISIOMER® Terra C17.4-MA contains a distribution of C14, C16, and C18 side chains and VISIOMER® Terra C13-MA contains a distribution of C12 and C14 side chains at the molecular level. The relative high Tg of the C17.4-MA homopolymer, –22 °C, versus the low Tg of the C13-MA homopolymer, –46 °C, is attributed to the crystallization of long alkyl side chains. Both monomers can be copo-lymerized with other co-monomers to make solvent- or water-based resins.
A solvent-based resin with a 75 % solids content was prepared by a free radical polymerization. A comparative
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osity
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original hardness value2-propanol methyl ethyl ketone
Results of the chemical resistance test with HDI cross-linked fi lms from polymers with linear LACE monomers
The VISIOMER Terra product family
VISIOMER® Terra product Chemical name Formula
Molecularweightg / mol
Boilingpoint°C / hPa
Glass transitiontemperatureTg °C
Standardstabilizationppm MEHQ* Bio-content**
IBOMA Isobornylmethacrylate
CAS No. 7534-94-3
o
o 222.3 258 / 0.6 150 150 ± 30 71 %
C13-MA Methacrylicester 13.0
CAS No. 90551-76-1
o
o [CH2]n CH3268.0 > 300 / 1013 – 46 100 ± 25 76 %
C17.4-MA Methacrylicester 17.4
CAS No. 90551-84-1
o
o [CH2]n CH3 330.0 > 250 / 1013 – 22 100 ± 25 81 %
* MEHQ = Hydroquinone monomethyl ether** Calculated as a ratio of C-number alcohol to C-number methacrylate
sample was prepared and its content of butyl acrylate and MMA was subsequently exchanged for 30 % of the respective long alkyl chain esters of methacrylic acid, VISIOMER® Terra C17.4-MA and Terra C13-MA. The resins were formulated into a clear coat with HDI cross-linker. Films were applied and thermally cured for further testing.
Results of the chemical resistance test with HDI cross-linked fi lms from polymers with linear LACE monomers:In order to obtain further information about the eff ect of the LACE monomers on the chemical resistance of coat-ing fi lms, diff erent liquids, such as 2-propanol and methyl ethyl ketone (MEK), were applied to the surfaces. A� er applying the test liquids, the surface hardness of the fi lms was determined using the Konig hardness test.VISIOMER® Terra C17.4-MA and Terra C13-MA only showed slight deviations from the original hardness val-ues, whereas the reference fi lm was strongly aff ected by the organic solvents
ContactJohn Wey
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Smart Formulating Journal | Issue 11 | March 2014
NANOPOL® ‒ Hardness and Transparency
SILIKOPHEN®AC 900 and SILIKOPHEN®AC 1000 – Novel Silicone Resins with Ambient Temperature Crosslinking
We all know the problem: scratches on a high gloss plastic surface are annoying and o� en downgrade the high qual-ity appearance of the object. 2-pack PUR coatings tech-nology has been combined with silica nanocomposites for lasting prevention of such defects without impairing utility. Scratch resistance of high gloss, 2-pack PUR clear coats is significantly improved without compromising other properties.
The innovative NANOPOL® products from Evonik Industries AG are based on a modifi ed sol-gel process. The advantage of liquid NANOPOL® is that an easy to handle product can be used for a wide application base which can be readily incorporated in a polyol matrix. This enables existing binders and the new nanosilica particle technol-ogy to be developed into high gloss, 2-pack PUR clear coats with greatly increased scratch / abrasion resistance.
The use of NANOPOL® products enables the scratch and abrasion resistance of solventborne, 2-pack PUR coatings to be increased by up to 10 %. As a rule, 5 to 10 % w / w in a formulation suffi ces without impairing
Two new ambient curing resins for high temperature applications up to 650 °C make it possible to coat very large objects, such as industrial fans and turbines, without the need for costly stoving.
SILIKOPHEN® AC 900 (methyl / phenyl silicone res-in, 90 % active substance) and SILIKOPHEN® AC 1000 (methyl silicone resin, 100 % active substance) are oligo-meric methoxysiloxanes which crosslink at ambient tem-perature via hydrolysis and a subsequent condensation
Nanosilica particle technology in solventborne, high-gloss, 2-pack PUR clear coats for plastics
Methyl/phenyl silicone resin
Methyl silicone resin
*TEGO® Kat 1: Tetra-n-butyltitanate, *TEGO® Kat 2: Tetramethylguanidine
SILIKOPHEN AC 900
SILIKOPHEN AC 1000
Catalysts:TEGO Kat 1* + TEGO Kat 2*
Catalyst:TEGO Kat 1*
Figure 1 Combinations of silicone resins and catalysts
Scratch resistance
Hardness
reaction using the appropriate catalysts TEGO® Kat 1 and / or TEGO® Kat 2.
The low viscosity at high active substance content off ers new possibilities for formulations with very low VOC content. Features of special note are rapid drying a� er application and the short curing time (1 to 3 hours) to touch dry. A further advantage is the very good resis-tance to solvents at low temperatures a� er only two days of room temperature curing.
SILIKOPHEN® AC 1000 distinguishes itself by excellent color fastness when subjected to high temperatures.
With its good fl exibility, pigment wetting and broad compatibility with other binders, SILIKOPHEN® AC 900 completes the portfolio of silicone resins.
ContactMarion Siemens
Heat resistance
transparency, gloss, condensation water test resistance or adhesion of the coating.
ContactMarco Heuer
Improved properties with silica nanocomposites
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Smart Formulating Journal | Issue 11 | March 2014
Leading the Race
In the Chinese year of the horse, Evonik Industries is beginning operation of world-scale isophorone and isoph-orone diamine plants in Shanghai. The Group has invested more than €100 million in the plants, which are scheduled to go onstream in the fi rst quarter of 2014. Commission-ing work on the multi-user site China (MUSC), Evonik’s production site in Shanghai, are well on track.
Evonik’s decision to build its isophorone production platform in Asia will enable to company to serve their customers even better. Proximity to this growing market allows the Group to act faster in this important region.
Once a single product, isophorone has developed into a technology platform that increasingly enables more and more forward-thinking applications.
For instance, today Isophorone (VESTASOL® IP) is used as a solvent in the paints and coatings industry, in cleaning and degreasing surfaces, in the formulation of crop pro-tection agents, or manufactured into isophorone diamine (VESTAMIN® IPD).
Evonik has succeeded in creating new applications and opening up new markets for its isophorone-based prod-ucts, o� en in close cooperation with customers.
Crosslinkers based on isophorone diamine can be found wherever strong bonding properties are required – for example, in industrial fl ooring that has to withstand heavy loads and chemicals, but also in parking garages,
In 2011, Evonik Industries decided to build isophorone and isophorone diamine production facilities in Shang-hai. Today the construction of Evonik’s fi � h integrated isophorone chain is completed – it’s time for commissioning.
DIY warehouses, hospitals, and just about any other place where fl oors have to be highly resistant to chemical and physical stress. These crosslinkers are also being used increasingly in lightweight components, which o� en con-tain composites made of glass or carbon fi bers along with an epoxy matrix. Here a crosslinker like VESTAMIN® ensures that the liquid matrix can be transformed into a solid matrix that bonds with the fi bers.
As the inventor of isophorone chemistry with long experience and constant improvements in the production
process, Evonik is a technology and market leader in this sector.
Additionally, the newly opened application technology services center, including onsite laboratory capacity in Shanghai, will ensure that customers can be served even more eff ectively with tailored solutions and with Evonik as a partner for technical development.
ContactDirk Reichel
Increase Chemical Resistance with TEGO® VariPlus DS 50From the family of TEGO® VariPlus ketone-aldehyde resins, used in solventborne as well as in waterborne coatings, TEGO® VariPlus DS 50 markedly improves the chemical and staining resistance of 2K, waterborne poly-urethane coatings.
Coatings with TEGO® VariPlus DS 50 show little to no negative eff ects from hand lotions or sunscreens and drastically reduce swelling a� er application. Resistance to caustic soda solution and hydrochloric acid (both up to 10 %) is improved.
TEGO® VariPlus DS 50 also improves gloss, hardness and adhesion to various substrates.
ContactHeiko Alzer
[email protected] Gloss Hardness
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Smart Formulating Journal | Issue 11 | March 2014
Green Solutions for Safety Road MarkingsGlobal challenges such as climate change, urbanization and aging populations are increasingly becoming more important in managing any industry today. Road markings must ensure traffi c safety. But there are diff erences among them – in terms of functionality and performance and eco-friendliness. Evonik Industries AG has conducted a certifi ed life cycle assessment for major road marking materials and application technologies to identify levers to minimize environmental impact. It has been found that DEGAROUTE®-based cold plastic agglomerate road markings protect not only road users but also the environment.
They shine like gems: tiny glass beads anchored on the surface of the marking material refl ect the light from headlights in the dark. This is why the markings are still visible at night. On wet or rainy nights the challenge is to drain off water from these glass beads to ensure the markings are visible at night even in wet conditions. Road markings featuring enhanced wet night visibility are usu-ally called Type II markings. Textured, three-dimensional agglomerate markings (see fi gure 1) provide particularly good water drainage and therefore excellent wet night vis-ibility. Additional audible functionality is given depending on the shape of the line texture, which alerts distracted drivers when they are about to depart from the lane. At the same time, such agglomerate road markings off er a longer functional life than fl at Type II markings: refl ect-ing glass beads embedded on the slopes of the texture are less exposed to traffi c wear than those on the surface of a fl at marking.
For textured agglomerate markings there are only two material options. One of these is cold-plastic based on reactive resin binders. DEGAROUTE® from Evonik Industries AG has proven itself as the leading cold plastic binder technolo-gy for over 50 years. Lately, however, it is not just safety but the environmental aspect that has begun to play a a more important role. Increasing traffi c volumes and more elderly drivers call for more durable markings with improved wet night visibility and additional safety features – but not at the expense of the environment.
This article reports on which system option is the most environmentally-friendly for agglomerate road mark-ings. In addition, it will be investigated whether there is confl ict between safety and environmental aspects when the choice is between thick-layer agglomerate markings which off er ultimate safety performance and thin-layer Type II markings that are spray-applied with much less material requirement for initial installation.
Environmental impact studyFor this reason, DEGAROUTE®-based cold-plastic road marking systems were compared with other common road marking systems, specifi cally thermo plastic, sol-vent-based paint and water-based paint, within a compre-hensive life cycle assessment (LCA) study [1,2]. LCA ana-lyzes the impact a product has on the environment over its entire lifespan. The entire value chain, from the raw materials, through production and application, to disposal or recycling, is taken into account. It even includes trans-port and packaging materials. In this case, a total of 8 dif-ferent environmental impacts, including global warming potential (GWP) were assessed.
All investigated road marking systems are commer-cial products and approved by German Federal Highway Research Institute (BAST). Comparison was made in typi-cal application scenarios as specifi ed by German guide-lines (ZTV-M). In this case, a two-lane, one-kilometer
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Smart Formulating Journal | Issue 11 | March 2014
section of roadway with a middle stripe and two edge stripes with an average traffi c of 10000 to 15000 cars per day was studied. The assessment period was ten years—after this time roads normally have to be resurfaced. Depending on the technology used, the markings have to be renewed at diff erent times during this period.
Results of the LCA study on various spray technologies have already been presented in this journal [3]. According to these results, cold spray plastic with DEGAROUTE® is far superior to the other thin-layer spray technologies. The study showed that, more than anything, the service life of a marking is key to its environmental impact: Over the assessment period of 10 years, the solvent-based paint or the water-based paint had to be reapplied ten times to maintain the functionality of Type II marking, while DEGAROUTE®-based cold spray plastic had to be reap-plied only four times, thanks to its longevity.
A study of thick-layer agglomerate markings, where the only choice is between two durable systems, namely cold plastic and thermoplastic, shows how strongly the environmental impact is determined by the application conditions and usage or wear characteristics. Thermoplas-tic is applied in the molten state at about 200 °C with rath-er high specifi c marking material consumption per square meter. The most signifi cant impacts on global warming potential (GWP) therefore originate from material con-sumption and from hot application, while broadcast glass beads contribute much less (see fi gure 2).
For DEGAROUTE®-based cold plastic it is the consump-tion of the marking material that dominates the CO2-bal-ance of the global warming potential, while application contributes much less. The cold plastic option off ers GWP savings of 42 % compared to thermoplastics, due to its comparatively lower material consumption, favorable application in terms of energy and its longer functional service life. Cold plastic road markings feature high abra-sion resistance and stability even at high ambient tempera-tures. Even if the retro-refl ecting glass beads are warn off by traffi c, the texture of cold-plastic road marking remains virtually unchanged. Old agglomerate markings made of cold plastic can therefore be renewed by re-coat-ing them with a very thin layer of cold spray plastic and fresh layer of glass beads broadcasted on top in a particu-larly resource-effi cient and environmentally friendly way. This is generally not feasible for thermoplastic which is subject to high abrasion by traffi c wear.
Even when compared to the best in class thin-layer spray system, namely DEGAROUTE®-based cold spray plastic, the global warming potential of agglomerate markings made of DEGAROUTE®-based cold plastic is only moderately higher (see fi gure 2). Again the longevity of the thick layer system largely compensates the higher material consumption. However, raw materials are most effi ciently utilized by combining both application tech-nologies: Cold spray plastic refreshment of cold plastic agglomerates provides functional Type II agglomerate
markings over long periods with minimum impact on the environment.
According to the LCA study, durability is also a decid-ing factor for environmental impacts in general and, therefore, the global warming potential of the individual systems. However, besides material technology, it is the application technology that provides a lever to minimize environmental impact of road markings. There is no con-f lict between environmental and safety aspects when using most durable DEGAROUTE®-based cold plastic technology for agglomerate markings providing ultimate traffi c safety.
The LCA study was conducted in accordance with ISO 14040 and ISO 14044 and critically reviewed by indepen-dent experts from industry, science and research.
ContactAlexander Klein
[1]: “Life cycle under the lens” Annual Showcase 2012, Intertraffi c World, P 202
[2]: “Vergleichende Ökobilanzstudie für Straßenmarkierungssysteme”, 77. Lacktagung, GDCH, 2012.
[3]: “Minimizing the Carbon Footprint of Road Markings”, Smart Formulat-ing Journal, Vol 10 2013.
Figure 1Regular (bottom) and stochastic (top) cold plastic agglomerate road marking
Figure 2Global warming potential of road marking systems with enhanced wet night visibility (Type II markings) per 10 years per kilometer made of thermo-plastic agglomerate (TP) or cold plastic agglomerate (CP) or cold plastic agglomerate with 0.3 mm cold spray plastic (CSP) refreshment or 0.6 mm cold spray plastic fl at marking (CSP) broken down to contributions from road marking material, broadcast material (mainly glass beads), transports, applica-tion and disposal. Material consumptions based on current approval test data of German Federal Highway Research Institute (BAST).
Global warming potential per 10 years per km
marking material
142%
100%
60%
89%
broadcasting materialtransportsapplicationdisposal
No of applications per 10 years
4 x TP 4 x CP 1 x CP + 3 x CSP (0.3 mm)
4 x CSP (0.6 mm)
Marking material kg / m2 14.8 8.4 4.2 3.8
Broadcast material kg / m2 1.60 1.20 1.36 2.40
System lifetime a 3 4 4 (2) 2.5
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Smart Formulating Journal | Issue 11 | March 2014
Complementary Building Blocks Fit for New Needs in the Packaging Coatings MarketDYNAPOL® polyester resins are well proven main binders for metal packaging coatings. Evonik is pushing the extension of the DYNAPOL® series for food contact applications. In addition, Evonik complements the range of raw materials for food contact coatings by the recently obtained US-food contact notifi cation for the crosslinking agent VESTANAT® EP-B 1186 A. Synergistic eff ects between both product groups have been observed, leading to coatings with a high degree of fl exibility in combination with good media resistance.
Nowadays, metal containers in the food packaging indus-try are as natural for us as a cup of coff ee in the morning. But this has not been the case since ever. Almost 200 years ago, a French confectioner came up with the idea of heating foodstuff in an air-sealed container to make it durable. Final-ly, the British merchant Durand took this idea and combined it with a metal container. The food can was born!
Today, a metal food can is a sophisticated and almost matchless type of packaging which is used to keep food-stuff fresh over a period of years. The dominance of metal packaging in food preservation can be traced back to its broad and unique property profi le. Metal containers can be brought into a wide variety of shapes, they off er an out-standing degree of recyclability, show increased effi ciency due to ever lower wall thickness and provide an unbeaten shelf life, not least due to the interior wall coating which prevents the metal from directly contacting the foodstuff and vice versa (see picture 1).
As one of the world's leading suppliers of coat-ing raw materials, Evonik offers polyester resins with the brand name DYNAPOL®. These medium to high molecular weight polyesters have been success-fully serving the market needs in the field of metal protec t ing & decorat ing paints for decades.
One of the key characteristics of polyester resins is the ability to help coatings to be fl exible and therefore shapeable for the can manufacturing process; at the same time they allow the paint to be mechanically resistant and durable against aggressive media. The right balance between fl exibility, hardness and resistance is essential for the fi nal application and can be adjusted by tailoring the polyester with respect to a wide range of properties.
Picture 2: A hard guess – which one is the reference? Comparison of test bodies pre-coated and shaped with DYNAPOL® L 912 based lacquer before and after retort. Testconditions: 121°C for 30 minutes in three different food simulating media (water, 3 % acetic acid and 2 % lactic acid).
Picture 1: Typical coating layers on metal cans.
1
23
45
1 Interior side seam protection
2 Interior coatings
3 Stamping enamels (e. g.base coat white)
4 Printing inks
5 Overprint varnish (clear coat)
Besides the technical performance of a coating, food safety aspects tip the balance more and more whether it is accepted and approved by the authorities and throughout the whole value chain. Given this fact, paint manufacturers and raw material suppliers place greater emphasis on legal frameworks which deal with food safety aspects when look-ing in new directions for future business orientation.
For example, the long lasting debate about food contact coatings which contain BPA (Bisphenol-A) is more relevant now than ever. France, for instance, has announced that it is going to ban food contact coatings which contain BPA and only accept coatings in food contact applications and to accept only coatings which are BPA-NI (Bisphenol-A non intentional) by the middle of 2015 [1].
This underlines the changing needs in the market for packaging coatings and is fueling the search for alterna-tives. Evonik is taking action in order to accompany its cus-tomers on this journey. The DYNAPOL® product portfolio opens the door to BPA-NI can coatings. Especially the high molecular weight DYNAPOL® L series is imparting the high performance characteristics wanted, e. g. DYNAPOL® L 952 & DYNAPOL® L 912.
Evonik is currently creating product developments which go beyond solutions which are available commercially from the competition.
To visualize the performance capability of DYNAPOL® based coating formulations, picture 2 shows pre-coated and shaped test bodies before and a� er retort in diff erent food simulating media. Clearly, each of the coating fi lms on the test bodies appears untouched even a� er the harsh test conditions.
Furthermore, Evonik is developing new solutions in cross business projects. The cooperation between Pre-Coated Metal as the market segment and habitat of the DYNAPOL® product group on the one hand, and the busi-ness line Crosslinkers as specialist for cross-linking agents on the other hand, has uncovered remarkable synergistic eff ects. These are observed between high molecular weight DYNAPOL® L-type polyesters and the blocked polyisocya-nate cross-linker VESTANAT® EP-B 1186 A. Such combi-nations lead to coatings with excellent fl exibility as well as outstanding media resistance and therefore thus, special feasibility for interior food can coatings with high steriliza-tion performance.
Since August 2013, Evonik has held a food contact noti-fi cation for VESTANAT® EP-B 1186 A as approved by the U.S. Food and Drug Administration (FCN No. 1268). This latest option of formulating PUR-coatings even for food contact applications off ers a variety of new developmental approaches for customers.
With a well-balanced product portfolio of long and estab-lished polyester grades, in combination with new innovative ones, Evonik is well prepared to supply high quality raw materials to the packaging coating industry.
ContactThorsten Brand
[1] http://gain. fas. usda. gov / Recent%20GAIN%20Publica-tions / French%20Law%20Banning%20Bisphenol%20 A%20in%20Food%20Containers%20Enacted_Paris_France_2-5-2013. pdf
11
Smart Formulating Journal | Issue 11 | March 2014
Novel Silane Resins Tool Box for Ambient Temper-ature Curable and Scratch Resistant CoatingsVESTANAT® EP-MF 201 is a solvent-free, ready-to-use self-crosslinking binder. It can be used either as a single binder or in combination with appropriate co-binders. Such low VOC formulations show outstanding scratch and chemical resistance. VESTANAT® EP-M 222 is a resin which is used to modify fl exibility while maintaining excellent drying performance and hardness development.
Aliphatic PUR coatings are known for their high chemi-cal resistances, good fl exibility, good adhesion and overall weathering properties, yet handling of isocyanates can be an issue, if applicators are not trained and protected prop-erly. Hence expertise and training is needed for proper han-dling of isocyanates and DIY use of isocyanates in of 2K PUR coating systems is not supported e.g. under REACH.
Two new alkoxysilane-resins, VESTANAT® EP-MF 201, based on a short-chain backbone, and VESTANAT® EP-M 222, which contains a higher molecular weight backbone for fl exibility reasons . These NISO crosslinkers include ure-thane linkages that give chemical resistances and adhesion properties typical to polyurethanes, but without the isocya-nate functionality.
There are two primary routes of silane crosslinking: the fi rst route involves a condensation reaction between two silanol groups. The other crosslinking mechanism is a transesterifi cation reaction with a polyol.
These two types of reactions allow for either a two com-ponent (2K) coating formulating a NISO cross linker with a polyol, or a one-component (1K) moisture cure coating where the NISO cross linker is the sole component of the binder matrix.
Ambient cure 1K NISO coatings based on VESTANAT® EP-MF 201 and VESTANAT® EP-M 222 for wood, metal and plastic substratesWhile two-component coatings are quite useful in order to build hardness and other properties fairly quickly, there are many applications where a one-component (1K) non-isocy-anate curing coating is desired. These include wood coat-ings where signifi cant improvements, especially with regard to scratch resistance, are observed, as shown in the pictures above. Even the pure VESTANAT® EP-MF 201 can be used as a single binder to formulate NISO ultra high solid, scratch resistant coatings for wooden substrates, as well as others.
Table 1 shows the properties of a 1K NISO coating based solely on VESTANAT® EP-MF 201 and applied and cured at ambient temperature for seven days. The initial hardness and chemical resistance of this coating is high. To improve the mechanical properties and increase fl exibility of the 1K NISO coating, VESTANAT® EP-M 222 was substituted for VESTANAT® EP-MF 201 at three diff erent levels: 70:30, 50:50 and 30:70 pbw, cured at room temperature and peri-odically tested for pendulum hardness and for full proper-ties a� er the seven days of curing had elapsed (Table 1). As the M 222 was added to the MF 201 formulations, both the impact resistance and Erichsen cupping values increased as expected. Despite the reduction of crosslink density, the MEK resistance was maintained and higher pendulum hardness was achieved. The only defi cit observed was an increase in the VOC content from 0.9 lb/gal to 3.0 lb/gal. Furthermore, the coatings were tested for 20° gloss and loss of gloss a� er a modifi ed Crockmeter test (wet abrasion) was applied, showing outstanding scratch resistance.
1K moisture cure NISO system for clear coat applications Excellent scratch resistance can be combined with high f lexibilit y, good chemical resistance and
Clear CoatStandard 2K PUR
Clear CoatAcrylic Polyol (of comparative example) + VESTANAT® EP-MF 201 (No isocyanate hardener included.)
Table 1. 1K NISO coatings using VESTANAT® EP-MF 201/ M 222 mixtures
MF 201 MF 201: M 222
‒ 70 : 30 50 : 50 30 : 70
Hardness [König] 1d / 7d 72 /132 56 / 158 36 / 164 15/ 168
Impact, direct [inch Ibs] 30 40 50 50
Erichsen cupping [mm] 1.5 3.0 3.5 6
MEK resistance [DR] 150++ 150++ 150++ 150++
VOC [lb / gal] 0.9 1.9 2.7 3.0
Gloss/ loss of gloss [20 °] 78 / 1 78 / 2 77 / 1 74 / 0
Touch dry [23 ° C] 1.25 h 2.0 h 3.0 h 5 h
Table 2. Chemical resistance of a 1K moisture-cured VESTANAT® EP-MF 201/ M 222 mixtures
MF 201 : M 22250: 50 2K PUR
Acetic Acid, 20 % 1 h4 d
01
05
Sodium Hydroxide, 20 % 1 h4 d
02
00
Distilled Water 1 h4 d
00
00
Ethanol / Distilled Water (1:1) 1 h4 d
03
46
Brake Fluid 1 h4 d
01
16
Gasoline 1 h4 d
01
22
good weathering durability of these NISO coat-ings. First results indicate that also pigmented systems exhibit a good storage stability as formulated
paints. More detailed studies are ongoing to support these promising results.
ContactMarkus Hallack
The chemical resistance of the 50 : 50 blend of MF 201 and M 222 shown below in table 2 was tested in reference to a 2K polyurethane coating against the six liquids, and found to be superior in the case of the NISO coating compared to the 2K PUR coating (0 = no changes / 6 = clearcoat destroyed).
Smart Formulating Journal | Issue 11 | March 2014
12
Smart Formulating Trade Fair Appearances 2013
Latin America Coatings Show
Asia Pacifi c Coatings Show
ChinaCoat
ImprintEditorEvonik Industries AGRellinghauser Straße 1 – 1145128 EssenGermany
Layout / DesignLiebchen+Liebchen Kommunikation GmbH www.LplusL.de Frankfurt am Main, Germany
PrintMargreff – Druck GmbH, EssenPrinted in Germany
Flexible Metal Coatings with DEGALAN® 1017 F
DEGALAN® 1017 F off ers formulators a thermoplastic methacrylic polymer which shows exceptionally good adhesion on a wide range of diff erent metal substrates. Besides adhesion on steel substrates, it is possible to achieve adhesion on aluminum and galvanized steel. Adhesion is also possible on thermoplastic substrates such as PC, PMMA, PS and PVC.
In addition to perfect adhesion, the polymer also shows good compatibility with other polymers such as PVC copolymers, NC, chlorinated rubber, epoxy resins, plas-ticizers and other thermoplastic methacrylic polymers.
The higher molecular weight of the polymer makes it possible to develop highly fl exible pigmented and unpig-mented coatings. The fi lms show impact resistance, they are tough and deliver excellent corrosion protection.
Possible application areas for this product are, for example, unpigmented coatings on metal staples and other highly fl exible durable metal coatings. It has been proven that the polymer can be used in the electronic industry as a binder for aluminum and also in screen printing inks containing silver powder to print electrical lines.
ContactAndreas Olschewski
The new grade integrates into the existing product portfolio and brings solutions to the electronic industry.
Evonik Commissions New Plant for Hydroxyl – Terminated Poly-Butadiene in MarlIn the future, Evonik will be selling functionalized polybutadiene for the adhesive and sealants market under the brand name of POLYVEST® HT. The market launch for the new product is scheduled for the second quarter of 2014. The new plant will have a capacity of several thousand metric tons per annum.
Evonik Industries is a leading supplier of liquid polybuta-dienes and stands out due to its many years of experience, technological expertise and its proximity to its customers.
In constructing the plant, the company is respond-ing to the growing requirements for sustainable product solutions and resource-effi cient systems. POLYVEST® HT is used for double and triple glazing in the window con-struction sector, for example, as well as for adhesives for lightweight vehicle construction. In the automotive sec-tor, adhesives are increasingly being used to supplement traditional welding processes or as a structural adhesive for ever-thinner sheet metals and plastics.
With its new POLYVEST® HT plant, Evonik is extend-ing its existing service portfolio, which consists of polyes-ters, methacrylates, amorphous poly-alpha-olefi ns and liq-uid polybutadienes for the adhesive and sealants industry.
ContactNico Haberkorn
DatesEvonikTrade Fair Appearances 2014
September 23 ‒ 25, 2014EuroCoat | France, Paris
October 23 ‒ 25, 2014Paintistanbul | Turkey, Istanbul
November 11 ‒ 23, 2014Chinacoat | China, Guangzhou
