Page 1
Versatility of Polyolefins in
Waterproofing and Roofing Systems
• Waterproofing applications
• State-of-the-art in polyolefins
• Additives and formulations
• Production technologies
• Proven formulations
• Designing future waterproofing solutions
Stefan Ultsch – Dow Europe GmbH
Page 2
Applications of flexible waterproofing membranes
Unballasted roofing
Ballasted/Green roof
Geomembranes, water liners
Tunneling
Page 3
Polyolefin-based waterproofing in civil engineering
Breathable
pitched roof
Vapor barriers
Ballasted or green roof
Parapet sealants
Adhered roofing
Expansion joints
Pool- and tankliners
Facade sealants
Subsoil waterproofing
Mechanically fixed roofing
Bitumen
compatibility and
modification
Page 4
– Simple
– Multipurpose
– Material usage
– Fire resistance
Unmet needs and development drivers
Installation Service-Life
– Flexible
– Reliable welding
– Material usage
– Longevity
–Energy saving
Optimized economics
– Fast product change
– Low scrap, economics
– Existing lines
ManufacturingDesign
Page 5
Design options for waterproofing membranes
Coextruded top layer, coating, laminated film...
Top layer
Scrim, fabric
Glasfleece
Bottom layer compound
Fleece backing, substrate for adhesion
Page 6
The Dow Polymer Portfolio
LLDPE
PP
RCP
ICP
Mo
du
lus LDPE
Mg(OH)2
Al(OH)3
CaCO3
TiO2
AO
…...
-EA
-MAH
PBE
HDPE
ULDPE
EPDM
OBC
POE
DOWLEX™
ATTANE™
ENGAGE™
INFUSE™
NORDEL IP™
AMPLIFY™
VERSIFY™
INSPIRE™
PE PPPP
Page 7
Freeport
AFFINITY™
AFFINITY GA™
INFUSE™
TarragonaAFFINITY™
ENGAGE™
VERSIFY™
PlaquemineENGAGE™
NORDEL™ Thailand (2011)AFFINITY™ENGAGE™
Seadrift
VLDPE
Dow Elastomers manufacturing sites
Page 8
ethylene-based olefin block-copolymers
Crystalline hard-blocksInterlinking soft blocks
Advantages: Flexibility (Modulus 2 to 4 MPa, Shore A = 55 to 70 º)
Temperature resistance (TM = 120 ºC)
Filler take up
Welding......
* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
™
Page 9
INFUSETM Block Copolymers: Heat resistance and Flexibility
20
40
60
80
100
120
140
1 10 100Flexural Modulus [MPa]
DSC Melting Temperature [ºC]
INFUSE™ Block Copolymers
Random Copolymers
• Heat resistance and flexibility in highly-filled formulations
• Ideal polymer for flexible B+C-formulations
* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
Page 10
random ethylene copolymers™
Octene-, Butene- or Propylene side chains
* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
Advantages: Flexibility (Modulus 2 to 100 MPa, Shore A = 55 to 90 º)
Cold temperature impact
High melt strength ....
• NEW XLT-grades offer significantly improved temperature resistance
• Flexibility and low temperature impact in highly-filled and easy-to-process compounds
Page 11
octene-based linear low-density polyethylene ™
Octene-side chains
* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
Major Advantages: Mechanical strength, tear strength
Excellent chemical resistance
• Stand-alone LLDPE in geomembranes with broadest approvals and listings
• Component for PE-based membrane formulations
DOWLEX
Page 12* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
propylene-based elastomers
Advantages: Flexibility (Modulus 2 to 120 MPa, Shore A = 70 to 90 º)
Outstanding welding...
• Excellent blending with PP and PE: the linking polymer
• Highly flexible, propylene-based TPOs
• Specific grades for building and construction membranes
isotactic polypropylene backbone
ethylene blocks
™
Plastomes and Elastomers
Page 13* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
flexible impact Polypropylene
Advantages: Flexible PP (Modulus 700 to 1000 MPa)
Heat resistance
Cold temperature impact
• Excellent blending, alloying with VERSIFY™
isotactic polypropylene backbone
™INSPIRE Performance Polymers
functional additives
Page 14* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
polymers with added functionalities
Compatibilizers to fillers and additives
scrims and fabrics
coatings, metal, substrates…..
™AMPLIFY, PRIMACOR
Tailored performance in combination with Dow olefins
ethylene acrylic acid
™
ethylene ethyl acrylate Maleic anhydride
Page 15
Tailored and tight tolerance of DOW polymers
• INSITE™-catalyst technology
• State-of-the-art reactor technologies
• No vis-break processes...
* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
• Excellent and lasting heat welding
• High degrees of filling
• Easy processing and excellent properties
Representative
Molecular Build-up
DOW Elastomers
2 43 5 6 7
0.2
0.4
0.6
0.8
1.0
1.2
no low-molecular
fraction
Differential molecular
weight distributionRepresentative molecular structure
no oligomers or low
molecular weight fraction
Log [Mw]
Page 16
Flame retardants
• Halogen-free flame retardants
• Purity, particle size distribution, surface coating are decisive parameters
• Processing and degradation characteristics are critical
Dow Elastomer formulations:
• Low melt temperatures allow high production rates with Al(OH)3
• Passing stringent norms (ENV 1187 t3) with very flexible membranes
60
70
80
90
100
0 100 200 300 400 500 600
Aluminum-trihydrate
Al(OH)3
Magnesium-hydroxide
Mg(OH)2
Temperature [ºC]
Wei
gh
t lo
ss [
%]
Page 17
Stabilizers and longevity
• Phenolics and hindered amines processing and longterm
• Titanium dioxide (TiO2) and carbon black UV-stabilizers and colorants
• Flame retardants and fillers purity affects longevity
ISO 4892-2 (0.5 W/m²) weatherometer testing
DOW olefins: high stabilizer additions without plate-out or impact on welding
0
20
40
60
80
100
120
0 2000 4000 6000 8000 10000 12000 14000
Customer reference
Reference with DOW
DOW standard TPO
DOW TPO without flame retardant
Exposure time [h]
Ret
ain
ed b
reak
elo
ng
atio
n [
%]
EN 12956: no cracks...
Page 18
Reinforcements
Scrims Fabrics Inserted knits Fleeces Combinations
• Tailored to manufacturing process, application- and norm-requirements.
• Mostly PETP- and glas-fibers. Occaionally PP-fibers.
Dow formulations
• high adhesion with standard fiber-coatings (no oligomers)
• for all type of reinforcements
Page 19
Formulation component strategy
LLDPE PP
RCP
ICP
LDPE
PBE
ULDPE
EPDM
OBC
POE
DOWLEX™
ATTANE™
ENGAGE™
INFUSE™
NORDEL™
VERSIFY™
INSPIRE™
Roofing (ballasted and unballasted)
Geomembranes, water liners
Tunnel liners
..... Expansion joints, flexibility
EPDM
PE- or PP-based formulations matching various applications
* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
Page 20
Multi-generation development
Generation 2: highly fire
resistant, flexible systems
Formulations for waterproofing and
membrane applications
Generation 3: specialty
elastomer systems
Generation 1: TPO systems
• European standards
• North American standards
• Unmet needs
Page 21
Compounding
Co-rotating,
intermeshing
Counter-rotating,
non-intermeshing
Reciprocating
co-kneaders
Dow Elastomers
• Formulation and compounding know-how and for all type systems
• Favorable process conditions and output rates up to 85 % filler levels
• Masterbatch- and pre-compound formulation know-how
Page 22
M M
Polymer 1
Polymer 2
Additive MB
Fillers
Flame retardantindividual
gravimetric
feeders
Gear pump
Flat-slit die
Calander
melting filler feed, homogenisation, dispersion homogenisation
Dow Elastomers: • Formulation component strategy
• Formulation- and process-know-how
• High throughput rates, low torque and die pressure
• Mass temperatures below 200 ºC enable use of ATH flame retardant
Direct extrusion on co-rotating twin-screw extruders
Diagram: courtesy of Krauss Maffei Berstorff, Hanover Germany
Page 23
Counter-rotating, intermeshing twin-screws
Single-screw and counter-rotating systems
• Usually PVC-lines run from dry-blend
• Low mixing performance, limited filler take-up
• TPO from pre-compound with temperature stable MgOH
Single-screw extruders
• Standard for low-filled formulations: geomembranes, liners
• Usually run from base materials and additive
masterbatches
• Start formulations and process know-how
Page 24
Calendering
Extrusion through flat slit die
Banbury, stock blender....
Supply of homogenuous melt
Extrusion of bottom layer
Fleece backing
Lamination of signal layers....
Supply of reinforcement
Formulation requirements:
• melt strength
• homogenuous banking
• reinforcement wetting
• adhesion to reinforcement
• no calander sticking
• dimensional stability after calandering
• Start formulations and process know-how
Page 25
Start Formulations for PP-membranes
• manufacturing technology
• filler and reinforcement properties
• end use and norm requirements
[phr]
flexible
PP
top bottom top bottom top bottom PE
INSPIRE™ ic-PP 20 35 35 40 10 15 35
VERSIFY™ PBE 75 65 65 60 60 55 65 50
ENGAGE™ POE 5 50
INFUSE™ OBC 30 30 50
ATTANE™ ULDPE 50
Flame ret. ATH or MgOH 60 90 60 60
Filler CaCO3 10 35 30 30 10 20 20 20 10
UV, color TiO2 6 1 6 1 6 1 6
UV, color Carbonblack 0.05 1 0.05 1 0.05 1 1 1 0.05
Stabilizer Phenolic, HALS 1 0.6 0.6 0.6 1 0.6 0.6 0.6 1
GeomembranesRoofing
unballasted ballasted
generation 2standard
unballasted
* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
Formulation database to adress:
Page 26
Benchmarking
DOW start: easy to process
passing EN and ASTM standards
excellent welding
Generation 2: excellent fire resistance (ENV 1187 t3) in combination with flexibility
¹ technical datasheets
EN 13956 1 2 3 4² 5 ² ballasted roof Start Gen. 2
Tensile strength [N] > 12 >12 > 13 > 5 > 15 17 12
Break elongation [%] > 15 ³ > 13 ³ > 19 ³ > 150 > 15 ³ ³ reinforced >600 > 1000
Peel resistance of joint [N/50mm] > 200 > 300 > 300 > 150 >500 >500
Shear resistance of joint [N/50mm] > 500 > 500 > 500 >1300 >1300
Tear resistance [N] > 250 > 300 > 320 > 150 > 300 >500 >500
Foldability at low temperature [ºC] < - 30 < - 30 < -30 < - 40 < -40 < -40 < -40
Fire resistance broof t1 broof t1 broof t1 broof t1 broof t1/t3
Artificial ageing [h] > 5000 4
> 5000 4
> 5000 4
> 3000 4 4
minimum requirem. >13000
Root resistance FLL FLL pass pass pass
ASTM D6878-03
Heat ageing 670 h at 116 ºC pass pass pass pass pass pass
Brittleness point pass pass fail pass pass pass
COMMERCIAL TPO¹ DOW
[MPa]
Page 27
Flexibility study
Page 28
Generation 2: testing of ENV 1187 bROOFt3
• 130 phr (65 wt%) flame retardant
• Flexibility modulus < 30 MPa
• Tensile strength > 9 MPa, Break elongation > 1500 %
A high margin pass
Page 29
Economic evaluation
Costs scheme of a TPO roofing membrane
• Database to optimize performance and system costs
Polymer
45%
Flame retardant
16%
Filler
1%
Colorant
10%
Stabilizer
3%
Reinforcement
13%
Manufacturing
9%
Scrap rate
3%
Costs/m2
Polymer Component stategy
High filler loading
Flame retardant Synergisms with fillers
Fillers Balance with polymer
Colorant Use as co-stabilizer
Stabilizer Top layers
Scrim Mesh width
Manufacturing Capacity usage
Scrap rate
Component stategy
Material usage
Aspects for Optimization
Page 30
Market Solutions & Application Versatility
DOW
• The broadest product mix of polyethylenes, olefin elastomers and polypropylene
• Unique polymers and process technology
• Global presence
• Formulation know-how for any waterproofing application and production process
• Technical support from polymer to end-use
• Development of future solutions in cooperation with technology leaders
www.dowelastomers.com
Page 31
Appendix: Dow Tradename Products
• AFFINITY™ Polyolefin Plastomers
• AMPLIFY™ Functional Polymers
• ATTANE™ Ultra Low Density Polyethylene Resins
• DOWLEX™ Linear Low Density Polyethylene Resins
• ELITE™ Enhanced Polyethylene Resins
• ENGAGE™ Polyolefin Elastomers
• INFUSE™ Olefin Block Copolymers
• INSPIRE™ Performance Polymers
• NORDEL™ IP Hydrocarbon Rubber
• VERSIFY™ Plastomers and Elastomers
* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow
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