Arkema Coating Resins Welcome to the 2014 ACR … 3 Caulks and Sealants...Arkema Coating Resins...
Transcript of Arkema Coating Resins Welcome to the 2014 ACR … 3 Caulks and Sealants...Arkema Coating Resins...
Arkema Coating Resins
Welcome to the
2014 ACR Webinar Series!!
April 25, 2014
Invest one hour with us and we’ll help you grow your business with
products and technology from Arkema Coating Resins
2014 ACR Webinar Series
Today’s Topic: Caulks and Sealants: Test methods, Product Classes, Competitive products and ACR Technology
Speaker: Rick Miner
Title: Senior Technical Account Coordinator
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Our training goal
Give you the knowledge necessary to answer your customer’s questions concerning caulks with confidence
• Outline the basics of formulating
• Describe the ASTM testing protocols
• Outline the characteristics of the different product classifications
• Highlight several Arkema products and describe their performance benefits
• Understand the cost structure of caulk formulations
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Today’s Agenda
What is a caulk?
ASTM Testing Methodology
The economics of a tube of caulk
Arkema Coating Resins Product Overview and competitive offsets
Product Spotlight
• ENCOR® 182, Vinyl Acetate-Ethylene Latex for Pigmented Caulks
• ENCOR® 9192, All-Acrylic Latex for “True Clear” Sealant Applications
• ENCOR® 9176, For Ambient Crosslinking Sealants
Recap
What is a caulk?
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Caulks are viscous materials which span gaps and fill voids
High solids; low shrinkage formulations
Low surface tack but flexible even at low temperatures
Adhesion to a variety of substrates
hydrophobic or resistant to water when dry
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Caulks are comprised of various ingredients
Latex binder
Pigments
Plasticizers
Thickeners
Additives
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The binder is a key component of a caulk
Binder holds pigment together
Binder provides mechanical properties and adhesion
Binder’s performance is dictated by recipe choices
● Monomer and surfactant type and level
● Type and level of adhesion promoters or other functional materials
● Process conditions such as reaction temperature and monomer addition policy
EXAMPLES
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Polymer properties can impact performance
Composition
● durability
● water resistance
● self thickening
● functionality
Minimum Filming Temperature (MFT)
● “softness”
● film forming ability
● co-solvent/plasticizer demand
Glass Transition Temperature (Tg)
● “hardness”
● dirt pick up resistance
● Tensile/Elongation
Molecular weight
● Exterior Durability
● “Toughness”
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Latex properties can also impact performance
Particle size /Distribution/Morphology
● Thickener efficiency
● Rheology
● Freeze/thaw stability
● Binding efficiency
● Adhesion
Surfactant package
● Stability
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Pigments function primarily as filler
Calcium Carbonate is the primary pigment used as a filler
● Will impart hardness, tensile strength and elongation properties
● 5 um or larger is typical
Titanium dioxide provides whiteness
● Used at much lower levels than architectural paints
Fumed silica imparts shear thinning rheology to the caulk
EXAMPLES
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Plasticizers enhance the flexibility of the caulk
Lowers the Tg of the polymer aiding flexibility of the caulk
Need to ensure that plasticizer selection is compatible with latex binder to achieve desired properties
Plasticizer can also improve the skrinkage of a caulk during drying
Many caulk manufacturers are moving towards non-phthalate plasticizers for environmental reasons
EXAMPLES
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Thickeners impart the proper flow characteristics
Consist of water soluble polymer, alkali swellable latexes, and fumed silica that impart suspension and stability
Type and level impact extrusion rate and slump resistance
EXAMPLES
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Additives enhance key properties
Glycols impart freeze/thaw resistance and increase open time
Dispersants and surfactants provide stabilization to the pigment particles and long term caulk viscosity stability
Silanes at low levels provide enhanced wet adhesion to glass
Defoamers reduce the surface tension of the formulation to minimize foaming of the caulk
Preservatives and mildewcides provide protection to bacteria and mildew growth
EXAMPLES
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Pigment to binder ratio is a critical formulation parameter
Pigment to Binder Ratio (P/B) :
% Plasticizer
P/B = Mass of Pigment (dry lbs)
Mass of binder (dry lbs)
Total P/B = Mass of Pigment (dry lbs)
Mass of binder + plasticizer (dry lbs)
% Plasticizer = Mass of Plasticizer (dry lbs)
Mass of binder (dry lbs)
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Increasing the P/B ratio in a caulk will:
Increase volume solids
Increase tensile strength
Reduce dirt pick-up
Increase surface hardness
Aid “paintability”
Reduce Shrinkage
Lower elongation
Reduce crack resistance
Lower cost
Reduce adhesion
Reduce tack
Lower gunnability
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Caulk Classification
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Caulks can be classified by appearance
Clear or “True Clear” - can see through; appears like glass
Translucent – can see through but has a haze
Pigmented – opaque; cannot see through
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These categories must be formulated differently
Caulk Type Clear Translucent Pigmented
Binder Solids, wt% 60 45 to 50 18 to 22
Binder Tg, oC -10 to +10 -25 to -10 -35 to 0
Pigment/Binder ratio 0 0.02 to 0.06 2.5 to 5.0
Solids Content, wt% 59 60 to 64 80 to 85
Solids Content, vol% 55 55 to 59 70 to 75
Density, lbs/gal 8.7 to 9.0 8.8 to 9.0 12.6 to 14.5
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Anatomy of a caulk
Clear (P/B=0:1)
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Pigmented (P/B=5:1)
Additives
Pigment
Plasticizer
Binder
Water
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ASTM classifies caulks and sealants based on
performance
Quality Levels
Non-spec
● Products used to seal or repair cracks in interior millwork
ASTM C 834
● Typically marketed with a 15 to 40 year warranty
● “Middle of the road” caulk (good performance)
● ASTM C 834 testing – Specification includes testing typically conducted for “non-spec” caulk plus:
- Artificial weathering - Low temperature flex - Extension recovery
ASTM C 920
● Typically marketed with a 40-year to lifetime warranty
● ASTM C 920 testing – Specification includes testing conducted for C 834 plus:
- Hardness - Cyclic movement - Adhesion/peel - Accelerated weathering
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Higher performing caulks have lower P/B
ASTM C834
Ingredients Class 25 Class 12.5
Plasticizer 123.0 100.9 92.6
Propylene Glycol 10.5 11.7 13.0
Hydroxyethyl cellulose thickener 2.0 2.0 2.0
Nonionic Surfactant 3.9 7.1 13.0
Dispersant 1.5 2.2 3.0
Preservative 2.0 1.3 1.3
Latex @ 58% solids 530.0 435.0 319.3
water 0.0 30.0 35.0
Calcium carbonate, 6 micron 453.6 673.7 925.9
Titanium dioxide 7.5 7.5 0.0
Organofunctional silane 1.2 1.0 1.5
Ammonium hydroxide, 28% 2.4 1.9 1.0
Rheotech 146 10.0 10.0 10.0
Mineral spirits 15.0 15.0 15.0
Caulk Properties
P/B 1.50 2.70 5.00
Total P/B 1.05 1.91 3.33
% Plasticizer 40 40 50
ASTM C-920
ASTM Specifications and
Methodology
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What is ASTM?
ASTM is an abbreviation for American Society for Testing and Materials
Organization dedicated to the development and delivery of international voluntary consensus standards
Standards benchmark performance
ASTM performance standards are accepted by the caulk and sealant industry
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Non-Spec Caulk
15 year or less warranty
Pigment to binder ratio of > 4:1
Tested for the basic properties
● viscosity, pH, slump (< 0.20”) and extrudability (> 2 grams/sec)
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ASTM C834 Sealant
15 to 40 year warranty
Good quality sealant typically used for interior applications
Pigment to binder ratio typically between 2:1 and 4:1
Testing more demanding than for non-spec
● viscosity, pH, slump (< 0.20”) and extrudability (> 2 grams/sec)
● artificial weathering, low temperature flex and extension recovery
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Summary of ASTM C834 Tests
C-731 Extrudability after package aging (20 days)
C-732 Aging effects artificial weathering (28 days)
C-733 Volume Shrinkage (29 days)
C-734 Low Temperature Flexibility (25 days)
● Grades NF, 0°C, and -17°C
C-736 Extension Recovery (16 days)
D-2202 Slump Of Sealants (1 day)
D-2203 Staining of Sealants (4 days)
D-2377 Tack Free Time (4 days)
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ASTM C834 Performance Requirements
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Test Requirements ASTM Test Method
Extrudability 2 g/s, minimum C1183
Artificial Weathering 500 h C732 Wash-out none, after weathering Slump none, after weathering Cracking none, after weathering Discoloration as acceptable to purchaser Adhesion loss 25% maximum
Volume Shrinkage C1241 Type OP 30% maximum Type C 50% maximum
Low-temperature flexibility C734 Grades -18°C and 0°C no cracking through to substrate or adhesion loss Grade NF none
Recovery Adhesion loss 75% minimum recovery, 25% maximum adhesion loss C736
Slump 4 mm maximum D2202 Stain index 3 maximum D2203 Tack-free time no material adhering to plastic strip D2377 Color as acceptable to purchaser 6.2
ASTM C920 Sealant
High performance caulk
40 year to a lifetime warranty
Pigment to binder ratio < 2:1
Testing even more demanding than for ASTM C834
● viscosity, pH, slump (< 0.20”) and extrudability (> 2 grams/sec)
● artificial weathering, low temperature flex and extension recovery
● cyclic movement, wet peel adhesion and accelerated weathering
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ASTM C920 Tests
C-510 Staining and Color change. (16 days)
C-603 Extrusion Rate (can use c-731) (1 day)
C-661 Indentation Hardness (21 days)
C-679 Tack free time (up to 21 days)
C-719 Adhesion & Cohesion under cyclic movement (approximately 55 days): Class 25 and Class 12.5
C-792 Heat Aging (weight loss, cracking, & chalking) (29 days)
C-793 Low temp flex ( -26 degrees C) (16 days)
C-794 Adhesion in Peel (30 days)
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ASTM C920 Performance Requirements
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Test Requirements ASTM Test Method
Rheological Flow Properties 4.8 mm maximum C639
Extrusion Rate 10 mL/min minimum C1183 proc. A Hardness 60 maximum C661 Adhesion and Cohesion Under Cyclic Movement
C719
Glass, aluminum, mortar 9 cm2 maximum adhesion loss for each substrate
Adhesion in Peel C794 Glass, aluminum, mortar 5 pli minimum average, 25% maximum adhesive failure
Effects of Accelerated Weathering -26 °C after 250 h weatherometer C793 no cracking greater than pictorial control
Effects of Heat Aging 7% maximum weight loss C1246
Stain and Color Change no visible stain C510 Color as acceptable to purchaser 6.2
Sealant Specs are typically printed on tube
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Artificial Weathering ASTM C732
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ASTM C719 Cyclic Tester
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ASTM C719 Cyclic Tester Chamber
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Slump Resistance ASTM D2202
Slump Video
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Effects of Accelerated Weathering ASTM C793
Passing LTF Video
Failing LTF Video
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Adhesion in Peel ASTM C794
Peel Adhesion Video
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Burrell Extrusion Rate Test
Extrusion Video
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The economics of a tube of caulk
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Pricing varies dramatically across grades
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Ingredients Quantity Price Cost
Plasticizer 33.1 $1.25 $41.38
Propylene Glycol 37.6 $0.65 $24.44
Hydroxyethyl cellulose thickener $3.00 $0.00
Nonionic Surfactant 5.1 $1.50 $7.65
Dispersant 0.0 $1.00 $0.00
Preservative 1.1 $4.00 $4.40
Latex @ 60% solids 781.5 $1.75 $1,367.63
water 0.0 $0.00 $0.00
Calcium carbonate, 6 micron 0.0 $0.10 $0.00
Titanium dioxide 0.0 $1.50 $0.00
Organofunctional silane 1.8 $6.00 $10.80
Ammonium hydroxide, 28% 1.5 $0.25 $0.38
Thickener 9.4 $1.00 $9.40
Mineral spirits 21.5 $1.00 $21.50
Raw Materials 892.6 $1,487.57
Unit RMC ($/10 oz tube) $1.16
Packaging $0.18
TOTAL ($/10 oz tube) $1.34
Selling Price ($/10 oz tube) $8.00
ASTM C-920 ClearIngredients Quantity Price Cost
Plasticizer 123.0 $1.25 $153.75
Propylene Glycol 10.5 $0.65 $6.83
Hydroxyethyl cellulose thickener 2.0 $3.00 $6.00
Nonionic Surfactant 3.9 $1.50 $5.85
Dispersant 1.5 $1.00 $1.50
Preservative 2.0 $4.00 $8.00
Latex @ 60% solids 512.3 $1.75 $896.58
water 17.7 $0.00 $0.00
Calcium carbonate, 6 micron 453.6 $0.10 $45.36
Titanium dioxide 7.5 $1.50 $11.25
Organofunctional silane 1.2 $6.00 $7.20
Ammonium hydroxide, 28% 2.4 $0.25 $0.60
Thickener 10.0 $1.00 $10.00
Mineral spirits 15.0 $1.00 $15.00
Raw Materials 1162.6 $1,167.92
Unit RMC ($/10 oz tube) $0.91
Packaging $0.18
TOTAL ($/10 oz tube) $1.09
Selling Price ($/10 oz tube) $4.33
ASTM C-920 Class 25 Pigmented
Ingredients Quantity Price Cost
Plasticizer 92.6 $1.25 $115.75
Propylene Glycol 13.0 $0.65 $8.45
Hydroxyethyl cellulose thickener 2.0 $3.00 $6.00
Nonionic Surfactant 13.0 $1.50 $19.50
Dispersant 3.0 $1.00 $3.00
Preservative 1.3 $4.00 $5.20
Latex @ 60% solids 308.7 $1.50 $462.99
water 45.6 $0.00 $0.00
Calcium carbonate, 6 micron 925.9 $0.10 $92.59
Titanium dioxide 0.0 $1.50 $0.00
Organofunctional silane 1.5 $6.00 $9.00
Ammonium hydroxide, 28% 1.0 $0.25 $0.25
Thickener 10.0 $1.00 $10.00
Mineral spirits 15.0 $1.00 $15.00
Raw Materials 1432.6 $747.73
Unit RMC ($/10 oz tube) $0.58
Packaging $0.18
TOTAL ($/10 oz tube) $0.76
Selling Price ($/10 oz tube) $1.59
ASTM C-834Ingredients Quantity Price Cost
Plasticizer 78.1 $1.25 $97.63
Propylene Glycol 12.4 $0.65 $8.06
Hydroxyethyl cellulose thickener 1.9 $3.00 $5.70
Nonionic Surfactant 11.2 $1.50 $16.80
Dispersant 2.8 $1.00 $2.80
Preservative 1.2 $4.00 $4.80
Latex @ 60% solids 294.6 $0.75 $220.98
water 126.3 $0.00 $0.00
Calcium carbonate, 6 micron 862.8 $0.10 $86.28
Titanium dioxide 5.3 $1.50 $7.95
Organofunctional silane 1.0 $6.00 $6.00
Ammonium hydroxide, 28% 1.5 $0.25 $0.38
Thickener 9.3 $1.00 $9.30
Mineral spirits 9.6 $1.00 $9.60
Raw Materials 1418.0 $476.27
Unit RMC ($/10 oz tube) $0.37
Packaging $0.18
TOTAL ($/10 oz tube) $0.55
Selling Price ($/10 oz tube) $1.45
Non-spec
C920 caulks deliver disproportionate value
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C920 Clear
10%
C920 Pigmented
20%
C834
30%
Non-spec
40%
C920 Clear
29%
C920 Pigmented
32%
C834
18%
Non-spec
21%
Volume Revenue
ACR is the market leader to this segment
with our Tool Box of Polymers
Broadest technology platform
● NEOCAR® Acrylic polymers
● Acrylic polymers
● Styrene acrylic polymers
● NEOCAR® polymers
● Vinyl acrylic polymers
● Vinyl acetate ethylene polymers
● Styrene-butadiene polymers
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Diverse product range to provide
options to our customers
Waterborne
Chemistry Arkema BASF DowAcrylic
Alkyd Dispersions
Styrene acrylic
Styrene butadiene
Vinyl acetate-
ethylene
Vinyl-acrylic
Vinyl versatate-
acrylic
Vinyl versatate-
vinyl acetate
Opacifier
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A range of products to cover the entire
spectrum of performance and cost
Product Chemistry Total
solids (%) Tg
(oC) Features
CONTRACTOR CAULKS/SEALANTS
ENCOR® 162 Vinyl acrylic 55 7 Contractor/DIY caulk
ASTM C 834 CAULK
ENCOR® 154S Acrylic 60 -4 Pigmented caulk
ENCOR® 182 Vinyl acetate
ethylene 55 11
Pigmented caulk, can be formulated
without modification to meet 0oC
flexibility requirement, must be blend with ENCOR 169S to pass -17oC flexibility
ENCOR® 9192 Acrylic 66 0 True clear caulk
ASTM C 920 CAULK
ENCOR® 163S Acrylic 58 -11 Pigmented caulk
ENCOR® 169S Styrene acrylic 62.5 -22 Translucent/pigmented caulk
ENCOR® 9176 Styrene acrylic 61 -21 Pigmented caulk; crosslinking; adhesion to low energy substrates
Products attributed are summarized in our Construction products selection guide
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More details are available in our enhanced technical data sheets
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ENCOR 182 Ethylene Vinyl Acetate Copolymer for Caulk Applications
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ENCOR 182 Properties
Total Solids : 56%
Glass Transition Temperature : 5oC
Particle Size : 0.42 micron
Brookfield Viscosity : 90 cP
ENVIA compliant ● No added formaldehyde ● APEO free ● Latex VOC < 5 g/L ● Low residual monomer : total < 500 ppm ● Below regulatory reporting limits for carcinogens, reproductive
toxins and ozone depleting compounds
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ENCOR® 182 Vinyl Acetate-Ethylene Latex for Pigmented Caulks
Vinyl Acetate-Ethylene based polymer designed for cost effective sealants meeting ASTM C834 specification
Passes ASTM C834 Grade 0oC specification
Can be formulated with higher performing acrylic polymers such as ENCOR 169S to meet ASTM C834 Grade -18oC
Compatible with many new non-phthalate type plasticizers
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ENCOR 9192 Acrylic polymer for true clear caulks and sealants
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ENCOR 9192 Properties
A 100% acrylic latex with:
● Very high solids
● Low color in dry film
● Rapid dry to clear
● Low surface tack
● The ability to self-thicken to formulated viscosity without addition of additional thickener
● Formulation latitude allowing a variety of different desirable properties to be achieved
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0
10
20
30
40
50
60
70
U9192 A B C D E F G H I
% C
lari
ty
3 day
14 day
Comparison of Formulated U9192 with Commercial Clear Sealants
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ENCOR 9176 Ambient cure crosslinking sealants
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ENCOR 9176 Properties
Total Solids : 61%
Glass Transition Temperature : -21oC
Particle Size : 0.35 micron
Brookfield Viscosity : 500 cP
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ENCOR® 9176 For Ambient Crosslinking Sealants
Unique waterborne polymer with ambient cure crosslinking technology providing elastomeric properties
High adhesive bonding to architectural substrates
Very good pigment binding capabilities for higher P/B formulations
Can be formulated into translucent and pigmented sealants meeting ASTM C920 Class 35
High gel content; poor flow
Low to moderate gel; good flow
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2
4
6
8
10
12
14
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Wet
Peel
Ad
hesio
n,
pli
ENCOR 9176 GE W&D
Pine
Wet Pine
Semigloss
Mortar
Wet Mortar
Lexan
Plexiglass
Formica
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Competitive Products and Suggested Offsets
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Product Technology Solids, % Tg, C Arkema Offset
Dow Chemical
Rovace 86 Vinyl Acrylic 55 5 ENCOR 162 ENCOR 182
Rhoplex 3805 Acrylic 58 -13 ENCOR 163S
Rhoplex A-920 Acrylic 62 2 ENCOR 163S ENCOR 169S
Rhoplex 928 Acrylic copolymer 62.5 5 ENCOR 9192
Rhoplex 2620 Acrylic 62 -26 ENCOR 169S
Momentive
Synthebond AC111 Acrylic 58 -11 ENCOR 163S
Synthebond E6016 Acrylic copolymer 63 -16 ENCOR 163S ENCOR 169S
Synthebond E6022 Acrylic copolymer 63 -22 ENCOR 169S
Synthebond E6260 Acrylic copolymer 64 -29 ENCOR 169S
Wacker
Vinnapas EF575 Vinyl acetate-ethylene Copolymer
55 0 ENCOR 182
Highlights of Today’s Webinar Summary
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Recap
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Today’s session was intended to provide you with a technical grounding in caulk formulation and product selection
Caulks can be classified base on their appearance or by ASTM performance category
ACR is the segment leader in caulks and sealants
ACR offers the broadest range of chemistries to the caulks and sealants market to meet a range of cost/performance requirements
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Questions? Please contact the Account Team
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Mary Chervenak [email protected]
Marlene Hernandez [email protected]
Mark Piggott [email protected]
Commercial Questions
Latin America
Commercial Questions
USA & Canada
Technical Questions
2014 ACR Webinar Series
Next Month’s Topic: Cementious Coatings
Speaker: Mike Kaufman
Title: Sr. Applications Development Leader
Friday May 16, 2014 @ 2:00pm ET 62
Arkema Coating Resins
Thank You for
Joining Us!!
See you in May!!
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