New systems for wind mill towers - Delegia · Pinholes NACE SP0188 Low voltage 90V OK OK Pull-off...
Transcript of New systems for wind mill towers - Delegia · Pinholes NACE SP0188 Low voltage 90V OK OK Pull-off...
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New systems for wind mill towers
Palle Gustafsson • Vamdrup • 20.05.2015
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Coating demands for Wind mill towers
• Excellent corrosion protection
• Excellent outdoor durability - Good gloss and color retention.
• Working conditions from – 40°-> +45°C
• Excellent resistent to salt, water and ice.
• Chemical resistant (lubricants, hydraulic fluids and cleaners).
• Environmental friendly
• Expected lifetime >25 years.
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• High output.
• Fast drying - preferebly at ambient temperature.
• Reliable – Repainting is costly.
• Environmental friendly – VOC compatible.
The production process
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Traditional system for towers
TEKNOS SPECIFIKATION STANDARD SYSTEM C5M-high
Product nameDFT(µm)
Volume solids(%)
Theo. Spreading(m2 / L)
VOC (g / L)
VOC (g / m2)
Drying time (h)
Paint volume (L/100m2)
EPOXY ZINC 90 60 53 8,8 450 51 1 h 11,36
EPOXY PRIMER (high solid)
2*100 66 3,3 320 97 2*4 h 30,30
POLYURETHAN 60 56 9,3 430 46 6 h 10,75
Total 320 194 15 52,42
High amount of VOC
High drying time
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Polyaspartic system for towers
TEKNOS SPECIFIKATION FAST DRYINGHIGH SOLID SYSTEM C5M-high
Product nameDFT(µm)
Volume solids(%)
Theo. Spreading(m2 / L)
VOC (g / L)
VOC (g / m2)
Drying time (h)
Paint volume (L/100m2)
EPOXY ZINC 90 60 53 8,8 450 51 2 h 11,36
POLYASPARTIC 240 77 3,2 240 75 1 h 31,25
Total 320 126 3 42,61
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Pure polyaspartic system for towers
TEKNOS SPECIFIKATION FAST DRYINGHIGH SOLID SYSTEM C5M-high
Product nameDFT(µm)
Volume solids(%)
Theo. Spreading(m2 / L)
VOC (g / L)
VOC (g / m2)
Drying time (h)
Paint volume (L/100m2)
TSM 60 100 16,6 0 0 6,02
POLYASPARTIC 240 77 3,2 240 75 1 h 31,25
Total 320 75 1 37,27
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Overview
0
50
100
150
200
250
VOC(g / m2)
Drying time (h) Paint volume (L/100m2)
Traditionel vs polyaspartics
Traditionelt Zn(EP) polyaspartic polyaspartic
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• Polyaspartics are very low viscous
• The have a very high reaction speed with isocyanates
• No reaction gasses are being build
What’s a Polyaspartic
The reaction of polyaspartics with isocyanates leeds to a polyurea coating
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Idea to market
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New but with 10 years experience
• Teknos was one of the first to introduce polyaspartic
technology to the European market.
• Development started in 2003 and the first implemented
products were used in 2005.
• TEKNODUR COMBI 3560 has been one of the most
succesfull products in the TEKNOS group
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Experiences
• Used in a range of system
• Solvent- and waterborne
• 1- and 2 component systems
• Used in several applikations
• General industry products
• Windmill towers
• Windmill wings
• Parts for towers
• ISO 12340 Norsok M-501 approved
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TEKNODUR COMBI 3560 Technology
Teknos Polyaspartics for metal are named:
TEKNODUR COMBI 3560
This new polyurea chemistry which provide:
• High solids ( 75 - 100 ) % by volume
• Adjustable curing speed
• From standard cure speed to extremely fast.
• Low viscosity
• Spraying with standard eqiupment
• Adjustable pot life
• From 7 min to 2 hours.
• High filmthickness in one coat possible
• Hard and though paint film
• Excellent corrosion protection and weatherability.
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Additional documentation
C3 system3560 (200µm)
C5M SystemTSM (60µm)
+3560 (240µm)
Pinholes NACE SP0188 Low voltage 90V OK OK
Pull-off ISO 4624 >15 Mpa >15 Mpa
Continiouscondensation ISO 6270 part of ISO 12944 480 hours 720 hours
Saltspray DS/EN ISO 9227 part of ISO 12944 720 hours Na (OK 1440)
"NORSOK": DS/EN 20340 passes 25 weeks
Thermal cycling NACE TM304-2004 Section 9 3 weeks 3 weeks
Flexibility testNACE TM304-2004 Section 12= NACE RP0394
2 degrees R200at 23 degrees Cat -18 degrees C
2 degrees R200at 23 degrees Cat -18 degrees C
Impact resistance test
NACE TM304-2004 Section 13=ASTM G14/ASTM D2794 equal to DS/EN ISO 6272-1 >15 inP >15 inP
Cold check Teknos internal specification 10 cycles 10 cycles
Immersion test ISO 2812-2 Na 4200 h
* Not part of ISO12944 – however no blistering rust ect.
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Example of test equipments
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• What will happend at deviation in mixing ratio
Proces window
3560-73 system C3M
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0
10
20
30
40
50
60
70
80
90
100
TEKNODUR3560-73
Udhærdningsgrad:70%
TEKNODUR3560-73
Udhærdningsgrad:80%
TEKNODUR3560-73
Udhærdningsgrad:90%
TEKNODUR3560-73
Udhærdningsgrad:100%
TEKNODUR3560-73
Udhærdningsgrad:110%
TEKNODUR3560-73
Udhærdningsgrad:120%
TEKNODUR3560-73
Udhærdningsgrad:130%
Min
ute
s
Drying time (drying recorder)
Dust dry
Dry to touch
Dry to handle
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0
1
2
3
4
5
6
TEKNODUR 3560-73Udhærdningsgrad:
70%
TEKNODUR 3560-73Udhærdningsgrad:
80%
TEKNODUR 3560-73Udhærdningsgrad:
90%
TEKNODUR 3560-73Udhærdningsgrad:
100%
TEKNODUR 3560-73Udhærdningsgrad:
110%
TEKNODUR 3560-73Udhærdningsgrad:
120%
TEKNODUR 3560-73Udhærdningsgrad:
130%
Evalu
ati
on
fro
m 0
-5
Chemical resistanse spottest
Spottest 24 h NaOH
Spottest 1h formic acid
Spottest 24 hours Xylene
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0,0
20,0
40,0
60,0
80,0
100,0
120,0
140,0
TEKNODUR 3560-73
Udhærdningsgrad:70%
TEKNODUR 3560-73
Udhærdningsgrad:80%
TEKNODUR 3560-73
Udhærdningsgrad:90%
TEKNODUR 3560-73
Udhærdningsgrad:100%
TEKNODUR 3560-73
Udhærdningsgrad:110%
TEKNODUR 3560-73
Udhærdningsgrad:120%
TEKNODUR 3560-73
Udhærdningsgrad:130%
Seco
nd
s
Mixing ratio
König hardness
HardnessKönig1 day
HardnessKönig2 day
HardnessKönig4 day
HardnessKönig1 week
HardnessKönig10 days
HardnessKönig2 weeks
HardnessKönig3 weeks
HardnessKönig4 weeks
HardnessKönig8 weeks
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Conclusion for process window
3560 has the safety in production needed to assure a safe and
full performing systems even at higher deviations in mixing ratio
than would be accepted.
• Always use 2-component equipment when usingpolyaspartics
• Keep track on mixing ratio and pot-life.
• Fix the mixing ratio to stay between +/-5% of set-point
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Documentation of repair system
• Repair system are based on
• Zn (EP) or 1-component
• 3560-53 (1 hour potlife)
• Tested on:
• Steel
• TSM
• Damage to both
• Primed surface
• Tested at standard conditions as well as extreme conditions
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Conclusion on repair system
• Repair system are showing the same performance as the original system
• Painting can be done by roller, brush or spray
• Painting on cold substrates and early exposure is possible
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Conclusion
EP/PU Powder Polyaspartic
VOC
Output
Energy
consumption
Isocyanate
Epoxy
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What´́́́s the cons
• Short pot-life – 2-K equipment is needed.
• Clean and rough surface is needed.
• Teknos recommends gritblasting to a roughness medium to rough.
• Compared to powder coating this system contains isocyanate like other PU’s
• If you want full control on drying time the condition needs to be controlled (Teknos recommends RH 40-60% and temp 20-25 degrees C).
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3560-73 3560-83 3560-53
Describtion Full automatic lines Manual painting with 2-K
equipment
Manual painting
Pot-life
(25 degrees C)
8 min 15 min. 1 hour
Mixing ratio
volume
4,5:1 4,5:1 4:1
Volume solid 77% 77% 83%
VOC content 240 g/l 240 g/l 170 g/l
Dry to handle at 23
degrees C (240 µm DFT)
70 minutes 90 minutes 4 hours
Flexible range
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Summary
• TEKNODUR COMBI 3560 is recommened for towers inside as well as outside C3 to C5 marine
• For C5 Marine conditions Zn-rich primer or TSM are approved and to be recommended
• For other parts several primers are tested for C5
• TEKNODUR COMBI 3560 will help you• Reduce amount of VOC needed for the painting process
• Reduce energy consumtiom needed for the drying process
• Reduce time of production
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New systems for wind mill blades
Palle Gustafsson • Vamdrup • 20.05.2015
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TEKNODUR COMBI 3572 – Polyaspartics for windmill blades
• Developed for windmill blades with strong adhesion (>8 MPa pull-off) direct to reinforced polyester and epoxy as well as PU and EP fillers
• With improved rain erosion resistance
• With excellent fatique resistance
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Rain erosion resistance of 3572
• Tested in chopper test with windmill tip at
• Speed 135 m/s
• Rainfall 60mm/h
• Passes test at 120 min !
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TEKNODUR COMBI 3572 for Windmills
• Blades:
• TEKNODUR COMBI 3572 1 x 160 µm
Total dry film thickness 160 µm
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System for windmill blades
• TEKNODUR 3572-02 has been tested and approved in accordance with customer specification.
• The full system is based on:
• Filler
• Intermediate filler
• polyaspartic possible -> 3574 sanding after 1h
• Topcoat: TEKNODUR 3572 dry to touch after 1 hour.
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Thank you!
Palle Gustafsson • Vamdrup •20-05-2015