Introduction for Bayer Polyurethane Product - Floor Coatings

Building Chemicals - General Introduction Training October 2004
Gerhard Ruttmann

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INTRODUCTION
TABLE OF CONTENTS:
Fields of applications Requirements Typical build up Technologies Production Application

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FIELDS OF APPLICATION
General Industrial Flooring

SPECIFICATIONS:

AGI - Guidelines, DIN - Standards

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FIELDS OF APPLICATION
FLOORING: Secondary Containment Systems

SPECIFICATIONS:

- Guideline of the DIBt, Berlin - DIN 28052

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FIELDS OF APPLICATION
Secondary (primary ) Containment Systems (primary)

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FIELDS OF APPLICATION
FLOORING: Coating Systems for the Food Processing and Pharmaceutical Industry
SPECIFICATION: - GMP

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FIELDS OF APPLICATION
Parking Decks

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FIELDS OF APPLICATION
Overlays

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FIELDS OF APPLICATION
Waterproofing Systems

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FIELDS OF APPLICATION
Gymnasium- / Sports Floors
SPECIFICATION: DIN 18032

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FIELDS OF APPLICATION
Roof Coatings

SPECIFICATIONS: - Guidelines of planing and applications of roofs coatings/waterproofing measures - DIN 4102/7: Resistance against radiated heat and fire

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FIELDS OF APPLICATION
SPECIAL APPLICATIONS: Crack - Injections

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FIELDS OF APPLICATION
SPECIAL APPLICATIONS: Embedding - Systems for Rails

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FIELDS OF APPLICATION
- Parking Decks - Industrial Flooring (general) - Secondary Containment - „Overlays“ (anti slip road-, ramp and ship deck coatings) - Sports Floors - Technologies of application: - rolling, - trowelling, - spraying (2 pack-PU spray coatings)

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Industrial Flooring - requirements, requirements, application and build up
requirements:
mechanical load
light middel high extrem rolling dragging beating

chemical load
-oil, lipids - solvents - acids - alkalines - detergents ½ short term ½ constant

thermal load
- heat (humid - dry) short term constant - cold short term constant - change in temperature

safety
- w aterproof - crack bridging - slip resistant - non-combustible - antistatic - ecological

surface
- evenness - structure - color - gloss - color fastness - w eather stability

comfort
- impact sound insulation - abilitiy of repair - cleaning - maintenance

wear coatings:

sealers / thin floor coatings / thick floor coatings / synthetic resin mortars pretreated underlayer for the wear coat

penetration primer / primer / levelling coat pretreatment opt. adhesion promoter opt. adhesion promoter opt. adhesion promoter

vacuum shot blasting, grinding, milling inspection of the substrate (humidity, contaminations, toughness, strength)

sound bearing constructions

cementous screeds

magnesite- / anhydrite screeds

bituminous floors

synthetic resin coatings

ceramic tiles

concrete

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POSSIBLE REQUIREMENTS FOR FLOOR COATINGS
Resistant against abrasion Resistant against impact Resistant against chemicals Impermeable to liquids Crack - bridging Skid resistance Electrically conductive Weather stability Color stability Ease of cleaning and care Evenness
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FLOOR COATINGS: Typical Build-Up

top coat (opt.)

self-levelling coating

levelling -coat (opt.)

primer

concrete

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Application: Requested Conditions of the Substrate
No laitance, free from loose and crumbly components, contaminants, peeling coatings, cracks and gravel pockets Tensile strength: ≥ 1,5 N/mm2 Water content of the concrete at a depth of 2 cm: ≤ 4% Conditions for the application: • Substrate temperature ≥ 3 K above dew point • Substrate temperature ≥ 8° 8°C
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Application: Inspection of the substrate

C-Aquameter
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Application: Inspection of the substrate

Pull-off Tester
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Application: Pretreatment of the substrate

Vacuum Shot Blasting Equipment
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Application

Mixing Equipment
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Application

Mixing Equipment
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Application

Mixing Equipment: Forced Action Mixer
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Application: Tools

lamb skin roller

spike roller

float plate vanishing roller

spiked shoes

squeegee

floor finsh scraper

-smooth trowel -toothed

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Application

Working and Safety Equipment
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TECHNOLOGY OPTIONS - Aromatic systems (Desmodur / Desmophen): - NCO/OH (2 pack PU, aromatic) - NCO/H2O (1 pack PU, moisture curing) - NCO/Amine (2 pack PU, amine-aromatic) - NCO/Polyolemulsion (3 pack PU, Desmolith) - Desmocap - 2 pack PU, water borne (Bayhydrol / Bayhydur ) - Aliphatic systems (Desmodur / Desmophen): - NCO/OH (2 pack PU, aliphatic) - NCO/H2O (1 pack PU, moisture curing) - NCO/latent Hardener (1 pack PU, moisture curing) - NCO/Amine (2 pack PU, Aspartates)

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TECHNOLOGY OPTIONS 2 pack PU with aromatic isocyanates

- Products: - Application: - Advantage:

- Desmodur VL / VL 50 / VL R20 - Desmophen 1150 / 1145 / VP LS 2284 / 550 U etc. - industrial flooring - solvent free, self levelling coatings - higher reactivity than EP at lower temperatures - soft to hard - adjustable properties

- Disadvantage: - sensitive regarding application conditions - hydrophilic / hydrophobic properties of polyols

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TECHNOLOGY OPTIONS 1 pack PU, moisture curing - with aromatic isocyanates - Products: - Application: - Advantage: - Desmodur E 21 / E 23 / E 29 - industrial flooring and parking decks as primer/sealer on concrete - less sensitive regarding application conditions - easy handling at the construction site - higher reactivity than EP at lower temperatures - Disadvantage: - low tolerance regarding film thickness - high viscosity of Desmodur E 21 / E 23 - formulations mostly solvent containing

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TECHNOLOGY OPTIONS 2 pack PU, with aromatic/ aromatic/aliphatic isocyanates and aromatic amines

- Products: - Application: - Advantage:

- Desmodur E 15 / VP LS 2371 - parking decks, balconies etc. waterproofing membranes in general - not sensitive regarding application conditions - highly flexible but relative hard coating material

also at low temperatures, used for water-proofing - Disadvantage: - higher raw material price - relatively high viscosity - use of aromatic (non carcinogenic) amines as hardener

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TECHNOLOGY OPTIONS Desmocap

- Products: - Application: - Advantage:

- Desmocap 11 / 1180 / 12 - parking decks, balconies etc. - Epoxyd- Elastification - less sensitive regarding application conditions - flexible to hard coatings depending EP/Desmocap ratio broad glass transition temperature range, used

for crack bridging systems - Disadvantage: - high viscosity (~ 100.000 mPas for D‘cap 11)

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Recommended Production Equipment

VACUUM BUTTERFLY DISSOLVER

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Trends of the Market ( WE; NAFTA )
- higher productivity: - lower raw material prices - lower prices of formulations (more filler, lower viscosity) - easier to apply - shorter through curing times / longer pot life - increased environmental protection and health care: - solvent free systems - no aromatic (non - carcinogenic) amines

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COMPARISON OF TECHNOLOGIES

PU PU--TECHNOLOGY TECHNOLOGY
FLEXIBLE FLEXIBLETO TOHARD HARDCOATING COATING SYSTEMS SYSTEMS CRACK-BRIDGING; CRACK-BRIDGING;TOUGH; TOUGH; ABRASION RESISTANT ABRASION RESISTANT SENSITIVE SENSITIVEREGARDING REGARDING APPLICATION APPLICATIONCONDITIONS CONDITIONS AND FAILURES AND - FAILURES

EP EP--TECHNOLOGY TECHNOLOGY
GENERAL GENERALPURPOSE PURPOSESYSTEMS SYSTEMS HARD, HARD,NON NON--FLEXIBLE FLEXIBLECOATINGS COATINGS HIGH HIGHCOMPRESSION COMPRESSIONSTRENGTH STRENGTH NON NONCRACK CRACKBRIDGING BRIDGING

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