Overview of Topcoats and FEVE TopcoatsWeatherability of FEVE TopcoatsAccelerated weatheringNatural weatheringCorrosion Resistance of FEVE TopcoatsSpecification ReviewLife Cycle Cost AnalysisCase Studi ID: 837284
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1 Winn Darden, AGC Chemicals AmericasTowar
Winn Darden, AGC Chemicals AmericasToward a 100 Year Bridge Coating System: Fluoropolymer Topcoats Overview of Topcoats and FEVE TopcoatsWeatherability of FEVE TopcoatsAccelerated weatheringNatural weatheringCorrosion Resistance of FEVE TopcoatsSpecification ReviewLife Cycle Cost
2 AnalysisCase StudiesPresentation Overvie
AnalysisCase StudiesPresentation Overview • Conventional Coating Systems Zinc rich primer, epoxy, and polyurethane topcoatOffer good corrosion protectionTopcoat begins to chalk and change appearance quickly Fluoropolymer Coating Systems Zinc rich primer, epoxy, and fluorinated
3 urethane topcoatFEVE (FluoroEthyleneViny
urethane topcoatFEVE (FluoroEthyleneVinyl Ether) technologyDeveloped in the early 1980’s; wide use by the 1990’sFEVE withstands UV exposure at least 23 times longer than conventional coating resins.Topcoat Overview The fluoroethylene(FE) segments impart durability, whereas
4 the vinyl ethers (VE) give a range of p
the vinyl ethers (VE) give a range of positive attributes to the FEVE resin including gloss, hardness, solubility, flexibility and the ability to crosslinkFEVE Fluoropolymer Structure Excellent weatherability (30+ year topcoat life)Superior gloss and color retentionGood corrosion r
5 esistanceSuperior resistance to chalking
esistanceSuperior resistance to chalkingShop or field applied (new construction and maintenance)Uses standard painting equipment & application methodsFormulated to meet all air quality regulationsResistant to airborne chemicals and acid rainResistant to cleaning solvents used to rem
6 ove graffitiFEVE Resin Topcoat Advantage
ove graffitiFEVE Resin Topcoat Advantages Accelerated Weathering TestsShort time frame for resultsLimitations in accurately simulating real environmentUsed as screening tool and comparing coatingsReal Time Weathering TestsAccurate resultsVery time consuming: up to 20 years to compl
7 eteOften done in harsh conditions, e.g.
eteOften done in harsh conditions, e.g. South FloridaWeathering Resistance Testing Accelerated Weathering: QUVB Weatherometer Testing Accelerated Weathering: EMMAQUA Testing 102030405060708090100110 Gloss Retention (%) Radiant Energy (MJ/m²) FEVE coating PVDF coating Acrylic Uret
8 hane coating Real Time Weathering: Sout
hane coating Real Time Weathering: South Florida Testing 100110 Gloss retention (%) Years of ExposureSouth Florida FEVE Yellow Coating FEVE Clearcoat Real Time Weathering: Okinawa Weathering FEVE vs. PVdF: Okinawa Weathering 050100150 0123456789101112 Years of Okinawa Exposure Gl
9 oss Retention, % FEVE PVdF Two coating s
oss Retention, % FEVE PVdF Two coating systems: Zn primer/Epoxy/Acrylic Urethane; Zn primer/Epoxy/FEVE tested on offshore platform in Suruga Bay, Japan (34.87 North 138.48 East)Real Time Weathering: Offshore Platform Polyurethane and FEVE topcoats were evaluated over a 20 year per
10 iodRated on scale of 0 (severe chalking
iodRated on scale of 0 (severe chalking over entire coating surface) to 10 (no chalking)Real Time Weathering: Offshore Platform Corrosion Resistance Drives Use of Coatings on Steel BridgesPrimary corrosion resistance provided by zinc primerTopcoat serves to block corrosion initia
11 tors like oxygen, water, and chlorideFlu
tors like oxygen, water, and chlorideFluorinated topcoats have low degradation rates maintaining corrosion protection over longer periods of timeCorrosion Resistance of Steel Bridges Coated scribed panels exposed to alternating UV/condensation and salt fog/dry exposure cabinetSalt
12 solution is 0.05% sodium chloride and 0.
solution is 0.05% sodium chloride and 0.35% ammonium sulfate5,040 hours of total exposureCorrosion Resistance of FEVE Coatings: ASTM D5894, Cyclic Prohesion Test Scribed coated panels exposed to 5% salt solution for 3,000 hours.Corrosion is measured by the amount of rust in the scr
13 ibe and under the coating adjacent to th
ibe and under the coating adjacent to the scribe as well as by blisters formed by corrosion products. In the test below, both topcoats were applied over a 3 mil epoxy primer.Left Panel: PolysiloxaneRight Panel: FEVE coatingCorrosion Resistance of FEVE Coatings: ASTM 117 Salt Fog
14 Test 3,000 hoursLeft Panel: Polyuretha
Test 3,000 hoursLeft Panel: PolyurethaneRight Panel: FEVE CoatingCorrosion Resistance of FEVE Coatings: ASTM 117 Salt Fog Test Corrosion Resistance of FEVE Coatings: ASTM B117 Salt Fog Test (3,000 Hours) Formula NameDFT (mils)Creep (mm)Creep Rating (ASTM D1654)Commercial Poly
15 siloxane White2.1Commercial Clear Polysi
siloxane White2.1Commercial Clear Polysiloxane2.0Commercial Polyurethane White2.6Fluorourethane Clear2.1Fluorourethane White1.5 EIS involves setting up a corrosion cell on a coated steel panel. As a coating degrades, water and other corrosion initiators move through the coating set
16 ting up a new corrosion cell. EIS measu
ting up a new corrosion cell. EIS measures the difference in impedance between the new and aged coating. The smaller the change in impedance, the better the corrosion resistance of the coating.Corrosion Resistance of FEVE Coatings: Electrochemical Impedance Spectroscopy (EIS) 024
17 681012 SWOM,1000 hrs.SaltSpray,500 hrs.S
681012 SWOM,1000 hrs.SaltSpray,500 hrs.SaltSpray,1000 hrs. Impedance, 100Mohms/Sq. Cm. FEVE Polyurethane ChlorinatedRubber Alkyd This was the 1990 Japanese National Specification for Bridge Topcoats. FEVE topcoats were required for use only in the most severe environments Bridge T
18 opcoat Specifications The Japanese Natio
opcoat Specifications The Japanese National Specification was changed to focus on preventive maintenance and to yield lower lifecycle cost. Fluoropolymer topcoats were required for all environments.Bridge Topcoat Specifications Bridge Coating Specification Steel Structures Coating
19 Specification: ISO 12944 Updated 20186.
Specification: ISO 12944 Updated 20186.2.5 Paints for polyurethane coatings (PUR)Singlepackpolyurethanepaintsdryinitiallysolventevaporation(wheresolventpresent)chemicalreactionwithmoisturefromtheTheprocessirreversible,meaningthatthecoatingcannotdissolvedtheoriginalsolventAromaticwe
20 llaliphatictypespolyurethanecoatingsarea
llaliphatictypespolyurethanecoatingsareavailableAromatictypesarenotrecommendedfortopcoats,theychalkTwopackpaintsforpolyurethanecoatingsdryevaporationsolvents,present,curechemicalreactionbetweenbasecuringagentcomponentThemixturebasecuringagenthaslimitedpotlifeThebindersthebasecompone
21 ntarepolymerswithfreehydroxylgroupspolye
ntarepolymerswithfreehydroxylgroupspolyester,acrylic,epoxy,polyether,fluororesin,whichreactwithsuitableisocyanatecuringagentsTheycancombinedwithnonreactivebinders,hydrocarbonresinsThecuringagentcomponentcontainsaromaticaliphaticpolyisocyanatespecialtypePURisbasedfluoropolymersPaints
22 forfluoropolymer/vinyletherpolymer(FEVE)
forfluoropolymer/vinyletherpolymer(FEVE)coatingsaretwopackcoatingmaterials,andbothwaterborneandsolventbornetypesareavailableSolventbornepaintsdrysolventevaporationandcurechemicalreactionbetweenbaseresinandcuringcomponentPaintsforFEVEcoatingsareambientcurablecoatingmaterialscrosslink
23 edwithisocyanatehardenerTheresinthebasec
edwithisocyanatehardenerTheresinthebasecomponentisfluoropolymerwithfreehydroxylgroupswhichreactswithsuitableisocyanatecuringagents Life Cycle Cost: Topcoat Cost Analysis Topcoat TypeTopcoat Thickness, Coating Cost, $/m2Alkyd1.47Polyurethane4.08Fluorourethane24.02 Life Cycle Cost:
24 Bridge Painting Activities 2010/11 DOT B
Bridge Painting Activities 2010/11 DOT Bridge Paint Program Work Activity Breakdown 27% 13% 39% 11% 10% Rigging andContainment SurfacePreparation Misc. PaintActivities Travel PaintApplication Life Cycle Cost Analysis: FEVE vs. Polyurethane and Alkyd Coating SystemAlkydPolyurethaneF
25 luorourethaneTotal Repainting Cost, $/m2
luorourethaneTotal Repainting Cost, $/m269.4885.65105.88EstimatedCoating Life, Years60Total Applied CoatingSystem Cost, $/m2/Year9.934.763.531.76Cost Index100 FEVE coating system applied in 1986.199320082016Case Study: TokiwaBridge, Near Hiroshima, Japan Case Study: Daiichi Mukoya
26 maBridge, Near Tokyo, Japan30 yearsNo co
maBridge, Near Tokyo, Japan30 yearsNo corrosion or degradation of topcoat Glossand Color ChangeInitial Gloss2008 Gloss2016 GlossBefore WipingGloss52.446.528.3Gloss RetentionN/A88.7%54.0%AfterWipingGloss52.449.938.7GlossRetentionN/A95.2%73.8%No chalkingFEVE coating system applied 198
27 6 U. S. Bridges with FEVE TopcoatsShelby
6 U. S. Bridges with FEVE TopcoatsShelby Street Bridge, Nashville, TN (2000)Gateway Bridge, Nashville, TN (2004)Woodland St. Bridge, Nashville, TN Victory Memorial Bridge, Nashville, TNTopeka Blvd. Bridge, Topeka, KS (2008)235 Pedestrian Bridge, Des Moines, IA (2003)17 Pedestrian B
28 ridge, Phoenix, AZBoynton Inlet Bridge,
ridge, Phoenix, AZBoynton Inlet Bridge, Boynton Beach, FL (2010)SkydancePedestrian Bridge, Oklahoma City, OK (2012)Blue Bridge, Grand Rapids, MI (2013)Salmon Creek Bridge, Albion, CA, Test patchDuquesne University Skywalk, Pittsburgh, PA (2006)Georgetown Pedestrian Bridges, Washingt
29 on, DC (2004) 65 Arch Bridge, Columbus,
on, DC (2004) 65 Arch Bridge, Columbus, IN, IN DOT (2007)Tucson Historic Depot Pedestrian Bridge, Tucson, AZNavy Pier Pedestrian Bridge, Chicago, IL (2017) Based on accelerated and real time testing, fluoropolymer topcoats offer outstanding weathering and corrosion resistanceExpect
30 ed topcoat life in Japan is 3060 years,
ed topcoat life in Japan is 3060 years, as close as possible to 100 year coatingShop and field applicationSubstantial life cycle cost advantagesEnvironmental advantagesConclusions Winn Darden, AGC Chemicals Americaswww.lumiflonusa.comToward a 100 Year Bridge Coating System: FEVE Fl