new systems for wind mill towers - delegia · pinholes nace sp0188 low voltage 90v ok ok pull-off...

New systems for wind mill towers

Palle Gustafsson • Vamdrup • 20.05.2015

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.

• High output.

• Fast drying - preferebly at ambient temperature.

• Reliable – Repainting is costly.

• Environmental friendly – VOC compatible.

The production process

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

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

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

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

• 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

Idea to market

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

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

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.

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.

Example of test equipments

• What will happend at deviation in mixing ratio

Proces window

3560-73 system C3M

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

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

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

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

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

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

Conclusion

EP/PU Powder Polyaspartic

VOC

Output

Energy

consumption

Isocyanate

Epoxy

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).

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

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

New systems for wind mill blades

Palle Gustafsson • Vamdrup • 20.05.2015

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

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 !

TEKNODUR COMBI 3572 for Windmills

• Blades:

• TEKNODUR COMBI 3572 1 x 160 µm

Total dry film thickness 160 µm

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.

Thank you!

Palle Gustafsson • Vamdrup •20-05-2015