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Versatility of Polyolefins in

Waterproofing and Roofing Systems

• Waterproofing applications

• State-of-the-art in polyolefins

• Additives and formulations

• Production technologies

• Proven formulations

• Designing future waterproofing solutions

Stefan Ultsch – Dow Europe GmbH

Applications of flexible waterproofing membranes

Unballasted roofing

Ballasted/Green roof

Geomembranes, water liners

Tunneling

Polyolefin-based waterproofing in civil engineering

Breathable

pitched roof

Vapor barriers

Ballasted or green roof

Parapet sealants

Adhered roofing

Expansion joints

Pool- and tankliners

Facade sealants

Subsoil waterproofing

Mechanically fixed roofing

Bitumen

compatibility and

modification

– Simple

– Multipurpose

– Material usage

– Fire resistance

Unmet needs and development drivers

Installation Service-Life

– Flexible

– Reliable welding

– Material usage

– Longevity

–Energy saving

Optimized economics

– Fast product change

– Low scrap, economics

– Existing lines

ManufacturingDesign

Design options for waterproofing membranes

Coextruded top layer, coating, laminated film...

Top layer

Scrim, fabric

Glasfleece

Bottom layer compound

Fleece backing, substrate for adhesion

The Dow Polymer Portfolio

LLDPE

PP

RCP

ICP

Mo

du

lus LDPE

Mg(OH)2

Al(OH)3

CaCO3

TiO2

AO

…...

-EA

-MAH

PBE

HDPE

ULDPE

EPDM

OBC

POE

DOWLEX™

ATTANE™

ENGAGE™

INFUSE™

NORDEL IP™

AMPLIFY™

VERSIFY™

INSPIRE™

PE PPPP

Freeport

AFFINITY™

AFFINITY GA™

INFUSE™

TarragonaAFFINITY™

ENGAGE™

VERSIFY™

PlaquemineENGAGE™

NORDEL™ Thailand (2011)AFFINITY™ENGAGE™

Seadrift

VLDPE

Dow Elastomers manufacturing sites

ethylene-based olefin block-copolymers

Crystalline hard-blocksInterlinking soft blocks

Advantages: Flexibility (Modulus 2 to 4 MPa, Shore A = 55 to 70 º)

Temperature resistance (TM = 120 ºC)

Filler take up

Welding......

* ®™Trademark of The Dow Chemical Company („Dow“) or an affiliated company of Dow

™

INFUSETM Block Copolymers: Heat resistance and Flexibility

20

40

60

80

100

120

140

1 10 100Flexural Modulus [MPa]

DSC Melting Temperature [ºC]

INFUSE™ Block Copolymers

Random Copolymers

• Heat resistance and flexibility in highly-filled formulations

• Ideal polymer for flexible B+C-formulations


random ethylene copolymers™

Octene-, Butene- or Propylene side chains



Cold temperature impact

High melt strength ....

• NEW XLT-grades offer significantly improved temperature resistance

• Flexibility and low temperature impact in highly-filled and easy-to-process compounds

octene-based linear low-density polyethylene ™

Octene-side chains


Major Advantages: Mechanical strength, tear strength

Excellent chemical resistance

• Stand-alone LLDPE in geomembranes with broadest approvals and listings

• Component for PE-based membrane formulations

DOWLEX


propylene-based elastomers


Outstanding welding...

• Excellent blending with PP and PE: the linking polymer

• Highly flexible, propylene-based TPOs

• Specific grades for building and construction membranes

isotactic polypropylene backbone

ethylene blocks

™

Plastomes and Elastomers


flexible impact Polypropylene

Advantages: Flexible PP (Modulus 700 to 1000 MPa)

Heat resistance

Cold temperature impact

• Excellent blending, alloying with VERSIFY™

isotactic polypropylene backbone

™INSPIRE Performance Polymers

functional additives


polymers with added functionalities

Compatibilizers to fillers and additives

scrims and fabrics

coatings, metal, substrates…..

™AMPLIFY, PRIMACOR

Tailored performance in combination with Dow olefins

ethylene acrylic acid

™

ethylene ethyl acrylate Maleic anhydride

Tailored and tight tolerance of DOW polymers

• INSITE™-catalyst technology

• State-of-the-art reactor technologies

• No vis-break processes...


• Excellent and lasting heat welding

• High degrees of filling

• Easy processing and excellent properties

Representative

Molecular Build-up

DOW Elastomers

2 43 5 6 7

0.2

0.4

0.6

0.8

1.0

1.2

no low-molecular

fraction

Differential molecular

weight distributionRepresentative molecular structure

no oligomers or low

molecular weight fraction

Log [Mw]

Flame retardants

• Halogen-free flame retardants

• Purity, particle size distribution, surface coating are decisive parameters

• Processing and degradation characteristics are critical

Dow Elastomer formulations:

• Low melt temperatures allow high production rates with Al(OH)3

• Passing stringent norms (ENV 1187 t3) with very flexible membranes

60

70

80

90

100

0 100 200 300 400 500 600

Aluminum-trihydrate

Al(OH)3

Magnesium-hydroxide

Mg(OH)2

Temperature [ºC]

Wei

gh

t lo

ss [

%]

Stabilizers and longevity

• Phenolics and hindered amines processing and longterm

• Titanium dioxide (TiO2) and carbon black UV-stabilizers and colorants

• Flame retardants and fillers purity affects longevity

ISO 4892-2 (0.5 W/m²) weatherometer testing

DOW olefins: high stabilizer additions without plate-out or impact on welding

0

20

40

60

80

100

120

0 2000 4000 6000 8000 10000 12000 14000

Customer reference

Reference with DOW

DOW standard TPO

DOW TPO without flame retardant

Exposure time [h]

Ret

ain

ed b

reak

elo

ng

atio

n [

%]

EN 12956: no cracks...

Reinforcements

Scrims Fabrics Inserted knits Fleeces Combinations

• Tailored to manufacturing process, application- and norm-requirements.

• Mostly PETP- and glas-fibers. Occaionally PP-fibers.

Dow formulations

• high adhesion with standard fiber-coatings (no oligomers)

• for all type of reinforcements

Formulation component strategy

LLDPE PP

RCP

ICP

LDPE

PBE

ULDPE

EPDM

OBC

POE

DOWLEX™

ATTANE™

ENGAGE™

INFUSE™

NORDEL™

VERSIFY™

INSPIRE™

Roofing (ballasted and unballasted)

Geomembranes, water liners

Tunnel liners

..... Expansion joints, flexibility

EPDM

PE- or PP-based formulations matching various applications


Multi-generation development

Generation 2: highly fire

resistant, flexible systems

Formulations for waterproofing and

membrane applications

Generation 3: specialty

elastomer systems

Generation 1: TPO systems

• European standards

• North American standards

• Unmet needs

Compounding

Co-rotating,

intermeshing

Counter-rotating,

non-intermeshing

Reciprocating

co-kneaders

Dow Elastomers

• Formulation and compounding know-how and for all type systems

• Favorable process conditions and output rates up to 85 % filler levels

• Masterbatch- and pre-compound formulation know-how

M M

Polymer 1

Polymer 2

Additive MB

Fillers

Flame retardantindividual

gravimetric

feeders

Gear pump

Flat-slit die

Calander

melting filler feed, homogenisation, dispersion homogenisation

Dow Elastomers: • Formulation component strategy

• Formulation- and process-know-how

• High throughput rates, low torque and die pressure

• Mass temperatures below 200 ºC enable use of ATH flame retardant

Direct extrusion on co-rotating twin-screw extruders

Diagram: courtesy of Krauss Maffei Berstorff, Hanover Germany

Counter-rotating, intermeshing twin-screws

Single-screw and counter-rotating systems

• Usually PVC-lines run from dry-blend

• Low mixing performance, limited filler take-up

• TPO from pre-compound with temperature stable MgOH

Single-screw extruders

• Standard for low-filled formulations: geomembranes, liners

• Usually run from base materials and additive

masterbatches

• Start formulations and process know-how

Calendering

Extrusion through flat slit die

Banbury, stock blender....

Supply of homogenuous melt

Extrusion of bottom layer

Fleece backing

Lamination of signal layers....

Supply of reinforcement

Formulation requirements:

• melt strength

• homogenuous banking

• reinforcement wetting

• adhesion to reinforcement

• no calander sticking

• dimensional stability after calandering

• Start formulations and process know-how

Start Formulations for PP-membranes

• manufacturing technology

• filler and reinforcement properties

• end use and norm requirements

[phr]

flexible

PP

top bottom top bottom top bottom PE

INSPIRE™ ic-PP 20 35 35 40 10 15 35

VERSIFY™ PBE 75 65 65 60 60 55 65 50

ENGAGE™ POE 5 50

INFUSE™ OBC 30 30 50

ATTANE™ ULDPE 50

Flame ret. ATH or MgOH 60 90 60 60

Filler CaCO3 10 35 30 30 10 20 20 20 10

UV, color TiO2 6 1 6 1 6 1 6

UV, color Carbonblack 0.05 1 0.05 1 0.05 1 1 1 0.05

Stabilizer Phenolic, HALS 1 0.6 0.6 0.6 1 0.6 0.6 0.6 1

GeomembranesRoofing

unballasted ballasted

generation 2standard

unballasted


Formulation database to adress:

Benchmarking

DOW start: easy to process

passing EN and ASTM standards

excellent welding

Generation 2: excellent fire resistance (ENV 1187 t3) in combination with flexibility

¹ technical datasheets

EN 13956 1 2 3 4² 5 ² ballasted roof Start Gen. 2

Tensile strength [N] > 12 >12 > 13 > 5 > 15 17 12

Break elongation [%] > 15 ³ > 13 ³ > 19 ³ > 150 > 15 ³ ³ reinforced >600 > 1000

Peel resistance of joint [N/50mm] > 200 > 300 > 300 > 150 >500 >500

Shear resistance of joint [N/50mm] > 500 > 500 > 500 >1300 >1300

Tear resistance [N] > 250 > 300 > 320 > 150 > 300 >500 >500

Foldability at low temperature [ºC] < - 30 < - 30 < -30 < - 40 < -40 < -40 < -40

Fire resistance broof t1 broof t1 broof t1 broof t1 broof t1/t3

Artificial ageing [h] > 5000 4

> 5000 4

> 5000 4

> 3000 4 4

minimum requirem. >13000

Root resistance FLL FLL pass pass pass

ASTM D6878-03

Heat ageing 670 h at 116 ºC pass pass pass pass pass pass

Brittleness point pass pass fail pass pass pass

COMMERCIAL TPO¹ DOW

[MPa]

Flexibility study

Generation 2: testing of ENV 1187 bROOFt3

• 130 phr (65 wt%) flame retardant

• Flexibility modulus < 30 MPa

• Tensile strength > 9 MPa, Break elongation > 1500 %

A high margin pass

Economic evaluation

Costs scheme of a TPO roofing membrane

• Database to optimize performance and system costs

Polymer

45%

Flame retardant

16%

Filler

1%

Colorant

10%

Stabilizer

3%

Reinforcement

13%

Manufacturing

9%

Scrap rate

3%

Costs/m2

Polymer Component stategy

High filler loading

Flame retardant Synergisms with fillers

Fillers Balance with polymer

Colorant Use as co-stabilizer

Stabilizer Top layers

Scrim Mesh width

Manufacturing Capacity usage

Scrap rate

Component stategy

Material usage

Aspects for Optimization

Market Solutions & Application Versatility

DOW

• The broadest product mix of polyethylenes, olefin elastomers and polypropylene

• Unique polymers and process technology

• Global presence

• Formulation know-how for any waterproofing application and production process

• Technical support from polymer to end-use

• Development of future solutions in cooperation with technology leaders

www.dowelastomers.com

Appendix: Dow Tradename Products

• AFFINITY™ Polyolefin Plastomers

• AMPLIFY™ Functional Polymers

• ATTANE™ Ultra Low Density Polyethylene Resins

• DOWLEX™ Linear Low Density Polyethylene Resins

• ELITE™ Enhanced Polyethylene Resins

• ENGAGE™ Polyolefin Elastomers

• INFUSE™ Olefin Block Copolymers

• INSPIRE™ Performance Polymers

• NORDEL™ IP Hydrocarbon Rubber

• VERSIFY™ Plastomers and Elastomers


Download - Versatility of Polyolefins in Waterproofing and Roofing ... · Versatility of Polyolefins in Waterproofing and Roofing Systems ... high stabilizer additions without plate-out or impact

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