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


Volume solids(%)


VOC (g / L)

VOC (g / m2)

Drying time (h)


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


Volume solids(%)


VOC (g / L)

VOC (g / m2)

Drying time (h)


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


TEKNODUR3560-73


TEKNODUR3560-73


TEKNODUR3560-73


TEKNODUR3560-73


TEKNODUR3560-73


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%


80%


90%


100%


110%


120%


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


TEKNODUR 3560-73


TEKNODUR 3560-73


TEKNODUR 3560-73


TEKNODUR 3560-73


TEKNODUR 3560-73


TEKNODUR 3560-73


Seco

nd

s

Mixing ratio

König hardness

HardnessKönig1 day

HardnessKönig2 day

HardnessKönig4 day

HardnessKönig1 week

HardnessKönig10 days

HardnessKönig2 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

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

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