Arkema Coating Resins

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2014 ACR Webinar Series!!
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May 16, 2014

 2014 ACR Webinar Series

Today’s Topic: Cementitious Coatings

Speaker: Mike Kaufman

Title: Sr. Application Development Leader

 Our training goal

Give you the knowledge necessary to answer

your customer’s questions concerning
cementitious coatings with confidence
• Outline the basics of cement and concrete
• Describe some of the testing protocols
• Outline the characteristics of the different product
classifications
• Highlight several Arkema products and describe
their performance benefits

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 Agenda

What is concrete and how is it made?

The unique requirements of coatings for concrete
Markets and Product Categories
Paint formulating and testing basics
ACR products for cementitious coatings
Recap

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Concrete Basics

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 Concrete is not a new invention
Concrete has existed for thousands of years.
● Archaeologist Heinrich Schliemann found
concrete floors in the royal palace of
Tiryns, Greece, c. 1400 BC.
● The Assyrian Jerwan Aqueduct built c. 688
BC made use of fully waterproof concrete.
● The Romans used concrete extensively
from 300 BC to 476 AD.
Roman concrete differed from modern
concrete
● It was made from quicklime, pozzolana
Flavian Amphitheatre (80 AD)
and pumice aggregate.
● Its widespread use in many structures,
freed Roman construction from the
restrictions of stone and brick and allowed
for revolutionary new designs.
● The knowledge of concrete production
was lost in the west with the fall of the
Roman empire
Modern concrete was made possible with the
invention of portland cement by Joseph
Aspdin in 1824. Pantheon (135 AD)
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 Cement is the “glue” in concrete

Cement is a basic ingredient of concrete.

Concrete is formed when cement reacts with water and binds sand and
gravel in a harden matrix.

Gravel (large aggregate)

Sand (small aggregate)

Cement

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 Cement manufacturing is a multi-step process
Common materials used to manufacture cement include limestone, shells, and
chalk or marble combined with shale, clay, slate, blast furnace slag, silica
sand, and iron ore.

These ingredients, when heated at high temperatures form a rock-like

substance called “clinker” that is ground into the fine powder that we
commonly think of as cement.

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Coating Concrete

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 Concrete structures must be protected from the
“elements”
Concrete is dimensionally stable but very porous

It is susceptible to deterioration through the actions of water, air (oxygen

and carbon dioxide) and salt(s)

Carbon dioxide from air will react with the calcium hydroxide in concrete
to form calcium carbonate, in a process called carbonation.

Concrete Carbonation

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 Steel reinforcement is it’s Achilles' heel

Steel reinforcing rebar is employed in modern concrete structures to improve

its tensile strength and ductility

Steel rebar is susceptible to corrosion

● The high alkalinity of the fresh concrete matrix protects the steel rebar
from corrosion
● Carbonation accelerates the rate of rebar corrosion by decreasing the
alkalinity of the surrounding concrete matrix. Below a pH of 10, the steel's
thin layer of surface passivation dissolves and corrosion is promoted.
● Water and oxygen can then corrode steel reinforcing rebar
● The presence of salt(s) greatly accelerate the rate of corrosion

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Rebar Corrosion
 Spalling accelerates the degradation of a
structure
Corrosion of rebar causes cracking of the concrete matrix and leads to
spalling

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 Coating concrete extents its service life

Numerous approaches are employed to reduce the rate of corrosion

● Positioning of the rebar within the concrete matrix to ensure there is a adequate
concrete cover (if the reinforcement is too close to the surface, early failure due to
corrosion may occur)
● Use of corrosion-resistant reinforcement such as uncoated, low carbon/chromium
(micro composite), epoxy-coated, hot dip galvanized or stainless steel rebar
● Addition of corrosion inhibitors, such as calcium nitrite [Ca(NO2)2], to the water mix
before pouring concrete
● Application of a sealant coating some time after curing

The benefit of coating concrete is additive

● Can be employed in conjunction with other anti-corrosion measures
● Can be employed after concrete structure is in place
● Works by reducing the permeability of concrete surface to water, air and salt(s)

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Cementitious Coatings Markets and
Product Categories

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 Numerous market segments….

Non-Residential Building
● Industrial
● Office & Commercial

Residential Building
● Exterior Broadwall
● Driveways & Sidewalks
● Flooring

Infrastructure
● Roads & Bridges
● Parking Structures and Stadiums

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 …..With some end use applications

Wall paints which improve performance and aesthetics on

masonry/concrete surfaces

Concrete stains that give high-end look to ordinary concrete patios

“Wet look” in demand for driveway and sidewalk sealers

Textured finishes refurbish “tired” concrete patios

Cure & Seals ensure maximum compressive strength and protects

from staining

Concrete sealers also offer utility for infrastructure maintenance

Paint Formulating and Testing

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 Paints are complex mixtures of raw materials

Component Function
Latex Polymer − Film Former

Coalescent − Plasticizer/Open Time

Primary Pigments − Hiding Power

Extender Pigments − Control Gloss

Dispersants & Surf. − Wetting

Defoamer − Eliminate Foam

Preservative/Mildewcide − Prevent Microbials

Thickener/Rheo. Mod. − Application

Misc. Additives − Anti-Mar, etc.

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 Pigments provide color and hiding

Prime – Hiding and color

● Titanium dioxide
Functional – imparts specific properties
● Zinc oxide: Used primarily in primers and exterior paints, it provides
mildew resistance and stain blocking properties.
● Zinc Phosphate : Corrosion control
Extender – flatness, sheen control, cost
● Calcium Carbonate: Used in both interior and exterior paints, a general
purpose, low cost, low hide pigment.
● Clay: Used mainly in interior paints, clay provides hiding power.
● Silica: Provides enhanced durability in exterior paints as well as scrub
and abrasion resistance.
● Talc: A soft, general purpose extender pigment.
● Diatomaceous silica: Consisting of fossilized organisms, this form of
silica is used to control sheen levels.
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 Binder holds the pigment together

Water-borne latex
● Acrylic
● Vinyl acetate/Versatate copolymers
● Styrene acrylic
Alkyds – not used on concrete due to saponification
resulting in failure

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 Additives are critical to making a usable
coating
Enhance numerous properties such as rheology, mildew
resistance and other specific properties
● Rheology modifiers – HASE, HEUR, Cellulosic, HEURASE, ASE
● Preservatives and Mildewcides
● Dispersant and Surfactants
● Mar and Slip additives
● Coalescing solvent – aids in film formation
● Ethylene and propylene glycol – freeze thaw protection and open
time extension

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 The proportion of raw materials affects quality

Higher quality coatings have more binder, less pigment and higher
volume solids

Gloss Quality Flat Low-cost Flat

Liquid Liquid Liquid

Binder Binder Binder

Pigment Pigment
Pigment

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 Pigment volume concentration is a key metric

Pigment Volume Concentration (PVC):

volume of pigment
PVC = volume of pigment + volume of binder solids x 100%

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 PVC tells us about the nature of the paint film

Critical Pigment Volume Concentration (CPVC)

● CPVC marks the transition from a system in which the pigment is dispersed
in a continuous binder matrix to one where there is insufficient binder to
completely encapsulate all the pigments.

pigment
paint film

substrate

Low PVC Film CPVC Film High PVC Film

(< CPVC) (> CPVC)

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 Coatings properties change dramatically at
CPVC

blistering
CPVC
gloss

film tensile

adhesion

permeability

rusting

PVC

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 Numerous paint properties affected by PVC

Property Low PVC High PVC

Stain Removal ………………………...…. Good Poor

Scrub Resistance ……………………...… Good Poor

Dry Hiding …………………………….…... Fair Good

Efflorescence Resistance ….………….. Good Poor

Block Resistance ….…………………….. Poor Good

Moisture Permeability …...…………….. Low High

Tensile Strength ………………………….. High Low

Stain Resistance ………………………….. Good Poor

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 Paints are formulated over the entire PVC
range
High Gloss Enamel
15
Gloss Trim
Paint Types Semigloss
25
Interior Satin
Exterior Sheen 35

Exterior Flat 45
Pigment volume
concentration
55

Interior Flat 65

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75
 Formulating coatings for cementitious substrates

Coatings used on concrete substrates:

● Vary in sheen from Gloss to Flat
– Covers the PVC range
● Vary in VOC content
– Texanol and Glycol impacted
● Will have varying strengths and weaknesses based on properties chosen
by developer
– Efflorescence and Alkali resistance two most important properties for concrete
coatings
– Tensile and Elongation important for Elastomeric coatings
● Can be applied either by brush, roller or spray gun
– Rheology modifiers impacted

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 Concrete presents some unique demands on a
coating
Highly Alkaline
● Fresh concrete substrates are extremely alkaline (pH > 12.5)
● The surface of aged concrete has substantially less alkaline (pH ~8.5) due to
carbonation

It can be an extremely porous material

● High permeable to water which may result in efflorescence and/or blistering

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 Key performance tests for cementitious
coatings

Efflorescence resistance
Alkali resistance
Water vapor permeability

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 Efflorescence is the migration of salts to the
masonry surface

Three conditions must be satisfied

for efflorescence to occur:
● There must be water-soluble salts present
somewhere in the wall.
● There must be sufficient moisture in the wall
to render the salts into a soluble solution.
● There must be a path for the soluble salts to
migrate through to the surface where the
moisture can evaporate, thus depositing the
salts which then crystallize and cause
efflorescence.

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 Concretes highly alkaline surface can degrade
the binder

Hydrolysis of polymer backbone

CH3 H3C
CH3 H3C C O
C O OH O
-OH
O + CH3-C-OH
( )n

( )n

CH3 H
O -OH O
C O C O + CH3OH

( )n ( )n

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 There is no single standard method for
evaluating efflorescence resistance

Efflorescence resistance
● Tombstone method
● Cleveland Humidity on Alkaline substrate
● ASTM C1400 - Standard Guide for Reduction of Efflorescence
Potential in New Masonry Walls
● ASTM D7072 - Standard Practice for Evaluating Accelerated
Efflorescence of Latex Coatings
● Numerous customer specific test methods

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 Nor for evaluating alkali resistance

Alkali resistance
● Alkaline soak
● Free film dissolution method
● ASTM D3643 - Standard Test Method for Acid Number of Certain
Alkali-Soluble Resins
● Numerous customer specific test methods

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 Permeability testing conducted via ASTM
protocols

Permeability
● ASTM D1653 - Standard Test Methods for Water Vapor Transmission
of Organic Coating Films
● ASTM E2338 - Standard Practice for Characterization of Coatings
Using Conformable Eddy-Current Sensors without Coating Reference
Standards

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ACR Product Overview

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 ACR’s broad toolbox offers the most options
for solving customer problems

Broadest technology platform

● NEOCAR® Acrylic polymers
● Acrylic polymers
● Styrene acrylic polymers
● NEOCAR® polymers
● Vinyl acrylic polymers
● Vinyl acetate ethylene polymers
● Styrene-butadiene polymers

37
 Polymer composition can affect coating
performance

NEOCAR®
Acrylics
+ Neo
Monomer
Conventional
Acrylics
NEOCAR®
LATEX
+ Neo
Vinyl Monomer
Acrylics
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 What is NEOCAR® Technology ?

They are modified Acrylic or Vinyl Acetate containing latexes

with the Neo Monomer via emulsion polymerization.
● NEOCAR Latex - VA/Neo
● NEOCAR Acrylic - Acrylic/Neo
What is Neo monomer
● Highly Branched Esters of Monocarboxylic Acid
● Extremely hydrophobic
– Low oxygen content and water solubility
● Offers increased flexibility and elongation due to its low Tg
– Neo Monomer ( Tg, oC=-3 & 60) vs. Styrene ( Tg, oC=100)
● UV transparent monomer that offers outstanding durability
● Benefits of Neo Monomers
– Increased Hydrophobicity to impart in coatings
- Exceptional water and alkali resistance
- Improves chemical resistance
- Exceptional flexibility and elongation

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 Decreasing polymer oxygen content -
Increasing hydrophobicity

Monomer Formula Mass % Oxygen

Vinyl Acetate C4H6O2 86 37%

Methy Methacrylate C5H8O2 86 32%

Butyl Acrylate C7H12O2 128 25%

Neo Monomers CnHmO2 159-210 14-17%

Styrene C8H8 104 0%

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 NEOCAR® Technology yields extremely
hydrophobic polymers

16%
14%
BA
12%
% Water Solubility

10%
8% Neo
6% monomers
4% Styrene ~0.01%
2% 2-EHA
0%
100 60 -3 -55 -65
Tg , °C of homopolymers

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 NEOCAR® Technology protects the polymer
backbone

Cn Cn
CH CH3 CH CH3
CH2 CH2
CH3 H3C C CH3 CH3 H3C C CH3 CH3
C O C O C O C O C O
O O O O O

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 ACR offers a range of products to cover the
entire spectrum of performance and cost
Total Tg
Product Chemistry Features
solids (oC)
Interior/exterior masonry wall with
Vinyl acetate/vinyl
NEOCAR® Latex 2300 55 5 excellent alkali and efflorescence
versatate
resistance
Vinyl acetate/vinyl General purpose binder for high-film build
NEOCAR® Latex 2535 53.5 10
versatate coatings with wet adhesion
Ultra-small particle size binder for water
NEOCAR® Acrylic 820 Vinyl versatate/acrylic 45 20
and blush resistance
Ultra-small particle size binder with
NEOCAR® Acrylic 850 Vinyl versatate/acrylic 45 50 ambient cross-linking for coatings with
block and chemical resistance
Suitable for primer and topcoats;
ENCOR® CL36 Acrylic 49 20
efflorescence resistance over masonry
Abrasion resistance coatings for athletic
ENCOR® 651 Acrylic 65 12
surfaces
Cost effective high solids acrylic binder for
ENCOR® 657 Acrylic 58 16
masonry and wall coatings
ENCOR® 7325 Styrene acrylic 46 50 Concrete sealer

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 Competitive products and suggested ACR
alternatives

Competitive Product ACR Alternative

The Dow Chemical Company
Rhoplex 2500 ENCOR 657, NEOCAR Latex 2300
Rhoplex CS-4000
NEOCAR Acrylic 820
Rhoplex AC630
Rhoplex ML-100, 200, 300 or 400 NEOCAR Latex 2535
Rhoplex AC261 NEOCAR Acrylic 850
Rhoplex SS4 ENCOR 651

BASF

Acronol 296D ENCOR 657, NEOCAR Latex 2300

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NEOCAR® 2300
Vinyl Versatate-Containing Latex for Cost-Effective Architectural Coatings

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 NEOCAR® 2300 delivers superior cost/
performance
Value Proposition
Offers our customers the ability to formulate an extremely
cost effective alkali resistant masonry paint
Product Overview
Typical end use
● Interior/exterior masonry wall coatings
Features
● Good interior/exterior durability
● Water resistance
● Good alkali and efflorescence resistance
● Zero VOC capable

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 NEOCAR® 2300 offers superior durability

600
Contractor Flat
500 Quality Flat
Scrub Resistance

400

300

200

100

0
Acronal NeoCAR ENCOR ENCOR NeoCAR
296D 2300 657 CL36 2535

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NEOCAR® 2535
Vinyl Versatate-Containing Latex for Cost-Effective Architectural Coatings

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 NEOCAR® 2535 delivers inherent film build

Value Proposition
Offers our customers the ability to formulate an extremely
cost effective exterior coating with inherent film build
Product Overview
Typical End Use Applications
● Exterior House Paint
– Wood, masonry and cement fiberboard
● EIFS repaint
Features
● Inherent film build
● Good exterior durability
– Grain crack and alkali resistance, color retention
● Zero VOC capable with non-VOC coalescing solvent

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 NEOCAR® 2535 has excellent alkali resistance

NEOCAR Latex 2535

Commercial
Acrylic(s)

50
NEOCAR® Acrylic 820
High Performance Polymer for Clear Coatings and Sealers

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 NEOCAR® Acrylic 820 delivers superior blush
resistance
Value Proposition
Offers our customers superior blush resistance performance
versus competitive acrylic and styrene acrylics
Product Overview
Typical End Use Applications
● Architectural and Industrial usage
● Surfaces requiring outstanding blush resistance
– Wood decks, ceramic roof tiles and concrete patios
● Masonry sealers
● Clear sealers
● Semi-transparent and solid color stains
Features
● Outstanding water and blush resistance
● Zero VOC capable with non-VOC hydrophilic coalescing solvent
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 NEOCAR® Acrylic 820 has significantly lower
water absorption

70
% Water Absorption

60 Conventional acrylic
NEOCAR acrylic
50
40
30
20
10
0
0.2 1 2 3 4 14 21 28
Days
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 NEOCAR® Acrylic 820 has significantly better
blush resistance

Vinyl Acrylic Acrylic NEOCAR Acrylic

54
 NEOCAR® Acrylic 820 superior hydrophobicity
yields water beading coatings

55
 NEOCAR® Acrylic 820 exhibits excellent
efflorescence resistance

Topcoat

NEOCAR Acrylic Sealer/Topcoat

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NEOCAR® Acrylic 850
High Performance Polymer for Clear Coatings and Sealers

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 NEOCAR® Acrylic 850 delivers unparalleled
performance
Value Proposition
Offers our customers the ability to formulate coatings with
the superior blush, chemical and block resistance
Product Overview
Typical End Use Applications
● Architectural and industrial usage
– Surfaces requiring outstanding hardness, blush and chemical resistance
- Garage floors, driveway pavers, tiles or concrete decks
● Concrete sealers
Features
● Outstanding blush resistance
● Excellent water and chemical resistance
● Outstanding hot tire pick-up resistance
● Capable of being formulated at 100 g/L VOC
58
 NEOCAR® Acrylic 850 employs a unique
ambient cure cross-linking mechanism

X X

Self Crosslinking
59
 This cross-linking yields films with excellent
solvent resistance

200
MEK Double Rubs

150
1 Day
100
7 Days

50

0
Competitive NEOCAR Acrylic

60
 NEOCAR Acrylic 850 can enhance the
appearance of stone pavers

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ENCOR® CL36
High Performance Polymer for Clear Coatings and Sealers

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 ENCOR® CL36 offers broad utility

Value Proposition
Offers our customers the ability to formulate both primers
and top coats for masonry substrates
Product Overview
Typical End Use Applications
● Barrier coatings
Features
● Excellent alkali and efflorescence resistance
● Flat coatings
● Good flexibility

63
ENCOR® 651
All-Acrylic High Solids Latex for Athletic Surface and Architectural Coatings

64
 ENCOR® 651 for durable sport surfaces

Value Proposition
Offers our customers the ability to formulate coatings for
sport surfaces
Product Overview
Typical End Use Applications
● Block fillers
● Barrier coatings
● Athletic surfaces (i.e. tennis courts)
Features
● Excellent alkali resistance
● Flat coatings
● Good flexibility

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ENCOR® 657
Versatile 100% Acrylic Latex for Interior, Exterior and Masonry Coatings

66
 ENCOR® 657 is a low cost option for a 100%
acrylic binder
Value Proposition
Offers our customers the ability to formulate low cost,
100% acrylic masonry coatings
Product Overview
Typical End Use Applications
● Interior/exterior architectural paints
● Exterior wood siding stains
● Masonry paints and stains
Features
● Broad formulation latitude
● Good balance of properties
– Washability and Stain Resistance
● Outstanding alkali resistance
● Good color retention
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ENCOR® 7325
Concrete Sealer

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 ENCOR® 7325 for cure and seal coatings

Value Proposition
Offers our customers the ability to formulate cure and seal
coatings for concrete floors
Product Overview
Typical End Use Applications
● Concrete sealers
Features
● Sealer for Interior and Exterior Concrete
● Outstanding Water Resistance
● Non-Yellowing
● Passes ASTM C309 and C1315 for water retention

69
 ENCOR® 7325 meets the performance
requirements of ASTM C309
Relevant test methods include ASTM C309, C156, D1308 and
D1644
● Application Rate: 200 ft2/gal
ASTM C309 test results
Test results Requirements
● Water Retention, kg/ m 2 0.44 0.55, max
● Drying Time to Touch, hours ~ 1.0 4.0, max
● Nonvolatile Content, % 15.8 15.0, min
 Recap

Today’s session was intended to provide you with a technical

grounding in paint formulating and product selection for
cementitous substrates
Fresh concrete is a very alkaline surface and care must be
exercised in the selection of raw materials and formulation of
masonry coatings
The three key performance tests of masonry coatings are
water vapor permeability, efflorescence and alkali resistance
ACR offers the broadest range of chemistries to the masonry
paint market to meet a range of cost/performance
requirements including:
● A variety of Acrylic latexes for use in broadwall and barrier
coatings
● NEOCAR® technology to extend the performance capabilities
of both vinyl acetate and acrylic-based latexes
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 Questions? Please contact the Account Team
Commercial Questions Commercial Questions Technical Questions
Latin America USA & Canada

Marlene Hernandez Mark Piggott Mary Chervenak

[email protected] [email protected] [email protected]

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 2014 ACR Webinar Series

Next Month’s Topic: Elastomeric Coatings

Speaker: John Dockery

Title: Technical Service Chemist

Friday June 20, 2014 @

2:00pm ET
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 Arkema Coating Resins

Thank You for

Joining Us!!
See you in May!!

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