Charmor: For Best-In-Class Intumescent Coatings Protecting People and Property

Charmor
for best-in-class intumescent coatings

Protecting people and property
Eugénie Charrière, Market Development Director

Overview
Charmor® main benefits
Introduction to Fire Protection Systems
Intumescent coatings: main characteristics and key components
Intumescent mechanism
Typical paint formulations - Fire Testing & Results
More About Charmor®
Summary
Charmor®
main benefits
Charmor® products from Perstorp provide better insulation in
intumescent coatings:
consistent high purity products
narrow particle size distribution
Intumescent coatings based on Charmor®:

offer safer alternative to asbestos
maintain aesthetics of steel beams freedom of design
provide lower maintenance and upkeep compared to sprinklers
Fire Protection Systems
Fire Prevention
This is to minimize ignition sources
e.g. fire safety education, fire drill, fire service response and emergency
evacuation, etc.
Active Fire Protection (AFP)

It is the action to control and extinguish the fire (if possible)
e.g. manual or automatic fire detection and fire suppression.
Passive fire protection (PFP)

It is to limit and control the fire once it has occurred
e.g. the use of fire-resistance rated walls and floors, and intumescent coatings
Charmor®
for intumescent coatings
MARKET TRENDS
Raised awareness of the risk of fire and the need for protection
Higher standards in fire protection
Increasing use of structural steel around the world
BENEFITS OF INTUMESCANT COATINGS MADE WITH CHARMOR®

Prolong evacuation time during fire breakout.
Limit structural damage to properties.
MECHANISM
This is an innovative coating technology which uses char formation to
prevent fire spread.
Intumescent coatings can swell up by a factor of 100 on heating (from
1mm to 10 cm thick foam).
Intumescent paint works as an active fire protecting surface treatment
which is activated at 150-200°C.
Intumescent paint:
main characteristics
Mostly physical drying, thermoplastic paint systems

High PVC
Three main active ingredients
Acid donor
Carbon donor
Blowing agent
High layer thickness (~1000 µm)
Applied by brush or spraying
Heat activated (200-250 °C) insulating paint
Swelling 40-80 times
Application: mainly structural steel
Main components of
Intumescent Paint
Carbon donor
e.g. Charmor® product
Acid donor O O O
f. ex. Ammonium Polyphosphate (APP) O P O P O P
ONH4 ONH4 ONH4
n
Blowing agent H2N N NH2
f. ex. Melamine
N N
Binder NH2
f. ex. Poly(vinylacetate)
n
O
O
Much more than
innovative chemical
solutions
How does it work?
The intumescing process starts at 200-250°C.

The main stages, when paint is exposed to fire and starts to intumesce, are as follows:
1. The binder melts, facilitating chemical reactions in a soft matrix

2. The acid donor decomposes to form polyphoshoric acid
3. The polyphosphoric acid reacts with the carbon donor to form polyphosphoric acid esters
4. The esters decompose to form a foaming carbon matrix
5. The blowing agent releases gases that cause the carbon matrix to create foam that expands
to form a tough insulating char barrier that adheres to the substrate
Charmor PM40 & PM15
in waterborne paint formulation
Materials
Part I, Grinding part Charmor® PM40 Charmor® PM15
Water 14.2 14.2
Procedure
Disperbyk 190 (BYK Chemie) 1.0 1.0 Grinding Part
Kronos 2063 (TiO2, Kronos) 6.0 6.0
Mix Part I in a
Charmor® PM40 (carbon donor, Perstorp) 9.0 -- high speed
Charmor® PM15 (carbon donor, Perstorp) -- 9.0 dissolver (3000-
Aerosil 200 (fumed silica, Evonik) 1.0 1.0 4000 rpm, 20-30
Melafine (blowing agent, DSM) 7.5 7.5 minutes), T°C
Exolit APP 422 (acid donor, Clariant) 22.0 22.0
should stay
below 50°C
BYK 080 (BYK Chemie) 0.25 0.25
Natrosol Hr 250 , 2 % water solution 4.0 4.0 Let Down
Part II, Let down Add Part I and
Mowilith DM 230 (PvAc dispersion, Celanese) 25.0 25.0 the rest of the
NX 795 (coalescing agent, Perstorp) 1.3 1.3 raw materials to
Sodium Polyphosphate , 10% water solution 0.75 0.75 the binder,
Water 8.0 8.0
stirring
continuously
Total 100.00 100.00
PVC, % 68±2 68±2
Density, g/l 1.28±0.01 1.28±0.01
pH 8.2±0.2 8.2±0.2
Viscosity, mPas 500 520
Fire Testing Method
Preparation of Test Specimens

Primed metal panels (4mm)
Applied with brush or airless spray
Film thickness – 800-1000 µm
Dry for 4 weeks @ 23°C & 50% RH
N.B.
To improve abrasion resistance and water resistance a thin coat of a
conventional paint may be applied to the intumescent paint.
Fire Test (Propane Burner)

Paint faced downwards on the furnace
No direct contact with the flame
Temperature registered with thermocouples on back side
Furnace temperature – standard fire curve (ISO 02 48 20 / (ISO
834—1975)
Fire test result
Waterborne paint formulation
Furnace Charmor
Temperature PM40
Charmor
PM15
Charmor® PM15 and PM40 both present excellent properties in water-borne intumescent
paints. Charmor® PM15 prolongs the time to reach 500°C, but the foam is slightly fluffier.
Charmor PM40
in solvent-based paint formulation
Materials Weight-%
Pliolite VTAC-L (vinyl toluene acrylate binder, Eliokem) 8.0
Pliolite AC3-H (vinyl toluene acrylate binder, Eliokem) 3.2
Topcithin 50 (soy lecithin, Cargill) 0.3
Guardion CP70 (chlorinated Paraffin Wax, Chance & Hunt) 5.8
Cereclor S 52 (chlorinated paraffin, INEOS) 2.7
Kronos 2063 (TiO2 pigment, Kronos) 6.4
Charmor® PM40 (carbon donor, Perstorp) 9.0
Melafine (blowing agent, DSM) 9.0
Exolit AP 422 (acid donor, Clariant) 27.6
Xylene (solvent) 28.0
Total charge 100.00
PVC, % 58.4
Non-volatile content, % 72
Density, g/l 1.29
Viscosity (Brookfield), mPas 7900
VOC, g/l 360
Fire test result
Solvent-based formulation
Intumescent mechanism started after 7-8 minutes

Time for test specimen based Charmor® PM40 to reach 500°C was 47 min
Possible improvements
Possible variations in formulation
Vary ratio of active raw materials
Vary PVC
Vary between grades of APP
Add inorganic flame retardants, like ATH (Aluminum Trihydrate)
Add halogenated flame retardants
Add inorganic fibers
Other important factors

Sufficient grinding
Good pretreatment (sand blasting)
Choice of primer
Application procedures
Drying
Product data summary
Charmor®
Property Charmor® PM Charmor® PT Charmor® DP
Delivery form White powder White powder White powder
Grades available Micronized (PM40) Micronized (PT40) Micronized (DP40)

Supermicronized (PM15) Supermicronized (DP15)
Melting point 260°C 250°C 222°C
Water solubility (% at RT) 5.25 4.70 0.22
Typical hydroxyl number 1,645 1,645 1,325

(mg KOH/g)
Density (kg/m3) 1,400 1,400 1,370
Main usage For basecoats and Versatile quality For superdurable outdoor
indoor applications coatings
Choice of grade affects:

1. Water resistance
Putting the care
2. Melting behaviour (initiation temperature)
into chemicals
3. Paint formulation (difference of OH-number)
Foaming performance
of Charmor® PM40 and PM15
Grade Particle size Expansion Foam characteristics

factor
PM40 <40 µm ~20 Homogenous, soft, compact, more stable
PM15 <15 µm ~30 Homogenous, soft, fluffier, better isolation
Conclusion:
Particle size matter
Consistency and reliability is important
Putting the care

into chemicals
Quality of Charmor®
Consistent high Purity products

Non-toxic
Non-hygroscopic
Small Particle size
Narrow particle size distribution
No coarse particles
Responsible for the entire production
process from formaldehyde to milling
Knowledge & reliability
Conclusions
Largest world capacity

Own production facilities
Recently installed modern milling technology in Germany
Real interest in fire protection
R&D resources, lab facilities
Installed fire test equipment
Broaden application areas – PUR foams, TPU, gel coats, polyolefins, PVC
Technical service and customer support
Key suppliers recommend our products
Global sales and distribution network
Charmor®
for intumescent coatings
Protecting people & property
For more information, please visit us on booth 2733

at the American Coatings Show 2010 in Charlotte, NC

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Charmor

for best-in-class intumescent coatings

Eugénie Charrière, Market Development Director

Intumescent coatings based on Charmor®:

Active Fire Protection (AFP)

Passive fire protection (PFP)

BENEFITS OF INTUMESCANT COATINGS MADE WITH CHARMOR®

Mostly physical drying, thermoplastic paint systems

f. ex. Ammonium Polyphosphate (APP) O P O P O P

ONH4 ONH4 ONH4

The intumescing process starts at 200-250°C.

1. The binder melts, facilitating chemical reactions in a soft matrix

Preparation of Test Specimens

Fire Test (Propane Burner)

Intumescent mechanism started after 7-8 minutes

Other important factors

Delivery form White powder White powder White powder

Grades available Micronized (PM40) Micronized (PT40) Micronized (DP40)

Water solubility (% at RT) 5.25 4.70 0.22

Typical hydroxyl number 1,645 1,645 1,325

Choice of grade affects:

Grade Particle size Expansion Foam characteristics

PM15 <15 µm ~30 Homogenous, soft, fluffier, better isolation

Putting the care

Consistent high Purity products

Largest world capacity

Protecting people & property

For more information, please visit us on booth 2733

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