fire retardant resins for mass transit and building...• gost 12.1.044-89 • uic 564.2 some...

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Ashland Performance Materials

Fire Retardant Resins for Mass Transit and BuildingII International conference «Composites without borders»

October 14-16, 2014

Open Innovation Expo, Technopolis Moscow

© 2014, Ashland

Registered trademark, Ashland or its subsidiaries, registered in various countries ™ Trademark, Ashland or its subsidiaries, registered in various countries With good chemistry great things happen.™

Dr Tim Pepper

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The flame retardant industry is the result of National and International Fire Protection Regulations and tests Procedures which have been implemented during the last 50 years.

Regulations cover 4 main industries:• Building• Rolling stock • Aircraft• Cruise boats

Why a flame retardant industry?

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Barriers to FRP use

• Building and construction industry heavily dependent on building codes, most codes do not address use of composite materials.

• More difficult for engineers and architects to specify, can complicate design and approval process

FRP in Architectural Applications

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Europe • NFF 16101 : France • BS 6853 : UK • DIN 5510 : Germany • UNI CEI 11170-3 : ItalyRussia • GOST 12.1.044-89 • UIC 564.2

Some National fire safety regulations for rail vehicles

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US • ASTM E 84 : Tunnel test • ASTM E 162 : Radiant panel test • ASTM E 662 : Smoke density

Europe • NFP 92501 : France • BS 476 : UK • DIN 4102 : Germany • UNI CEI 11170-3 : Italy

International • UL 94 : Vertical flame test • LOI : Limit Oxygen index test

Fire safety codes worldwide for building

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EN 13501-1 – Fire Classification of construction products and building elements • This first version of this Fire Classification has been implemented in 2002.

EN 45545-2 – Fire protection on Railway vehicles • The European standard was given the status of National standard in 2013, and conflicting with national standards will be withdrawn at latest by march 2016.

European fire safety regulations

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Barriers can be overcome

• Case histories being used to help satisfy clients and authorities that composites are suitable

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R1 : Surface products (wall, ceiling)

Apparatus Parameter and Unit Requirements HL1 HL2 HL3

radiant panel CFE kW/m2 Minimum 20 20 20

cone calorimeter MARHE kW/m2 Maximum 90 60

smoke chamber Ds(4) dimensionless Maximum 600 300 150

smoke chamber VOF4 Minutes Maximum 1200 600 300

smoke chamber CITg dimensionless Maximum 1,2 0,9 0,75

EN 45545-2 - Material requirement sets

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Apparatus Parameter and Unit Requirements A1 A2 B C D E Bomb calorimeter PCS - MJ/kg Maximum 2,0 3,0 Non combustibility furnace DT - °C Maximum 30 50 Dm - % Maximum 50 50 tf - s Maximum 0 20 Single burning item FIGRA - W/s Maximum 120 250 750 THR600s - MJ Maximum 7,5 15 Small burner Fs - mm Maximum 150 150 150 150

Apparatus Parameter and Unit Requirements s1 s2 s3 Single burning item SMOGRA - m2/s2 Maximum 30 180 not s1 or s2 TSP 600s - m2 Maximum 50 200 not s1 or s2

Apparatus Parameter and Unit Requirements d0 d1 d2 Single burning item No flaming droplets - s Maximum 0 10 not d0 or d1

(excluding flooring and linear pipe products)

EN 13501-1- Classes of reaction to fire performance for construction products

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FRP provides unique properties

• Aesthetic appeal• Excellent mechanical, physical and thermal properties• Can be molded into complex shapes• Excellent corrosion, flame, and weathering resistance• Resistant to rot and insect attack• Easy to assemble and install• Lightweight

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• Wood, steel, aluminum, concrete used most often due to years of experience• Wood - rots, not resistant to insects, moisture and fire• Steel - very heavy, hard to form, rusts• Aluminum - more costly, less strength and stiffness• Concrete - heavy, requires reinforcement, sensitive to moisture and salt degradation

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Architectural applications

• Building panels• Columns• Domes• Facades• Fascia panels• HVAC ducting• Doors, window frames• Bridge structures and enclosures• Polymer concrete

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Architectural applications

• Lightweight & Versatile• Cost Effective• Corrosion Resistant• Excellent Weathering• Maintenance Free

Before After

FRP Benefits in Architectural Applications

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Architectural FRP Restorations

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Commercial Building Exterior Applications

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Columns, Facades & Cornices

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Custom Shapes

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Interior Applications

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• Structural Beams• Doors• Ducting• Cable Tray• Grating & Platforms• Roofing & Siding• Translucent or Opaque

Industrial Building Structures

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FRP Panel

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Day-Lighting Panels

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Ducting

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Cable Tray

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Grating, Stairs & Handrails

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Composite Bridges

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A solution for builders, by builders

A clean, engineered solution for the replacement of concrete walls that combines strenght, integrated stud cavities for mechanicals, insulation top plate and damp proofing in a single step.

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• Extensive use of forms, rebar and concrete • Labor Intensive and time consuming to set up and tear down (7-10 days) • Guaranteed to crack and leak – humid damp living environment • High carbon footprint. Poor energy conservation.

Current “Cast in Place” Concrete Foundation Technology

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Value Proposition

Builders deliver a higher value, more energy efficient home, faster • Integrated studs – ready to finish• R 16.5 (3-4X R-Value of concrete)• Installed in 90 min rather than 7-10 days• Uses builder’s own crew rather than another subcontractor

Home buyers receive a warmer, drier, more energy efficient, ready-to-finish basement

Cost competitive to poured concrete

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• Fast construction time with multiple benefits - House enclosed from weather faster - Builder gets money faster on each home - More homes per season with same crew

• Simple installation on site - High quality construction in controlled fabrication shop – ready to use - Few connection points designed with the builder in mind - Fewer steps, no subcontractors. More predictable construction timeline. Less potential for delays

• Builder can use same crew for all facets of home construction

• Extended construction season - installation in cold climates

Key Builder Benefits

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• Energy savings / green - Estimated 15% reduction in energy costs - Smaller carbon footprint compared to concrete

• High quality living space - Warm, dry, comfortable living space w/o added expense of finished basement

• Larger interior floor plan - “free” 10 x 10 room

• No maintenance

• Greatly improved flexibility to modify / finish basement space

Key Homeowner Benefits

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• Light Weight• High Strength to Weight Ratio• Low Maintenance• Excellent Thermal Insulation Properties

Why Use FRP Composites in Mass Transit Applications

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Where Can FRP be Used in Mass Transit Applications?

• Interior/Exterior Panels• Doors• Interior Components• Roofs/Floors• Seating• Sleeper Compartments

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Where Can FRP be Used in Mass Transit Applications?

• Lavatory Compartments• Third Rail Covers• Maintenance Gratings• Cable Trays• Consoles

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FRP Applications

Panels for Railway Rolling Stock FR Railway Seat Shell

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FRP Applications

FRP Seats and wall panels

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FRP Applications

Engineers Console

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FRP Applications

Cable Trays for the Channel Tunnel

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FRP Applications

Lavatories

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Ashland’s Value to FRP Fabricators

• Largest global supplier of Fire Resistant Resins• >50 years of successful applications experience• Unmatched product portfolio • FR solutions tailored to application needs - Fabrication processes - FR requirements (Low flame spread – low smoke) - Mechanical performance targets• Secondary selling into focus market segments• Strong ongoing commitment to technology development and customer support

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Aropol F 207 TPB Lloyds for survival craft material Class A-UTAC ,

B2 DIN 4102, BS 476: Class 2, NF16101: M3

Aropol F 195 LN Sweden: NT Fire 006

Hetron F 830 TE 95/28/CEE, BS 476: Class 2, NF16101: M2

Ashland FR non filled resins

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Hetron F 805 TF M1F2 / S4SR2ST2 / Class 1/ Bs3d0 / V-0 / Class A / GOST 12.1.044-89

Hetron F 240 TF M2F2 / S4SR1ST2 / Class1 / Cs3d0 / V-0 / Class A

Hetron F 250 TF M2F2

Ashland FR filled resins

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Enguard AE M1 F3 with Hetron F 804 TF

Maxguard FR M2F2 Class 2 with Hetron F 240 TF / M2F1 S4 SR2 ST2 with Hetron F 640 TF

Ashland gelcoat line card

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Aropol F 195 LN

Case histories

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Aropol F 207 TPB

Case histories

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Hetron F 240 TF

Case histories

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Hetron F 660 TFE

Case histories

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Common Fire Retardant raw materials today;

• Decabromo phenylether: defined as a substance of very high concern (SVHC)

• Antimony trioxide: - classified in the EU with risk phrase R40 (DPD) - limited evidence of a carcinogenic effect - classified in the EU as a category 2 carcinogen (CLP CARC 2) - suspected of causing cancer

EHS impact on raw materials usage

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To meet the more demanding standards and to minimize the impact to human health and the environment.

Ashland offers right now a new product range of flame retardant UP resins which complies with the highest standards:

• HETRON F 235 • HETRON F 640 TF • HETRON F 645 TF • HETRON F 660 TF

Ashland new generation resins

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HETRON F 640 TF filled resin is a performing new generation resin which meets: • B s2 d0 according EN 13501 • HL2 according EN 45545

HETRON F 640 TF key features: • Low viscosity • Easy processing • Recommended for hand lay up, spray up and RTM

Hetron F 640 TF


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• HETRON F 235 unfilled resin is a new halogen free and antimony free UP which can meet the highest standards when filled with Aluminium hydrate. • Its very low viscosity allows it to be loaded with ATH from 50phr to 200phr.

• HETRON F 235 resin is recommended for RTM, infusion, pultrusion.

Hetron F 235


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Our Targets:

• Designed for lower impact to human health and the environment (halogen-free, antimony free, very low styrene content)

• Meeting the highest standards (ASTM E84, EN 45545, EN 13501)

• Outstanding processability (pultrusion, RTM, spray and hand lay-up)

• Versatility and easyness of use (filled and unfilled versions)

Ashland next generation resins

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What we design:

• New patented technology• Highly improved processability with vast majority of ATH grinds

ATH# 1

Visc

osit

y cP

20r

pm

500

1000

1500

0

ATH# 2

ATH# 3

ATH# 4

ATH# 5

ATH# 6

Standard FR polyester resin

Ashland new generation resin


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What we design:

Upon customer needs, our new generation resins will be delivered • unfilled • prefilled with ATH (100phr) End user can still add up to 200phr of ATH

Applications: • Pultrusion • RTM • Spray • Hand lay-up


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What we design:

Into details: • Low viscosity resins (90 – 120 cps) • Very low styrene content (15%) • Halogen free, antimony free • High mechanical properties: • HDT>90°C, high elongation >2.5% • Outstanding storage stability compared to standard filled polyester resins: No significant fillers settlement after 4 months


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What we design:

Fire certifications targets: • ASTM E162 Class 1 • ASTM E662 Class 1 • EN 45545 HL3 • EN 13501 Bs1d0


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For more information, please contact our sales/technical representatives


® Registered trademark, Ashland or its subsidiaries, registered in various countries ™ Trademark, Ashland or its subsidiaries, registered in various countries

With good chemistry great things happen.™

fire retardant resins for mass transit and building...• gost 12.1.044-89 • uic 564.2 some...

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