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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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Ashland Performance Materials
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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Ashland Performance Materials
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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Ashland Performance Materials
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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Ashland Performance Materials
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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Ashland Performance Materials
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European standard was given the status of National standard in 2013, and conflicting with national standards will be withdrawn at latest by march 2016.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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Ashland Performance Materials
FRP in Architectural Applications
Barriers can be overcome
• Case histories being used to help satisfy clients and authorities that composites are suitable
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Ashland Performance Materials
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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Ashland Performance Materials
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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Ashland Performance Materials
FRP in Architectural Applications
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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Ashland Performance Materials
FRP in Architectural Applications
• 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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Ashland Performance Materials
FRP in Architectural Applications
Architectural applications
• Building panels• Columns• Domes• Facades• Fascia panels• HVAC ducting• Doors, window frames• Bridge structures and enclosures• Polymer concrete
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Ashland Performance Materials
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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Ashland Performance Materials
Commercial Building Exterior Applications
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Ashland Performance Materials
Columns, Facades & Cornices
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Ashland Performance Materials
Custom Shapes
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Ashland Performance Materials
Interior Applications
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Ashland Performance Materials
• Structural Beams• Doors• Ducting• Cable Tray• Grating & Platforms• Roofing & Siding• Translucent or Opaque
Industrial Building Structures
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Ashland Performance Materials
FRP Panel
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Ashland Performance Materials
Day-Lighting Panels
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Ashland Performance Materials
Ducting
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Ashland Performance Materials
Cable Tray
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Ashland Performance Materials
Grating, Stairs & Handrails
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Ashland Performance Materials
Composite Bridges
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Ashland Performance Materials
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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Ashland Performance Materials
• 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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Ashland Performance Materials
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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Ashland Performance Materials
• 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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Ashland Performance Materials
• 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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Ashland Performance Materials
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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Ashland Performance Materials
FRP Applications
Engineers Console
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Ashland Performance Materials
FRP Applications
Cable Trays for the Channel Tunnel
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FRP Applications
Lavatories
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Ashland Performance Materials
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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Ashland Performance Materials
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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Ashland Performance Materials
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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Ashland Performance Materials
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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Ashland Performance Materials
Aropol F 195 LN
Case histories
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Ashland Performance Materials
Aropol F 207 TPB
Case histories
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Hetron F 240 TF
Case histories
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Ashland Performance Materials
Hetron F 660 TFE
Case histories
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Ashland Performance Materials
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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Ashland Performance Materials
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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Ashland Performance Materials
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
Ashland new generation resins
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Ashland Performance Materials
• 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
Ashland new generation resins
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Ashland Performance Materials
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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Ashland Performance Materials
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
Ashland next generation resins
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Ashland Performance Materials
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
Ashland next generation resins
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Ashland Performance Materials
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
Ashland next generation resins
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Ashland Performance Materials
What we design:
Fire certifications targets: • ASTM E162 Class 1 • ASTM E662 Class 1 • EN 45545 HL3 • EN 13501 Bs1d0
Ashland next generation resins
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Ashland Performance Materials
For more information, please contact our sales/technical representatives
Ashland Performance Materials
® 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.™