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Life Cycle Cost Considerations in Selecting
Fluoropolymer Coatings
Webinar for Durability and Design Magazine May
18th, 2012
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FEVE Fluoropolymer Resins for High-Performance
Coatings

• What is an FEVE Fluoropolymer???
• A hybrid fluoropolymer resin with the ability to
  be used in standard coatings formulations like
  any other conventional coating resin
• A high performance resin that can withstand
  severe ultraviolet light exposure 2-3 times
  longer than conventional coatings resins

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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Fluoroethylene Vinyl Ether (FEVE) Resins

FLUORINATED SEGMENTS Weatherability, chemical
resistance VINYL ETHER SEGMENTS Gloss,
solubility, crosslinking
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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Advantages of FEVE Fluoropolymer Resins
• Ambient Cure
• Field application
• OH Functional - Crosslinkable with
  isocyanates
• Solvent Soluble
• Conventional application techniques (airless
  spray)
• Wide range of gloss (90 _at_ 60º)
• Fluoropolymer Segments
• UV Resistance
• Corrosion resistance

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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Markets for FEVE resin-containing coatings
• Architectural Coatings for commercial buildings
• Industrial Maintenance Coatings for water towers,
  bridges, and assorted metal and concrete
  structures
• Aerospace coatings
• Applications in Marine environments

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FEVE Fluoropolymer Resins for High-Performance
Coatings
QUV Weatherometer Exposure Testing
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FEVE Fluoropolymer Resins for High-Performance
Coatings
QUV Weatherometer Exposure Testing
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FEVE Fluoropolymer Resins for High-Performance
Coatings
Sunshine Weatherometer Exposure Testing (Carbon
Arc)
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FEVE Fluoropolymer Resins for High-Performance
Coatings
EMMAQUA Testing (Outside Test Fence Arizona)
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FEVE Fluoropolymer Resins for High-Performance
Coatings
South Florida Test Fence Exposure
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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Corrosion Resistance Test of FEVE Coatings
• LOCATION Suruga Bay Marine Test Station
  (offshore)
• LENGTH OF TEST 16 years
• COATINGS SYSTEMS ON TEST
• 1) Zinc-rich primer / Epoxy Midcoat / Acrylic
  Urethane Topcoat
• 2) Zinc-rich primer / Epoxy Midcoat /
  Fluorourethane Topcoat
• THICKNESS OF COATING
• PRIMER 3 mils / MIDCOAT 6 mils /
  TOPCOAT 1 mil(25 microns)

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FEVE Fluoropolymer Resins for High-Performance
Coatings
Measurement of Total Erosion of the Topcoat
ACRYLIC URETHANE TOPCOAT FLUOROURETHANE TOPCOAT
INITIAL MEASUREMENT (microns) 25 25
FINAL MEASUREMENT (microns) 0 (after 13 years) 21
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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Life Cycle Cost Advantages
• Initial Cost of FEVE-based Topcoat
• 5 -10 higher than standard polyurethane
  topcoat
• FEVE-based Topcoat Life Expectation
• 30 - 60 years
• Expected Repaints of Std. Polyurethane Topcoat
• in this Time Frame
• 2 to 3 (based on topcoat erosion data from
  offshore test)
• Additional Costs of Repaints
• facility downtime

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FEVE Fluoropolymer Resins for High-Performance
Coatings
Breakdown of Total Cost of Recoating a Bridge Breakdown of Total Cost of Recoating a Bridge Breakdown of Total Cost of Recoating a Bridge
  3 Coat Epoxy, 2 Coat Polyurethane System 3 Coat Epoxy, 2 Coat FEVE Urethane System
Staging Costs 38.96/ m² 38.96/ m²
Surface Preparation 8.44 / m² 8.44 / m²
Labor Cost For Paint Application 26.22 / m² 26.22 / m²
Total Cost of Coatings 12.03 / m² 15.96 /m²
Total Repainting Cost 85.65 / m² 89.58 / m²
Prices of Construction Materials and Wages
October 2006 (Published in Japan)
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FEVE Fluoropolymer Resins for High-Performance
Coatings
Estimation of Total Applied Cost Per Year (Coating System) Estimation of Total Applied Cost Per Year (Coating System) Estimation of Total Applied Cost Per Year (Coating System) Estimation of Total Applied Cost Per Year (Coating System)
Coating System Total Repainting Cost Estimated Life of Coating System Total Applied Cost per year of Service
Polyurethane Topcoat System 85.65 / m² 18 4.76 / m²
FEVE Urethane Topcoat System 89.58 / m² 30 3.00 / m²
FEVE Urethane Topcoat System 89.58 / m² 60 1.50 / m²
FEVE Urethane Topcoat System 94.21 / m² (estimated) 30 3.14 / m²
FEVE Urethane Topcoat System 94.21 / m² (estimated) 60 1.57 / m²
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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Some things to consider
• FEVE polyols can be blended with other polyols to
  formulate coatings to specific life cycle
  targets.
• Lower percentages of FEVE polyols in the
  formulation will reduce raw material costs
  compared to 100 FEVE polyol formulations.
• Coatings formulated for longer life durability
  will hold their gloss and color better than
  conventional polyurethane topcoats. This may be
  an important factor when the appearance of the
  coating needs to be superior 24/7.

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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Shelby Street Bridge
• (Nashville, TN)
• --- coated in 2004
• --- 3 coat system on steel
• 1) zinc-rich primer
• 2) epoxy midcoat
• 3) fluororurethane topcoat

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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Gateway Bridge
• (Nashville, TN)
• --- opened in 2004
• --- Red Support Girder coated with
  FEVE- containing coating

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FEVE Fluoropolymer Resins for High-Performance
Coatings
Akashi-Kaikyo Ohashi road train bridge (1997)
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FEVE Fluoropolymer Resins for High-Performance
Coatings
Mercedes-Benz Museum, Stuttgart , Germany Coated
2004-2005 VERNICRON FP
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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Clinton Presidential Library
• Little Rock, Arkansas, USA

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FEVE Fluoropolymer Resins for High-Performance
Coatings
Birmingham Airport Car Park Birmingham, U.K.
ALPOLIC
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FEVE Fluoropolymer Resins for High-Performance
Coatings
Project Update Katsushika Harp Bridge

• Construction Completed in 1986
• Shop coating begun 1982
• Three Coat System
• Concrete Bridge Piers
• Elastomeric Primer
• 2 Fluorourethane Topcoats
• Steel Encasement for Earthquakes in 2007

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FEVE Fluoropolymer Resins for High-Performance
Coatings

• New Steel Encasement Original Concrete Foot
• Coated 2007 Coated 1987

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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Conclusion
• For 30 years, FEVE resins have been included in
  exterior coatings for multiple end uses.
• Their excellent weatherability and corrosion
  resistance make them attractive for inclusion in
  topcoats for steel and concrete surfaces.
• In the long run they can reduce the cost of
  maintaining both a decorative and a protective
  finish on many exterior substrates.

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FEVE Fluoropolymer Resins for High-Performance
Coatings

• Acknowledgements
• Takasi Takayanagi
• Sho Masuda
• Isao Kimura
• Takuma Yamamoto