1. Architectural Protective Coatings FEVE RESIN Technology
Presented by: AGC
55 E. Uwchlan Ave., Ste. 201
Exton, PA 19341
Architectural Protective Coatings FEVE RESIN Technology
Introduce yourself, the company you represent and what qualifies you to present this material.
Presenter: Please remember, this course should be covered in 50 minutes with 10 minutes remaining for course review questions (no proprietary questions during the course or the review Q&A)
Course Number: IAG09B
Provider: AGC Chemicals Americas, Inc.
Credit: 1 AIA HSW CE Hour
© InfoSpec, Inc

2. Architectural Coatings
An introduction

3. The Role of Protective Coatings
Buildings need protection against:
The elements (UV rays, wind, rain, ice, etc.)
Corrosion
Abrasion
Impact
A picture in the mind or a conceptual sketch of a perfect architectural design can diminish once built in the real world, where it is subject to the elements, corrosion, abrasion, etc.
Without protection from UV rays, wind, rain, and other impacts, a beautifully constructed project can quickly lose its luster. These factors can result in deterioration and render aesthetics awash of their former brilliance, leading to extensive costs to repair, correct and restore.

4. The Role of Protective Coatings
Prevents deterioration from impact and environmental factors
Reduces maintenance costs
Increases life of the structure
The architectural and construction industry have been specifying and utilizing protective coatings for generations. These coatings work to prevent deterioration caused by impact and environmental factors to maintain durability and aesthetics while greatly reducing maintenance costs and increasing the life of the finish.
archiexpo.com

5. Application Substrates
Suitable Substrates:
Steel
Aluminum
Copper
Zinc & other metals
Glass
Plastic
Concrete
Wood
Original metal applications, such as curtain wall applications, have grown to include many other surface types, such as glass, plastic, and concrete, in a diverse spectrum of projects.
Evolving coating technology has brought about variations of coating types as well, including liquid, powder, etc., to support optimal applications in various settings.
corporate.heraeus.com

6. Considerations When Selecting a Coating
Ease of application
Curing time/method
Ability to maintain color/gloss
Mechanical strength
Weatherability
Durability
Fluoropolymers are known for their durability and ability to maintain initial performance over long time periods. 
Specifying coatings with high performing characteristics ensures a finish will endure through time while still exhibiting that initial luster.
Varying attributes to consider include ease of application, curing time/method, ability to maintain color/gloss, mechanical strength, weatherability and durability.
Among protective coatings, fluoropolymer resins are commonly used for their superior performance. These coatings are known for their durability and ability to maintain initial performance over long time periods. 

7. Fluoropolymers
A comparison

8. Properties of Fluoropolymers
Used in coatings for over 40 years
Advantages:
Low surface energy
Excellent weatherability
Corrosion, abrasion, temperature and chemical resistance
Disadvantages:
Difficult to apply
Require heat to soften or melt, then apply
Fluoropolymer Resins have been used in coatings for over 40 years. These coating systems show superior UV protection, excellent chalking resistance, good mechanical properties and therefore are primarily used for exterior applications.
Their advantages include:
Low surface energy
Excellent weatherability
Corrosion, abrasion, temperature and chemical resistance
Their main disadvantage:
Difficult to apply
Require heat to soften or melt, then apply to substrate

9. Properties of Fluoropolymers
Examples of Fluoropolymers used in coating applications include:
PTFE
FEP
ETFE
PVdF
PVF
Examples of Fluoropolymers used in coating applications include:
PTFE or Teflon®
FEP
ETFE
PVdF
PVF
PVF and PVdF are the most commonly used.

10. PVF and PVdF Characteristics
PVF resins
Limited use in coatings (melting and decomposition temperatures too close)
Require additives
PVdF Resins
Better processing characteristics than PVF
Tendency to form pinholes
Poor adhesion
Blended with acrylic resin (70/30) to improve adhesion
Form pinhole-free coating with good adhesion at 250˚C
PVF resins
Limited use in coatings (melting and decomposition temperatures too close)
PVFs require additives
PVdF Resins
Better processing characteristics than PVF
Tendency to form pinholes
Poor adhesion
Blended with acrylic resin (70/30) to improve adhesion
Commonly referred to as Kynar/Hylar
Form pinhole-free coating with good adhesion at 250˚C
Between these two, PVdF coatings possess more durable and flexible characteristics.

11. PVdF Coatings PVdF coatings exhibit the following advantages:
• Over 20 years durability • Good gloss & color retention over the life of the coating • Good chemical resistance • Flexibility required to fabricate pre-coated construction components
Speaker: Please read slide

12. PVdF Coatings PVdF coatings exhibit the following disadvantages:
• Coating is applied to substrate at high temperatures which leads to limited field and shop applications • Limited gloss range • Pigment compatibility also limited -- Limits amount and type of colors available
Speaker: Please read slide

13. FEVE Resins
The next generation of fluoropolymer technology

14. FEVE Technology Developed in the 80’s for field and shop applications
FEVE (Fluoroethylene Vinyl Ether) is the next generation fluoropolymer coating technology
Architectural coatings
Aerospace coatings 
Industrial Maintenance
Automotive
Alternative Energy
FEVE resins were developed in the 80’s as solvent-soluble fluoropolymers that could be cured at room temperature conditions, so they could be used on-site for field applications such as heavy-duty architectural and aerospace coatings, as well as for oven-baked coatings. 
Over the past 25 years, fluoropolymer coatings based on FEVE technology have been produced by many coating manufacturers worldwide.
Coated with FEVE Technology

15. FEVE Technology Known for their high performance properties:
Exceptional resistance to UV degradation
Superior chemical resistance
Excellent thermal resistance
Good corrosion resistance
Known for their unique formulation properties:
Solvent soluble
Can be cured at room temperature
Can be cured at elevated temperatures
Can achieve high gloss coatings
FEVE coatings were designed not only to overcome the limitations of PVdF resins, but also to possess the same weatherability as PVdF coatings. This strength is derived from a unique alternating polymer chemical structure discussed later in the Life Cycle Cost section of this course.
Known for their high performance properties:
Exceptional resistance to UV degradation
Superior Chemical Resistance
Excellent Thermal Resistance
Known for their unique formulation properties:
Solvent soluble
Can be cured at room temperature
Can achieve high gloss coatings

16. Advantages of FEVE Resins
Excellent pigment compatibility, broad range of colors
Solution polymers (brighter colors)
Broad range of gloss possible
Ideal for recoating applications at room or elevated temperatures (shop or field applied)
These coatings exhibit excellent pigment compatibility, enabling a broad range of colors.
FEVE resins are solution polymers, offering brighter, more vivid colors.
They also offer a broad range of gloss possibilities, from completely flat to high gloss.
Because FEVE coatings can be field applied, they are ideal for recoating applications.

17. FEVE Resin Application Advantages
Characteristics of both fluoropolymers and urethanes offer excellent bonding to substrates ranging from aluminum and steel to fiberglass
Bonds well with primers and undercoats (epoxies/polyurethanes)
Can be recoated and used to repair and refinish other fluoropolymer coatings
Because FEVE resins exhibit characteristics of both fluoropolymers and urethanes, FEVE based coatings offer excellent bonding to substrates ranging from aluminum and steel to fiberglass.
FEVE coatings also bond well with primers and undercoats such as epoxies and polyurethanes.
FEVE coatings can be recoated and can also be used to repair and refinish other fluoropolymer coatings.

18. Ideal FEVE Resin Substrates
Steel, aluminum, copper, zinc, and other metals
Concrete
Construction Plastics (FRP, polycarbonate, PET)
Recycled Plastics (polyethylene, polypropylene, PET)
Glass
Wood
FEVE based coatings are available for multiple substrate applications including:
Steel, aluminum, copper, zinc, and other metals
Concrete
Construction Plastics (FRP, polycarbonate, PET)
Recycled Plastics (polyethylene, polypropylene, PET)
Glass
Wood

19. Summary of Attributes Broader gloss range Brighter colors
Field, shop or factory application
Excellent corrosion resistance
Excellent hardness and mar resistance
Water based, solid resins, and powder coating resins for low/zero Volatile Organic Compound (VOC) coatings
FEVE coatings pass the most stringent air quality standards (better for human health and the environment)
Broader gloss range
Brighter colors
Field, shop or factory application
Excellent corrosion resistance
Excellent hardness and mar resistance
Water based, solid resins, and powder coating resins for low/zero Volatile Organic Compound (VOC) coatings
FEVE coatings pass the most stringent air quality standards (better for human health and the environment)

20. FEVE Coating Types
And their applications

21. FEVE Coating Types Solvent Based Solid Resins Water-Borne
Used in most of U.S.
Field or shop application
Solid Resins
Low/Zero VOC coatings
Water-Borne
Low odor requirements
Field or shop application
Powder Coatings
Factory applied
Currently, there are four types of FEVE based coatings available for different applications:

22. Solvent Based For ambient cured FEVE coatings
Field applied
High or elevated temperature cured
Powder coatings
Coil & extrusion coatings
For ambient cured coatings based on FEVE resins, xylene is the solvent currently used. Xylene is used because of its physical properties and low cost.
Xylene content of FEVE resins range from 40-67%.
The coil coating industry uses FEVE resins blended with alternative solvents.

23. Solid FEVE Resins
Developed as an alternative to solvent based resins to meet stringent environmental air pollution standards
Can produce low-VOC coatings
Meet strictest standards: South Coast Air Quality Management District (SCAQMD) 100 g/l VOC
Used in ambient cured or field applied coatings
Due to more stringent environmental air pollution standards, solid FEVE resins have been developed as an alternative.
These solid resins can be used to produce low-VOC and hazardous air pollutant (HAPS) free coatings.
Meet strictest standards: South Coast Air Quality Management District (SCAQMD) 100 g/l VOC.

24. Water-Based
FEVE water-based resins were developed to meet air quality standards and with limited odor
Single component FEVE water-based resins can also be used to produce coatings
Primarily air dry or ambient cure coatings
FEVE resins can be emulsified with surfactants, compounds that lower the surface tension of a liquid, to make water based fluoropolymer resins.
They can also be blended to produce fluorourethane coatings that offer excellent weathering properties.
Single component FEVE emulsions can also be used to produce coatings.

25. Powder Coatings Solvent-free
As much as 95% usage efficient with little to no waste in application
Does not require a substrate primer
Used in aluminum extrusions & curtain walls
Factory or shop applied
FEVE resins can be made in a powder version that offers all of the weatherability and properties of their liquid counterpart along with other advantages:
The powder versions offer the benefits of being solvent-free and little to no waste in application. Powder versions can be as much as 95% usage efficient.
Unlike PVdF, the powder version of FEVE does not require a substrate primer.

26. FEVE Coating Versatility in Application
Factory or Shop Application:
Field Application:
Coil coatings (metal composite materials)
Powder coatings
New construction
Repainting existing structures
Coil or powder coating repair
Field color match to shop applied coatings
Speaker: Please read slide

27. FEVE Resins for Field Applied Coatings
Uses:
To recoat existing structures previously coated with PVdF
Ideal for structures that are difficult to repaint, e.g. tall buildings, water towers, bridges, etc.
To repaint other coatings, e.g. urethane
Surface Preparation Requirements:
Sandblasting
Removal of loose materials
Prepare and prime substrate
Advantages of FEVE Resins:
Use standard paint application equipment
Water based, solvent based and solid grades can be used
Example:
Used to repair existing PVdF applied coatings
Used for difficult structures, e.g. tall buildings, water towers, bridges, etc.
Surface Preparation:
Sandblasting
Removal of loose materials
Prepare and prime substrate
Advantages of FEVE:
Use standard paint application equipment
Water based, solvent based and solid grades can be used

28. FEVE Resins for Shop or Factory Application
Uses:
Exterior cladding applications including metal extrusions and metal composite
Automotive exteriors
Solar cells
Coil Coatings
Surface Preparation Requirements:
Proper treatment of substrate
Apply coatings directly to metal surface, no primer required
Advantages of FEVE Resins:
Application cost savings since PVdF require a primed substrate
Can be used on multiple metallic surfaces including ACM, Steel, etc.
Can be used on surfaces such as construction plastics/polycarbonate
Example:
Typically used for exterior cladding applications
Automotive exteriors
Solar cells
Surface Preparation:
Use substrates that have been properly treated
Apply coatings directed to metal surface, no primer required
Advantages of FEVE:
FEVE offers application cost savings since PVdF’s require a primed substrate
Can be used on multiple metallic surfaces including ACM, Steel, etc.

29. Powder Coatings Uses: Surface Preparation Requirements:
Aluminum extrusions for windows
Curtain walls
Architectural accessories
Surface Preparation Requirements:
No primer required
Properly treated substrates
Advantages of FEVE Resins:
Excellent stain and mar resistance
Excellent corrosion resistance of
properly treated metal substrates
Example:
Aluminum extrusions for windows
Curtain walls
Surface Preparation:
No primer required
Use substrates that have been properly treated
Advantages of FEVE:
Excellent stain and mar resistance
Excellent corrosion resistance of properly treated metal substrates

30. Life Cycle Cost
Contributing factors

31. Life Cycle Cost Advantages
Initial applied cost of FEVE-based topcoat:
5-10% higher than standard polyurethane topcoat
FEVE-based topcoat life expectation:
years
Expected maintenance of standard polyurethane topcoat in this time frame:
2-3 repainting cycles
Additional costs of repainting:
Asset downtime
Staging costs
Environmental costs
Emissions and CO2 from equipment
Relevant life cycle cost is dollars/sq.ft./year
Repainting and maintenance work on buildings, bridges, and other structures can cause both financial and operating disruptions.
There are also significant environmental costs associated with repainting operations. FEVE resins minimize these costs.
In addition to low VOC content, low life cycle costs make FEVE technology a more environmentally friendly choice.
In a typical scenario, FEVE based coatings are more expensive than polyurethane coatings on a $/gallon basis.
However, due to FEVE’s superior weatherability, they will last at least twice as long as most coatings before recoating is necessary.

32. Life Cycle Cost Analysis
In this chart, the relative applied cost encompasses the cost of each portion of the coating system (for FEVE system it is around 85, for the initial polyurethane it is about 76). The total cost for each coating system is divided into the applied cost for each coat-that includes the cost of the coating and the cost of applying the coating.  The initial applied cost of the urethane is somewhat lower than that of the FEVE coating.  After 10 years, the urethane must be replaced because it has degraded over that time. So the life cycle cost of the FEVE coating (85) is lower than that of the polyurethane (around 123). 

33. Weathering Properties
High-bond energy of the carbon-fluorine bond and unique polymer structure prevents UV degradation and maximizes gloss retention
Comprehensive testing has been achieved for real-time and accelerated weathering 
The outstanding weatherability of FEVE resins is due to the unique high bond energy of the carbon-fluorine bond, and to their unique polymer structure.
FEVE resins successfully prevent UV degradation thus maximizing gloss retention. 

34. Accelerated Weathering: EMMAQUA Test
EMMAQUA (Equatorial Mount with Mirrors for Acceleration with Water)
EMMAQUA (Equatorial Mount with Mirrors for Acceleration with Water) is one of the most widely used outdoor accelerated weathering test method in the world today. This diagram compares the weatherability of FEVE vs. PVdF and Polyurethane.

35. Natural Weathering: Gloss Retention
Absolute Gloss %
Absolute Gloss %
EMMAQUA (Equatorial Mount with Mirrors for Acceleration with Water) is one of the most widely used outdoor accelerated weathering test method in the world today. This diagram compares the weatherability of FEVE vs. PVdF and Polyurethane.

36. Natural Weathering: Okinawa
This chart displays weatherability over a 12 year period, confirming FEVE’s comparability to PVdF in durability.
FEVE
PVdF

37. Corrosion Resistance of FEVE Coatings
Effective against corrosion initiators, e.g. salt, water
Can be expected to last up to 60 years
Resists degradation due to weathering and exposure to ambient chemicals
Over the course of many years, loses little of its thickness
Keeps corrosion initiators from getting past the topcoat and degrading the zinc-rich primer underneath
Has an estimated coating life of 60 years or more
Fluorourethanes made with FEVE resins can perform effectively for several years in the presence of such corrosion initiators as chloride ions, water and oxygen.
This advantage is due to the fluorine atom making the FEVE Coating “tight” and its inherent low levels of coating degradation.
When applied at adequate thickness, FEVE based topcoats can be expected to last up to 60 years.

38. Corrosion Resistance
This accelerated corrosion test shows the superior performance of the FEVE coating.  The horizontal line indicates no change in the corrosion protection of the FEVE coating.  Competitive coatings suffer a loss of corrosion protection as they age, indicated by the sloping lines.

39. Corrosion Resistance of FEVE Coatings
The ASTM B-117 Salt Fog Corrosion Test exposes scribed coated panels to a 5% salt solution over a period of time, in this case 2,000 hours. Corrosion is measured by the amount of rust in the scribe and under the coating adjacent to the scribe as well as by blisters formed by corrosion products. In the test below, both topcoats were applied over a 3 mil epoxy primer. Can be expected to last up to 60 years
Left Panel: Polyurethane Topcoat
Right Panel: FEVE Topcoat
Fluorourethanes made with FEVE resins can perform effectively for several years in the presence of such corrosion initiators as chloride ions, water and oxygen.
This advantage is due to the fluorine atom making the FEVE Coating “tight” and its inherent low levels of coating degradation.
When applied at adequate thickness, FEVE based topcoats can be expected to last up to 60 years.

40. Sustainability

41. Sustainability of FEVE Coatings
The weatherability, longevity and low VOC coatings of FEVE resins are all features that contribute to its sustainability
FEVE coatings can last up to 30 years without fading, reducing life cycle costs related to the maintenance, re-application and/or replacement of underlying surfaces.
Possible LEED v4 credits:
Materials and Resources credit Building Life-Cycle Impact Reduction
Sustainable Sites Credit Rainwater Management
Sustainable Sites Credit Heat Island Reduction
Energy and Atmosphere Prerequisite Minimum Energy Performance
Repainting and maintenance work on buildings, bridges, and other structures can cause both financial and operating disruptions.
There are also significant environmental costs associated with repainting operations. FEVE resins minimize these costs.
In addition to low VOC content, low life cycle costs make FEVE technology a more environmentally friendly choice.
In a typical scenario, FEVE based coatings are more expensive than polyurethane coatings on a $/gallon basis.
However, due to FEVE’s superior weatherability, they will last at least twice as long as most coatings before recoating is necessary.

42. Case Studies and Project Applications

43. Eerie on the Park Location: Chicago, IL 10 years of exposure
Recoated with a zinc primer and FEVE resin-based coating

44. The Mohegan Sun Casino Location: Wilkes-Barre, PA
Construction damage to ACM
Affected panels repaired with a zinc primer and FEVE resin-based coating which matched the factory color of the metallic panels. Zero metallic flop.
Daiichi Mukaiyama Bridge, Japan
Located in mountainous area
Some parts coated with FEVE, some with Alkyd
Exposure after 14 years

45. Corporate Office Building
Location: Washington, DC
Installation damage to curtain wall
Affected areas repaired with a zinc primer and FEVE resin-based coating which matched the original color of the metallic curtain wall. Zero metallic flop.

46. Projects Ferrari World, Abu Dhabi U.A.E Substrate: Aluminum
Presenter: Please describe the unique qualities of these application examples (this information must remain non-branded/non-proprietary. Please deliver this information in an educational format)
Ferrari World, Abu Dhabi U.A.E
Substrate: Aluminum
Coss Y Leon Building, Mexico
Substrate: Aluminum Composite

47. Projects Winnie Palmer Hospital, USA Substrate: Aluminum Composite
Presenter: Please describe the unique qualities of these application examples (this information must remain non-branded/non-proprietary. Please deliver this information in an educational format)
Winnie Palmer Hospital, USA
Substrate: Aluminum Composite
Burj Al Arab Hotel, Dubai U.A.E
Substrate: Aluminum Composite

48. Projects Windmill Substrate: Fiberglass NTT Sekimoku Network Center
Presenter: Please describe the unique qualities of these application examples (this information must remain non-branded/non-proprietary. Please deliver this information in an educational format)
Windmill
Substrate: Fiberglass
NTT Sekimoku Network Center
Substrate: Steel

49. Projects Kiyosu Bridge, Japan Rosemont Water Tower, USA
Presenter: Please describe the unique qualities of these application examples (this information must remain non-branded/non-proprietary. Please deliver this information in an educational format)
Kiyosu Bridge, Japan
Substrate: Steel
Rosemont Water Tower, USA
Substrate: Steel

50. Conclusion

51. In Summary
FEVE is the next-generation architectural coating technology.
Its chemical make up produces un-matched weatherability and long service life.
It also allows versatility in terms of substrate (adhesion) and field or shop application (able to cure at room temp.)
It achieves brighter and wider array of colors.
Last but not least, FEVE coatings can protect and maintain the initial luster and aesthetics of a project for 20+ years.
FEVE is the next-generation architectural coating technology.
Its chemical make up produces un-matched weatherability and long service life.
It also allows versatility in terms of substrate (adhesion) and field or shop application (able to cure at room temp.)
It achieves brighter and wider array of colors.
Last but not least, FEVE coatings can protect and maintain the initial luster and aesthetics of a project for 20+ years. In some cases, FEVE coatings are meant to last more than 50 years.

52. Course Summary Now, the design professional will be able to:
Compare and contrast polyvinylidene fluoride (PVdF) and fluoroethylene vinyl ether (FEVE) architectural coatings in terms of application and performance.
Knowledgably determine which FEVE coating type to apply based on field or shop application and substrate (solvent-based, solid resins, water-borne, powder).
Discuss the low-VOC/HAPS-free attributes of FEVE coatings and the importance of meeting South Coast Air Quality (SCAQMD) standards.
Discuss the attributes and benefits of FEVE technology when applied to a project exterior, including long-lasting protection from the elements (UV rays, wind, rain, corrosion) and reducing the use of resources and costs associated with maintenance/repair.

53. Questions?
The next 10 minutes will be focused on discussing the course material. Please reserve any questions pertaining to specific products for after the conclusion of this course. Presenter: do not advance off questions slide until the Q&A session has concluded
The next 10 minutes will be focused on discussing the course material.