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1Fire Retardant Resinsfor Mass Transit and BuildingII International conference «Composites without borders»October 14-16, 2014Open Innovation Expo, Technopolis Moscow 2014, AshlandDr Tim PepperRegistered trademark, Ashland or its subsidiaries, registered in various countries Trademark, Ashland or its subsidiaries, registered in various countriesAshland Performance MaterialsWith good chemistry great things happen.

Why a flame retardant industry?The flame retardant industryis the result of National andInternational Fire ProtectionRegulations and tests Procedureswhich have been implementedduring the last 50 years.Regulations cover4 main industries: Building Rolling stock Aircraft Cruise boatsAshland Performance Materials2

FRP in Architectural ApplicationsBarriers to FRP use Building and construction industryheavily dependent on building codes,most codes do not address useof composite materials. More difficult for engineersand architects to specify,can complicate designand approval processAshland Performance Materials3

Some National fire safety regulations for rail vehiclesEurope NFF 16101 : France BS 6853 : UK DIN 5510 : Germany UNI CEI 11170-3 : ItalyRussia GOST 12.1.044-89 UIC 564.2Ashland Performance Materials4

Fire safety codes worldwide for buildingUS ASTM E 84 : Tunnel test ASTM E 162 : Radiant panel test ASTM E 662 : Smoke densityEurope NFP 92501 : France BS 476 : UK DIN 4102 : Germany UNI CEI 11170-3 : ItalyInternational UL 94 : Vertical flame test LOI : Limit Oxygen index testAshland Performance Materials5

European fire safety regulationsEN 13501-1 – Fire Classification of constructionproducts and building elements This first version of this Fire Classification hasbeen implemented in 2002.EN 45545-2 – Fire protection on Railway vehicles The European standard was given the statusof National standard in 2013, and conflictingwith national standards will be withdrawn atlatest by march 2016.Ashland Performance Materials6

FRP in Architectural ApplicationsBarriers can be overcome Case histories being usedto help satisfy clientsand authorities thatcomposites are suitableAshland Performance Materials7

8EN 45545-2 - Material requirement setsR1 : Surface products (wall, ceiling)ApparatusParameter and UnitRequirementsHL1HL2HL3CFE kW/m2Minimum202020Maximum9060radiant panelcone calorimeterMARHE kW/m2smoke chamberDs(4) dimensionlessMaximum600300150smoke chamberVOF4 MinutesMaximum1200600300smoke chamberCITg dimensionlessMaximum1,20,90,75Ashland Performance Materials

EN 13501-1- Classes of reactionto fire performance for construction products(excluding flooring and linear pipe products)ApparatusBomb calorimeterNon combustibility furnaceParameter and UnitRequirementsA1A2BCDEPCS - MJ/kgMaximum2,03,0DT - CMaximum3050Dm - %Maximum5050tf - sMaximum020Single burning itemFIGRA - W/sMaximum120250 750THR600s - MJMaximum7,515Small burnerFs - mmMaximum150150 150 150ApparatusSingle burning itemParameter and UnitRequirementss1s2s3SMOGRA - m2/s2Maximum30180not s1 or s2TSP 600s - m2Maximum50200not s1 or s2ApparatusSingle burning itemParameter and UnitNo flaming droplets - sAshland Performance MaterialsRequirementsMaximumd00d110d2not d0 or d19

FRP in Architectural ApplicationsFRP provides unique properties Aesthetic appealExcellent mechanical, physical and thermal propertiesCan be molded into complex shapesExcellent corrosion, flame, and weathering resistanceResistant to rot and insect attackEasy to assemble and installLightweightAshland Performance Materials10

FRP in Architectural Applications Wood, steel, aluminum, concrete usedmost 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 degradationAshland Performance Materials11

FRP in Architectural ApplicationsArchitectural applications Building panelsColumnsDomesFacadesFascia panelsHVAC ductingDoors, window framesBridge structures and enclosuresPolymer concreteAshland Performance Materials12

FRP Benefits in Architectural ApplicationsArchitectural applications Lightweight & VersatileCost EffectiveCorrosion ResistantExcellent WeatheringMaintenance FreeBeforeAshland Performance MaterialsAfter13

Architectural FRP RestorationsAshland Performance Materials14

Commercial Building Exterior ApplicationsAshland Performance Materials15

Columns, Facades & CornicesAshland Performance Materials16

Custom ShapesAshland Performance Materials17

Interior ApplicationsAshland Performance Materials18

Industrial Building Structures Structural BeamsDoorsDuctingCable TrayGrating & PlatformsRoofing & SidingTranslucent or OpaqueAshland Performance Materials19

FRP PanelAshland Performance Materials20

Day-Lighting PanelsAshland Performance Materials21

DuctingAshland Performance Materials22

Cable TrayAshland Performance Materials23

Grating, Stairs & HandrailsAshland Performance Materials24

Composite BridgesAshland Performance Materials25

A solution for builders, by buildersA clean, engineeredsolution forthe replacementof concrete walls thatcombines strenght,integrated stud cavitiesfor mechanicals,insulation top plateand damp proofingin a single step.Ashland Performance Materials26

Current “Cast in Place” Concrete Foundation Technology Extensive use of forms,rebar and concrete Labor Intensive and timeconsuming to set up and teardown (7-10 days) Guaranteed to crack and leak– humid damp livingenvironment High carbon footprint.Poor energy conservation.Ashland Performance Materials27

Value PropositionBuilders deliver a higher value,more energy efficient home, faster Integrated studs – ready to finishR 16.5 (3-4X R-Value of concrete)Installed in 90 min rather than 7-10 daysUses builder’s own crew rather than another subcontractorHome buyers receive a warmer, drier,more energy efficient, ready-to-finish basementCost competitive to poured concreteAshland Performance Materials28

Key Builder Benefits 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 controlledfabrication shop – ready to use- Few connection points designed with the builder in mind- Fewer steps, no subcontractors. More predictableconstruction timeline. Less potential for delays Builder can use same crew for all facets of home construction Extended construction season - installation in cold climatesAshland Performance Materials29

Key Homeowner Benefits Energy savings / green- Estimated 15% reduction in energy costs- Smaller carbon footprint compared to concrete High quality living space- Warm, dry, comfortable living spacew/o added expense of finished basement Larger interior floor plan - “free” 10 x 10 room No maintenance Greatly improved flexibility to modify / finish basement spaceAshland Performance Materials30

Why Use FRP Composites in Mass Transit Applications Light WeightHigh Strength to Weight RatioLow MaintenanceExcellent Thermal Insulation PropertiesAshland Performance Materials31

Where Can FRP be Used in Mass Transit Applications? Interior/Exterior PanelsDoorsInterior ComponentsRoofs/FloorsSeatingSleeper CompartmentsAshland Performance Materials32

Where Can FRP be Used in Mass Transit Applications? Lavatory CompartmentsThird Rail CoversMaintenance GratingsCable TraysConsolesAshland Performance Materials33

34FRP ApplicationsPanels for Railway Rolling StockAshland Performance MaterialsFR Railway Seat Shell

FRP ApplicationsFRP Seatsand wall panelsAshland Performance Materials35

FRP ApplicationsEngineersConsoleAshland Performance Materials36

FRP ApplicationsCable Trays for the Channel TunnelAshland Performance Materials37

FRP ApplicationsLavatoriesAshland Performance Materials38

Ashland’s Value to FRP Fabricators Largest global supplier of Fire Resistant Resins 50 years of successful applications experienceUnmatched product portfolioFR 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 technologydevelopment and customer supportAshland Performance Materials39

Ashland FR non filled resinsAropol F 207 TPBLloyds for survival craft material Class A-UTAC ,B2 DIN 4102, BS 476: Class 2, NF16101: M3Aropol F 195 LNSweden: NT Fire 006Hetron F 830 TE95/28/CEE, BS 476: Class 2, NF16101: M2Ashland Performance Materials40

Ashland FR filled resinsHetron F 805 TFM1F2 / S4SR2ST2 / Class 1/ Bs3d0 / V-0 / Class A / GOST 12.1.044-89Hetron F 240 TFM2F2 / S4SR1ST2 / Class1 / Cs3d0 / V-0 / Class AHetron F 250 TFM2F2Ashland Performance Materials41

Ashland gelcoat line cardEnguard AEM1 F3 with Hetron F 804 TFMaxguard FRM2F2 Class 2 with Hetron F 240 TF / M2F1 S4 SR2 ST2 with Hetron F 640 TFAshland Performance Materials42

Case historiesAropol F 195 LNAshland Performance Materials43

Case historiesAropol F 207 TPBAshland Performance Materials44

Case historiesHetron F 240 TFAshland Performance Materials45

Case historiesHetron F 660 TFEAshland Performance Materials46

EHS impact on raw materials usageCommon 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 cancerAshland Performance Materials47

Ashland new generation resinsTo meet the more demanding standards and to minimizethe impact to human health and the environment.Ashland offers right now a new product range offlame retardant UP resins which complies with the highest standards: HETRON F 235HETRON F 640 TFHETRON F 645 TFHETRON F 660 TFAshland Performance Materials48

Ashland new generation resinsHetron F 640 TFHETRON F 640 TF filled resin is a performing new generation resin which meets: B s2 d0 according EN 13501 HL2 according EN 45545HETRON F 640 TF key features: Low viscosity Easy processing Recommended for hand lay up, spray up and RTMAshland Performance Materials49

Ashland new generation resinsHetron F 235 HETRON F 235 unfilled resin is a new halogen free andantimony free UP which can meet the highest standards whenfilled with Aluminium hydrate. Its very low viscosity allows it to be loaded with ATH from 50phr to 200phr. HETRON F 235 resin is recommendedfor RTM, infusion, pultrusion.Ashland Performance Materials50

Ashland next generation resinsOur 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 Performance Materials51

52Ashland next generation resinsWhat we design: New patented technology Highly improved processability with vast majority of ATH grindsStandard FR polyester resinAshland new generation resinViscosity cP 20rpm150010005000ATH#1Ashland Performance MaterialsATH#2ATH#3ATH#4ATH#5ATH#6

Ashland next generation resinsWhat 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 ATHApplications: Pultrusion RTM Spray Hand lay-upAshland Performance Materials53

Ashland next generation resinsWhat 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 filledpolyester resins: No significant fillers settlement after 4 monthsAshland Performance Materials54