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NU-ROOF

NU-ROOF. MAYEN 24M GENERAL ASSEMBLY January 16th-17th 2012. Agenda. Current status of the project. WP1: concept. WP2: research. WP3: application guidelines and thermal modeling. WP4: knowledge management system. WP5: demo. WP6: business models. WP7: training. WP8: management.

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NU-ROOF

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  1. NU-ROOF MAYEN 24M GENERAL ASSEMBLY January 16th-17th 2012

  2. Agenda

  3. Current status of the project WP1: concept WP2: research WP3: application guidelines and thermal modeling WP4: knowledge management system WP5: demo WP6: business models WP7: training WP8: management Duration: 36 Months Start: January 2010 End: December 2012

  4. Advancement on Product Development STILL SOME MINOR TECHNICAL ISSUES TO SOLVE (shrinkage, stiffness) LAB TESTS START: TO BE DISCUSSED START: TODAY! NATURAL AGEING TESTS 6 MONTHS APPLICATION TESTS AND TRAINING ARTIFICIAL AGEING TESTS 6 MONTHS UNYA ALMOST DONE, MAYBE ANOTHER ROUND IS NEEDED START: SPRING 2012 ONE OR TWO FINAL PRODUCTS: DEMO

  5. Advancement on the Knowledge Base Module 1: DOCUMENTS SEARCH Module2: COLLABORATIVE TOOLS Module 3: CUSTOMIZATION SUPPORT SYSTEM Module 4: E LEARNING AND APPLICATION GUIDELINES OK, TO BE TESTED WITH ASSOCIATIONS OK, TO BE TESTED WITH ASSOCIATIONS 80% READY, TO BE TESTED WITH ASSOCIATIONS NOTHING YET!

  6. Objectives of this meeting • Sara willremind the Financial Issues • Wehaveto start the applicationtrials and learnasmuchaspossible • ActionPlantofix the remainingproblems on the membrane (shrinkage, stiffness) • Wehaveto decide aboutnextageingtests • Wehavetoplan the nextapplicationtrials (March 2012?) and the DEMO start up (June 2012) • Redhada and DAPP need a feedback for the KM platform • Wehavetomake the first decisions on Exploitation

  7. 24 Month Meeting Productionof Top Layers Romy

  8. Top layer: situation in summer 2011 • At the meeting in Delft first prototype compounds for top layer were presented. • Occurring problems: • Delamination of layers • Oil staining  oil resistance of the coated nonwoven layer was too low • Main activities in WP2 after the meeting in Delft • were to improve the top layer and find technical solutions to prevent delamination and oil staining • close cooperation with Börner, NOTT, TNO and NANOPHOS

  9. Top layer: variant 1 • Variant 1: Application of PVB • First Attempt: Back coating with Polyvinylbutyral (PVB) granulate • PVB has good properties concerning oil resistance and adhesion • NRVII nonwoven (PA; 35 g/m²) was coated in September 2011 with PVB granulate using a flatbed lamination unit. Coating was possible, but to achieve an even surface, a relatively thick PVB layer had to be applied • onto the nonwoven. • Results: • This led to a stiff and rigid material  great disadvantage for the subsequent top coating with SURFA paint. Nonwoven material could not be fixed onto the needle belt for coating since it was immediately destroyed when fixed. •  first attempt failed TwolayersofNanophosSurfapaint NRVII nonwoven PVB granulate (or film)

  10. Top layer : variant 1 • Variant 1: Application of PVB • Second Attempt: Back coating with Polyvinylbutyral (PVB) film • Solution against stiffness and uneveness was to use a PVB film • Tests with different thicknesses  thin films with about 70 µm are suitable • Film was delivered to STFI by Börner • Results: • Easy to apply onto the nonwoven layer by lamination • Coating at the lab unit possible without problems • Coating paint was SURFA paint with 3% Arginotec • Water permeability behaviour: very good • Material was sent to Börner for further assembling • Manufacturing cost estimation: 6,40 €/m² (STFI machinery and personnel cost + raw materials, high costs due to the material price for PVB film) • Testing results on the overall membrane will be given by Börner and TNO in their presentations

  11. Top layer – machineryfor variant 1 Flatbedlamination unitat STFI Coatingunit at STFI

  12. Top layer: variant 2 • Variant 2: • Back coating with Ethylenvinylacetat (EVA) incl. 10% ARGINOTEC and compound with a second nonwoven layer (spunbondnonwoven) • EVA granulate with 10% ARGINOTEC was delivered by NOTT • First processing step: application of EVA with 10% ARGINOTEC onto the NRVII nonwoven (PA; 35 g/m²) was done at the hotmelt unit • Application of EVA to the NRVII nonwoven without problems TwolayersofNanophosSurfapaint NRVII nonwoven EVA incl. 10% Arginotec

  13. Top layer: variant 2 • Variant 2: • Back coating with EVA incl. 10% ARGINOTEC and compound with a second nonwoven layer (spunbond nonwoven) • Second processing step: a spunbond nonwoven was laminated onto the EVA layer by a flatbed lamination unit. • Processing at the flatbed unit and therefore an additional heating of EVA led to better adhesion of the EVA at the nonwoven layer. • Manufacturing cost estimation: 6,50 €/m² (STFI machinery and personnel cost + raw materials)  high costs due to the second nonwoven layer and an additional processing step NRVII nonwoven TwolayersofNanophosSurfapaint EVA incl. 10% Arginotec Second layerofspunboundnonwoven

  14. Top layer : variant 2 • Variant 2: • Back coating with EVA incl. 10% ARGINOTEC and compound with a second nonwoven layer (spunbond nonwoven) • Material was sent to Börner for assembling and further testing • Results: Staining could not be prevented completely • Solution: application of EVA granulate with 20% ARGINOTEC  already delivered to STFI by NOTT • Next trials with hotmelt unit not possible before mid of January due to machine failure and needed maintenance • Coated hand samples were sent to TNO for NIR testing • Testing results on the overall membrane will be given by Börner and TNO

  15. Top layer – machineryfor variant 2 Hotmelt unitat STFI

  16. Conclusions • Variant 1: • easy to manufacture • resists to delamination and oil penetration  following first testing results from Börner • has good water permeability properties • the raw material is expensive (especially the PVB layer) • Variant 2: • is a more complex composite • Version with 20% Arginotec has probably better performances concerning delamination and oil staining but has still to be produced at STFI • high costs due to second nonwoven layer and an additional processing step (lamination)

  17. NU-ROOF Optimisation of the Top Membrane by using Arginotec as an additive for functionalization (Variant 2) Mathias

  18. System: The back sideofthe top membraneisapplicatedwith an EVA- hotmelttojointogetherthe top membrane (carryingthe top coat) withthebasemembrane. The EVA-hotmeltchoosenby STFI is a commercialproductnamed KLEIBER 713.0 (advantagesare: approvedcommercialproduct, lowcost)

  19. Task caused of problems in detail: • Preventionof • diffusionofoilfromthebitumenbasemembraneintothe top membrane • becauseofthat, partial delaminationofthe top membranefromthebasemembrane • andcolouringofthe top coat

  20. Approach to solution: • Arginotecbrings • barrierproperties • andhas a sorptioncapacity • Wehaveverygoodexperiences in realizationofsuccessfuldevelopments in EVA. • Weareabletoproduce an Arginotecmodifiedcompound in EVA.

  21. Trials: Due toourexperiences in barrierproperties an amountof 10 % is a minimum. In contrasttothisfillers will reduceadhesion. So westartedcarefullyproducing a 10 % compound (based on Kleiber EVA) withourextruderlinespeciallyconfiguratedforthisproduct.

  22. First experiences: Save Applicationispossible (Kleiber enablestorisetemperature in application, STFI improvesapplication in detail). A goodapproachforblockingoildiffusionisshown.

  23. Further adaption: RiseuptheamountofArginotecto 20 % (toimprovebarrierproperties). Riseuptemperature in application (toimproveadhesion). Modifiedcompoundisalreadyproducedanddeliveredto STFI forapplication. Configurationofeqipmentforproductionisfinished so weareabletocalculate a prizeof 0,33 €/m² (based on theamountusedby STFI).

  24. Production of the final products Gerhard

  25. Productfornewroofs (selfadhesive/ welded) NUROOF concept: prefabricatedreflective top layer Press section Top surfacecoater Release foilsupply Impregnationvat Bottomsurfacecoater PartiallyRecycled Polymer Modified Bitumen

  26. Productforrefurbishmentofoldroofs (selfadhesive/welded) NUROOF concept: prefabricatedreflective top layer Release foilsupply Coatingvat Bottomsurfacecoater

  27. Results

  28. Projected Retail Prices • Cost of top layer = 6,4€ (Romy) • RetailPrices fortheoverallmembrane (excl. VAT):  • Product for new roofs, self adhesive, 4,5 mm       : € 13,60 • Product for new roofs, to be welded, 4,5 mm       : € 12,40 • Product for refurbishment, self adhesive, 3 mm    : € 12,50 • Product for refurbishment to be welded 3,5 mm : € 11,80

  29. Conclusions: • SOLUTION N.5 seems to have chances to succeed on market • Shrinkage and flexibility problems should be solved, • Solution n.2 (EVA - arginotec)is, anyway,good plan B • Top layer cost must be reduced • The following material will be tested today for application: • two rolls, 0,5x2 m with a very flexible traditional polymer bitumen sheet including woven glass reinforcement (WELDING) • one roll, 0,5x2 m with the basic self adhesive waterproofing compound including PES/glass reinforcement. (SELF ADHESIVE BUT STILL QUITE STIFF) Tasks andtargets

  30. Key learningsfromyesterdaydiscussions: Self adhesive is more indicated than welding for NUROOF Abutments: a white liquid applied membrane is needed We have to find a white commercial liquid applied or, alternatively, develop something specific Increasing flexibility can also avoid the need of liquid applied membranes (-> refurbishment version is already flexible) Curing time on the overlaps is excessive New or different applications could be possible (corrugated sheets, ...)

  31. Day 2:

  32. Day 2: FIRST STEPS TOWARD AN AGREEMENT ON EXPLOITATION RULES Antonio

  33. The basic rules of our Consortium Agreement The RTDs are not allowed to own the results of the NUROOF project, but they can ask to access some of those results at “fair and reasonable conditions”; 2. The industrial intellectual property should go to the SMEs (Borner, Nott, Nanophos) having risked more on the project but also the other SMEs must, on the other hand , have rightful access to the results; 3. If we do dissemination without protection it will be impossible to patent afterward; 4. As Coordinator D’Appolonia will facilitate the arbitration until a general agreement is reached. In case of contrast, the General Assembly will use the voting procedure.

  34. The RESULTS 1)the top reflective layer 2)the “concept 1” base layer (bitumen and recyclable materials) 3) the “concept 2” base layer (Phase Change material) 4) the Knowledge Base (including the source code and installation into server)

  35. A possible Exploitation Strategy (D’Appolonia proposal) • CO-OWNERSHIP OF THE NUROOF PATENTS, WITH DIFFERENT WEIGHTS AND USE CONDITIONS • OWNERSHIP OF THE KNOWLEDGE BASE SOFTWARE AND INSTALLATION IN SERVER • SPECIAL PRIVILEGE FOR SALE / PRODUCTION OF NUROOF FUTURE PRODUCTS • (EXCLUSIVENESS, DISCOUNTS,…) • RIGHT TO USE THE NUROOF KNOW HOW FOR NON COMPETITIVE FUTURE RESEARCH

  36. Objectives of parallel session 1 • Wehavetoplan the newapplicationtrials (March 2012? Where?) • ActionPlantofix the remainingproblems on the membrane (shrinkage, stiffness) • Wehaveto decide aboutnext round ofageingtests (natural, artificial?) • Wehaveto take a decision on whiteliquidappliedbitumenmembranes • Wehaveto validate the conceptof the e-training system (especiallyfor self adhesive) • Redhada and DAPP need a feedback formodule 1,2 3 Objectives of parallel session 2

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