WATERPROOFING STARTS HERE: Α-HYBRIDS FOR LIQUID MEMBRANES CONSTRUCTION I HYBRID POL YMERS
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CREATING TOMORROW’S SOLUTIONS Construction I Hybrid polymers WaterProofing starts here: α -Hybrids for Liquid membranes
Moisture damage in buildings is fairly common, even in advanced economies. In 2008, 14% of Germany’s population lived in apartments or houses damaged by moisture [1]. This makes waterproof- ing a top issue. At the same time, new toxicological and environmental regula- tions have made it difficult to formulate high performance waterproofing mem- branes. The answer to these challenges are WACKER’s new α-hybrid polymers GENIOSIL® WP. 2
Discover the new Potential
for Liquid Waterproofing Systems
Cold applied, liquid waterproofing sys- Advantages of Liquid Systems VOC vs. H2O
tems have become indispensable in the Besides traditional single-ply rolled sealing Other systems contain significant quanti-
construction industry. With the new membranes, liquid waterproofing systems ties of volatile organic solvents (VOC),
GENIOSIL® WP α-hybrid polymers have become popular, especially for sur- which are necessary to achieve the low
WACKER presents an innovative binder faces with many joints and wall penetra- viscosity required for their application.
technology for formulations which tions, as well as for more complex shapes. Water-based waterproofing systems, on
combine the benefits of different liquid These types of liquid waterproofing sys- the other hand, have poor drying charac-
sealing systems, but avoid their draw- tems cure after being applied to a solid teristics in moist and cold surroundings.
backs. material, forming a seamless waterproof A few of the common systems even con-
membrane that adheres to the substrate. tain low-molecular weight isocyanates,
which recently require special labeling for
Typical Applications of Liquid toxicity reasons.
Membranes
• Waterproofing of flat roofs The Solution: α-hybrids
• Sealing of balconies and patios With its patented α-technology, WACKER
• Waterproofing of interior and exterior has developed new α-silane-terminated
basement walls polyethers designed specifically for use
• Air barrier coatings as a binder for liquid waterproofing sys-
• Waterproofing of cracks in roofs and tems. They allow the formulation of systems
walls which, after curing, form a well adhering
• Sealing of indoor and outdoor connec- membrane. Even ETAG 005 compliant
tions, dome lights, guttering etc. formulations are feasible.
• Moisture barrier under floor screeds
• Under-tile waterproofing
Existing Technologies and Their
Drawbacks
However, available liquid waterproofing
systems have a number of drawbacks.
Some are two-component systems and,
therefore, have to be mixed directly at
the construction site before application,
entailing the risk of improper mixing,
which may affect sealing properties.
[1] German Federal Statistics Office, GENIOSIL® is a registered trademark
Zahl der Woche No. 035, August 31, 2010 press release of Wacker Chemie AG.
3
innovation starts here:
The α -technology
Hybrids: Benefits at a Glance Silane-modified polymers have been
used since the 1980s as binders for
adhesives & sealants. These binders,
Silicones Polyurethanes though innovative at that time, displayed
certain disadvantages. Following exten-
UV resistant paintable sive screening, α-silane chemistry could
high elasticity good mechanical properties address many of the drawbacks.
In recognition that this approach proved
correct, WACKER was conferred with
the “Construction Sealants New
Hybrids Product Innovation Award” in 2011,
+ acknowledging this technology as truly
easy processing
ground-breaking.
broad adhesion profile
GENIOSIL® α-hybrids: Building on
the Performance of Existing Hybrids
With the GENIOSIL® α-technology
WACKER introduced a new group
α-hybrids
+ of silane-terminated polyethers. Formula-
fast & reliable curing tions based on this technology building
tin-free formulations on the performance of traditional systems.
long shelf-life They encompass those characteristics
attainable with established systems and
take the formulator yet a step further by
offering greater advantages:
What are hybrids? Hybrids are silane-crosslinking organic polymers that combine properties typical
of both silicones and polyurethanes. They are highly versatile yet easy and safe to use as they are • Fast & complete curing
isocyanate- & solvent-free and – in case of the α-hybrids – don’t need tin-catalysts for curing. • T in-free formulations thus avoiding side-
reactions leading to greater shelf-life
• Low viscosity for easy dosing and
plasticizer-free formulations if desirable
• Straightforward & cost-efficient
compounding
• Tack-free surfaces
1) The “Construction Sealants New Product Innovation
Award” in 2011 is awarded by the prestigious consulting
firm Frost & Sullivan
4
The Technology The Key to Differentiation: State-Of-The-Art Applications
Silane-modified polymers generally con- The α-effect Silane-terminated polymers have for
tain silane components that are coupled The WACKER experts noticed that the years served as the binder of choice in a
to an organic polymer backbone and condensation reaction proceeds par- a variety of applications. These are typi-
which can be used for curing through ticularly rapidly when the two silane cally transparent sealants, wood-flooring
hydrolysis and subsequent condensation. components of the hybrid polymers are adhesives, universal assembly adhesives
linked to the polymer backbone via a and industrial adhesives. However the
The silane-terminated polyethers from methylene group, which represents the hybrid technology was hardly found in
Wacker, also belong to this group of shortest possible spacer. In this case, waterproofing applications until recently.
hybrid polymers. These have a polyether the nitrogen atom of the urethane group
chain as their organic polymer back- is located in the α-position relative to A New Dimension in Waterproofing
bone, with di- or trialkoxysilyl groups at the silicon atom of the silane component, The new hybrid polymers GENIOSIL®
its ends (see graph 1). This structure is and accelerates the crosslinking conden- WP now enable the use of α-silane tech-
achieved through urethane coupling, with sation reaction as a result of the so-called nology for waterproofings. In terms of
an aliphatic bridge positioned between “α-effect.” their mechanical properties, the cured
the urethane group and the silane com- formulations based on these polymers
ponent. In commercially available grades, Because of their short methylene bridge, make advances into the previously ex-
this aliphatic bridge is either a methylene α-silane-terminated polyethers can clusive domain of polyurethane-based,
or a propylene group. The methylene crosslink without the aid of a tin catalyst isocyanate curing systems – whilst being
group leads to an α-silane-terminated (α-effect, see graph 2). one-component yet solvent-free. Con-
polyether, the propylene group produces sequently, these new hybrid polymers
a γ-silane-terminated polyether. The absence of tin provides a number present a number of advantages to both
of advantages: formulators and end-users.
• Elimination of toxicological risks in
storage & handling
• Reduced tendency for
transesterification → less additional VOC
• Long shelf-life of formulated products
Graph 1:
Structure of a Silane-Terminated Polymer. R Independantly can be Alkyl or Alkoxy
functional silane functional silane
R R
––
––
R –– Si ––
functional polymer –– Si –– R
––
––
R R
Graph 2:
Structure of an α-Dimethoxysilane-Terminated Polyether
OCH3 O H
N OCH3
––
––
––
––
––
––
H3C –– Si –– CH2 C –– O –– Polyether –– O –– C CH2 –– Si –– CH3
––
––
––
––
––
––
N O OCH3
OCH3 H
5
GENIOSIL ® WP: The first low
viscous hybrid polymers for
waterproofings
With the newly developed GENIOSIL® WP These developments were spurred by the
polymers formulators of liquid membranes new regulatory chemical classification for
can now use the unique α-technology for diphenylmethane diisocyanate (MDI), a
formulation of innovative waterproofings. commonly used isocyanate component
These products combine the advantages in liquid polyurethane waterproofings,
of various liquid sealing systems currently as well as by an increasing demand for
available on the market whilst avoiding solvent-free systems.
their drawbacks. Products will have the
application viscosity, curing and post-cure A New Standard in Waterproofing –
properties of conventional one-compo- GENIOSIL® WP
nent polyurethane-based products thus The polymers have been optimized to
providing long-term reliability. Being sol- have the lowest possible viscosity. Espe-
vent-, isocyanate- and tin-free formulated cially GENIOSIL® WP 1 was designed to
products meet all health, occupational have a higher density of silane groups
safety, and environmental requirements, than conventional silane terminated
even if these become more stringent in polymers. The greater degree of poly-
the future. mer functionally results in an enhanced
three-dimensional network formed dur-
ing curing. The network is significantly
more tightly linked thus rendering good
mechanical properties and high chemical
resistance to the cured formulation.
Comparison of Viscosities of Silane-Modified Polymers
60000
Viscosity mPa·s
50000
40000
30000
20000
10000
0
GENIOSIL® WP Conventional silane Conventional silane
polymers terminated polymers terminated polyurethanes
The new specialty polymers have a viscosity of less than 1000 mPa·s at 25 °C (Brookfield, Spindle 1,
2.5 rpm), which is far below the viscosity of conventional types of silane-terminated polyethers/polyure-
thanes. Such low-viscosity silane-crosslinking polymers have not been commercially available until now.
6
Reference Formulation for Preparing a Solvent-free, One-Component Waterproofing To produce a liquid waterproofing system,
Based on GENIOSIL® WP the polymer will be mixed with a water
Mass fraction in % Component Product designation scavenger. Afterwards stabilizers for UV-
50 Base polymer GENIOSIL® WP and weather resistance will be added.
1.5 – 2.0 Water scavenger GENIOSIL® XL 10 Fillers are contributing to the mechanical
1.5 Stabilizer package e.g. UV absorber, antioxidant, performance and a rheological additive is
HALS stabilizer used to adjust workability properties. At
40 – 50 Filler e.g. Aluminum trihydroxide trihydrat the end the formulation will be activated
(ATH), untreated, Talcum,
by adding an aminosilane which acts as
Calciumcarbonate
a catalyst and adhesion promoter. During
0.5 – 1.5 Pyrogenic silica HDK® H18 or H2000
the final production step air bubbles will
1.0 – 1.5 Catalyst/Adhesion promoter GENIOSIL® GF 96
be removed by using vacuum and the for-
mulation will be filled into the packaging
in the presence of a nitrogen blanket.
7
The corresponding finished
products display a multitude
of advantages
One-Component Yet Solvent-free At Any Weather Condition High Resistance to Chemicals and
Plus Rapid Curing Because the curing mechanism is largely Solvents
With the new GENIOSIL® WP polymers it independent of the weather, waterproof- Laboratory tests have shown that the
is now for the first time possible to formu- ing products formulated with the new cured membranes offer very high resis-
late one-component liquid systems that hybrid polymers can be applied under tance to chemicals and solvents.
are isocyanate- and tin-free and require practically any weather conditions, even Pieces of 14 days cured membranes
no solvents for viscosity reduction. on cold, wet days, and on moist sub- have been put into solvents and acids
With their high crosslinking speed – which strates – the only exception is stagnant e.g. ethanol, isopropanol, ecetone
is typical for α-silanes – the specialty water. The tack-free sealing membrane or 5% citric, sulfuric or acetic acid.
polymers contribute to rapid curing of the which results from the curing is water- After 40 days of storage, none of the
formulation. The cured end-products ex- proof (hydrostatic pressure resistance > specimens were dissolved or turned
hibit good mechanical properties and ex- 6 bar) but vapor-permeable (sd value of crumbly, none disintegrated on slight
cellent crack-bridging which correspond ~ 1.0 m for a 1.5-mm layer thickness). finger pressure. Furthermore the 180°
to the performance of a one-component bending test was ok in any case. No
polyurethane-based waterproofing. Broad Adhesion Spectrum turbidity of solvents was visible.
Formulations based on GENIOSIL® WP Therefore this technology is also suitable
Application with Standard Methods adhere to most common substrates in for undertile-coatings in highly stressed
Forming a Reliable Sealing the construction industry, even without wet areas like breweries or dairies, thus,
Liquid waterproofing systems based priming, for example on: offer an alternative to two-component
on GENIOSIL® WP can be applied by • Concrete, even on fresh concrete epoxy systems.
roller, brush or airless sprayer, whichever • Glass
method is preferred. Depending on the • Glazed tile
formulation the waterproofing has a work- • Steel, and stainless steel
ability of 30 – 40 minutes, assures early • Aluminum
rain resistance (~ 1 hour) and will fully • Copper
cure to a tack-free membrane after • Zinc
~ 2 – 3 hours. • Wood
• Certain types of asphalt sheeting
8Advantages at a Glance
For the formulator:
• Based on a-technology For the applicator:
– Fast compounding • 1-component system, no mixing
– Non-hazardous raw materials • Solvent & NCO free
– No tin catalysts • Readily applied with roller or brush
– Long shelf-life • Processable under humid or cold
• 100% reactive material conditions
• Low viscosity for easy handling • Short drying times → fast working
• Formulation in standard dissolver • Excellent adhesion to many substrates
• No special packaging needed without primer
• ETAG 005 compliant products feasible • No shrinkage
Product Overview
GENIOSIL® WP 1 GENIOSIL® WP 2
Property Test method Value Value
Density at 25 °C 1013 hPa 0.95 g/cm³ 0.97 g/cm³
Flash point ISO 2719 132 °C 140 °C
Viscosity, dynamic Brookfield 700 mPa.s 800 mPa.s
at 25 °C
Autoignition temperature EN 14522 300 °C 370 °C
(liquids)
9With the new hybrid polymer GENIOSIL® WP 1 it is now for the first time possible to formulate ETAG 005 compliant waterproofings based on α-Silane technology. 10
The number 1 for standard
compliant formulations:
GENIOSIL ® WP 1
Setting New Standards Mechanical Properties of a GENIOSIL® WP 1 Sample Formulation
Using this new hybrid polymer, building Density (ISO 1183-B) 1.3 g/cm³
material and coatings manufacturers can Hardness Shore A (DIN 53505-A-87) 70
formulate liquid waterproofing systems Elongation at break 250%
which have long-term reliability and which Tensile strength (DIN 53504-85/S1) 2.3 N/mm²
are suitable to meet the necessary stan- Resistance to further tearing ASTM D 624 B - 91 13 N/mm
dards of regulated construction projects Tensile adhesion strength in combination with tiles 1.4 N/mm²
for waterproofing of flat roofs. Formula- (DIN EN 14891 A.6.2)
tions with GENIOSIL® WP 1 comply with Skin-over time 40 min
the European Technical Approval Guide- Water absorption (cured membrane 28 days stored in water) < 0.5%
lines for liquid applied roof waterproofing Viscosity at 25 °C (Brookfield, Spindle 6, 50 rpm) 5,000 mPa·s
kits (ETAG 005) specifically, for all listed Crack bridging 2 mm
use categories, minimum thicknesses,
load classes, and performance levels.
Performance Comparable to PU Strength and Curing Time May be Also Suitable for Applications with
In a benchmark test with a commercially Varied High Hydrostatic Pressure
available one-component PU water- By varying the formulation, it has also Liquid waterproofing systems based
proofing for professional use it has been been possible to achieve strengths which on GENIOSIL® WP 1 are also suited for
proven that GENIOSIL® WP 1 provides surpass those of the benchmark product. cases in which high hydrostatic pressure
comparable performance plus additional In addition, the skin-over time may be set resistance needs to be achieved. Not
benefits. between 10 minutes and 2 hours by vary- only outstanding values of positive pres-
ing the formulation. The skin-over time sure resistance of minimum 6 bar but
depends primarily on the quantity of the also negative pressure resistance of up
aminosilane catalyst that is used, but is to 4 bar can be achieved. This opens
also affected by the fillers. up further applications as e.g. sealing
of an interior wall against external water
pressure.
Chemical Properties of Waterproofings Formulated with Geniosil® WP 1 are Comparable to 1K PU Products
80 4 20
60 3 15
40 2 10
20 1 5
0 0 0
Shore A hardness Tensile strength N/mm2 Tear resistance N/mm
Hybrid PU
Additional benefits
1K but solvent-free, NCO-free, plasticizer-free, tin-free = No labeling required
11The innovative GENIOSIL® WP 2 hybrid polymer is the ideal choice for formu- lating general-purpose waterproofing and filling compounds for a host of applications ranging from basements to roofs. 12
THE PERFECT ALL-IN-ONE PRODUCT
FOR POT TING & WATERPROOFING:
GENIOSIL ® WP 2
An All-Rounder with a Unique Profile Simple, Yet Efficient Formulations Highly Elastic and Able to Bridge
Its first-class properties come to the fore The viscosity of the liquid sealant can Cracks
whenever different kinds of repair work be adjusted easily using fillers and rheol- A further advantage of formulations
require highly efficient and environmen- ogy additives. This therefore enables based on GENIOSIL® WP 2 is their con-
tally compatible sealing systems. Typical the formulation of products used both siderable elasticity. The cured membrane
applications include: the reliable sealing in vertical (e.g. basement-wall sealing) achieves elongation values of up to
of connecting parts and pipe penetra- and in horizontal applications (e.g. seal- 600% and crack-bridging of approx.
tions; the repair of gutters; undertile coat- ing underneath screed). Due to the low 5 mm. This is a reliable way to compen-
ings for balconies, patios and bathrooms; viscosity of GENIOSIL® WP 2, no solvents sate for structural stresses.
the dependable sealing of structural parts are needed to lower viscosity.
in contact with the ground (such as base- Meeting DIN 18195 Criteria
ment rooms); and sophisticated air barrier The specific formulation will determine
coatings. What’s more, formulations whether liquid sealants based on
based on GENIOSIL® WP 2 are the ideal GENIOSIL® WP 2 meet the requirements
potting compound for horizontal expan- of DIN 18195, Table 9.
sion and movement joints.
Mechanical Properties of a GENIOSIL® WP 2 Sample Formulation
Density (ISO 1183-B) 1.5 g/cm³
Hardness Shore A (DIN 53505-A-87) 30
Elongation at break 400%
Tensile strength (DIN 53504-85/S1) 1.2 N/mm²
Resistance to further tearing ASTM D 624 B - 91 6.0 N/mm
Tensile adhesion strength in combination with tiles 0.7 N/mm²
(DIN EN 14891 A.6.2)
Skin-over time 40 min
Viscosity at 25 °C (Brookfield, Spindle 6, 50 rpm) 5,500 mPa·s
Crack bridging 5 mm
13ExpErtisE and sErvicE nEtwork
on FivE continEnts
• Sales and production sites, plus 20 technical WACKER is one of the world’s leading of the climate and environment. Spanning
centers, ensure you a local presence worldwide.
and most research-intensive chemical the globe with five business divisions,
companies, with total sales of €4.91 billion. operating 25 production sites, WACKER is
Products range from silicones, binders currently active in over 100 countries. The
and polymer additives for diverse industrial Group maintains subsidiaries and sales
sectors to bio-engineered pharmaceutical offices in 29 countries across Europe, the
actives and hyperpure silicon for Americas and Asia – including a solidly
semiconductor and solar applications. As established presence in China. With a
a technology leader focusing on sustain- workforce of 17,200, WACKER sees itself
ability, WACKER promotes products and as a reliable innovation partner that
ideas that offer a high value-added develops trailblazing solutions for, and in
potential to ensure that current and future collaboration with, its customers. WACKER
generations enjoy a better quality of life also helps them boost their own success.
based on energy efficiency and protection Our technical centers employ local
14specialists who assist customers world- Visit us anywhere, anytime around the
wide in the development of products world at: www.wacker.com
tailored to regional demands, supporting
them during every stage of their complex
production processes, if required.
WACKER e-solutions are online services
provided via our customer portal and as
integrated process solutions. Our
customers and business partners thus
benefit from comprehensive information
and reliable service to enable projects
and orders to be handled fast, reliably
and highly efficiently.
all figures are based on fiscal 2011.
15Wacker Chemie AG
6932e/09.12
Hanns-Seidel-Platz 4
81737 München, Germany
Tel. +49 89 6279-0
info.geniosil@wacker.com
www.wacker.com
The data presented in this brochure are in accordance with the present state of our knowledge but do not absolve the user from carefully checking all supplies immediately on
receipt. We reserve the right to alter product constants within the scope of technical progress or new developments. The recommendations made in this brochure should be
checked by preliminary trials because of conditions during processing over which we have no control, especially where other companies’ raw materials are also being used.
The information provided by us does not absolve the user from the obligation of investigating the possibility of infringement of third parties’ rights and, if necessary, clarifying
the position. Recommendations for use do not constitute a warranty, either express or implied, of the fitness or suitability of the product for a particular purpose.You can also read
