Hydropas R&D Facilities by Miha Skvarč

Technology Research Centre

PRESENTATION OF MORE SIGNIFICANT DEVELOPMENT ACTIVITIES AND LABORATORY CAPABILITIES FAÇADE-RESEARCH WALL AREA The façade-research wall area on the southern façade of the Centre is a unique laboratory in this part of Europe for the testing of the behaviour of façade systems and elements, which are built in such systems, in real conditions of use. Examined elements are built into the wall area as exterior walls of test cells, where microclimatic conditions can be maintained or optionally changed: air temperature between +15 and +35 °C and relative air humidity between 30 and 80 %. On traditional “exterior testing wall areas” examined elements are exposed only to effects of sun, rain, wind, frost, and similar, but on this wall area they are simultaneously exposed also to loads caused by microclimatic conditions on the inside of buildings, such as diffusion of water vapour, condensation of this vapour in façade systems as well as temperature changes and heat output, which is elicited by them, through the body of the examined façade system. Such a test wall area offers a study of results of synergy effects of different kinds of warming, cooling, dampening or drying of each side of the façade system or an element, which is built into this façade system, in real time and space. The good comprehension of these results forms a base for a successful development of new, innovative façade systems and also for a potential rationalisation of presently known solutions and the development of suitable technologies of renovation and maintenance interventions. Also, it enables the conformity check and the planning of new calculation models for designing façade systems as well as studies and the development of installation details for windows, doors and other façade elements. The wall area encompasses sixteen separated test fields, which are tended from twelve service cells and the access to it is enabled from an exterior aerial platform. The desired microclimatic state within the test cells is ensured by means of equipment for warming, cooling, dampening and dehumidifying of air. Such equipment is self-contained by each cell. A cell façade wall presents the examined façade system or the examined façade element. Sensors, which are built into or onto it, enable the measuring or checking of the temperature of the exterior and interior surface as well as temperatures of individual coatings of the examined subject, changes of humidity in individual layers, heat output, elongations and shrinkages caused by temperature changes, dehumidifying, drying out, and similar. The wall area was built in the framework of the project entitled “Active façade system”, where JUB in cooperation with Mitol from Sežana has been developing new versions of façade thermal insulating systems.

The project was part-financed by the European Regional Development Fund. Inter alia, the project also includes a research into possibilities of rational use of heat and light energy, which falls onto façade surfaces, therefore, the wall area has been upgraded with measuring equipment for measuring the quantity of electric energy, acquired by photovoltaic elements, which are built onto a façade, as well as with measurement equipment for measuring the quantity of heat energy, acquired by façade elements, which would be exploited as heat receivers. The regulation of conditions in the cells and the control of the established state as well as the management of measuring processes and saving of measurement data are conducted via a control computer system, which is also connected with the local weather station situated on the eastern side of the Centre’s building. The station conducts all standard meteorological measurements: of temperature and air humidity, barometric pressure, precipitation, wind speed and direction, quantity of thermal radiation, and other measurements, which are needed when analysing measurement results of physical quantities on test fields.

CLIMATIC CHAMBERS The climatic chambers being on hand for experts, who check usable characteristics of materials, mainly of those, which are installed in façade systems, are the most important acquisition in the new building of the Centre. They enable the examination of product applicability in completely optional in repeatable microclimatic conditions. In the chambers, it is possible to choose and maintain air temperature between –40 and +70 °C and relative air humidity between 10 and 95 %, it is possible to simulate wind with the speed of up to 100km/h, it is possible to simulate rain by jetting demineralised water (1 l/m2/min) onto test surfaces, and it is possible to substitute the effect of direct solar radiation onto test surfaces by irradiating them with infrared heaters (3 x 300 W). Thus it is possible to check the so-called “open times”, i.e. pot lives, of products, applied onto walls (adhesive compounds, decorative renders, paint coatings, and similar), in different “real microclimatic” conditions, which enables the development of such products, which can be applied easily in conditions that are normal for such works as well as in more or less extreme environments, mainly in conditions of accelerated or decelerated drying and hardening.

These examinations can be performed if each climatic chamber within the complex of climatic chambers “operates” completely separately from another climatic chamber. The functionality of the complex has been expanded by uniting the chambers into two interconnected pairs. A 5 m2 large testing wall can be built into the intermediate wall of each of these pairs. This wall can be exposed to different microclimatic conditions from one as well as from the other side. Since desired conditions of the interior can be simulated on the one side and any other exterior conditions on the other, and since parameters of selected conditions can be maintained by the programme or also almost optionally quickly changed, such a testing wall can be exposed to the process of “accelerated ageing” for as long as we like. “Accelerated ageing” is based on the proportionately quick and extremely intensive change of affecting factors on one or both sides of the testing wall. In this way, consequences of loads performed on the testing wall in a month or two are very similar to those of exposure of the same wall to real conditions in ten, twenty or even more years. In this manner it is possible to examine the durability of façade thermal insulation and other systems, to determine rational coating thicknesses and the optimum quality of materials built in these coatings, to set the optimum time limits for maintenance interventions, and to check the efficiency of technological solutions of planned maintenance interventions.

Similarly to the façade research wall area on the southern façade of our Centre, the following can also be done on testing walls, built between two chambers: the measuring of the temperature of both surfaces and the temperatures of individual coatings of the examined subject, the changes of humidity of individual layers as well as the heat output, elongations and shrinkages caused by temperature changes, dampening and drying out. The complex of climatic chambers also includes a special room for sample “maturing”, where certain “normal” or “standard” conditions, which are set by material testing standards, can be maintained. Walls, built for testing, – they are built on specially modified trolleys – usually “mature” in such conditions for at least 28 days. This maturing room also conditions other samples for testing of the strength and other characteristics of building physics, which are performed in the JUB’s own laboratories or control laboratories in Slovenia and abroad. A component part of the climatic chambers is also their own production of demineralised water, which is needed for air dampening and the simulation of rain in the complex of chambers, as well as for the humidifying of air in the cells of the façade-research wall area on the southern façade of the Centre’s building.

DEMO HOUSE Our “house within a house” or the demo house, as it is called, is a wall area for the development and research work in the field of technical solutions for details in external wall thermal insulation systems, details at the implementation of damp proofing systems with damp proofing coatings and in case of other systems solutions from the field of finishing building works. Most of JUB’s efforts are devoted to contacts of façade thermal insulating linings with other façade elements, including window and door frames, window sills, eaves. A very demanding area includes tubular and other breaches of damp proofing systems in sanitary facilities, the mplementation of damp proofing systems on balconies, terraces and thermally insulated subterranean exterior walls, the installation of lights, security cameras, photovoltaic elements into façade thermal insulating systems, and similar. JUB is mainly looking for technical solutions for the bonding of elements, which extend and shrink differently when heated and cooled or are not compatible with each other for other reasons. The demo house has been designed so that it can be used also for educational, promotional and other activities. Due to its steel construction, which enables simple remodelling and quick changes of the building, it can be adapted to respective needs, for example, for filming of educational films about the correct installation and application of products as well as the correct implementation of technical details, filming of the image part for presentation materials and training aids. These activities are enabled by a turntable, which ensures for the whole object, detailed solutions on its façade or in its interior or a presentation of product application, to be observed or filmed from a suitable distance and from the most appropriate or the best angle of view. Details can be observed from close up also on the first floor of the building, which is enabled by the roomy staircase, while details on its façade can be beheld from modern movable scaffolds, which can be built for this purpose at the building in a short period of time.

SYSTEM OF MOVABLE BILLBOARDS Movable billboards can be used for comparative or sorting tests of useful characteristics of product samples in different – mainly initial development phases. The billboard system helps to maintain an exceptionally large number of differently treated surfaces on a small ground plan surface, which minimizes the time from the order of applied testing to its implementation. This significantly affects reduction of times, which are necessary for implementation of comprehensive development projects.

Billboard load-bearing framework is made of steel pipes onto which a wooden sub-construction is fixed, which is closed by a lining made of gypsum-cardboard boards. Treatment of this lining is standardised for different types of applied tests and it usually includes bandaging of board contacts and smoothing of the surface with a suitable levelling compound. Applied linings can be easily and quickly substituted with new ones. Furthermore, the movable billboards are used also as surfaces for practical work in training of siding contractors, painters and floor tilers, and also as surfaces on which it is possible to demonstrate the painting process, the smoothing and levelling of wall surfaces, the application of decorative renders, and different techniques of the more demanding decoration of interior and façade surfaces. The main emphasis concerning practical work on seminars is put on the correct implementation of external wall thermal insulation systems, especially details around façade openings. The implementation of such a programme is enabled by simplified building models – billboards in U-form, on which practical work can be performed by as many as 25 participants at once. The combination of U-billboards and flat panels into four batteries ensures the optimum utilisation of available space and a rational preparation of a larger number of working and testing surfaces.

ROOMS ON THE FIRST FLOOR The gallery on the first floor offers the best view to the top part of the demo house and to what is taking place there. The gallery also enables practically unlimited possibilities for taking photos and filming when the house is appropriately rotated and opened from the top, i.e. when its roof is taken off and any of its walls removed, without interrupting the work of the demonstrators. The preparation of educational materials on the demo house allows savings without any high costs for the building of improvised buildings in filming studios and overhead costs for a rental of these studios. The savings will reimburse funds invested in this movable building in up two years. On the first floor, there are also a contemporarily equipped lecture room and two smaller meeting rooms all of which are separated by movable walls so that in a few minutesâ&#x20AC;&#x2122; time they can all be joined into one multipurpose room, which is, in one part, open to the gallery at the demo house. With such a reorganisation of the space, it is possible to entertain a larger number of people, which allows JUB to organise annual marketing conferences and expert meetings on the Holding level.

On this floor, there are also the following rooms: a library, a reception desk with archives, the TRC Directorâ&#x20AC;&#x2122;s office, and rooms intended for expansion of the Centreâ&#x20AC;&#x2122;s activities in the field of consultancy concerning efficient use of energy in dwellings and other buildings as well as activities in the field of recovery of renewable energy sources at the energy supply of buildings. As a partner of the University of Ljubljana, the Centre has been actively participating in the Sustainable Energy Europe Campaign managed by the Mobility and Transport DG of the European Commission in Brussels. In the future, JUB is going to reinforce and expand these activities.

CHEMICAL LABORATORIES ON THE SECOND FLOOR On the second floor of the Centre, there are research and development laboratories for the fields of development of interior and exterior wall dispersions. The two fields encompass the following programmes: · Programme of coatings for the interior, · Programme of coatings for the exterior, · Programme of paste-like renders, · Programme of coatings for wood, and · Programme of coatings for metal.

Interior and exterior dispersion programme The programme of interior and exterior coatings for mineral surfaces presents the most important manufacturing programme of the JUB company, which broke new ground on the area of ex-Yugoslavia as far as manufacture of dispersion wall paints with an organic (acrylate) binder is concerned. In 1969 the first JUPOL was put on shelves of shops and today, it still signifies a generic name for a dispersion wall paint in these areas. During the years, the coating programme was joined by the render programme, which is based on a similar raw material basis and uses related methods of preparation and testing.

The central laboratory with two related dedicated laboratories (mixing facilities) is intended for the improvement of existing and the development of new interior and exterior decorative coatings from the Jupol and Acrylcolor families, special functional coatings and renders. The two mixing facilities are dedicated to the preparation of homogenous liquid and paste-like dispersions with organic and mineral binders and are equipped with the so-called dissolvers, i.e. high-energy mixers, whose mixing elements have the shape of a circular saw. The experts employed in the central laboratory perform elementary measurements of coatings, such as measurements of dry weight, density, viscosity, and pH-value. They apply coatings for the visual assessment onto lacquered paper with a special devices and perform coulometric measurements of paint parameters as well as measurements of gloss and opacity.

More demanding measurements, which are performed in accordance with the applicable European standards, include measurements of the paint’s resistance to wet scrubbing, of blocking or bonding, of the paint’s adhesion onto different surfaces, of the strength under Köning, and some other measurements. In specially conditioned rooms, experts perform measurements of the paint’s permeability for water vapour and of the so-called “open time”, i.d. pot life, and age samples in standard conditions. Each of these measurements simulates the behaviour of a coating in specific situations. With the programme of coating development for interior surfaces, JUB emphasizes the use of ecological raw materials and has been a leading company at ensuring strict nature protecting criteria with acquired certified ecological designations (TÜV Schadstoffgeprüft). Taking account of European goals and policy of environment management, the coating development for interior use constantly strives to improve ecological characteristics of materials, to reduce the burdening of the environment with dangerous substances, and, subsequently, to improve the quality of living.

The above mentioned natural resources for the preparation of construction materials and guidelines of sustainable construction demand the increase of building quality and extension of the lifetime of already built facilities. In the field of exterior finishing coatings (mainly renders), researches of the functionalisation of surfaces have thus presented one of the core issues in the last decade. The development programme for protection of exterior mineral surfaces is based on researches of modern advanced faรงade systems, which enable a good thermal insulation of buildings, a long mechanical and aesthetical lifetime as well as a low water and dirt absorption. The new modern equipment enables a successful transfer of acquired solutions into practice. The two chambers, namely the weather and the microclimatic one, are intended for the simulation of conditions in nature and thus for researches of surface persistence, the searching for ways to prolong the lifetime, the increase of efficiency of functional layers, the development of modified layers with special characteristics, and the integration of newly developed materials to functional layers. The microclimatic chamber in various simulated weather conditions provides reliable information about serviceable characteristics of finishing coatings.

Programme of coatings for wood and metal The development sector of dispersion coatings also includes the development programme of coatings for wood and metal, which has been increasingly gaining market value. A particular specialised laboratory is dedicated to the preparation of water dispersions with a high binder portion. It is equipped with dissolvers for the work in an exceptionally wide area of revolutions. The programme shares a general measuring equipment, which is installed in the central laboratory, with other programmes. A wall area of natural weather exposure, which is situated in JUB’s own courtyard (a stand with patterns at a 45° angle, facing south) and modern laboratory microclimatic chambers are used to test coatings concerning resistance to weather conditions. The latest success of this programme is an innovative product called Jubin Metal, a water-based ecologically and technologically advanced coating for metal, which is distinguished by a unique characteristic, anticorrosion protection without a prior application of a primer and the possibility of being applied directly to rust. The anticorrosion protection of Jubin Metal complies with the SIST EN ISO 12944/6:1998 standard and is tested in a special chamber under humid and salty conditions.

Physico-chemical laboratory The new physico-chemical laboratory as an essential upgrading of the former laboratory presents a new landmark in the development of TRC’s analytical capacity. Its design enables the making of a wide variety of traditional chemical analyses and it offers the use of the most up-to-date instruments for physical and chemical examinations. Some of them are presented below. JUB’s products contain granulated materials of inorganic as well as organic origin, which encompass a wide area of dimensions from hundredths of micrometres to a few millimetres. Fillers and pigments are in the form of fine-granulated inorganic or organic material either as dry powders or water dispersions or suspensions. Organic binders are also in the form of a fine water dispersion. To achieve required characteristics of finishing coatings, it is extremely important to have the knowledge of the size of the particles the coatings are composed of. With the granulometer, which the Centre disposes of, it is possible to encompass a wide range of particle sizes in one analysis and the analyser enables a quick determination of the distribution for organic as well as for inorganic samples either in a wet or a dry form.

A rheometer is a laboratory device used to determine rheological characteristics of liquids, dispersions (or suspensions) or pastes (mastics, renders). Rheological characteristics describe the mutual interaction of different parameters, which are connected with interactions between liquid constituents and which are reflected on the outwards by the way they move under different conditions. In practice and in the industry of coatings and renders this means that it is possible to conclude from rheological characteristics of a product how the product will behave in production (blending of components), storage (stability or stratification of suspension) and use (application by a brush, a roller, a smoothing trowel, or by spraying). A rheometer enables measuring of overall rheological profiles in the rotation method of approach and performance of oscillating tests on samples, where, during the rotation measurement, an irreversible structure breakdown occurs. Through the interpretation of rheological profiles, experts acquire information about the energy required to apply a certain render (heavy/light) and about how much of the render will fall off the wall during application or dribble or lower on the wall after application. Oscillating tests provide information about the time stability of a coating and the speed of re-structuring, which provides indirect information about flowing and spilling.

he infrared light is a part of the spectrum, which a human eye cannot see, but which can be partly sensed in the form of warmth. It is the part of the spectrum, where the wavelengths are longer than those of the visible light. As in the case, where a reflection of visible light provides certain information about characteristics of a material (e.g. about its colour), also a reflection (or absorption) of the infrared light, which is detected and analysed by the IR spectrophotometer, provides information about the material. It turns out that it is exactly this part of the spectrum that provides some pieces of information about molecular sample composition, namely about the type of compounds, which are present in it. By using an IR spectrophotometer, for example, it is possible to distinguish some groups of polymers (binders), such as, for example, chlorinated (PVC), non-chlorinated (PE, PP), ester (PVA, PMMA) and aromatic ones (PS), with relative ease and speed. Likewise it is possible to distinguish between different fillers and different pigments, which are coloured in a similar way in the visible spectrum.

The physico-chemical laboratory is designed to enable further growth. In the near future, JUB is going to equip the laboratory with new instruments (for gas chromatography and differential scanning calorimetry (DSC)), which will allow experts even more in-depth analysing and understanding of materials and processes, which occur in JUBâ&#x20AC;&#x2122;s products.

Microbiological laboratory A novelty of the Technology Research Centre is also JUBâ&#x20AC;&#x2122;s own microbiological laboratory. JUB has been led to establish such a laboratory by previous experience with its handy laboratory, where experts monitored the state of potential microbiological contamination of raw materials and production processes, but mainly by greater needs since up to now other microbiological tests had to be performed by different external institutions. New laboratory capabilities will enable TRC to start engaging also in research and development activities in the field of microbiology, which relate to the control of the microbiological stability and contamination and to the development of new protection strategies. Above all, the laboratory will enable JUB to independently examine the biocidal protection in the direction of the conservation and storage stability as well as the fungicidal and algicidal protection of its products. Through the performance of the research and development tasks from the above mentioned field, experts will be able to choose and determine new protection systems by using another system or by replacing presently used biocidally-active substances. First, the laboratory will start conducting standard examinations of the verification of product protection and microbiological stability. It will also carry out all operational tasks for the needs of the purchasing body and production support. In the future, all these activities will enable JUB to be even more effective at the reduction of the potential risk level of negative environment effects by the use of imminent biocidally-active substances.

CHEMICAL LABORATORIES ON THE THIRD FLOOR The third floor is intended for the following research and development programmes: · Development programme of the HYROPAS® tinting system, · Development programme of pigment preparations, · Development programme of powdery preparations, and · Development programme of acrylic marble renders.

HYDROPAS® tinting system with development of pigment preparations Colouristic systems fall within the most demanding products in the production of paints and coatings from the technological point of view. In its size class, JUB classifies among rare producers, offering a tinting system, which is a result of their own knowledge and experience. It is marketed under the HYROPAS®brand name. Laboratories of the HYROPAS® programme are specialized in the preparation of viscose pigmented water suspensions (pastes), which contain particles in the size of a few nanometres to a few micrones, and which are intended for tinting of coatings and renders. To be able to prepare tinting suspensions, JUB’s development laboratory is equipped with a laboratory sand mill, which enables the input of great energies and a high level of supervision of manufacturing parameters. The laboratory for colourmetrics uses specialized colour spectrophotometers and software to determine colouristic parameters. A special feature is represented by the possibility of computer modelling of colour space and shade assessment.

The laboratories of the HYROPAS® programme employ a group of top experts, which is composed of specialists from the field of tinting (the colourists) and experts from the field of preparation and testing of coatings. In its work, JUB cooperates with different external partners and takes part in diverse scientific research projects.

Laboratory microclimatic chambers The compliance of products with requirements has to be fulfilled at the time being as well as after longer exposure to exterior weather effects. Thus the chambers for simulation of weather loads, which are positioned on the ground floor of the building, have a special place among the laboratory equipment. The equipment range is composed of two chambers for the simulation of natural weather phenomena (simulation of solar radiation with xenon lamps, rain simulation, simulation of dry and humid climate), two chambers for cyclic weather tests under conditions of dry and wet warming and cooling (including frosting) and a chamber for simulation of exposure to ultraviolet radiation (UVA and UV-B) with the possibility of simulation of rain and condensed atmospheric humidity. In order to develop a new product as quickly as possible, the weather chamber system enables accelerated testing, which causes the exposure of a façade system to weather effects in the period of a few months. Such an exposure can be compared to the exposure of the product on the building in the period of a few years. Since all the described systems simulating rain consume a lot of demineralised water, a station for demineralisation of water was included in the building plan of the new TRC, which functions on the principle of reverse osmosis. The station’s capability amounts to 4.5 m3 of demineralised water per day and through means of secondary ion exchangers it ensures extremely clean water (resistance over 10 MΏ/cm).

Powdery programme The development laboratory for powdery materials enables the development of products, which are based on mineral binders, i.e. cement, lime and gypsum. The powdery programme of building chemistry encompasses fields of building adhesives (insulation, ceramics), tile grouts, damp proofing compounds, levelling compounds as well as mineral and renovation renders. Most of JUBâ&#x20AC;&#x2122;s products comply with European norms (EN and ETAG norms) on the basis of which required tests are performed. Also, external institutes (ZAG, IGH, etc.) exercise supervision over JUBâ&#x20AC;&#x2122;s products several times a year. A special department in TRC, which is equipped with top, highly specialised equipment, prepares and tests powdery products. Highly qualified staff is engaged in continuous training in the field of building chemistry and develops own and incorporates standardised test methods into laboratory work. Experts are competent to conduct numerous tests on different materials: they measure adhesion, shrinkages, elongations, abrasion, and pore content in materials. A modern stress measurement equipment, which allows loads with the force of 100kN, is available for measurements of pressure and flexural strength of a material and for determination of the E-module (Youngâ&#x20AC;&#x2122;s modulus). The possibility of applying two measuring cells (1kN and 100kN) allows experts to operate in a wide measuring range with high precision (precision class is 0.5), which makes them competent to carry out physical measurements with required reliability and repeatability. A component part of the machine is also a technologically advanced assembly of extensometers, which are used to measure elastic moduli that provide information about the stiffness of materials.

Dol pri Ljubljani 28 1262 Dol pri Ljubljani, Slovenia