High-Performance

Polycarbonate
Security Solutions for
Facades
“Facades Design and Delivery” Conference
Chicago, Illinois, USA, September 19-21, 2012
Roger Rumer and Karl Wiecking
Public Sector Business
Today’s Discussion
Your Challenges What We Hope to Do Today

 Aesthetic designs  Offer an update on recent

 Durable structures developments we think are

 Energy efficiency relevant to your challenges

 Security for people, property,  Address historical concerns

& assets with polycarbonate glazing

 with limited stand-off  Offer more choices

for your designs
 A cost-effective solution

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 : recognized within industry as
an innovative, global-leader in material solutions

2011 Global Sales: $15 Billion

R&D Expenditure: $300 Million
Forbes Magazine 2011 Survey: #4 “Most Respected Chemical Company”
Bayer Invented and is a Global-Leader in:
Polyurethanes Polycarbonates
 High insulation-value foams for energy-efficient  A clear, lightweight, impact-resistant thermoplastic
buildings. used for:
 “Eco-Commercial Building” group for  Signs / Point of Sale
sustainable structures up to “net zero”  CDs and DVDs
 Elastomers absorb shock and vibration.  Optical lenses
 High-performance coatings for aerospace,  Automotive headlamps
automotive, consumer goods, & construction  Successfully used for decades in security shielding
and architectural / structural sheet

Note: Sales, R&D expenditure were calculated with exchange rate of 1 € = 1.4 USD

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High-Performance Materials
Makrolon EX
monolithic sheet multi UV laminates

Page 5
High-Level Comparison:
Polycarbonate & Glass
Basic Properties Polycarbonate Glass

Transparency Optical Clarity Optical Clarity

Can be Tinted Yes Yes

“Green” Yes* ???

Yes for monolithic

Recyclable Yes
No for laminates
1.2 –
Weight – specific gravity (g/cc) 2.6
Less than half of glass
Type of Material / Ductile / Brittle /
Breakability Virtually Unbreakable “Manage Breakage”
* “Halogen Free”: DIN/VDE 0472, part 815, “Heavy Metal Free”: US CONEG Compliant

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What about historical concerns with
polycarbonate…
durability, abrasion-resistance, & cleaning?

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Newest generation products give greatly improved
exterior durability and abrasion resistance
Key Concerns with Older Polycarbonates Newest Generation Product

Outdoor Weathering Abrasion Resistance 15’s hard-coat is:

• based on proven automotive-coating

Proven
& technology
Warranted
• backed by Bayer’s 15-year
Latest
1st Generation Limited Product Warranty
Generation
Appearance After Accelerated Weathering

• Upon exposure to UV radiation, older • unprecedented durability and abrasion

generation polycarbonate weathered* over time resistance for architectural glazing
applications
• Uncoated polycarbonate is significantly less
Benefits
abrasion-resistant than glass • builds on the inherent toughness /
shatter-resistance of polycarbonate

* Weatherability can be quantified by degree of yellowness,

or “Yellowness Index” (YI) as measured in
ASTM D1925 Test Method for Yellowness Index of Plastics

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 15
backed by a 15-Year Limited Product Warranty
Compares Favorably to Typical Blast-Glass Warranties of 5 or 10-Years

Weathering Performance in Vertical Orientation*

14.0
Old Generation
12.0 Uncoated Hard-Coated
Polycarbonate Polycarbonate
10.0 Level at which
YelIowness Index

yellowing
8.0 may become
New Generation apparent
6.0 Hard-Coated
PC for
4.0 Sentinel
2.0

0.0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Years*
* Based upon Xenon WOM accelerated weathering for UV dose at mid-latitude location

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Better abrasion resistance, as well, from the
latest-generation, durable hard-coat
Testing Performed
Abrasion resistance is determined by ASTM D1044
“Standard Test Method for Resistance of Transparent Plastics to Surface Abrasion”
• Sample rotated under rotated abrasive wheels, haze measured before and after 100 rotations

Delta Haze (%) 30

30

25

20 • 15
outperforms abrasion
15 resistance of acrylic
• Exceptional level of abrasion
10
and mar resistance to
4 4.4 withstand routine abuse and
5
2 cleaning.
0.6
0 • Approaches abrasion
Glass Makrolon® 15 Acrylic Competitive General resistance of glass
Coated-PC Purpose PC

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 Cleaning Recommendations:
PC & Glass
Recommended
Glass **
Cleaning Procedures polycarbonate sheet *

Rinse with “Soak” with

To start cleaning warm, clean water clean water & soap solution

Use a mild, approved, non-

“Yes” for both
abrasive, cleaning solution

Don’t use scrapers or

razors or allow abrasive
“Yes” for both
material between cleaning
materials and surface

Rinse with lukewarm, Use a squeegee to remove

After cleaning
clean water rinse all cleaning solution

* http://www.sheffieldplastics.com/web_docs/MakrolonCleaning.pdf
** Source: “Glazing Assoc. of North America” GANA 01-0300 “Proper Procedures for Cleaning Architectural Glass Products “

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 Today‘s products are significantly
improved over earlier generations

FDA - Approved UV-Resistant Multi-wall Transportation 15-Year UV &

For Food Contact Grades Sheet Glazing Abrasion-resistant

Time

Monolithic Flame Abrasion Security Targeted Optical

Sheet Retardant Resistant Laminates Performance
Grades Grades

and
polycarbonate sheet polycarbonate laminate
Aesthetic designs:
More commonly known application areas
Windows Storefronts Facades Thermal Walls

and
polycarbonate sheet polycarbonate laminate

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 Innovative architectural applications
with polycarbonate sheet
Baltic Arena Gdansk
Poland

Changsha Railway Station

China

Wuhan Train Station

China

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Architectural Applications:
Transparent Roofing

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Architectural Applications:
Innovative Facades

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Architectural Applications:
Innovative Facades

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 Case Study: Advanced Security Application
 Sentinel Structural-Envelope

 Essential Elements & Value Proposition

 Aesthetics

 Energy Efficiency and Sustainability

 Security Performance & Cost Savings Potential

Page 18
 Sentinel : Essential Elements

Structural-envelope panels
Shock-wave attenuating
of transparent & light-weight supported by structural
buffer gap between
polycarbonate steel frame attached to
panels & building
laminate panels building at each floor

Closer View

Artist’s Rendition of a building protected by Hygard® Sentinel

Sentinel provides advanced blast protection

without sacrificing aesthetic performance

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 Sentinel :
a new level of performance & value in protection
1
Minimizes Casualties
and Injuries
Blast protection exceeds the most
rigorous standards
Meets standards at reduced stand-off

2
Promotes Resilience
Structural integrity and personnel
protected to absorb the impact of and
rapidly recover from a disruptive event

3
Provides More Security
Combines blast, ballistic, forced-entry,
and storm protection in a single solution.
Signal defense functionality
is an option.

Artist’s rendition of a building protected by Hygard® Sentinel

* Note: BL80 is designed to protect up to
80 psi peak pressure and 380 psi-msec impulse

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 Sentinel :
a new level of performance & value in protection
4
Preserves Aesthetics
Transparent, without horizontal members
provides more visibility / day-lighting

5
Suitable for Retro-Fit

To Harden Existing Structures

or for New Construction

6 Favorable Value /
Possible Cost-Avoidance

Compares favorably to moving

operations or new construction

Protection at reduced stand-off can

translate into real-estate savings
Artist’s rendition of the view from inside a Hygard® Sentinel structure

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 Sentinel : Open-arena,
live-explosive blast-protection verification

Simulated Truck
Bomb
2400 lbs NH4NO3
& 6% fuel oil (ANFO)
detonated with C4 primer
equivalent to
2000 lbs of TNT

Simulated
Building
Façade
& Control Structure

Two tests at 80 and 70 ft stand-off

distance. Closer than most
demanding requirement.
Source: BMS

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 Sentinel Blast Testing:
Two-Story Prototype Structure
Front View Back View
laminate-clad envelope 2-Storey
on 4 sides facing the blast Multi-Bay Building

Pressure Pressure
Gauge 1 Gauges 7 & 8
(Exterior (Interior Pressure at
Concrete “Witness Wall”:
Blast) Witness Wall)
Simulating Protected Building Structure
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 2nd Test of Same Structure Exposed to 1st Blast:
View from Inside the Test Structure

Sentinel

Protects by flexing to
absorb and deflect
blast
shock wave

despite peak pressures of

> 80 psi and an impulse of
>380 psi-msec.

Cue video by clicking to next slide

Page 24
 2nd Test of Same Structure Exposed to 1st Blast:
View from Inside the Test Structure

Sentinel

Protects by flexing to
absorb and deflect
blast
shock wave

despite peak pressures of

> 80 psi and an impulse of
>380 psi-msec.

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 Sentinel : blast protection performance
exceeded expectations in live and simulated tests

Crater from first blast at Unprotected test wall HYGARD BL80

80 ft. stand-off was destroyed Test Structure
after two blasts

System Performance
 The Sentinel prototype withstood two detonations of 2000 lbs. of TNT
equivalent with each test exerted more than100 psi peak on the structure
 After 2nd test, laminate panels showed some damage but were still intact
 Shock-wave pressure attenuated to <5 psi in 1st blast and < 10 psi in 2nd blast.
 Open-arena verified shock-tube and computer-modeled performance expectations.
Source: BMS

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 Sentinel: a customizable design approach
allows to address the needs of many project types

Sentinel coverage

New Construction Retrofits Entire Façades Partial Façades

 Maximize functional building  Flexible design can be built  Delivers a complete blast  Modular panel design allows
area with shorter stand-off into a wide range of existing protection solution a solution to be designed for
distances structures  Offers a more attractive one or more building
 Bayer’s blast-protection  Structural-envelope: open look and feel to the sections
solutions team will minimal or no operational building exterior  Team approach to
collaborate with the design downtime during retrofit incorporate protection into
and construction teams installation existing aesthetic

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Case Study  Sentinel Structural-Envelope

 Essential Elements & Value Proposition

 Aesthetics

 Energy Efficiency and Sustainability

 Security Performance & Cost Savings Potential

Page 28
 high-performance laminate versus
comparable BlastGlass IGUs with low-e coatings
“Diplomatic Security” Level Protection

Panel Thickness [mm] Weight [lbs/ft2] Visible Transmission

86 34 with low-E Coating
65 63 64%
23 57% 60% 54%
46 20
10

Hygard FEBR IGU 1 IGU 2 Hygard FEBR IGU 1 IGU 2 Hygard FEBR IGU 1 IGU 2
IGU IGU IGU

Thinner and lighter Comparable or higher

visible transmission

Note 1: BL80 Shock-Wave Sentinel which performs at 80 psi / 380 psi-msec level of blast-resistance.
Note 2: Blast-glass lGU’s meeting Diplomatic Security specifications.

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Case Study  Sentinel Structural-Envelope

 Essential Elements & Value Proposition

 Aesthetics

 Energy Efficiency and Sustainability

 Security Performance & Cost Savings Potential

Page 30
 Sentinel: Laminate Thermal Properties
in comparison to Glass IGUs with low-E coating

“Diplomatic Security” Level Protection

U-Value [BTU/hr-ft2-°F] Solar Heat Gain Coefficient

0.45 0.77

0.56 0.55
0.25 0.26 0.25 0.44

Hygard FEBR IGU IGU 1 IGU 2 Hygard FEBR IGU IGU 1 IGU 2

Higher U-value than IGUs Transmits more solar energy

Note 1: BL80 Shock-Wave Sentinel which performs at 80 psi / 380 psi-msec level of blast-resistance.
Note 2: Blast-glass lGU’s meeting Diplomatic Security specifications.

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 Sentinel : Energy Study

 Objective: Model annual energy demand, monthly HVAC capacity

requirements, and

 Study Conducted by :

 Typical Office Building – more detail next slide

 Climates:

 Moderate: Washington, DC

 Colder: Moscow

 Warmer: Dubai

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 Energy Modeling:
Baseline & with Structural-Envelope
Baseline Structure Baseline with Sentinel

Building floor area (ft2) 300,000 ft2 on 5 floors

Building space programming & Operation Schedule Typical Office / 8:00 am to 6:00 pm

Heating = 68F; Cooling = 75F

Set Points
50% RH

ASHRAE 62.1-2007
Ventilation minimum ventilation requirements
(5 cfm per person & 0.06 cfm/ft2)

Page 34
Energy Study: Annual Energy Savings vs. Baseline:
1) Structural Envelope vs Base Gap Ventilation
2) Sentinel laminate vs Glass-Laminate

4.0% 3.6%
Base Case
% Annual Energy

3.0%
2.3% 2" Gap at Base
Savings

2.0%
4" Gap at Base
1.0% 0.8%
Base Case with
0.0% Glass-Lam
0.0%
Washington, DC
High Level Conclusions:
 Sentinel complete structural envelope without gap at base
showed better results than variations with gaps at base
 Sentinel laminate based structural-envelope gave more energy
savings than one using a blast-resistant glass-laminate

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Energy Study: Annual Energy Savings vs. Baseline
10.0%
7.3%7.8%
% Annual Energy

8.0%
6.0% 4.7%
Savings

3.6% Wash, DC
4.0%
Moscow
2.0%
Dubai
0.0%
-2.0% Total Energy HVAC Energy
-1.5%
-4.0% -3.0%
High Level Conclusions: structural envelope yielded
 Significant energy and HVAC savings in DC and Moscow
 Higher energy and HVAC use in Dubai
 Hot climate deficit to be addressed with operable ventilation

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Case Study  Sentinel Structural-Envelope

 Essential Elements & Value Proposition

 Aesthetics

 Energy Efficiency and Sustainability

 Security Performance & Cost Savings Potential

Page 38
 Sentinel blast-resistance
is more robust than 2” Blast Glass //SGP or PVB IGU*
Pressure - Impulse Diagram
Performance Acc. to GSA Test for Glazing Air-blast Loading ASTM F 1642
6' x 10', Source: Wingard PE

50

Rating From Hygard

4= “Low Hazard” Laminate
5 = “High Hazard”
SGP
Pressure (psi)

PVB
Hygard
PVB Laminate

SGP

Rating From
1 = “No Break” Glazing
2 = “Break / No Air-blast Loading
ASTM F 1642
Hazard”
5
100 1000 Detail
Impulse (psi-msec)

* Note: 2” Blast Glass IGU Layup: 0.5” tempered glass – 0.18” SG or PVB – 0.5” tempered glass – 0.25” air gap –
Page 39 0.22” heat-strengthened glass – 0.09” SG or PVB - 0.22” heat-strengthened glass.
 Sentinel extends the protected zone
to include recent bomb attacks which exceed
government blast-standards
BL80 PREDICTED PROTECTION ZONE
FAILURE OF CONCRETE BLOCK WALLS SEVERE DAMAGE TO REINFORCED PROBABLE DESTRUCTION
CONCRETE STRUCTURES OF MOST BUILDINGS

160 6
PSI

140 4
PSI
10
PSI
TARGET (FT)

120

Protection zone moved

40
100 PSI from 100 feet stand-off
to <60 feet stand-off
FROM

80
Hygard® BL80 Protects
DISTANCE

HYGARD® BL80
60 From A Given Threat (lbs TNT) PREDICTED
PROTECTION ZONE
At A Closer Distance For
GOVERNMENT BLAST
Sites With Less Than STANDARDS
40
Desired Stand-Off OPEN-RANGE
BLAST TESTING OF
HYGARD ® BL80
20 PROTECTABLE
TERRORIST VBIED
ATTACKS SINCE 1990

0
40 100 500 1,000 2,000 4,000 10,000
THREAT LEVEL (LBS OF TNT)
Auto Bombs Van Bombs Truck Bombs

Sources: New York Times, CNN, BBC, Guardian, Factiva, US Department of State
Note 1. Excludes bombing events that occurred at zero distance, inside a building, in open space, on a moving target, or where no major damage occurred
Note 2. Private Sector includes restaurants, hotels, infrastructure, shopping malls, marketplaces, schools, hospitals, and religious sites
 Basis of Real-Estate
Cost Savings Case Study
Without Hygard® Sentinel… With Hygard® Sentinel …

100 ft.. 60 ft..

100 ft.. 100 ft.. 60 ft.. 60 ft..

Building Building

100 ft..
60 ft..

… additional stand-off distance is required to …stand-off distances can be decreased since

protect the building from the threat of explosive Hygard® Sentinel provides superior protection.
blasts.
 Reduces the need to purchase additional real
 Requires the purchase of additional real estate estate

 Restricts the size of the building  Allows for a larger building on the same piece of
land

Page 41
Conclusions: London Embassy Case Study

 Sentinel can provide superior protection at decreased stand-off distance

 It is possible to purchase less land to give equivalent protection

Stand-Off Land
Land Required
Distance Cost

BASE CASE: 100 feet in all

4.4 acres $569 Million
London Embassy directions

Case with 60 feet in all

2.9 acres $375 Million
Hygard Sentinel directions

Potential
1.5 acres $194 Million
Savings

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 Sentinel : Development Concept
1
Demonstrate Robust Blast-
Protection Performance
Prototype with blast protection to meet or
exceeds the most rigorous standards
Meets standards at reduced stand-off

2
Develop Initial Solution with
Complete Design
Complete fully engineered concept with
full design to delivery described
Prepare to adapt to feedback

3
Adapt to Individual Project
Requirements
Customize working with key
architectural, design, engineering &
construction firms..

Artist’s rendition of a building protected by Hygard® Sentinel

Page 44
 Your Challenges / Our Solutions
 Aesthetic designs
 Durable structures
 Reduced energy / sustainability
 Security for people, property, &
assets
 with limited stand-off
 A cost-effective solution
 Transparent and light-weight
 Virtually unbreakable
- 15-year warranty available
 Good insulating properties can
reduce energy consumption
 Meets multiple security needs
 New blast-protection solution
 Protection with less stand-off
 Cost-effective solutions

and
polycarbonate sheet polycarbonate laminate

Page 45
 Thank you!

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