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Periodic Report Summary 1 - BARRIER PLUS (One component waterborne barrier coatings)

Project Context and Objectives:
This report covers the work carried out during the first reporting period ( 01 January 2014 – 31st March 2015) of the European commission Framework 7 project ‘BarrierPlus’- One Component Waterborne Barrier Coatings.
Steel is the most used metal in construction and the costs of protecting Europe’s structural steel installations and assets from corrosion is thought to be 3% of GDP (or about €375BN). However, there are two factors that will increasingly affect future protective coatings developments: VOC emissions and health/safety issues. Firstly there is a strong mandate to apply VOC emissions legislation to protective coatings (and in particular extend the Paint Products Directive to include them). Secondly REACH, together with increasing effects of chemicals on humans supported through medical literature, may prevent the use of some coating materials.
Our vision for BARRIER-PLUS is to develop one-component waterborne barrier coatings that are competitive in performance to two component coatings. One component waterborne coatings have a number of advantages over two component coatings and solventborne systems: low VOC emissions; low fire risk; lower insurance issues; no exposure to isocyanates, epoxy resins or amines; no waste or poor film performance arising from pot life problems. Our approach is to build upon recent research in the organic/inorganic nanocomposites field to create enhanced film barrier properties.
Although this project is focused on the protection of steel, the technology developed will have application in the protection of other substrates, eg concrete, brickwork and stonework.

Project Results:
refer to table 1.2 of theh attachment.
WP No. Work Package Title Main Work Tasks Achieved Start End
WP1 Development of amphiphilic block copolymers and surfactant-free latices • Four model surfactant-free latices produced
• Four amphiphilic block copolymers produced
• Interim surfactant-free latices and characterisation report developed 1 15
WP2 Development of organic/inorganic hybrid latices • Four model polymer-encapsulated inorganic latices developed
• Four model Pickering stabilised latices developed
• Interim polymer-encapsulated inorganic/Pickering stabilised latices with characterisation report completed 1 15
WP3 Interim characterisation data and accelerated weathering/corrosion
testing • Interim characterisation data and accelerated weathering/corrosion testing conducted 1 15
WP4 Advanced structural characterisation and evaluation of film formation • Interim report on structure of barrier coatings and comparison to structure in computational models completed 1 15
WP6 Dissemination and exploitation • Protection of IPR & exploitation plan considered
• Interim Plan for the use and dissemination of knowledge developed 1 15
WP7 Consortium management • Consortium agreement signed
• EC & Consortium communication plan developed

Description of the Main Results Achieved:
Milestone 1: Four model surfactant-free latices using amphiphilic block copolymers for WPs 3 & 4
Milestone 2: Four model polymer encapsulated inorganic and Pickering stabilised
Milestone 3: Four amphiphilic block copolymers for WP3
Potential Impact:

1.3 Expected Final Results and their Impacts
The project consortium believes that a number of intellectual proprietary materials will be generated during the duration of the BARRIER PLUS project, inclusive of patents and know-how. The innovations and outcomes (and broad method of protection) of the BARRIER-PLUS project will be:
Result 1: Procedure for making surfactant-free self-crosslinking latices
Result 2: Procedure for making polymer encapsulated inorganic particles
Result 3: Procedure for making Pickering stabilised latices
Result 4: Model developed for barrier properties of 1K waterborne coatings
Result 5: Formulation of 1K waterborne protective coating
Result 6: Testing of 1K waterborne protective coating
These innovations and outcomes will provide the following benefits to the SME AGs:
• The SME AGs will generate revenue (license fees and/or royalty payments per litre) from initial manufacturing licences (offered initially to SHW ) and access to patents filed during the project;
• Offering a safer product to our SME membership;
• Re-investment of revenue generated post project to enable future R&D projects, training and dissemination activities for the benefit of our SME members; and
• Increased membership due to the ability to raise their profile and deliver benefits to the SME members,
• Securing existing membership and creating new members across the SME AGs.
The validation of the BARRIER PLUS technology will be undertaken by the presentation of the results of the industrial validation trials undertaken by PRA and SHW, and assessed independently by the SME AGs. NSA and CECM will independently assess and validate the application performance of the coatings, whilst CECM, NSA and EFC will assess and validate the corrosion protection provided by the trial coatings.
Intellectual Property Management:
The BARRIER PLUS project contains a number of innovative approaches to the development of a waterborne 1K barrier coating for metal surfaces and will generate significant intellectual knowhow and patentable innovations: in particular, at this time we expect IPR developments in the fields of surfactant-free self-crosslinking latex particles,
polymer encapsulated inorganic particles and Pickering stabilised latices, and important knowhow in the fields of barrier property models of 1K waterborne coatings, formulation and testing of these products. As such, the SME AGs and RTD performers will dedicate specific project resources to this activity. The Exploitation Committee will comprise one representative from each of the SME AGs and UCBL, and will meet every 3 months. The function of the Committee will be to formulate a strategy to permit the consortium to accelerate the exploitation of the results.

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United Kingdom
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