Advances in Polyurethane and

Polyurea Technology
Presented by:
Jayson L. Helsel, P.E.
KTA-Tator, Inc.
 Learning Objectives
Comprehension of the Advances in Polyurethane and
Polyurea Technology Webinar will enable the
participant to:
 List various types of polyurethane coatings

 Describe the properties of polyurethane coatings

 List various types of polyurea coatings

 Describe the properties of polyurea coatings

 Recognize two SSPC Performance-based Paint

Standards for polyurethane and polyurea coatings
 Learning Objectives (cont.)
List the basic performance differences between
polyurethane and polyurea coatings
Describe the surface preparation requirements for
concrete and steel
 Describe the coating application equipment typically
employed
 List the common applications (when and where
polyurethane and polyurea coatings are used)
 Basic Chemistry/Properties

 Polyurethanes
 Polyureas
 Hybrid coatings
 Polyurethanes

 Polyurethanes are formed by the reaction

between a polyisocyanate and hydroxyl
(-OH) containing resin blend
 Polyurethanes

 Disocyanate can be aromatic or

aliphatic
 Wide variety of formulations
 Polyurethanes

 Conventional 2-part (thin film)

 Waterborne formulations
 Moisture cure polyurethane single
component
 End product can be polyurethane or
polyurea chemistry
 100% Solids/Elastomeric
 Polyurethanes

 Conventional 2-part (thin film)

 Slower cure, longer pot life
 Waterborne formulations
 Use water dispersible polyisocyanates
 SSPC Paint Specification No. 36
 “Two-Component Weatherable Aliphatic
Polyurethane Topcoat, Performance-Based”
 SSPC Paint No. 36

 Weathering levels for color and gloss

(accelerated or Florida exposure)
 Level 1 (<1000 hrs or <24 months)
 Level 2 (<2000 hrs or < 48 months)
 Level 3 (>2000 hrs or > 48 months)
 Color: max 2.0 ∆E, Gloss: max loss 30
 Polyurethanes

 Thin-film polyurethanes properties:

 Typically aliphatic
 Slower cure
 Excellent color and gloss retention
 Good chemical/solvent resistance
 Good hardness/abrasion resistance
 Polyurethanes

 100% Solids/Elastomeric
 Typically aromatic
 Fast cure
 Hi build, up to 100+ mils
 Polyurethanes

 100% solids polyurethane properties:

 Elongation/flexibility
 Excellent chemical/solvent resistance
 Moisture sensitive application
 Can be applied in low temperatures (below
freezing)
 Low VOC
 Polyureas

 Formed by the reaction between an

isocyanate component and an amine-
terminated (-NH2) resin blend
 Polyureas

 Isocyanate can be aromatic or aliphatic

 Aromatic resins will yellow but not crack
 Aliphatic resins have excellent
weatherability
 Wide variety of formulations possible
through particular resin blend
 Typically 100% solids
 Polyureas
 100% solids polyurea properties:
 Elongation/flexibility
 Excellent chemical/solvent resistance
 Not sensitive to moisture during application
 Can be applied in low temperatures (below
freezing)
 Thermal shock resistance
 Minimize down time
 Low VOC
 Polyureas

 Polyaspartic ester based polyureas are

a newer technology
 Resin blend based on aliphatic
polyaspartic ester
 Can have much slower reaction time
 Thinner film application
 Typical use is analagous to conventional
polyurethanes
 Polyurethane/Polyurea
Hybrids

 Hybrid coatings are formed by the

reaction between an isocyanate
component and a resin blend
component
 Resin blend may contain amine-terminated
and/or hydroxyl-terminated polymers
 Wider range for reaction time and
performance properties
 Polyureas

 Fast cure
 Moderate cure
 Hybrid systems
 SSPC Paint Specification No. 39
 “Two-Component Aliphatic Polyurea
Topcoat Fast or Moderate Drying,
Performance Based”
 SSPC Paint No. 39

 Type 1: Fast Drying (less than 30

minutes)
 Type 2: Moderate Drying (30 minutes to
2 hours)
 Weathering levels
 SSPC Paint No. 39

 Weathering Levels
 Accelerated weathering levels
 1A – 500 hours, max 2.0 ∆E, 20% gloss loss
 2A – 1000 hours, max 3.0 ∆E, 30% gloss loss

 3A – 2000 hours, max 3.0 ∆E, 40% gloss loss

 Outdoor weathering levels

 1N – 12 months, max 2.0 ∆E, 35% gloss loss
 2N – 24 months, max 3.0 ∆E, 50% gloss loss
 SSPC Paint No. 39

 Other tests
 Solvent Resistance
 No visible topcoat removal (100 double rubs)
 Pull-Off Adhesion
 Average (3 pulls) ≥ 600 psi
 Minimum 500 psi
 Polyurethane vs Polyurea

 Polyureas are faster cure, e.g. seconds

 Polyureas not moisture sensitive
 Polyurethanes cure slower but are
moisture sensitive
 May have fewer adhesion problems with
polyurethanes
 Surface Preparation

 Steel
 Abrasive blast cleaning to SSPC-SP 10,
Near White
 Angular surface profile
 Surface Preparation

 Concrete
 Abrasive blast cleaning
 Profile/roughening required
 Specialized primer may be necessary
 Check moisture content
 Application Equipment

 Thin film polyurethanes and polyureas

(polyaspartics)
 Conventional or airless spray
 100% solids polyurethanes and
polyureas
 Plural component spray
 Application Equipment

 Plural component spray equipment

 Heats and mixes resin (part A) and curing
agent (part B) components automatically in
correct proportions
 Paint mixture travels directly to spray gun
for immediate application
 Some coatings may be brush/roller
applied
 Application Equipment

 Plural component spray equipment

 Storage to deliver unmixed material
 Proportioning Device
 Pressure Pump
 Mixing Device
 Static mixer or air impingement
 Delivery system (spray gun)
 Flushing system
 Application Equipment

 Plural component application

 Equipment as recommended by coating
manufacturer
 Requires trained/licensed applicators
 Involve coating manufacturer technical
representative for projects
 Single application (multiple passes)
Application Equipment
Application Equipment
Application Equipment
 Polyurethane Applications

 Roof coatings
 Pipe
 Tank interior/exterior
 Truck bed liners
 Railcars
 Parking decks
 Anti-graffiti coatings
 Caulk/joint/sealant materials
 Polyurea Applications

 Roof coatings
 Pipe
 Tank linings
 Truck bed liners
 Railcars
 Parking decks
 Caulk/joint/sealant materials
 Polyurethane Systems

 Conventional polyurethane for steel

structures (exterior tank, bridges)
 Surface preparation: SP 10, profile 2-3 mils
 Application:
 Zinc primer @ 3 – 5 mils DFT
 Epoxy intermediate @ 4 – 6 mils DFT

 Aliphatic polyurethane @ 3 – 5 mils DFT

 Polyurethane Systems

 Waterborne polyurethane for steel

/concrete (anti-graffiti coating)
 Surface preparation: abrasive blast cleaning
 Application:
 Sealer/primer for concrete
 2 coats waterborne urethane primer @ 2 – 3 mils

DFT/coat
 2 coats waterborne urethane finish @ 2 – 3 mils

DFT/coat
 Polyurethane Systems

 Waterborne polyurethane properties

 Tensile strength: 5950 psi
 Elongation: 150%
 Taber abrasion: <45 mg loss/1000 cycles
 Graffiti resistance: Level 3, ASTM D6578
 Polyurethane Systems

 Waterborne polyurethane chemical

resistance
 MEK double rubs, 300+ cycles
 Gasoline: no effect after 7 days
 50% NaOH: no effect after 24 hours
 10% HCl: no effect after 24 hours
 Toluene: no effect after 4 hours
 Polyurethane Systems

 Steel pipe (exterior) coating

 Surface preparation: SP 10, profile 2.5 mils
minimum
 Application:
 100% solids polyurethane @ 13 – 15 mils DFT
 Polyurethane Systems

 Concrete tank lining

 Surface preparation: ASTM D4259/ ICRI
03732, CSP 5
 Application:
 Epoxy primer @ 5 – 7 mils DFT
 100% solids elastomeric polyurethane @ 60 – 80

mils DFT
 Polyurethane Systems

 Elastomeric polyurethane properties

 Shore A hardness: 60
 Adhesion to concrete: 350 psi
 Elongation: 400%
 Tear strength: 150 psi
 Tensile strength: 900 psi
 Polyurethane Systems

 Elastomeric polyurethane chemical

immersion
 Acetic acid, 10%
 Hyrdochloric acid, 10%
 Methanol
 Nitric acid, 10%
 Phosphoric acid, 10%
 Sulfuric acid, 30%
 Polyurea Systems

 Steel tank lining

 Surface preparation: SP 10, profile 3 mils
 Application: 100% solids aromatic
elastomeric polyurea @ 60 – 80 mils DFT
 Polyurea Systems

 Elastomeric polyurea properties

 Shore D hardness: 50
 Elongation: 250%
 Tensile strength: 2125 psi
 Tear strength: 390 psi
 Polyurea Systems

 Elastomeric polyurea chemical immersion:

 Acetic acid, 10%
 Ammonium hydroxide, 20%
 Hydrochloric acid, 10%
 Phosphoric acid, 10%
 Sulfuric acid, 10%
 Polyurea Systems

 Concrete tank lining

 Surface preparation: SP 13 / ICRI 03732,
CSP 3-5
 Application:
 Epoxy primer @ 3 – 5 mils DFT
 100% solids aromatic polyurea @ 60 – 100 mils

DFT
 Polyurea Systems

 Steel structures (exterior tank, bridges)

 Surface preparation: SP 10, profile 2-3 mils
 Application:
 Zinc primer @ 3 – 4 mils DFT
 Aliphatic polyaspartic @ 6 – 9 mils DFT
 Polyurea Systems

 Polyaspartic properties
 Abrasion resistance: 90 mg loss/1000 cycles
 Adhesion: 825 psi
 Corrosion weathering: 15 cycles ASTM
D5894, Rating 10 blistering/corrosion
 Freeze/thaw: 30 cycles, no adhesion loss
 Polyurea Hybrid Systems

 Concrete floor coating

 Surface preparation: abrasive
blasting/mechanical roughening
 Application:
 Epoxy primer @ 3 – 5 mils DFT
 100% solids elastomeric polyurea hybrid @

30+ mils DFT

 Polyurea Hybrid Systems

 Elastomeric polyurea hybrid properties

 Shore D hardness: 60
 Tensile strength: 2300 psi
 Elongation: 100%
 Tear resistance: 330 psi
 Taber abrasion: 25 mg/1000 cycles
 Summary of Key Points

 Polyurethanes
 Thin film conventional and waterborne
 Single component moisture cure
 100% solids thick film
 Polyureas
 100% solids thick film
 No moisture sensitivity
 Thin film polyaspartics
 Summary of Key Points (cont.)

 Blast cleaning generally required

 Plural component application for 100%
solids polyurethane/polyurea
 May allow for low temperature applications
 Minimize down time
 Advances in Polyurethane and
Polyurea Technology

 Questions?