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Polyurethane and Polyurea Coatings Technology

This webinar covers advances in polyurethane and polyurea technology including types, properties, performance standards, and applications of these coatings. It also discusses differences, chemistry, properties, and application equipment for polyurethanes and polyureas.

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Polyurethane and Polyurea Coatings Technology

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  1. Advances in Polyurethane and Polyurea Technology Presented by: Jayson L. Helsel, P.E. KTA-Tator, Inc.

  2. 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

  3. 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)

  4. Basic Chemistry/Properties • Polyurethanes • Polyureas • Hybrid coatings

  5. Polyurethanes • Polyurethanes are formed by the reaction between a polyisocyanate and hydroxyl (-OH) containing resin blend

  6. Polyurethanes • Disocyanate can be aromatic or aliphatic • Wide variety of formulations

  7. Polyurethanes • Conventional 2-part (thin film) • Waterborne formulations • Moisture cure polyurethane single component • End product can be polyurethane or polyurea chemistry • 100% Solids/Elastomeric

  8. 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”

  9. 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

  10. Polyurethanes • Thin-film polyurethanes properties: • Typically aliphatic • Slower cure • Excellent color and gloss retention • Good chemical/solvent resistance • Good hardness/abrasion resistance

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

  12. Polyurethanes • 100% solids polyurethane properties: • Elongation/flexibility • Excellent chemical/solvent resistance • Moisture sensitive application • Can be applied in low temperatures (below freezing) • Low VOC

  13. Polyureas • Formed by the reaction between an isocyanate component and an amine-terminated (-NH2) resin blend

  14. 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

  15. 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

  16. 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

  17. 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

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

  19. SSPC Paint No. 39 • Type 1: Fast Drying (less than 30 minutes) • Type 2: Moderate Drying (30 minutes to 2 hours) • Weathering levels

  20. 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

  21. 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

  22. 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

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

  24. Surface Preparation • Concrete • Abrasive blast cleaning • Profile/roughening required • Specialized primer may be necessary • Check moisture content

  25. Application Equipment • Thin film polyurethanes and polyureas (polyaspartics) • Conventional or airless spray • 100% solids polyurethanes and polyureas • Plural component spray

  26. 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

  27. 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

  28. 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)

  29. Application Equipment

  30. Application Equipment

  31. Application Equipment

  32. Polyurethane Applications • Roof coatings • Pipe • Tank interior/exterior • Truck bed liners • Railcars • Parking decks • Anti-graffiti coatings • Caulk/joint/sealant materials

  33. Polyurea Applications • Roof coatings • Pipe • Tank linings • Truck bed liners • Railcars • Parking decks • Caulk/joint/sealant materials

  34. Application

  35. Application

  36. Application

  37. Application

  38. Application

  39. Application

  40. 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

  41. 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

  42. Polyurethane Systems • Waterborne polyurethane properties • Tensile strength: 5950 psi • Elongation: 150% • Taber abrasion: <45 mg loss/1000 cycles • Graffiti resistance: Level 3, ASTM D6578

  43. 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

  44. Polyurethane Systems • Steel pipe (exterior) coating • Surface preparation: SP 10, profile 2.5 mils minimum • Application: • 100% solids polyurethane @ 13 – 15 mils DFT

  45. 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

  46. Polyurethane Systems • Elastomeric polyurethane properties • Shore A hardness: 60 • Adhesion to concrete: 350 psi • Elongation: 400% • Tear strength: 150 psi • Tensile strength: 900 psi

  47. Polyurethane Systems • Elastomeric polyurethane chemical immersion • Acetic acid, 10% • Hyrdochloric acid, 10% • Methanol • Nitric acid, 10% • Phosphoric acid, 10% • Sulfuric acid, 30%

  48. Polyurea Systems • Steel tank lining • Surface preparation: SP 10, profile 3 mils • Application: 100% solids aromatic elastomeric polyurea @ 60 – 80 mils DFT

  49. Polyurea Systems • Elastomeric polyurea properties • Shore D hardness: 50 • Elongation: 250% • Tensile strength: 2125 psi • Tear strength: 390 psi

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