7

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7

The Polyurea
Revolution: Protective
Coatings for the

21st Century

7.1 History .................................................................................

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1
7.2 Polyureas versus Polyurethanes/Chemistry.......................

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7.3 Application Characteristics.................................................

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2
7.4 General Performance ..........................................................

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7.5 Weathering Characteristics .................................................

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7.6 Chemical, Water, and Corrosion Resistance......................

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7.7 Safety....................................................................................

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7.8 Conclusion...........................................................................

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Welcome to the new world of polyureas. In the time it is taking you to read this sentence, a polyurea
elastomeric coating, mixed and sprayed onto a surface, will have reached its initial set.

7.1 History

Polyureas were rst developed in the 1970s, but the development of any practical application was impeded
by their extremely short set times of 1 to 3 sec. In the early 1980s, sophisticated, plural-component heated
equipment was able to mix quickly and dispense the polyureas into a usable form. Throughout the 1980s
and 1990s, improvements in polyurea chemistry led to products with set times that ranged from 3 sec
to 25 min. This led to a wide variety of practical applications.

7.2 Polyureas versus Polyurethanes/Chemistry

Polyureas, as the name suggests, are closely related to polyurethanes. Both polyureas and polyurethanes
are based on a two-component system, with one component being an isocyanate material. Polyureas
second component is a polyether polyamine, whereas polyurethanes second component is a polyether
polyol. Polyurethanes require a catalyst to speed up the reaction time of the components, whereas
polyureas do not. The polyurethane reaction is sensitive to low temperatures and moisture due to the
addition of catalysts. Low temperatures inhibit the reaction time. Moisture interferes with the reaction
by creating carbon dioxide, which causes blistering in the polyurethanes. Polyureas, on the other hand,
require no catalyst, so they are able to cure at any temperature and in the presence of moisture. The fast
curing ability of polyureas is inherent in their chemistry, which gives them several unique advantages.

Bruce R. Baxter

Specialty Products, Inc.

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Coatings Materials and Surface Coatings

In substitution of the polyols used in the urethanes, polyoxyalkylene diamines, triamines, and amine
chain extenders are used with the isocyanate to form the linkage for the ureas. The amine reaction with
the isocyanate, even without any catalyst, is much quicker than with the hydroxyl of the polyol or water.
Because of the speed of the reaction times, polyurea systems can be sprayed on damp or wet surfaces
with no detrimental reactions on performance.

7.3 Application Characteristics

Polyurea coatings are sprayed through standard 1:1 ratio heated plural-component equipment. This
equipment, depending upon model type, creates between 1000 to 3000 lb (7 to 20 Mpa) of pressure.
Because the gel time is near instantaneous, polyureas can be built to any thickness in one coat with no
microcellular development in one pass. This is of particular importance on vertical and overhead surfaces
to be coated. The polyurea surface can be walked on in 30 sec or less for inspection. If recoating of thin
spots or holidays is required, this can be done immediately or within hours with no additional prepara-
tion. Curing of polyureas is attained even when the product is applied to damp or cold surfaces. The
polyurea elastomers can be sprayed directly on water or ice and at temperatures lower than 40

F with
minimal effects on tack-free times. Polyureas require no catalysts to cure, which imparts greater shelf life
to the components. This also eliminates wasteful premixing of excess materials at the job site.

7.4 General Performance

The main area of performance is its resistance to physical rupture, water, chemicals, and weather. The
tear strength of unsupported (free lm) polyurea elastomer is around 3 Mpa (450 Pli) and will exceed
4 Mpa (600 Pli) when backed with a geotextile fabric. Abrasion resistance, which is important in heavy
trafc areas, has also tested well. On a Tabor Abrasion test (1 Kg H-18 wheel), only 110 mg were lost
after 1000 revolutions. Polyurea coatings also adhere well to different substrates. The combination of
lm toughness and adhesion qualities helps to maintain good seals even where different materials make
contact. Due to the lack of catalysts in polyurea systems, moisture and ambient temperature concerns
are eliminated.
In one study, samples of steel, concrete, and asphalt were coated with polyurea elastomer. They were
then sprayed for 30 sec with a stream of liquid nitrogen (196

C) 30.5 cm from the surface. There was
no damage. The concrete sample was dropped 1.8 m. The concrete shattered, but the polyurea elastomeric
coating was undamaged and held the concrete shards together.

7.5 Weathering Characteristics

Installed polyurea elastomeric systems have held up well in exposed applications for several years. A
number of these sites are located in areas where extreme weather conditions exist. Roong and secondary
containment in both Arizona (100

F+) and Alaska (55

F) have proven to work well using polyurea
systems. Polyurea systems are aromatic and sensitive to ultraviolet (UV) radiation. Discoloration, loss of
gloss, and some chalking are to be expected if the system is exposed. This exposure, however, does not
affect the performance or quality of the system. If aesthetics are a concern, an aliphatic urethane or other
color stable material is suggested for a topcoat.

7.6 Chemical, Water, and Corrosion Resistance

Polyurea systems are resistant to water- and petroleum-based chemicals such as acetone, gasoline, MTBE,
and motor oil. They are also resistant to sulfuric acid, acetic acid, and to caustics at low concentrations
(5%). At higher concentrations (50%) some discoloration will occur. These results are from watch glass

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The Polyurea Revolution: Protective Coatings for the 21st Century

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testing according to the ASTM D 1308 test method. Using polyurea systems in areas exposed to strong
acids and oxidizing agents is not recommended (Table 7.1).
On-site testing on metal structures veries test results that predict outstanding corrosion protection.
After exposure to salt spray for 1000 h, no blistering occurred in a 25 mil polyurea system spray applied
to 2 mil blast prole steel panels. The corrosion was 4 mm from the scribe (Table 7.2).

7.7 Safety

Polyurea elastomeric coating systems contain 100% solids and thereby do not release any solvent vapors
(0 VOC). Fumes from the hardener (B component), however, can cause irritation to the respiratory tract
and are also a mild skin irritant. When working with any polyurea system, provide adequate ventilation

TABLE 7.1

Chemical Resistance Testing for Polyurea Spray Elastomers

Chemical Resistance ASTM D 3912
Chemical 12-Month Exposure

Methanol S, selling, <48 h
Gasoline Slight surface change, no hardness loss
Diesel fuel No visible damage
Toluene S, swelling, <24 h
MTBE Slight surface change
5% MTBE/gasoline Slight surface change
Motor oil Slight surface change, no hardness loss
Hydraulic uid Slight surface change, no hardness loss
2-Methylbutane No visible damage
Water
Room temperature No visible damage
82

C, 14 days No visible damage
10% NaCl/water
Room temperature No visible damage
50

C, 14 days No visible damage
10% Sugar/water No visible damage
Sulfuric acid
5% No visible damage
10% No visible damage
3%, 50

C, 14 days No visible damage
Hydrocholoric acid
5% No visible damage
10% No visible damage
Phosphoric acid
10% No visible damage
Ammonium hydroxide
10% No visible damage
20% No visible damage
Sodium hydroxide
10% No visible damage
20% No visible damage
50% Slight surface discolor, no hardness loss
1%, 50

C, 14 days Slight surface discolor, no hardness loss
Potassium hydroxide
10% No visible damage
20% Slight surface discolor, no hardness loss
Acetic acid
10% No visible damage

Source

: From Technical Bulletin 0197, March 1996, Specialty Products, Inc.,
Lakewood, WA.

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of the area and wear chemically impervious gloves and eye protection at all times. If the polyurea system
being used is the spray type, a respiratory mask should be worn at all times.

7.8 Conclusion

Polyurea elastomeric coating systems are becoming the coating of choice, because they are easily applied
in one coat and set rapidly, thus providing minimal down time and extraordinary sealing character-
istics. A wide variety of imaginative uses are developing as people gain experience with polyurea
elastomeric systems.

TABLE 7.2

Aromatic Polyurea Spray

Weatherability Characteristics

a

Test Method Percent Retention

QUV 3800 hours
Shore D 100%
Tear 100%
Elongation 80%
Tensile 97%
QUV 1000 hours
Shore D 100%
Tear 100%
Elongation 87%
Tensile 100%
Xe arc 1000 hours
Shore D 90%
Tear 100%
Elongation 85%
Tensile 100%

a

Elastomer physical properties: Tensile strength,
psi 2265; Elongation, % 190; Tear strength,
pli 460; Shore D Hardness 52.

Source

: Technical Bulletin 0197, March 1996, Spe-
cialty Products, Inc., Lakewood, WA.

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