1. Polyurethane, Polyurea and Hybrid Lining Technology
Presented by: Dudley Primeaux, PCS
VersaFlex Incorporated

2. Introduction
This webinar reviews application of polyurea, polyurethane, or polyurea/polyurethane hybrid thick film coatings to steel or concrete surfaces using plural-component spray application

3. SSPC Standards
SSPC-Paint 45, Two-Component, Thick-Film Polyurea and Polyurea/Polyurethane Hybrid Coatings, Performance-Based
Expected to be released by December 2013
SSPC-PA 14, Application of Thick Film Polyurea and Polyurethane Coatings to Concrete and Steel Using Plural-Component Equipment

4. SSPC-Paint 45
A coating standard that contains minimum performance requirements for polyurea and polyurea/polyurethane hybrid coatings

5. SSPC-Paint 45 Coating Types
2 types defined
Type 1
Polyurea
1a, Fast Cure
Dry in less than 2 minutes
1b, Moderate Cure
Dry time is 2 minutes – 30 minutes
Type 2
Polyurea/Polyurethane Hybrid
2a, Fast Cure
2b, Moderate Cure
Dry time is 2 minutes-30 minutes

6. Polyurea
A coating material which is the reaction product of an isocyanate and a polyamine.

7. Polyureas Isocyanate Component can be aromatic or aliphatic
Resin / Polyamine Component can be aromatic or aliphatic
Aromatic based systems will yellow or fade but not crack
Aliphatic based systems have excellent weatherability

8. Polyurea Properties Good elongation and flexibility
Excellent chemical/solvent resistance
Can be applied in low temperatures
Good thermal shock resistance
Turn Around Time
100% Solids

9. Polyurea Standard
SSPC Paint No. 39, Two-Component Aliphatic Polyurea Topcoat Fast or Moderate Drying, Performance Based
Type 1: Fast Drying
Less than 30 minutes
Type 2: Moderate Drying
30 minutes to 2 hours

10. SSPC Paint 39 Exposure Test Performance Level Exposure Time
Color Retention Per ASTM D2244
Maximum Gloss Reduction From Original Reading Per ASTM D523
ASTM D4587
Level 1A
500 h
≤ 2.0 ∆E
20%
Level 2A
1000 h
≤ 3.0 ∆E
30%
Level 3A
2000 h
40%
ASTM D1014
Level 1N
12 mo
35%
Level 2N
24 mo
50%
From Table 1: Summary of Performance Testing Results to be Reported

11. Polyurethane
A coating binder material formed by the reaction of an isocyanate with hydroxyl-containing substances (polyols) to produce an organic polymer compound known as a urethane

12. Types of Polyurethanes
Conventional 2-part (thin film)
Moisture cure polyurethane single component
100% solids/elastomeric (thick film)

13. Conventional 2-Part Polyurethane
Waterborne formulations
Use water dispersible polyisocyanate
Slower cure
Longer potlife
Typically aliphatic
SSPC Paint Specification No. 36
Two Component Weatherable Aliphatic Polyurethane Topcoat, Performance-Based

14. Accelerated UV-A Testing
SSPC Paint No. 36
Accelerated UV-A Testing
Performance Level
Hours to Noticeable Change
Months to Noticeable Change
Level 1
500 to 999
12 to 23
Level 2
1000 to 1999
24 to 47
Level 3
2000 or more
48 or more
From Table 1: Time Corresponding to Each Performance Level

15. SSPC Paint No. 36
Exposure Test
Performance Level
Exposure Time
Color Change ASTM D2244
Maximum Gloss Reduction ASTM D523
Accelerated Weathering ASTM D4587
Level 1
500 h
Less than 2.0 ΔE
25% from original reading
Level 2
1000 h
Level 3
2000 h
South Florida Weathering ASTM D1014
12 mo
35% from original reading
24 mo
48 mo
From Table 2: Summary of Performance Testing Results to be Reported

16. Conventional 2-Part Polyurethane
Excellent color and gloss retention
Good chemical/solvent resistance
Good hardness/abrasion resistance

17. Characteristics of Moisture-Cured Urethane Coatings
Moisture-Cured Urethane (MCU) Coatings
Advantages
Limitations

18. Polyurethane Advantages
Turn Around Time
100% Solid
Can Have Some Limited Ability to Apply During Winter Months
Unique “Self-Inspecting” Property

19. Hybrid
A blend of polyurea and polyurethane

20. 100% Solids/Elastomeric Typically aromatic Fast cure
High build, up to 100+ mils (2.5+ mm)
Good elongation and flexibility
Excellent chemical and solvent resistance
Can be applied in low temperatures
Low VOC

21. Thick Film Greater than 20 mils (500 µm) dry film thickness
Shown here is a wet film gage used in some Moderate Cure systems
Fast Cure systems would require the use of either a Type 1 magnetic or Type 2 electronic gage, or an ultrasonic gage

22. Service Environments
SSPC-Paint 45 coatings are suitable for application in the following SSPC environmental zones:
1A (Interior, normally dry)
1B (Exterior, normally dry)
2A (Frequently wet by fresh water, excluding immersion)
2B (Frequently wet by salt water, excluding immersion)
2C (Fresh water immersion)
2D (Salt water immersion)

23. Surface Preparation of Steel
Removal of Visible Contaminants
SSPC-SP 1, Solvent Cleaning
Removal of Non-Visible Contaminants
SSPC Guide 15, Field Methods for Retrieval and Analysis of Soluble Salts on Steel and Other Nonporous Substrates
Minimum Surface Profile of 3 mils (76 µm)
ASTM D4417, Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel
Method B
SSPC-PA 17, Procedure for Determining Conformance to Steel Profile/Surface Roughness/Peak Count Requirements

24. Surface Preparation of Concrete
Verify that the concrete substrate is sound and solid
ASTM C805, Standard Test Method for Rebound Number of Hardened Concrete
Repair surface defects such as: bugholes, voids and cracks
Clean the surface so it is free of dust, dirt, grease and oils, contaminants, laitance, and loosely adhering concrete (SSPC-SP 13)
Create a surface roughness within ICRI 310.2, CSP range of 2-6

25. Rebound Hammer and ICRI 310.2 CSP replicate plaques
ASTM D7682, Standard Test Method for Replication and Measurement of Concrete Surface Profiles Using Replica Putty

26. Coating Material Receipt
Check that coatings delivered:
Are in original, unopened containers with labels intact
That containers are not damaged
Have readily accessible PDS’s and SDS’s
Each container is marked, showing: coating identification, date of manufacturer, batch number, and basic chemical composition
Coatings are stored in accordance with applicable federal, state and local safety regulations
Coatings are stored in accordance with manufacturer’s recommendations
Are within applicable shelf life

27. Mixing
Mix each individual component of the coating system in accordance with manufacturer’s instructions
Verify proper mix ratio of coating components prior to placement into plural component equipment

28. Mixing

29. Pre- Application Checks
Prior to application of the coating check:
Ambient conditions
Coating is not to be applied in wind, snow, fog, mist or rain.
Coating is not to be applied to wet or damp substrates
Temperature
The surface temperature, temperature of the coating and ambient air temperature must be within coating manufacturers requirements

30. Pre-Application Checks (Cont’d)
Humidity
Coating shall not be applied when the surface temperature is less than 5 degrees Fahrenheit (3 degrees Centigrade) above the dew point
Concrete Substrate Moisture
The moisture level of the concrete shall comply with the coating manufacturer’s requirements as determined by the measurement method specified on the PDS
Steel Substrate Moisture
Apply coating to dry substrates that are free of any water in seams, fasteners or joints

31. Application Equipment
Coating are applied by high-pressure or low-pressure plural component spray equipment
Equipment is capable proportioning and heating the fluid
The spray gun is capable of mix and dispense of the thick film coating to the desired DFT and pattern specified on PDS
DFT can be achieved in 1-3 overlapping passes

32. Mixing at the Gun
Air purge gun
Mechanical purge gun

33. Test Area Prior to spraying project area, create a test area
~11 square feet (1 square meter) in size
Test adhesion
For steel test in accordance of ASTM D4541, Method D or E
Average of 3 pulls
For concrete test in accordance of ASTM D7234

34. Application Primer Topcoat Applied in accordance with PDS
Applied in a visually continuous film with overlapping at the edges of the spray pattern
Topcoat
Not applied until primer has cured
Applied within recoat window of primer

35. Coating Thickness The coating thickness is verified by:
Steel: SSPC-PA 2, Procedure for Determining Conformance to Dry Coating Thickness Requirements
- Type 1 (magnetic) or Type 2 (electronic)
Concrete: SSPC-PA 9, Measurement of Dry Coating Thickness on Cementitious Substrates Using Ultrasonic Gages

36. Coating Continuity
Inspect coating for a cured film that is continuous and pinhole free
NACE SP0188, Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates
ASTM D4787, Standard Practice for Continuity Verification of Liquid or Sheet Linings Applied to Concrete Substrates

37. Summary
By following appropriate test methods and good practices, polyurea, polyurethane and hybrid coatings can provide excellent corrosion protection for concrete and steel substrates
This protection includes a variety of interior and exterior coating work, as well as immersion lining application areas

38. Questions?