JPCL Web Helsel Poly21
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Transcript of JPCL Web Helsel Poly21
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?