New generation Coatings…The Polyurea…

Ashish Kumar

Research project on Polyurea

(AT -VIP Polyurea, Munich, Germany)

MSc Surface Coating Science & Technology

Dept of Color & Polymer Chemistry

University of Leeds

UK.

Polyurea Vs Polyurethane /Epoxy

• Polyureas are closely related to polyurethanes. Both are two component systems made with Isocyanate-based materials. However, while the second component in polyurethane is polyol resin, the second component in polyurea is a polyether amine.

• In terms of performance, conventional polyurethanes require a catalyst, which is sensitive to temperatures and moisture. Low temperatures can slow the reaction and moisture can interfere with the reaction causing blistering and other negative effects. Polyureas, on the other hand do not require a catalyst. Reactivity for these coatings is fast, typically 3-10 seconds. Consequently they are able to cure at temperatures as low as -20 C and in the presence of moisture.

• In terms of performance, unlike polyureas, epoxies require a catalyst. They are sensitive to temperature, humidity and moisture, giving them a narrow window for application. Unlike polyureas, epoxies have extensive cure time and little or no elongation properties. This leads to frequent failure of the coating with expansion or movement of the substrate

The Comparison chart

Properties Polyurethane Epoxy Polyurea VIP QuickSpray

Working times Slow Slow Extremly fast (5 seconds to 45 minutes)

Moisture sensitivity Yes Yes No, moisture insensitve

Elongation 600% Tend to get brittle Upto 700%

Colour stability Average, yellowing Average, yellowing Aromatics: averageAliphatics: 100% UV resistant and colour stable

Abrasion resistance Average Good Very good

Superior tensile strength

Good Average Good

Chemical resistance Good Good Excellent

VOC free No No Yes

Temperature resistance From -30°C to +140°C From -20°C to +110°C From -50°C to +200°C

Seamless No No Yes, unlimited mil thickness with one layer

Coverage Different Different Average 1L = 1m2 = 1mm

Duration Good Average Excellent

Different version of Polyurea

• QuickSpray provides a huge range of application possibilities. The most popular applications worldwide are:

Steel30%

others10%

Truck & Transport10%

Roofs10%

Concrete40%

POLYUREAQuickSpray

Sales world wide (in Mio. L)

• 2006    PU                 2.400 Mio L            No change (90% solvent based)            PURA                30 Mio L            1,25% of PU sales

appr. growth rate for PURA 45% pa:

• 2008    PURA                  65 Mio. L       2,7% of PU sales Intermediate terms:

• Current Market shares: 50% US, 35% Asia, 15% Europe• Polyurea to reach 45% of total PU surface coating market• Add´s up to 800 Mio. Liters -> 8 Bio. Euro Market

World Market forecast

Source: PDA Europe and Beyer Material Science

• Protects steel pipes & tanks from chemically corrosive environments

• Applicable during primary construction or re-development

• Superior elongation & tensile strength

• Usable for pipes with PU-foam insulation

• Reduces maintenance services and costs

• Fast cure decreases return-to-service time

• Supports environmental stewardship

• Refineries, tank exteriors, oil platforms, piplines, gas stations, etc.

• Please ask for separate VIP presentation „Pipeline Coating“

QUICKSPRAY application:

► Petrochemical Industry

• High bandwidth form potable water to hazardous wastewater

• No VOC, no effect on potable water

• Specific VIP- systems for potable water approved (USDA/US, WRAS/UK)

• Virtually no permeability to water

• Great acid and microbial resistance

• Withstands constant immersion

• Remains flexible and resilient

• Short construction window makes it highly cost-effective

• Less expensive than previous GRP liners

• Potable water reservoirs, sewage treatment plants, primary/secondary containments, chlorination basins, clarifiers, filtration systems, pump stations, aeration tanks, digesters, sludge compartments, etc.

QUICKSPRAY application:

► Water & Wastewater Treatment

WRAS: Water Regulations Advisory Scheme (UK)

• Offers a longer lasting protection against corrosion, chemical attack and high temperatures

• Nuclear, fossil, hydro, wind and alternative generation

• Prevents transmission towers and substation structures form weathering

• Flooring systems for power plants

• Nuclear containment structures

• Oil, water and chemical storage tanks and containment areas

• Tank liners, cooling towers, stack, secondary containment, splash zones, cable ducts, etc.

QUICKSPRAY application:

► Power Industry

• Rehabilitaion of manholes & sewer systems• Excellent adhesion to brick, block and concrete• Resistant to caustic or corrosive chemicals/ gases• Moisture insensitive• Maintains tensile strenght and flexibility• Excellent crack-bridging ability• Protects cavity from sediment• Provides structural enhancement• Long-term stability and life• Fast cure decreases the return-to-service time• Less expensive than previous GRP liners

QUICKSPRAY application:

► Manhole & Sewer linings

GRP vs. QUICKSPRAY

Technical Property GRP Lining Polyurea - VIP QuickSpray

100% Solid Content No Yes

Monolithic No Yes

Seamless No Yes

Application Speed Very slow Very fast

Complextity of application Difficult Simple

Method of application Hand applied Unique plural component machine

Temperature resistant From +10°C to +80°C From -60°C to +150°C

Moisture sensitivity Yes No

Adhesion to concrete No adhesion > 3,5 MPa

Adhesion to metal Good > 20 MPa

Tensile Strength Very poor > 30 MPa

Chemical Resistance Good Excellent

Elongation 1% > 400%

Repair & Maintenance Difficult Simple

Application at critical areas Difficult Simple

Material costs more expensive less expensive

► Quick processing ► Extreme durability ► High chemical resistance ► Reduction of maintenance cycles► Professional and industrial look

QUICKSPRAY application:

► Industrial flooring

Hospitals Warehouses Power industry Pharmaceutical areas Manufacturing industryFood & Beverage production

• QuickSpray bedliners form a durable, permantent, water-tight liner

• Abrasion resistance protects from harsh environments against rust and corrosion

• Easy to clean

• Available in many colors

• Pick-up trucks, animal transport, refrigerator trucks, dump trucks, cement mixers, rail cars, steel containers, mining trucks, etc.

QUICKSPRAY application:

► Transportation & Trucks

Chemical resistance to sweat, suncremes, UV-exposure and chlorine

Replacement for paint and fiberglass

Ability to form custom shaped walls

Variety of colors

Waterscapes, molded slides, coating for seats in wet/dry conditions, aquariums, pools, non-skid areas, ponds, etc.

QUICKSPRAY application:

► Hotel & Leisure park industry

• Effective in protecting steel, aluminium and fiberglass above and in water

• Sound attenuation for engine compartments

• Non-skid application on decks

• Cruise ship, tankships, cargo ships, container vessels, jet-skis, buoys & fender, etc.

QUICKSPRAY application:

► Marine / Gel Coating

Superfast reaction times

• Polyurea's fast reaction time (5-15 seconds) leaves

polyurethane and epoxy materials in the proverbial dust.

Tremendous savings because of minimum

downtime for facilities.

Especially important for traffic, manufacturing

industry, energy and petrochemical market.

POLYUREAQuickSpray - QuickFill

Superior tensile & structural strength

• Excellent adhesion on steel, aluminium, GRP, plastics,

concrete, wood, isolating foams

• High tensile strength (3000psi/ ≥ 20MPa) while still having excellent elongation

POLYUREAQuickSpray - QuickFill

Deformation from moving substrate shifts will be reduced

Polyurea adapts to sonic and vibratory attack

High abrasion resistance

• High abrasion resistance (ASTM 4060-90)

• Superior elongation (upto 700%) ►stays soft, elastic and extremely flexible

• No cracking when exposed to constant pounding

Tremendous savings because of much longer maintenance intervalls. Epoxies crack and have to be repaired and re- coated. Polyureas guarantee a lifetime of 10 years and more after proper application

POLYUREAQuickSpray - QuickFill

High chemical resistance

• Polyurea is the choice of facility managers for storage of diluted acids, alkali, salt solution, organic solvents and oils

• Polyurea provides a strong barrier to spills from reaching the environment

• Ideal for petrochemistry, chemical processing facilities, (portable) water systems, reservoirs, sewage processing, manholes, holding tanks, secondary containment protection…

POLYUREAQuickSpray - QuickFill

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Thermal resistance

0 32

-60 -76

-32 -25

+60 +140

+150 +302

°C °F

Applicable without having

any influence on curing time

Temperature resistance

POLYUREAQuickSpray - QuickFill

Can be used in moist environments

Moisture insensitivity • Polyurea does not contain a catalyst

• The reaction of component A and component B (polyamines) is so fast that the moisture reaction cannot occur

Polyurea is not affected by moisture and outperform any product on the market today.

Polyurea is unbeatable in climates or regions with high humidity and moisture

No pinholes, less costs: No further measures for deaeration and set-up of a closed-porositiy surface

POLYUREAQuickSpray - QuickFill

• Grit / shot blasting– Removes surface latence– Exposes blow holes

• Repair blow holes, spalls, grind fins and ridges

– Fills voids reducing polyurea consumption

– Provides uniform surface– Helps prevent pin holing

• Prime substrate– Promotes adhesion– Reduces pin holing

POLYUREApreparation/concrete

• Abrasive blasting to near white is recommended– Removes oxidation & contamination– Provides surface profile promoting

adhesion– Often a specification requirement:

• NACE No2• SSPC – SP10• ISO Sa 21/2

• Solvent wipe– Required after abrasive blasting– Removes residues

POLYUREApreparation/steel

Different versions of Quick Spray Polyurea

1) Quick Spray Industrial

2) Quick Spray Eco

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Polyurea has great future as innovative coating material.For more details contact : india@vip-gmbh.com

Thanks a lot!!!