Polyurea Basic Concepts Rev 0918 1

Polyurea Basic Concepts Rev 0918_1

Primeaux Associates LLC

Informal Casual Atmosphere

• Welcome to the Polyurea Basic Concepts Course • Follow a PowerPoint Presentation – Course Manual • Ask questions when you have them • Get to know the people in the room – Material suppliers – Equipment suppliers – Contractors – Inspectors – Consultants – Newcomers to the business

Introductions

• Instructor – Dudley Primeaux II, PCS, CCI – > 50 Technical Publications – Named inventor on > 30 Patents

• Class Self Introductions

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Polyurea Disclaimer • Not all polyurea’s are created equal • Material covered & physical properties do not apply to all polyurea’s • Many different aspects determine a successful application of polyurea – Material selection for project – Surface preparation – Equipment setup & use – Application techniques

What is Polyurea?

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What is a “Polyurea”?

“Polyurea” is a description of a technology and it in itself is not a coating / lining material.

Polyurea Technology

• Polyurea is a thermoset material, not a thermoplastic • As with all thermoset materials, there is some “shrinkage” associated with cure • Can be between 0.5 – 5.0% linear!

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Polyurea Technology

Typical Shrinkage, general values

Hardness, Shore D Elongation, % Shrinkage, % 60 – 70 < 100 3 – 5 % 50 – 60 ~200 – 250 2 – 4 % 40 – 50 ~250 – 500 1.5 – 2.5 % < 35 ~250 – 800 0.5 – 1.0 %

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Polyurea Definition

•A pure polyurea coating / elastomer is derived from the reaction product of a polyisocyanate component and an amine-terminated resin blend.

For reference purposes, a polyurethane / polyurea hybrid coating / elastomer is the reaction product of a polyisocyanate component and a resin blend component. The resin blend may be made up of blends of amine-terminated and / or hydroxyl-terminated polymer resins.

Polyurea Definition

From the PDA / SSPC Definition: • Two-part system • One part is Isocyanate component – reactive isocyanate groups ( -NCO) • Other part is a Resin blend component – reactive group is amine (primary or secondary)

–( -NH2 or -NH-) • Reaction of the two components yields a urea linkage

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Polyurea Reaction

Urea linkage

Polyurea Technology

Polyurea

Hybrid’s

Polyurethane

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Polyurea Technology

MDI - aromatic • some TDI based

IPDI - aliphatic • also HDI and

H12MDI derivatives

Polyurea Technology

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Polyurea Technology

• Primary Amine –fast

• Secondary Amines –slower

• Aliphatic Amines – Aliphatic systems

Also some hindered primary amines

Aspartic Technology of “Polyurea”

Polyaspartic (Aspartic) Ester Polyurea Systems • Introduced in the early ‘90s – 2° aliphatic diamine + polisocyanate (usually aliphatic) • Slower Cure / Airless Spray – potlife: 2 - 60 min. – tack free dry: 5 - 120 min. • Often Used in Thin Film (<15 mils, < 400µm) Topcoat Applications – non-yellowing/gloss retention – 70 - 100% solids

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Aspartic Technology of “Polyurea”

• Applications - High Productivity Concepts when “time is money” – Metal Coatings • DTM for Railcar • Powder Coating Replacement for metal poles

– Concrete Surface Coatings • Interior Surface of Tunnel (topcoat over conventional polyurea) • San Mateo Bridge Topcoat (over conventional polyurea) • Flooring topcoat (roller applied over epoxy primer)

Chemistry Overview

• From a chemistry perspective, polyurea is that system were the reaction is with isocyanate and amine terminated resin - no polyols / hydroxyls • Does not always require plural component equipment for application • Can be fast or slow setting • Growing technology

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Chemistry Overview

Formulation Basics vs Technology Type For the resin blend component (traditional system)

Resin Component Chain Extender System Type Polyetheramine / polyamine Amine terminated Polyurea Polyether polyol (-OH terminated) Amine terminated Polyurea/Polyurethane Polyetheramine / polyamine Glycol (-OH terminated) Polyurethane/polyurea Polyether polyol Glycol (-OH terminated) Polyurethane

No such thing as a “% Polyurea System”

History of the Technology

• 1981 - Developed for Automotive RIM

• 1986 - Polyurea Spray Systems Developed – Primary objective was for PU Spray Foam Coating • 1987 - Polyurea Spray Technology Introduced to Industry • 1988 - First Commercial Use

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Characteristics

• Fast, consistent reactivity / no catalysts – Fast return to service • Relative environmental process insensitivity – Extended working season • Excellent mechanical properties – Flexible, seamless, moderate chemicals • Good adhesion to a variety of substrates – With proper surface preparation • 100% solids formulations – No solvents, VOC’s, little to no odor

Polyurea Technology

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Technology Introduction

Texaco Video

Systems Available

• Aromatic Based Spray Formulations - limited color stability in outdoor applications • Aliphatic Based Spray Formulations - excellent color stability in outdoor applications - more costly than aromatic based systems • NSF/ANSI 61.5 Potable Water Approved • Direct Food Contact approved • Polyaspartic Ester Polyurea (thin film) • Slow Set Joint Sealants • Hand Mix Systems for Repair

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Polyurea Elastomer Testing

Typical Physical Properties

Tensile strength, psi up to 6500 (45 MPa) Shore Hardness A 25 to D 80 Elongation, % up to 1000 Tear strength, pli 250 to 600 (43 – 105 kN/m) 100% Modulus, psi 500 to 2000 (3.5 – 13.8 MPa) Burst strength, psi 250 to 500 (1.7 – 3.5 MPa) Flex/Crack Bridging > 1/8 inch (> 3 mm) -26°C / -15°F

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Property Testing: Technical Data Sheets

Important Aspects for Applicator Gel Time and Tack Free Time - used to confirm proper processing

Shore Hardness - used to affirm that applied on-ratio

Property Testing

Reactivity and Cure

Gel Time: the time, in seconds or minutes, in which the mixed components of a polyurea system change from a liquid / fluid state to a solid.

Tack Free: the time, in seconds or minutes, in which there is a absence of tack or stickiness in an applied polyurea system surface.

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Property Testing

Reactivity and Cure Cure Time: The period of time when a polyurea material attains it’s ultimate physical properties. Caution here as many systems may reach a “cure point” within a short period of time that would allow use in a particular application, but have NOT reached ultimate physical properties. The cure time varies on different formulations, with the high hardness, low elongation systems reaching full cure faster that the slower, higher elongation systems. This ultimate “cure” may be 24 to 48 hours plus after application.

Tensile & Elongation

For elongation

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Tensile Strength

ASTM D-638, D-412, EN 12803 • Measure of the relationship of stress to strain. Sometimes referred to as modulus or tensile modulus. Measured in psi (pounds per square inch) or mPa.

In lay terms, how much force is required to “move” or “stretch” the elastomer film.

Elongation

ASTM D-638, D-412, EN 12803 • Measure of the amount of stretch, at break, of the elastomer. Measured in %.

Keep in mind, this is related to the Tensile Strength.

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Tear Strength

ASTM D-624, ISO 34 • Measure of the force per unit thickness it takes to propagate a tear in the standardized elastomer sample. Measured in pli (pounds per linear inch) or N/m (Newton/meters). -(propagation)

Hardness

ASTM D-2240, ISO 868 • Measure of the resistance of a material to deformation, indentation or scratching (surface). It is a relative term and should not be confused with wear and abrasion resistance. Measures resistance to penetration by a “point”. Use either Shore D or Shore A.

Often times confused with stiffness or flexural modulus.

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Hardness

ASTM D-2240, ISO 868 • Can be used to give an indication as to if coating system has been applied “on-ratio”

Hardness

ASTM D-2240, ISO 868

Shore A Shore D 100 58 95 46 90 39 85 33 80 29 75 25 70 22 65 19 60 16 55 14 50 12 45 10

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Flexibility & Crack Bridging

ASTM C 836 / C 1305 Measure of a coating / lining material’s ability to bridge an existing crack that may move in the substrate. Commonly used for concrete flooring type applications.

• Many fast set polyurea elastomer systems note the following result: > 1/8 of an inch (3.2 mm) at -20°C

- Need to be cautious of “memory” in the polymer system.

Abrasion Resistance

ASTM D-4060, DIN 53 754 • Test Method for the Abrasion Resistance of Organic Coatings by the Taber Abraser. • Used as a comparative test method between coating systems. Will give an indication as to how the coating system may perform in a highly abrasive environment.

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Abrasion Resistance

Abrasion Resistance: ASTM D-4060

Must be sure that you are comparing proper test wheels to the resultant data:

CS Wheels: “Rubber Wheels”, Resilient CS-17 (Rubber and abrasive grain, harsh)

H Wheels: “Stone Wheels”, Non-resilient H-18 (vitrified, medium coarse)

Coefficient of Friction

From Lab Testing, not field work:

ASTM D 1894, stainless steel platen

Smooth finish 0.14 - 0.15 Orange peel 0.25 - 0.40 Textured 0.40 - 0.75 Polyethylene (reference) 0.20

ASTM D 2047, dry & wet leather Dry Wet Smooth 0.85 0.64 Medium texture 0.93 > 1.20 Heavy texture 0.94 > 1.20

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Coefficient of Friction Use of a Portable Slipmeter – Field Work ASTM F 609 Standard Test Method for Using a Horizontal Pull Slipmeter (HPS) ANSI/NSFI B101.1 – BOT 3000E ≥0.50 CoF is deemed nonhazardous walking surfaces OSHA = ≥0.50; ADA ≥0.60, with ≥0.80 for ramps

UL AND ASTM DESIGNATIONS

Coefficient of Friction Designation CERAMIC TILE INSTITUTE DESIGNATIONS 0.60 or above Very safe Coefficient of Friction Designation 0.50 to 0.59 Relatively safe 0.60 or above Slip resistant 0.40 to 0.49 Dangerous 0.50 to 0.59 Conditionally slip resistant 0.35 to 0.39 Very dangerous Less than 0.50 Questionable 0.00 to 0.34 Unusually dangerous

Coefficient of Friction

The Coefficient of Friction can be enhanced by the addition of aggregate, NOT Sand, onto the polyurea elastomer during installation. This can be light, or broadcast to rejection. This is then topcoated with a light coat of polyurea or other suitable system (polyurethane).

2 2 For broadcast to rejection, use 1/2 lbs / ft (2.44 kg/m ). Top coat

Light addition Broadcast to Rejection

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Coefficient of Friction

The Coefficient of Friction can be also enhanced by the addition of a treated rubber additive either into during formulation of the system or onto the polyurea elastomer during installation. Need a slow set system to properly accept material. A common treated rubber crumb is VISTAMER® 4030PU. For broadcast to rejection, use 2/10 lbs aggregate / ft2.

Formulated in Broadcast to Rejection

Coefficient of Friction

For polyaspartic ester (slow cure polyurea systems) the Coefficient of Friction / slip resistance can be enhanced by the addition commercial powdered polyethylene into the coating system during mixing of the two components. For use, add 1 pint to each 5 gallons of blended system.

• Behr Non-Skid; H & C™ SharkGrip®

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Coefficient of Friction

Coefficient of Linear Thermal Expansion (CLTE) ASTM C-531 • The CLTE is the ratio of change of a linear dimension to the original dimension of the material for a unit change in temperature.

•This is NOT shrinkage of the material during the cure stage.

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Coefficient of Linear Thermal Expansion (CLTE) Industry Reported Values (CLTE):

µin / in - °F µm / m - °C Polyurea, typical 2 - 6 4 - 13 Steel 6 - 7 12 - 13 Concrete 5 - 6 9 - 11 Glass 4 - 5 8 - 10 Plywood 3 - 4 5 - 6 Vinyl Ester 10 - 11 18 - 20 FRP 15 - 16 27 - 29 Polyurethane, typical 53 - 85 100 - 150 Epoxy 20 - 25 35 - 55

Moisture Vapor Transmission

ASTM E-96, D 1653 • This is a measure of the Moisture Vapor Transmission (MVT) rate through a specific film of elastomeric coating / lining system. This is NOT water. • In general, aromatic polyurea systems have shown an MVT value of 0.02 “perms” (30 mils / 0.76 mm of polyurea). Can also be used to evaluate the perm rating for other chemicals. • Check to make sure proper reporting units!!!!

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Cold Wall Effect

Adhesion Characteristics

Substrate Elcometer Adhesion, psi (mPa) Concrete, dry 400 (2.8 mPa), SF Concrete, primed > 400, SF Steel, 2-mil blast profile > 2000 (13.8 mPa) Aluminum, cleaned > 2000 Wood 250 (1.7 mPa), SF Polyurea, cleaned = cohesive strength

SF = Substrate Failure

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Adhesion Characteristics

- over concrete, note level of substrate failure.

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Performance Issues

Performance Type Polyurea Polyurethane Polyester Epoxy Vinyl Ester Acrylic Polysulfide Physical strength Low-High Low-Mid High High High Mid-High Low-Mid Elongation High High Low Low Low Low-Mid High Impact resistance High Mid-High Mid Mid Mid Mid-High Mid-High Abrasion resistance High Mid-High Mid-High Mid-High Mid-High Mid-High Mid Adhesion to concrete Low-High Low-Mid Mid High Mid Low-Mid Low-Mid Cure shrinkage Low Low High Low High High Low Permeability Low Mid-High Low Low Low Low-Mid Mid-High UV Resistance Mid-High Low-High Mid-High Low Mid High High Creep Low High Low-Mid Low-Mid Low-Mid Low-Mid High Temperature limit Low-High Mid Low-Mid Mid-High Mid-High Mid Low-Mid

Chemical Resistance Mineral acids Low-Mid Low-Mid Mid-High Mid-High Mid-High Mid Low-Mid Organic acids Mid Low-Mid High Mid High Mid Low-Mid Alkalis Mid-High Low-Mid Mid High High High Low-Mid Chlorinated solvents Low-Mid Low-Mid Low-High Low-High Mid-High Low-Mid Low-Mid Oxygenated solvents Low-Mid Low-Mid Low-High Low-High Mid-High Low-Mid Low-Mid Hydrocarbon solvents Low-Mid Low-Mid Mid-High Mid-High Mid-High Low-High Low-Mid Salts High Mid-High High High High High Mid-High Water High Low-High Mid-High Mid-High Mid-High Mid-High Low-High

Performance Issues

From Huntsman Corp

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Performance Issues

• UV Stability - Aromatic Based Systems

250 hours 3000 hours 3250 hours 3000 hours

QUV Weatherometer testing, ASTM G-53 , UVB-313 bulbs

Performance Issues

• UV Stability - Aliphatic Modified Systems

After 20-hours After 97-hours exposure exposure

QUV Weatherometer testing, ASTM G-53 , UVB-313 bulbs

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Performance Publication

•From JPCL July 2010

PROCESSING BASICS

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Processing Characteristics

• Spray Systems • Joint Sealant / Joint Filler Systems • Hand Mix Systems

Spray Applications

Three Basic Requirements: – Develop high pressure – High Temperature, lower mix viscosity – Material volume flow, greater than the capacity of the spray gun setup

Drum pump output must exceed total equipment output

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Plural Component Equipment

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High Pressure Spray Guns

Must be impingement mix

- Moving mixing chamber air purge guns

- Fixed mixing chamber / moving valving rod; mechanical purge

Material must enter chamber, mix and exit rapidly

High Pressure Spray Guns

Reactivity and Cure

Cure Time: The period of time when a polyurea material attains it’s ultimate physical properties. The same “cure” characteristics reported earlier for fast set polyurea systems are also affected by the spray gun used. It has been shown that the Air Purge spray guns gives rise to larger “spray” droplets and tend to require longer “cure times” to reach final physical properties as opposed to the use of the Mechanical Purge spray guns with a spray tip. The Mechanical Purge spray guns produce finer “spray” droplets.

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Caulk / Joint Sealant Units

Caulk / Joint Sealant Systems

• Should have matched material viscosity; ISO to Resin • Use a 24 to 36-element mix tube • Shorter tubes better for hand-crank guns • Can heat to help flow / mix, especially in cool environments and application areas

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Hand Mix Systems

• Always add the resin to ISO part • Mix in small quantities / batches • Minimize “air entrapment” during mixing

MATERIAL BASICS

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Material Storage

· Store material at 60°F to 110°F (16°C to 45°C). Do not store outside exposed to weather. · Store on pallets and not on bare concrete; · Keep lids sealed and drums away from moisture; · Keep away from extreme heat; · Only open containers when ready to use; and, · Use air desiccant or nitrogen blanket before sealing opened containers; · Always agitate the resin blend before use as pigments do settle.

Silica Gel Dryer

• In almost any area this is a must on the “A” ISO Drum to prevent reaction to moisture. • When the blue turns pink, you can take out and rejuvenate it in a oven or microwave.

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Drum Mixer / Blades

• For proper mixing the blades should be 1/3 the diameter of the drum, 24” (61 cm) drum needs a 8” (20 cm) blade. • Air supply or hydraulics. • Auger type mixers, don’t work. • ISO Drum – Should Never mix! Only use in the “B” Resin drum.

Drum Heaters

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SAFETY

Safety

• Safety is First and Foremost!

- Material handling - Application safety issues - high pressure / high temperature - Jobsite safety issues - confined space, scaffolds, etc.

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Safety: Isocyanates

• Health Issues – Skin and Respiratory Irritation – Skin and Respiratory Sensitization

• Polyisocyanates will react with water to form CO2 – Contamination with water can lead to dangerous build up of pressure in a closed container, e.g., a drum • Polyisocyanates have essentially no odor – may not know that you have been exposed – spray and/heating operations should take special precautions to prevent exceeding exposure limits

Safety: Isocyanates

• Medical Surveillance • Training of Personnel • Workplace Monitoring • Implementation of Engineering Controls (i.e. Spray Booths and Local Exhaust Ventilation) • Protective Equipment (i.e. Respirators, Clothing, and Gloves)

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Safety: Isocyanates

In process of update within SSPC

Safety: Amine Resin Blends

• Shipping of the B resin Material requires the rules and regulations of shipping a corrosive product. – Some companies have tested, not corrosive from DOT shipping

• Shipping of the A ISO drum requires that it does not freeze in shipment during the Winter Months.

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Safety:

• Full face Organic vapor cartridge with HEPA particle pre-filter • Full body protection, no short sleeves, etc • Proper gloves / hand protection • Read and understanding SDS, and labels • Everyone help to keep it safe

APPLICATION PROCESS

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Application Concerns

• Substrates – prepared properly • Environmental – check conditions • Service Conditions – ask questions!

Low numbers = Acid / High numbers = Alkaline example: 0.36% HCl solution - pH = 1

What is a “Polyurea”?

“Polyurea” is not an excuse NOT to perform the proper / required surface preparation.

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Application Concerns

Substrates:

Remember:

You are only as good as what you are sticking to!

Application Process

Surface Preparation

Cost per area

Water wash least cost Power wash cleaning Hand Tool cleaning, SP-2 Power tool cleaning, SP-3 Commercial blast, SP-6 Near white blast, SP-10 most cost

Note: The least costly may not be the best surface preparation for a successful application!

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Application Concerns

Substrates: Concrete

• Porous substrate • Low tensile strength • Moisture Vapor Emission

Living, Breathing Material!

Substrate Preparation

Concrete Surfaces:

• For high build coating / lining systems – 10 - 125 mils (100 µm - 3 mm) applied polyurea

Suggested use of CSP 3 to CSP 6 for concrete surfaces for optimum performance in polyurea systems

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Application Concerns

Substrates: Steel

• Sound substrate • Must be clean, dry and free to contaminants • Good blast profile to enhance mechanical adhesion (SSPC-SP 5 or SP 10, NACE No. 1 or No. 2)

Substrate Preparation

• Methods for Metal – SSPC SP / NACE No. / ISO 8501-1 preparations – SP 10 to SP 5 (near-white to white metal) • Caution applying over flash rust / rust – soluble salts – especially in immersion applications – Visible sign for non-visible contaminants • Need to specify a profile – i.e. 2 - 3 mil (50 – 76 µm), etc – immersion should be a minimum 3-mil profile (76 µm)

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Application Concerns

Environmental:

• weather issues (wind, rain, dew point) • substrate contaminants • temperature of exposure • chemical exposure environment

Application Concerns

Service Conditions:

• chemical exposure • temperature exposure • traffic / load

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Environmental Testing

• You need to know your temperatures for dew point • Moisture in the concrete • Wind speed • Surface temperature monitoring for exotherm • Close inspection and working on the modules

Environmental Testing

Kestrel 4000 Unit (ASTM E 337)

• wind speed • temperature - both dry and wet bulb • dew point • humidity • altitude Substrate temperature must be 5°F (3ºC) above dew point and rising!

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TECHNOLOGY APPLICATIONS

Application Interests

• Encapsulate Corpses • Human Form Targets • Polyurea Particles • Line manholes • Road Striping

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Application Interests

• Encapsulate Corpses • Human Form Targets • Polyurea Particles • Line manholes • Road Striping • Making horseshoes

First Major OEM Application

• Wire Harness Program for Chrysler • Today, we have the handles coated with polyurea spray for Sebring Convertible

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First Major OEM Application

• NISSAN OEM Bedliner – Aliphatic Polyurea System

Hopper Car Lining

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Hopper Car Lining

Concrete Coatings • Secondary containment

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Concrete Coatings

• Secondary containment

-primed - sprayed same day (100 mils)

Concrete Coatings

• Clean rooms / food processing

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Concrete Coatings

• Installation of Polyaspartic Ester polyurea system in a flooring application

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Concrete Coatings

• Marine

• Corpus Christi, TX Seawall, PCSI

Concrete Coatings

Beau Catcher Tunnel in NC; since been topcoated with aliphatic polyaspartic ester polyurea system for color stability.

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Concrete Coatings

• Boston CA/T Project • Boston MBTA Project

Concrete Coatings

• De-Con Work

Flooring in nuclear application areas

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Concrete Coatings

• De-Con Work

Pit lining for ease of decontamination of low level radioactive waste.

Concrete Coatings

• San Mateo Bridge

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Concrete Coatings

• Pentagon Remote Delivery Facility Deckcoating

Concrete Coatings

• Detroit Edison / Fermi 2 - Water Inlet Room, Marley Class Cooling Tower - 250,000 gals/min inlet flow, - Replaced stainless plates - 2004 in service

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Concrete Coatings

• Concrete Tank Linings – 16.8 million gallon chiller tank, glycol and water – Primed, 80 mils PUA, 3 inches PU foam, 80 mils PUA – Several projects specified by local engineering firm

Tank Linings

• Concrete tanks / waste-water

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Tank Linings

• Water storage

Tank / Linings

• Reactor Cavity – Oyster Creek – Completed 2010

• Encapsulation – Oak Ridge Nuclear Labs – Completed 2010

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Corrosion Protection

• Sand pump casing

Decorative / Water

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Geotextile Spray Work

Sprayed-in-place

Pre-sprayed panels

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Geotextile Coatings

• Contaminated Ground Umbrella / Cap

– CH2M Hill Hanford, underground leakage – 70,000 ft2 – Completed 2008

Roof Coatings

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Agricultural / Zoo

Industrial

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Industrial

International

• Tank Top Repair

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Interesting Application Work

Bridge Deck Waterproofing

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Bridge Deck Waterproofing • Concrete Deck Waterproofing – High Speed Rail Line – China – From Beijing to Shanghai – 1318 km in length – 12,000,000 m2 surface area – 25,000 tons Polyurea used • More projects to follow

Interesting Application Work

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• “Ballistic” Applications • Protection of Structures – Public Buildings – Chemical facility control rooms • Protection of “vehicles”

Ballistic retro-fit

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Interesting Application Work

• Pipe Lining Work - Wastewater

Robotic Pipelining

• Robotic Pipe-Lining Rehabilitation – Technology introduced in 2000, but slow to start – Robotic Spray-In-Place Pipe (SIPP) – Up to 200 meters in-place, 2.5 cm to 2.5 m diameter – Municipal or Chemical plant use – High pressure rating • 76 mm dia hole, 6 mm thickness, > 2.8 MPa pressure hold – Electrostatic deposition also available • New ASTM Standard on SIPP – Class IV Structural ANSI/NSF 61 potable water

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Miscellaneous

APPLICATION USE

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Application Process

Typical Application Thickness

Polyurethane foam: 25 - 40 mils (0.64 - 1.0 mm) Foot traffic: 40 – 60 mils (1.0 – 1.5 mm) Vehicular traffic: 60 – 80 mils (1.5 – 2.0 mm) Heavy traffic: 80 – 125 mils (2.0 – 3.2 mm) Wall applications: 30 – 60 mils (0.8 – 1.5 mm) Immersion service: > 80 mils (> 2.0 mm) Geotextile fabric: > 60 mils (> 1.5 mm)

From: General Guidelines: Polyurea Elastomeric Coating / Lining Systems PDA, 2003. SSPC-Paint 45, The Society for Protective Coatings, Dec 2013

Application Process

Primer and Polyurea Requirement: US Units (theoretical):

gal / ft2 = dry film thickness (mils) / (1604 * % solids) example: 50 mils of 100 % solids polyurea gal / ft2 = 50 mils / (1604 * 1.00) = 0.03 gal / ft2 or 3 gals / 100 ft2

5 mils of 70% solids primer (per 100 ft2) gal / ft2 = (5 mils / (1604 * 0.70)) * 100 = 0.44 gal / 100 ft2

Remember, for 100% solids, 1 gal of mixed system covers 100 ft2 at 16 mils (0.016 inches) DFT

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Application Process

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Application Process

Primer and Polyurea Requirement: Metric Units (theoretical):

L / m2 = dry film thickness (mm) / (1 * % solids) example: 2 mm of 100 % solids polyurea L / m2 = 2 mm / (1 * 1.00) = 2.0 L / m2

0.05 mm of 80% solids primer (per 100 m2) L / m2 =(0.05 mm / (1 * 0.80)) * 100 = 6.0 L / 100 m2

Remember, for 100% solids, 1 liter of mixed system covers 1 m2 at 1 mm (40 mils) DFT

Application Process

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Application Process

In calculating costing, need to include a “loss” factor: Industry standard for spray application is minimum15% loss for spray application work Example: 26,000 ft2 over concrete at 65 mils, polyurea is $38.50 / gallon1 (65 mils / 16) * $38.50 * 1.15 (loss factor)) / 100 = $1.80 / ft2 This is just the cost of the polyurea system, does not include surface prep, primer use, application and related equipment expenses. Refer to SSPC-TU 9 “Estimating Costs for Protective Coatings Projects”

1 The pricing information listed here does not reflect / imply the current market pricing for polyurea spray elastomer systems. The number used is just for purposes of completing the calculation / example.

Application Process

Coverage per Hour

Coverage (ft2) per hour

Equipment output, gal/min 0.5 1.0 1.5 2.0

Film thickness: 16 mils (0.4 mm) 3000 6000 9000 12000 32 mils (0.8 mm) 1500 3000 4500 6000 48 mils (1.2 mm) 1000 2000 3000 4000 64 mils (1.6 mm) 750 1500 2250 3000 80 mils (2.0 mm) 600 1200 1800 2400 96 mils (2.4 mm) 500 1000 1500 2000 112 mils (2.8 mm) 429 857 1286 1715

Polyurea Basics, Rev 0918.1 73 Primeaux Associates LLC

Application Process

Spread Sheet Program

Application Process

Weight per Unit Area

Film thickness: lbs / ft2 kgs / m2 16 mils (0.4 mm) 0.08 0.4 32 mils (0.8 mm) 0.16 0.8 48 mils (1.2 mm) 0.24 1.2 64 mils (1.6 mm) 0.32 1.6 80 mils (2.0 mm) 0.40 2.0 96 mils (2.4 mm) 0.48 2.4 112 mils (2.8 mm) 0.56 2.8

Note: These weights are approximate

Polyurea Basics, Rev 0918.1 74 Primeaux Associates LLC

Associations

• The Society for Protective Coatings www.sspc.org • National Association of Corrosion Engineers www.nace.org • Spray Polyurethane Foam Alliance www.sprayfoam.org • Polyurea Development Association www.pda-online.org, www.pda-europe.org

Industry Specifications • SSPC: The Society for Protective Coatings – Paint Specification No. 39 (SSPC-Paint 39) • Two-Component Aliphatic Polyurea Topcoat, Fast or Moderate Drying, Performance- Based – Coating System SSPC-PS 28.01 • Two-Coat Zinc-Rich Polyurethane Primer / Aliphatic Polyurea Topcoat System, Performance-Based – Coating Application Standard No. 14 (SSPC-PA 14) • Application of Thick Film Polyurea and Polyurethane Coatings to Concrete and Steel Using Plural Component Equipment – Coating Standard No. 43 (SSPC-Paint 43) • Direct-To-Metal Aliphatic Polyurea Coating, Performance Based – Coating Specification No. 44 (SSPC-Paint 44) • Liquid-Applied Organic Polymeric Coatings and Linings for Concrete Structures in Municipal Wastewater Facilities, Performance-Based – Coating Standard No. 45 (SSPC-Paint 45) • Two-Component, Thick-Film Polyurea and Polyurea/Polyurethane Hybrid Coatings, Performance Based

• Committee Work: Polyurea – C.1.3D Polyurethane Coatings – C.1.9 Polyurea Coating – C.1.13 Coatings for Wastewater Facilities

Polyurea Basics, Rev 0918.1 75 Primeaux Associates LLC

Industry Specifications

• ACI 515.2R-13 – “Guide to Selecting Protective Treatments for Concrete”

• Canada CAN/ULC-S668-12 – “Standard for Liners Used for Secondary Containment of Aboveground Flammable and Combustible Liquid Tanks”

What is a “Polyurea”?

“Polyurea” is a description of a technology and it in itself is not a coating / lining material.

Polyurea Basics, Rev 0918.1 76 Primeaux Associates LLC

Conclusion

• Technology evolved since 1986 introduction • Improved formulations / raw materials • New equipment designs • Vast industry acceptance

Polyurea Basics, Rev 0918.1 77 Primeaux Associates LLC

Polyurea Basics, Rev 0918.1