Fast set Polyureas and Polyurethanes
Fast set polyureas and polyurethanes have revolutionised the protective coatings industry. Where flexibility and fast turnaround are required. With physical properties such as elongation of up to 400%, gel times of under 10 seconds and being applicable to an unlimited thickness in a single pass they are truly remarkable.
Because of the extremely rapid gel time of these products specialist impingement mix plural spray equipment is required. At our disposal to apply Polyurea and fast set polyurethane products we have two Wiwa PU460 spray units and for smaller areas a Gamma Easy Spray.
This specialist equipment requires correct maintenance and trained operators/applicators. Unlike other contractors who do not fully understand the complexities of this rapid set technology all of our applicators are trained by the Polyurea development association. At the time of undertaking our training we were only the second contracting company from the UK to have undertaken the week-long training course.
Corroless Eastern have been Polyurea applicators since 2005 and have since successfully installed Polyurea bund linings, Polyurea Tank linings and Polyurea roofing membranes. Although extremely versatile each usage of Polyurea technology presents a unique challenge. Through our experience and training, we appreciate the intricacies of each project and adapt to suit them.
Benefits of our Polyurea Applications:
- Abrasion resistant.
- Chemically resistant.
- Fire retardant.
- Quick application.
As a waterproofing solution polyurea offers many benefits compared to conventional coating and membrane systems.
The first and most obvious of which is the materials flexibility and elongation. With the ability to elongate typically in excess of 300% and up to 900%, a polyurea membrane will expand and contract with a building without cracking a splitting. This ensures that water remains out of your property, avoiding costly and disruptive remedial works.
The high tensile nature of polyurea means that it is extremely durable once applied. This offers benefits on construction sites with regard to resisting damage from following trades.
A properly installed polyurea membrane has an expected service life measured in decades and will provide an extremely long lasting solution.
Because polyurea membranes are spray/liquid applied, plinths/up stands/pentrations can all be incorporated to give a seamless leak free finish. Unlike sheet membrane systems which rely on the integrity of welds and joints made in a site environment.
Polyurea is an ideal material for lining of secondary containment bunds due to its combination of strength, chemical resistance and elasticity.
The majority of bunds are constructed from concrete or blocks or a combination of the two. The crystalline nature of these materials makes them susceptible to cracking if subsidence or movement occurs. Whilst this cracking may not be detrimental to the structure itself, it will often lead to the inability of the bund to hold liquids in the event of a spill.
Because polyurea materials typically elongate in excess of 300% but up to and in excess of 900%, they can accommodate cracking and movement that may be present in a secondary containment structure without cracking or splitting – thus maintaining fluid tightness. When storing hazardous chemicals this if of critical importance.
There are a vast range of polyurea materials available from a range of manufacturers with differing physical and chemical properties – there is no one polyurea that is suitable for all bund linings. As we have been applying polyurea since 2005 we will use or experience to select the best manufacturer and product for your polyurea bund lining project.
Since its invention by the Texaco chemical company polyurea has been used as a roof coating – with one of the earliest trials being the Texaco factory roof. The high elongation properties make it particularly suitable for seamless flat roofing.
Unlike other forms of liquid roofing which commonly use polyester or polyurethane resins reinforced with chopped glass matt, polyurea is sufficiently high tensile so as not to require this reinforcement.
The spray application of polyurea roofing means that details such as vents, skylights and services can be seamlessly incorporated to ensure a leak free finish. Furthermore a polyurea is completely free from seams and joints.
A properly installed polyurea roof has an expected service life in excess of 25 years, providing an excellent return on your investment. This is supported by our meaningful installation warranties.
Unlike EPDM roofing polyurea can be heavily trafficked and will not puncture or tear easily.
Polyurea is an extremely versatile material and one of its many uses is in the relining of process and storage tanks. One area where it is particularly useful is the lining of tanks and vessels which may be subjected to dynamic movement – such as sectional and bolted tanks. This is because the high elongation properties of the material (often in excess of 300%) mean that flexing and movement can be accommodated without cracking and splitting the tank lining.
This flexibility also makes polyurea particularly suitable for the lining and relining of concrete tanks which always have the potential for cracking due to the nature of their construction. This ensures that the contents of your storage tanks remain where they should.
Another significant advantage of using polyurea for lining tanks is that the cure time following application is significantly less than alternative epoxy and polyurethane materials commonly used. This means that your tanks can be returned to service much quicker following relining.
The high tensile strength of polyurea means that it effectively creates a ‘tank within tank’, allowing the refurbishment of tanks that could not conventionally be refurbished.
Polyurea comes in many formulations and from many manufacturers. Different formulations offer varying levels of elasticity, chemical resistance and gel time. There is no one material that can fulfil all tank lining requirements. We have been applying Polyurea tank linings since …… and can draw on our years of experience to select the correct manufacturer and material for your tank lining project. From WRAS approved polyurea tank linings for drinking water, to hydrocarbon resistant storage tank linings, we have the solution.
Many less experience contractors make the mistake of thinking the normal rules of coating application do not apply when using this fantastic material – much to their detriment. As with all of our tank relining projects, polyurea tank linings are subjected to the same stringent quality assurance – from preparation through to spark testing for pin holes.
We are experts in Polyurea Applications, and we’ve done hundreds of projects in our 25 years of operation. Below are just a handful of some of our recent projects, from water tank repairs, to swimming pool linings, we’ve done it all.
What is Polyurea?
The technical definition of Polyurea is as follows;
Polyurea is a type of elastomer that is derived from the reaction product of an isocyanate component and a synthetic resin blend component through step-growth polymerization. The isocyanate can be aromatic or aliphatic in nature. It can be monomer, polymer, or any variant reaction of isocyanates, quasi-prepolymer or a prepolymer. The prepolymer, or quasi-prepolymer, can be made of an amine-terminated polymer resin, or a hydroxyl-terminated polymer resin.
The resin blend may be made up of amine-terminated polymer resins, and/or amine-terminated chain extenders. The amine-terminated polymer resins do not have any intentional hydroxyl moieties. Any hydroxyls are the result of incomplete conversion to the amine-terminated polymer resins. The resin blend may also contain additives or non-primary components. These additives may contain hydroxyls, such as pre-dispersed pigments in a polyol carrier. Normally, the resin blend does not contain a catalyst(s).
How is Polyurea applied?
The majority of polyurea coatings are applied using heated plural spray equipment that mixes the two components using an impingement method within a spray gun. The reason this method of mixing is required for the majority of polyurea coatings is that they generally have a very fast (sub 10 second) gel time that would make conventional airless or plural spray application unfeasible.
There are exceptions to this general rule with hand mixed polyurea coatings being available that have been modified to extend their gel time to as long as twenty minutes which can be applied by brush, roller or trowel.
What is the best Polyurea?
There is no such thing as a best polyurea as each material from different manufacturers has different technical limitations that must be considered. A common misconception is that all Polyurea is the same. This would be like saying that all types of cheese are the same. Much like cheese you can get both soft and hard polyurea along with a whole host of other varying characteristics such as elongation, chemical resistance, UV stability etc
What can Polyurea be applied to?
Depending on the preparation and priming required polyurea can be applied to;
- Steel/Iron/Stainless Steel
- Stainless Steel
What can Polyurea be used for?
Polyurea is a very versatile material and can be used for a whole array of projects such as the following;
- Polyurea Tank Linings
- Polyurea Bund Linings
- Polyurea Roofing
- Polyurea Waterproofing
- Polyurea Blast Mitigation
- Polyurea set Design
Why choose Polyurea?
Polyurea offers the following advantages that can be useful;
- Elongation properties of up to 900% are possible with polyurea coatings, making polyurea an excellent material for protecting substrates prone to cracking or dynamic movement – such as concrete or sectional tanks.
- Impact Resistant – The flexible nature of polyurea means that it offers good impact resistance for surfaces that are likely to receive mechanical loads
- Chemical Resistance – Depending on the formulation polyurea materials can have excellent chemical resistance to hydrocarbons, effluents, acids and alkalis.
- Long Service Life – Polyurea coatings typically have an expected service life in excess of 20 years.
- Rapid Cure – The fast curing nature of polyurea means that it can be returned to service rapidly, typically within 24 hours of application.
What should I look for in a Polyurea applicator?
The three key things to look for when choosing a polyurea applicator are;
- Training – Polyurea is one of the most complex coating materials to apply. Incorrectly applied Polyurea will cost more to remove than to apply. The Polyurea Development Association or quality manufacturers offer a training course which is typically a week long. This teaches you how to apply polyurea correctly, including preparation and testing techniques. Why would you gamble with and untrained polyurea applicator?
- Experience – Whilst correct polyurea training sets the foundations, experience in applying polyurea is also required as nothing beats first-hand knowledge in using and more importantly maintaining and repairing your polyurea application equipment. Would you be prepared to be your contractors learning curve with the costly mistakes that this can entail?
- Reputation – Poor workmanship quickly leads to a bad reputation. A good polyurea contractor would be happy for you to speak to previous clients as when applied correctly polyurea speaks for itself.
How much does polyurea cost?
There is a lot more to a polyurea project than just turning up and spraying. The preparation and repairs required prior to polyurea application can create significant variance to the price, therefore a job specific quote is always required.