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2019/6/11 Polyurea Spray-Applied Systems for Concrete Protection
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September1,2003
PolyureaSpray-AppliedSystemsforConcreteProtection
Polyureaspraycoatingstechnologyisarecentdevelopmentinthe
polyurethanecoatingsindustry.Polyurethanechemistryhasbeenin
existenceforapproximately60years,whileelastomericurethanecoatings
havebeenavailablesincethe1970s.Polyureaelastomertechnologywasintroducedsome10yearslater.
ThetwomainapplicationareasareReactionInjectionMoulding(RIM)andsprayablecoatings.
Polyureacoatingscombineextremeapplicationpropertiessuchasrapidcure(evenattemperatures
wellbelow0øC),andinsensitivitytohumidity,withexceptionalphysicalpropertiessuchashigh
hardness,flexibility,tearandtensilestrength,andchemicalandwaterresistance.Thisresultsingood
weatheringandabrasionresistance.Thesystemsare100%solids,makingthemcompliantwiththe
strictestVOCregulations.Duetoitsspecificcuringprofileandexceptionalfilmproperties,the
polyureaspraycoatingtechniquehasbeenintroducedintomanyareas,includingcorrosionprotection,
containment,membranes,liningsandcaulks.
Figure1/IsocyanateChemistry
DefinitionsTheterm'polyurea'hasbeenwronglyusedinthepast.Urethanecoatingschemistrycanbedividedinto
threesegments:polyurethanecoatings;polyureacoatings;andhybridpolyurethane/polyureacoatings.
Allthreearelinkedtodifferentisocyanatereactions(Figure1).Eachofthesesegmentsdealswith
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systemsthatcanbearomatic,aliphatic,orablendofbotharomaticandaliphatic.Pigments,fillers,
solventsand/oradditivescanbeintroducedtoallofthem.
Apolyurethanecoatingistheresultofareactionbetweenanisocyanatecomponentandaresin
blendmadewithonlyhydroxyl-containingresins.Thefinalcoatingfilmwillcontainnointentional
ureagroups.Apolyurethanesystemwillmostprobablycontainoneormorecatalysts.
Apolyureacoatingistheresultofaone-stepreactionbetweenanisocyanatecomponentanda
resin-blendcomponent.Theisocyanatecanbemonomerbased,aprepolymer,apolymerorablend.
Fortheprepolymer,amine-and/orhydroxyl-terminatedresinscanbeused.Ontheotherhand,the
resinblendshouldonlycontainamine-terminatedresinsand/orchainextendersandnotanyhydroxyl
reactivepolymercomponents.Allthepolyureacoatingsmentionedinthepapercomplywiththis
requirement.
Apolyurethane/polyureahybridcoatinghasacompositionthatisacombinationoftheabove-
mentionedtwo-coatingsystems.Theisocyanatecomponentcanbethesameasthe"pure"polyurea
systems.Theresinblendisablendofamine-terminatedandhydroxyl-terminatedpolymerresins
and/orchainextenders.Theresinblendmayalsocontainadditives,ornon-primarycomponents.To
bringthereactivityofthehydroxyl-containingresinstothesamelevelofreactivityastheamine-
terminatedresins,theadditionofoneormorecatalystsisnecessary.
Thewater/isocyanatereactionalsoproducesurea-groupsattheendoftheprocess.However,this
reactionshouldnotbeconsideredtobeapolyureareactionasthemechanismisatwo-stepprocess,
whichiscontrolledbythemuchslowerisocyanatewaterreactionandproducescarbondioxide.
Figure2/ApplicabilityoftheDifferentPUChemistries
ThePolyurethaneLandscapeThechoicebetweenthedifferentpolyurethane(PU)technologiesisbasedupondifferentparameters
(Figure2).Polyurethanepresentsthebestcompromisebetweencostandquality,butislimitedbythe
applicationperformance.Thepolyurethanesystemissusceptibletoblisteringwhenthesubstrate
containsmorethan5%humidity.Thisisduetocompetitionbetweenhydroxyl-polyolsandwaterfor
thereactionwithanisocyanategroup.Thehumiditycontentoftheenvironmentandtheapplication
temperaturearelimitingfactorsforpolyurethanesandotherchemicallyreactingsystems.
Hybridsystemsalreadyhavealargerscopeforapplicationconditions,butthepresenceofcatalystsin
hybridsmakesthemmoresensitivetohumiditythan"pure"polyureasystems.Moreover,becausethe
catalyzedpolyol/isocyanatereactionbehavesdifferentlyfromtheamine/isocyanatereactionto
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changingapplicationtemperatures,thesystembecomeslessrobust.
Polyureacanbeusedinextremeconditions.Whenitisusedonsubstratesalmostsaturatedwithwater,
polyureawillnotprovokeblisteringnorwillblisteringoccurwhentheaircontainshighamountsof
humidity.Evenatverylowtemperatures(aslowas-20degC)thepolyureacoatingwillstillcure.
Polyureacoatingscombinehighflexibilitywithhardness.Theyarethemostsuitablecoatingswhenthe
followingisrequired:
highcuringspeed;
applicationunderhighhumidityand/oratlowtemperatures;
extremeabrasionresistance;
impermeablemembranes;
highthicknessbuildup;
chemicalresistance.
ApplicationsforPolyureaCoatingsAgoodunderstandingofthepropertiesofpolyureaspraycoatingsisrequiredtospecifytheright
application.Table1providesageneraloverviewofthephysicalandchemicalpropertiesthatcanbe
expectedofpolyureasprayproducts.Polyureasystemsareknowntobeverytough.Theycombinehigh
elasticitywithhighsurfacehardness,resultinginverygoodabrasionresistance.
ThemarketdevelopmentstartedintheUnitedStates,followedbyAsia,withverystronggrowthduring
thesecondhalfofthe1990s.Inthefirststageofdevelopment,polyureawasusedasaprotectivelayer
overpolyurethaneinsulationfoamforroofingapplications.InEurope,thepolyureaspraycoatings
marketonlystartedtodevelopinthelastfewyears.
Thebroadwindowofapplicationconditions,withahightoleranceforhumidity,bothfromthe
environmentandfromthesubstrateandtemperature,makespolyureaaverysuitablecoatingfor
concreteinconstructionapplicationssuchasroofrepair,containmentliners,membranes,carpark
decks,bridgesandoffshore.Thehighabrasionresistanceleadstoitsapplicationinlinersfortruck,
bulktransportwagons,freightersandconveyorbelts.Table2presentsanoverviewoftheapplication
fieldswherepolyureaischosenbasedononeormoreofitsuniqueapplicationand/orfilmproperties.
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RawMaterialsApolyureaspraycoatingformulationconsistsoffivedifferentelements:theisocyanatecomponent;
(reactive)diluent;polyetheramines;chainextenders;andadditives,fillersandpigments.
IsocyanateSincethemostcommonlyusedisocyanateisdiphenylmethanediisocyanate(MDI),thispaperfocuses
onMDI-basedproducts.AliphaticsystemscanbeusedwhereUVstabilityisanissue.
StandardpolyureaspraycoatingsuseMDIprepolymerswithanNCOcontentof15to16%.InthisNCO
range,agoodcompromisebetweenviscosityofthematerialandthereactivityofthesystemis
obtained.Lower-NCOprepolymershaveahigherviscosity,butgivehigherelasticityandslower
reactivity.Higher-NCOprepolymersarelowerinviscosity,whichprovidesaneffectivemixtureofthe
twocomponents.However,theybecomemuchmorereactive,withtheriskofbuildingupmoreinternal
stress.Higher-NCOprepolymerswillbeusedifhighersurfacehardnessisneeded.Table3providesan
overviewofthemainpropertiesoftheMDIprepolymersusedforpolyureaspraycoatingsinEurope.
Diluent
Figure3/CarbamateStructure
JEFFSOL(r)PC,orpropylenecarbonate,isareactivediluentforpolyurea.Propylenecarbonatehasa
highflashpoint,lowtoxicityandshouldnotbeconsideredasavolatileorganiccompound(VOC).The
mainadvantagesofusingpropylenecarbonateare:
improvedshelflifeoftheisocyanate-prepolymer;
acompatibilizerforthemixingofthetwocomponentsinthemixingchamberofthespraygun;
aviscosityreducerforisocyanate-prepolymers;
improvedlevelingoftheappliedfilm.
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Propylenecarbonatereactswithanaminetogiveacarbamatestructurecontainingasecondary
hydroxylgroup.Duetothequickreactionbetweenisocyanateandamine,thesecondaryhydroxyldoes
nothavetheopportunitytoreactwithanisocyanategroup.Thepropylenecarbonatemoleculeshould,
therefore,beconsideredasamono-functionalmolecule(Figure3).
Inapplicationswherecontactwithwatercannotbeavoided,theuseofpropylenecarbonateshouldalso
belimited,aspropylenecarbonateiscompletelymisciblewithwater,andunreactedpropylene
carbonatecouldbeextracted,increasingthewaterpermeabilityofthefilm.
HuntsmanPetrochemicalCorp.ownscertainpatentsrelatingtotheuseofpropylenecarbonatein
polyureaelastomers.Othersolventsorviscosityreducerscanbeusediftheyarecompatiblewiththe
isocyanatecomponent.TheymaybeconsideredasaVOC.However,theywillincreasetheshrinkage
effect.
PolyetheraminesTheamineblendusedinpolyureaspraycoatingsisamixtureofpolyetheraminesandchainextenders.
Themaincomponentoftheresinblendisamixtureofamine-terminatedethyleneoxideand/or
propyleneoxidepolyetherwithmolecularweightsvaryingfrom200to5000g/mole.Theprimaryamine
groupsprovideaveryfastandreliablereactionwiththeNCOgroupsoftheisocyanatecomponent.
Table4presentsthepropertiesofthepolyetheraminescommonlyusedinpolyurea.
ChainExtendersDiethyl-toluenediamine,orDETDA,isthestandardchainextenderusedinaromaticpolyureaspray
coatings.DETDAcontributestothehardblockandimprovestheheatresistanceofthecuredfilm.Itis
themostreactiveamineintheresinblendbut,becauseofthephaseseparationduringthecuring,it
controlsthereactionmechanismandmakesitpossibletosprayapolyureafilm.
Otherchainextenderslikedimethylthio-toluenediamine(DMTDA),N,N'-di(sec.butyl)-amino-biphenyl
methane(DBMDA)or4,4'-methylenebis-(3-chloro,2,6-diethyl)-aniline(MCDEA)slowdownthe
reactionsignificantly.Table5listsvariouschainextendersandtheircharacteristics.Significantly
slowingdownthereactionalsomeansthatthecompetitionwiththewaterreactionbecomesmore
importantandprecautionsneedtobetaken.
Additives,Fillers,Pigments
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Dependingontheapplication,solvents,additives,pigmentsand/orfillersareintroducedtothe
formulation.Adhesionpromoterslikesilanesareusedtoenhancetheadhesiononsteelandconcrete.
UVabsorbersareusedtoslowdowntheyellowingeffectofaromaticpolyureasystems.Fillersareadded
tolowertherawmaterialcostand/orimprovethephysicalpropertiesofthecoating.Theadditionof
pigmentand/orfillersislimitedbecausetheviscosityofthetwocomponentsattheapplication
temperaturehastobekeptundercontrol.Higheramountsoffillersandreinforcementfillerscanbe
addedtothesystemasathirdcomponent.
Product-ApplicationSpecificsThemostimportantelementofhandlingpolyureacoatingsisthemixing.Goodmixingwillbeobtained
inasuitablemixingmodulebyimpingementwithmechanicalpurge.Theoperationalpressureand
temperatureoftheproductswillalsohelptooptimizethemixingefficiency.
Duetothehighcurespeedofpolyureaandtheshortmixingtime,theproductsaremixedby
impingementathighpressure.Indeed,forfieldapplicationsitispreferabletoformulatetheproducts
onafixed1:1volume-mixingratio.Thepressureusedinthefieldwillvarybetween150and250bar.
Theviscosityoftheproductsatapplicationtemperatureideallyneedstobelowerthan100mPa.s,and
theviscosityofthetwocomponentsneedstobeatthesamelevel.Thepropertiesoftheseprepolymers
canbefoundinTable3.Theviscosityoftheresinblendat25degCisapproximately900mPa.s,
droppingbelow100mPa.satapplicationtemperature.
Experimentsprovethatpolyureafilmsproducedat65degC,70degCand80degChavedifferent
properties,andthesepropertiesimprovewithincreasingtemperatures.Thesprayingequipmenthas
improvedsignificantly.Thenewsprayequipmentallowsdifferenttemperaturesettingsforthetwo
components,ensuringanoptimummixinginthesprayhead.Otherfeaturesareeasiervariableratio
settings;easyoutputcontrol;andeasymonitoringofapplicationparameters.
Theindexofapolyureasystemistypicallykeptataslightover-indexoftheisocyanateintherangeof
1.05-1.10.Astheisocyanategroupreactstohumidity,theexcessisocyanatecompensatesforthe'loss'
ofisocyanategroupsduringstorageand/orapplication.Thefilmpropertiesofthe1:1volumeratio
sprayedsystemweremeasuredforanindexvariationbetween0.90and1.15.Thetestresultsindicate
thatthefilmperformsbestatanindexof1.05andhigher.Belowanindexof1.05theresultscanvary
significantlyandbecomeunpredictable,evenforsmallindexshifts.
AspectsofSprayPolyureaTechnologyPolyureaapplicationhadsomeproblemsduringtheinitialstart-upphase,whichareattheoriginofthe
still-existingmisconceptionsaboutpolyureatechnology.Theseproblemscanbeattributedpartlyto
thelackofexperienceatthetimeofthetechnologyintroduction,partlyduetothelackofadequate
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applicationequipment,andpartlytothefactthatthisnewtechnologycouldnotbeappliedinthesame
wayasthecurrentcoatingssystems.
Initially,polyureaspraycoatingslookedtooeasytoapply.Polyureaisveryfast-thecoatingcanbeput
intoserviceimmediatelyaftertheapplication,andthefinalpropertiesofthecoatingareobtainedonly
afewhoursafterwards.Polyureaisnotwater-ortemperature-sensitive,andiseasytoformulateand
produce.Thefirstsystemsonthemarketwereindeedveryfast,withageltimeoflessthantwo
seconds,andinitiallyanumberofproblemswerelinkedtothereactivityofthesystems.
Atfirst,substratewettingwasaproblem.Thisproblemwaslinkedtothedevelopmentphaseof
polyureawiththeuseofextremelyfastspraysystems.Developmentprogramsfocusingonadhesionon
concrete,withpolyureasystemspresentinggeltimesofthreetofourseconds,resultedincohesive
adhesionfailureintheconcrete.Inpractice,tolimittherisksundervariablefieldconditions,amulti-
layersystemisapplied,madeofaprimerandatopcoat.
Asecondproblemnotedinthefieldwasthelackofintercoatadhesion.Labtests,withtimesbetween
coatsofseveralweeks,haveshownthatintercoatadhesionisverygood.Whenproblemsoccurwith
intercoatadhesion,mostofthetimetheycanberelatedbacktoproblemswiththerawmaterials,the
manufacturingofthesystemsorthesprayequipment.Sprayequipmentproblems,oradisturbanceof
thefeedingofoneorbothcomponentstowardsthemixingmodule,cancausepoormixing.Adapting
themachinesettingsofthespraycansolvethis.
Duetothehighreactivityofthesystems,thesurfacequalityofthesprayedfilmwasinitiallyverypoor.
Fine-tuningthesprayingequipmentwasafirststeptowardssolvingtheproblem.Theuseofnon-VOC
reactivediluentsandthedevelopmentofnewMDIprepolymerswithhigher2,4'-isomercontent
resultedinperfectsurfacequalitywithoutcompromisingonworkingtime.
Thecostofpolyureaspraycoatingstechnologyisseenasabarriertoentry."Pure"polyureasystemsare
moreexpensive,whenconsideringrawmaterialscostalone,butcanbeappliedinareaswhereallother
systemswillfailorwheretheyarenotsuitable.Alsotheinitialinvestmentinequipmentisrather
costly.
However,whenestimatingthecapitalcostforaproject,polyureaismorecompetitivewhenboththe
processingtimeandthewaitingperiodbeforethecoatedsubstrateisputbackintoserviceare
included.
Asdiscussedabove,thesuccessoftheprojectisveryequipment-andapplicator-dependent,andwe
believethatthehighentrybarriercanonlyguaranteequalityservicesfromspecializedandskilled
operators.
Construction-RelatedAspectsPolyureaspraycoatingscanbeusedunderdifficultweatherconditionsbecausethechemistryisvery
fastandtheydonotexperiencenegativesideeffectscausedbythepresenceofhumidity.Theyalsocure
attemperaturesbelow0degC.However,whenusingpolyureacoatings,anumberofprecautionsstill
havetobetaken.
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Ifprimersareconsidered,agoodapproachistostartwiththeevaluationofexistingprimerswith
knownperformanceonthesubstrate.Itisimportanttodeterminetheadhesionperformanceofthe
polyureacoatingontheprimersandtocheckwhethertheapplicationconditionsoftheprimerandthe
re-coatingconditionsfortheprimerstillworkforasystemwithpolyureaasafinish.
ConcreteSurfaceDefectsandSurfacePreparationThelowcost,highstrengthandstructuralpropertiesofconcretemakeitthematerialofchoiceforthe
constructionindustry.Someofthetypicalpropertiesofconcretelikethelimitedchemicalresistance,
dustreleaseandporosityorpermeabilitymakeitnecessarytoputaprotectiveand/ordecorativelayer
ontothesurface.
Thepreparationofthesurfaceisextremelyimportant.Dependingonthesurfacequalityofthe
concrete,oneormoreofthefollowingactionsneedstobetaken:
waterjetand/orsolventcleaning;
gritblasting;
bugholeandcrackfilling;
repairlayerofconcrete;
priming.
SteelSurfaceDefectsandSurfacePreparationThelifecycleofsteelconstructioncoatingsdependslargelyupontheprotectivesystemputinplace.
Thelifeoftheprotectivecoatingitselfisstronglydependentonthesurfaceconditionpriortothe
applicationofthecoating.Theprotectionofthesubstrateismainlyobtainedbyensuringagood
adhesion.Twoadhesionmechanismsarepossible:
molecularattractionoftheinterfacialforcesfromboththecoatingandthesubstrate,
mechanicalbondingoranchoringofthecoatingonthesubstrate.
Dependingontheconditionofthesurface,oneormoreofthefollowingpre-treatmentswillbe
necessary:cleaninganddegreasingwithsolvents,waterjetordetergents;handorpower-toolcleaning;
gritblasting.
Onfreshlygrit-blasted,dust-freesteelwithasurfaceroughnessSA21/2toSA2accordingtothe
specificationISO8501-1,veryhighadhesionvaluescanbeobtainedforpolyurea,evenwithouttheuse
ofprimers.
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Figure4/MixingEfficiencyInfluenceonthePhysicalPropertiesofaPolyureaCoating
MixingEfficiencyThemixingefficiencyoftheapplicationequipmentisofvitalimportance.Whenformulatingasystem
ormodifyinganexistingsystem,itisnecessarytoverifythemixingefficiencyconstantly.Figure4
showstheinfluenceofchangingthemixingonthephysicalpropertiesofaformulatedproduct.The
tensilestrengthalmostdoublesfrom14N/mm2to23N/mm2,theangletearincreasesfrom75N/mm
to85N/mmandtheelongationincreasesfrom390to430percent.Inthiscase,theinfluenceonthe
otherphysicalpropertiesislimited.
Figure5/PhysicalPropertyVariationsatVaryingSystemIndex
SystemIndexInfluenceonFinalFilmPropertiesEarlierexperimentsrevealthatapolyureacoatingneedstobeformulatedatanindexabove1.00,
meaningwithaslightlyhigheramountofisocyanate-groupsthanamine-groups.Atanindexof1.00or
lower,thephysicalpropertiesofthecoatingbecomeunreliable.Figure5demonstratesthatmost
propertieshaveverygoodvaluesatindexesfrom1.10to1.30.Aboveanindexof1.30theperformance
tendstodropagain.
Takingintoaccountthat,inpractice,slightvariationsmightoccurintheapplicationparameters,
relatedtotheprecisionofthesprayequipmentandvariationsinapplicationconditions,itissaferto
workataminimumindexof1.10to1.15.
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Figure6/PhysicalPropertyDevelopmentasaFunctionofFillerContent
FillerInfluenceonPhysicalPropertiesAddingfillerstoapolyureasystemcanbeusefulfordifferentreasons,suchasareductionintheraw
materialcostorimprovementinphysicalproperties.Inorganicfillershaveadifferenthardnessand
somewillabradepartsofthesprayequipmentmorethanothers.Themostsensitivepartsarethe
mixingchamberandthenozzleofthespraygun.Thefilledsystemsneedtobecarefullyfilteredbefore
packaging.
Dependingontheperformanceofthesprayinstallation,thedosingoffillercanvary.Weaddedupto
40%offillertotheresinblend.Themainlimitingfactorfortheprocessingistheincreaseinviscosity
ofthefilledcomponent.Thiscanresultindifficultieswiththepumpingunitand/orpoormixingdueto
bigdifferencesinviscosityforbothcomponents.
Addingfillersimprovesthesurfacehardness,theangletearandflexuralbendingmodulusbuthasa
negativeinfluenceontheelongationandthetearpropagationortrousertear(Figure6).
Figure7/WaterAbsorptionforDifferentSUPRASECPrepolymers
WaterAbsorptionForcorrosionprotection,themainconsiderationforgoodperformanceisadhesiontothesubstrate.
Furthertestingprovedthat,evenwithverygoodadhesion,theresistancetocathodicdisbondmentfor
somesystemsfails.Sincecathodicdisbondmentoccursoveralongertermandcertainlyisnotasimple
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testmethod,wemeasuredthewaterabsorptionoveraperiodof10daysat80degCandadded3%
sodiumchloridetothewater.
AscanbeseeninFigure7,theunmodifiedstandardpolyureaspraycoatingsgiveonlyalimited
protectionagainstcorrosion.ThewaterabsorptiondropssignificantlywithincreasingtheNCO-
contentfortheprepolymer.Furtherfine-tuningofthepre-polymerresultedinwaterabsorptionbeing
wellbelow0.5%after10days.Cathodicdisbondmenttestingonthissystemgaveverysatisfyingtest
results.
Anti-SkidPerformanceFlooring,carparksandsportsfloorsarekeyapplicationsforpolyureaduetoitshighabrasion
resistance,goodmechanicalpropertiesandinsensitivitytoblisteringduringthecuringprocessin
humidconditions.
Oneexampleistheoutdoor,impact-absorbingplaygroundflooring.Thesystemtestedisbasedon
SUPRASEC2049,formulatedtobeappliedina1to1volumeratio.Thefilmpropertiesare70ShoreA
hardness,600%elongationand13N/mm2tensilestrength.TheresultsinTable6showthatitis
perfectlypossibletoformulateasystem,whichcomplieswiththeantiskidneedsofaflooringsystem,
inthiscaseforaflexiblesubstrate.
ConclusionsPolyureaspraycoatingtechnologyisdifferentfromothercoatingchemistriesandcanexpandthe
applicationrangeofcoatingstoareasandconditionswhereothercoatingsystemswillfail.
Polyureasareverysuitableforconstructionapplications.Thefastcuringmakesitpossibletousewhen
onlyveryshortdisturbanceperiodsareallowed.Thefactthattheisocyanate/waterreactionisnot
affectingthephysicalpropertiesoftheappliedfilm,expandstheuseofpolyureatohighrelative
humidityconditionsanddoesnotsetsuchstringentlimitsonthewatercontentofsubstrateslike
concrete.Althoughtheyslowdownatcoldertemperatures,polyureacoatingsstillcureattemperatures
whereotherchemistriesfail.
Theformulationofpolyureaspraycoatingshastobeapproachedsimilarlytoanyothercoatingsystem.
Carefulselectionofrawmaterialsforfine-tuningoftheformulationandevaluationofthesystem,in
thesometimesdifficultconditionswherethecoatingistobeapplied,isstillnecessary.
Polyureaspraycoatingtechnologymeanshandlingreactivechemicals.Whilehandlingthechemicals
duringtheirmanufacturing,packagingandapplication,thecorrectprotectiveclothingshouldbeworn
atalltimes.
AcknowledgementsTheauthorwouldliketothankStefanPriemenandDomienBerdenfortheapplicationandtestingof
thepolyureasamples,WesleyVerbekeforthesupportwiththetestingofthesystemsandallother
Huntsmanstaffwhohelpedtorealizethispaper.
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Formoreinformation,e-mailMarcBroekaertatmarc_broekaert@huntsman.com.
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