A Primer on Polyurethane, Polyurea, and Polyaspartic ... PDA 2018... · 1980s First use of 2K Thick...

2018 Annual ConferenceSeptember 10 – 12

A Primer on Polyurethane, Polyurea, and PolyasparticConstruction Coatings


Agenda

• The History

• Naming Conventions

• Basic Technology and Properties

• Case Histories: Industrial and Commercial

• Summary and Comment


This class of coatings have been around for over 80 years

Timeline of Technologies - Past to Present

1930s Urethanes developed by Otto Bayer

1940s First use of Aromatic hardeners in Polyurethane coatings

1960s Development of Aliphatic hardeners for Polyurethane coatings

1970s Waterborne Polyurethane Dispersions (PUDs) introduced

1970s Two Component (2K) Solventborne (SB) Polyurethane coatings

1970s 2K Solvent Free (SF) Aromatic coatings

1980s First use of 2K Thick Film Polyurea coatings

1980s 2K Polyaspartic and 1st gen 2K Waterborne (WB) coatings

2000s 2nd gen 2K Waterborne polyurethane coatings

2010s Low viscosity and flexible Polyaspartic technology


There are two keys to their higher properties

Millions of mini-magnets

C N

HO

O

N

H

C O

O

Hydrogen Bonding and Crosslinking

Tangled and knotted up


Naming Conventions


There are often many names used in this category of coatings

which can be confusing

POLYURETHANE

POLYASPARTICHIGH BUILD

MOISTURE CURE THICK FILM COATING

PRECATTWO PACK

SOLVENT FREE

SOLVENTBORNE

HIGH SOLIDS

WATERBORNE

POLYUREA

CATALYZED

HYBRID

FAST SET1K

2KRESIN

HARDENER

THIN FILM

TOPCOAT

BASECOATGROUT LAYER

URETHANE

DISPERSION

SEALER

MCU

ALIPHATIC

AROMATIC

ONE PACKPUA

PU

PAS


These types of coatings exhibit a broad range of properties dialed in

to the specific aesthetics, service, and exposure needs

The different classes of infrastructure coatings can be formulated using a variety

of choices:

Hardener:

Aromatic (yellowing) vs. Aliphatic (light stable)

Backbone:

Polyester, Polyether, Polycarbonate, Polycaprolactone

Carrier:

Solventborne (SB), Waterborne (WB), Solvent-free (SF)

Number of Components:

1K (moisture cure - MC or PUD), 2K (SB, WB, SF)

Let’s lay this kennel of dogs out straight…

If coating technologies were dogs:

Dogs

One particular type of dog would be Polyurethanes

Dogs

PolyurethaneLabrador Retriever

And another type of dog would be Polyureas

Dogs


PolyureaPoodle

But of course there are different types of Labs and Poodles

Dogs


PolyureaPoodle

There are Aliphatic Polyurethanes

Dogs


PolyureaPoodle

AliphaticChocolate Lab

And Aromatic Polyurethanes

Dogs


PolyureaPoodle


AromaticYellow Lab

There are many similarities between these two dogs

Dogs


PolyureaPoodle


AromaticYellow Lab

Polyureas can also be Aromatic based

Dogs


PolyureaPoodle


AromaticYellow Lab

AromaticStandard Poodle

Or Aliphatic based

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

Now, there can be many forms of each of these breeds

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

You might have Jake, a 2K Solventborne Polyurethane

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJake

Or Daisy, a Moisture Curing Polyurethane

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJake

MC PUDaisy

Or Max, a 2K Waterborne Polyurethane

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJake

MC PUDaisy

2K WB PUMax

Aromatic Polyurethanes have some similar forms

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJake

MC PUDaisy

2K WB PUMax

There’s Molly, the Moisture Cure Polyurethane

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly

Ben, the 2K Solventborne Polyurethane

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly

2K SB PUBen

Or Buddy, the thick film Solvent Free Polyurethane

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly

2K SB PUBen

2K SF PUBuddy

Polyureas have several similar types

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly

2K SB PUBen 2K SF PU

Buddy

There are 2K Solvent Free Polyureas

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


Buddy2K SF Polyurea

CoCo

And Moisture Cure Polyureas

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


BuddyMC Polyurea

Toby

2K SF PolyureaCoCo

Or a 2K Solventborne Polyurea

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


BuddyMC Polyurea

Toby

2K SF PolyureaCoCo

2K SB PolyureaSophie

Just like the Aliphatic Polyurethanes, there are different types

of Aliphatic Polyureas

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


Buddy

MC PolyureaToby

2K SF PolyureaCoCo


There are thick film Solvent Free Polyureas

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


Buddy

MC PolyureaToby

2K SF PolyureaCoCo


2K SF PolyureaQueenie

And a special type of 2K Aliphatic Polyurea called

PolyasparticDogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


Buddy

MC PolyureaToby

2K SF PolyureaCoCo



2K PolyasparticThor

In dog terms, this is the majority of Purebred types

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


Buddy

MC PolyureaToby

2K SF PolyureaCoCo



2K PolyasparticThor

However, you can have Hybrids of these technologies, such

as:

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


Buddy

MC PolyureaToby

2K SF PolyureaCoCo



2K PolyasparticThor

2K SF PU

LabradoodleLeo

Now, let’s take a closer look at a few of these technologies

Dogs


PolyureaPoodle


AromaticYellow Lab


AliphaticToy Poodle

2K SB PUJasper

MC PUDaisy

2K WB PUMax

MC PUMolly


Buddy

MC PolyureaToby



2K PolyasparticThor

2K SF PolyureaCoCo


Basic Technology and Properties

Aliphatic 2K Solventborne

Polyurethane Coatings

Jasper


Aliphatic 2K Solventborne Polyurethane coatings are a proven

technology used for years to protect infrastructure

2K SB Polyurethane Technology: High crosslink

density yields long lasting, chemical and abrasion

resistance coatings

The stalwart of PU protective coatings

• High crosslinking gives desirable properties but requires solvent to thin down

• Typically used in exterior applications like bridges and water towers

• Used in interior flooring topcoat applications for chemical resistance

• Typically 100-300+ g/L solvent depending on prevailing regulations


High crosslinking increases the desired properties of the

coating but requires solvent to lower the viscosity

Chemistry:

2K aliphatic polyurethane based on polyesters, polyethers, or polyacrylics

and aliphatic hardeners

OCNNCO

Dries and reacts to

form

A Polyurethane Coating

Resin Aliphatic Hardener


Benefits:

• Excellent durability and

weatherability

• Excellent color/gloss retention

• Very good working time

• Proven performance from

decades of in-field use

• Favorable cost/performance ratio

Drawbacks:

• VOC/solvent odor

• High humidity can cause bubbling in higher film builds

• May not be permitted for certain applications due to VOC limits

Aliphatic 2K Solventborne Polyurethanes are selected for

their physical properties and longer working time



Aliphatic 1K Moisture Cure


Daisy


Aliphatic 1K Moisture Cure Polyurethane Coatings

Moisture Cure Polyurethane: 1K technology

that uses moisture to crosslink

yielding excellent overall properties

Faster cure, easy to use, and durable

• Largest use in maintenance applications due to ease of use

• More forgiving in high humidity and marginally prepared surfaces i.e. residual rust

• Faster cure via multiple thin coats, can be applied in a single shift (overcoating)


Aliphatic Moisture Curing Polyurethane coatings are

ready to use right out of the can

Chemistry:

1K aliphatic moisture curing polyurethane coating

Dries and reacts to

form


Moisture Curing

PolyurethaneMoisture in the Air


Benefits:

• More forgiving on marginally

prepped surfaces

• Very good color/gloss retention

• Easy to Use – One component

• Can complete a multi-coat, moisture

cure system in one shift

• Can be applied in cold and damp

environments

Drawbacks:

• Over-application of film thickness or puddling generates bubbles or blistering

• Hot and humid can create more chances for defects

• Although 1K, still have a finite potlife in the can (moisture exposure)

Aliphatic Moisture Curing Polyurethanes are more forgiving on

substrate prep but sensitive to applied thickness



Aliphatic 2K Waterborne


Max

Aliphatic 2K Waterborne Polyurethanes are used as alternatives to

waterborne and solventborne sealers and coatings

Waterborne Polyurethanes:

2K technology with similar properties as

2K solventborne

“Water is Green”

• Early “waterborne” coatings had as much as 300g/l of co-solvent

• New commercial systems are now as low as < 50g/L

• Offer viable replacement products to solventborne systems

• Achieves high chemical/abrasion resistance in a waterborne product


Crosslinking increases the properties of the 2K Aliphatic

Waterborne Polyurethane but adds a mixing step

Chemistry:

2K aliphatic waterborne polyurethane based on polyurethane or

polyacrylate dispersions and aliphatic hardeners

OCNNCO

Dry and react to form


Polyurethane Dispersion Aliphatic Hardener


Benefits:

• Excellent durability

• Excellent color/gloss retention

• Gloss to matte finish available

• Long working time

• Ultra low VOC (<15g/L)

• Very low odor

• Low viscosity - can be used as sealer

over polished concrete or pavers

Drawbacks:

• Cold weather/high humidity lengthens cure time

• Two component - requires mixing step

• Once cured, needs sanded or abraded in order to recoat

Aliphatic 2K Waterborne Polyurethane coatings typically have

excellent long term durability and low odor



Aromatic 1K Moisture Cure


Molly


Aromatic 1K Moisture Curing Polyurethanes are used

typically as primers or basecoats for good adhesion

Aromatic moisture cure coatings:

1K technology that adheres to concrete and

steel but needs a topcoat for color stability

A step up in primer/basecoat technology

• Aromatic moisture cure polyurethanes exhibit very good impact resistance

• Typically contain solvent to reduce the viscosity for good wet-out

• Finite potlife since they react with moisture in the air and substrate


OCN ̶ ̶ NCO

Aromatic Moisture Curing Polyurethane coatings are

popular in corrosion and flooring coatings

Chemistry:

1K aromatic polyurethane coating based on a polyurethane prepolymer

Reacts and Dries to

form


Aromatic Prepolymer Moisture in the Air


Benefits:

• Ease of use – one component

• Excellent adhesion to substrates

• Tough and impact resistant

• Very good abrasion/chemical

resistance

• Relatively fast dry-to-touch time

Drawbacks:

• Cold weather/low humidity lengthens cure time

• Yellows in sunlight so needs a topcoat for colorfastness

• Over-application or 70%+ RH can cause bubbles

Aromatic Moisture Cure Polyurethane coatings are a good

balance of performance and cost



Aromatic 2K Solvent-Free

Polyurea Coatings

Coco


Aromatic 2K Polyurea coatings have grown from a niche to

mainstream technology since they first debuted

Aromatic Polyurea Coatings: Plural component, fast curing, high build

coatings with excellent abrasion, chemical, and tear resistance

Thick Film Coatings

• Early use was for spray-in truck bed liners

• First systems were either fast or fast…

• New developments yield slower setting versions

• Use has expanded into many construction

segments such as secondary containment,

waterproofing, roofing, and general industrial


OCN ̶ ̶ NCONH2 ̶ [ ̶ R ̶ O ̶ ]n ̶ NH2

Aromatic 2K Polyurea coatings get mixed together at the jobsite typically

using plural component spray equipment

Chemistry:

2K aromatic polyurea based on amine resins and aromatic hardeners

Polyetheramine and

Amine ResinsAromatic Hardeners or

Prepolymers

React to form

A Polyurea Coating


Aromatic 2K Polyurea coatings are known for the benefits

of fast cure, moisture insensitivity, and high build

Benefits:

• Excellent abrasion and cut

resistance

• Fast cure

• High build per coat

• Typically zero VOC

• Low temperature application

possible

Drawbacks:• Fast cure usually requires

plural component equipment

• Difficult to apply smooth finish

• Speed can limit adhesion



Aliphatic 2K

Polyaspartic Coatings

Thor


Aliphatic 2K Polyaspartic Coatings have become popular as an

alternative for solventborne acrylics, epoxies, and urethanes

Polyaspartic Coatings: High build, fast cure floor and balcony coatings with

excellent clarity, longevity, and ‘color pop’

“Paint on Steroids”

• Many floor coatings dry less than 4 mils thick

• The saying, “Like watching paint dry” means

more labor time

• Polyaspartic technology allows for one coat, high

build finishes

• Cure times are greatly improved and allow for

faster turn-around


Polyaspartic coatings are light stable and have a longer

working time than traditional polyureas

Chemistry:

2K aliphatic polyurea based on polyaspartic resins and aliphatic hardeners

OCNNCOPolyaspartic Resins Aliphatic Hardener

React to form

A Polyaspartic Coating


Polyaspartic coatings are known for the benefit of

fast return to service

Benefits:

• Excellent weathering/durability

• Fast return-to-service

• High build per coat

• VOC compliance

• Low temperature application

possible

• A ‘polyurea’ that is brush/roll

• Excellent ‘color pop’ over decorative

stained floors

Drawbacks:• Cure time affected by humidity

• Difficult to downgloss/matte

• Two component - requires

mixing


Case History Examples


Case Histories: Industrial Flooring

Parking Decks, Balconies and Garages: Fast cure

means shorter return-to-service time and less

revenue loss

Healthcare: Resistance to constant mopping with

strong disinfection chemicals such as bleach

Hangars and Warehousing: High

durability dust-down coatings with

excellent chemical/hot tire resistance


Case Histories: Decorative Flooring

Stadiums and other Venues: Durable high gloss

coatings go back into service quickly and take the

abuse from customers

Commercial Space: Hotels, restaurants and

universities like the seamless, low odor

decorative finishes and quick installation

Retail and Education: Grocery store and schools are

increasingly using polished concrete as a design element

62

Location: Hammond, IN

Contractor: Era Valdivia Contractors

Completed: March 2005

Maintenance of Water Infrastructure – Case History

• Cold water pipes had nearly constant

condensation

• 35K ft2 of hard-to-reach piping prepped using

SSPC SP6 and SP10

• A multi-coat system: 1K aromatic moisture

curing polyurethane primer/intermediate

coats, 1K aliphatic moisture curing

polyurethane topcoat

63

Location: Pittsburgh, PA

Contractor: Semans Contracting

Completed: January 2015

• 80 year old trade school floor was

cracked and spalled

• Cementitious overlay applied and

significant remediation performed

• Final finish was a clear satin 2K aliphatic

waterborne polyurethane coating on

30,000 ft² surface

Energy Innovation Center – Case History

Location: Naples, FL

General Contractor: Suffolk and Kraft

Completed: August 2007

• Initial 80,000 ft² project was spec’d in marble but

proved to be too costly

• A durable, low-VOC, and ADA compliant floor coating

system with the look of aged leather was desired

• Decorative soy based stain was applied followed by

zero-VOC 2K aliphatic clear polyaspartic topcoat

Ave Maria University - Case History

Location: Washington, PA

General Contractor: Allegheny Inc.

Completed: October 2016

• Bakery floor had sheet vinyl in place for

years with many peeling seams

• Owner wanted an easier to clean but good

looking floor

• Pigmented 2K aliphatic polyaspartic

basecoat, color chips then clear

polyaspartic topcoat was applied

Springhouse Market and Bakery - Case History


Polyurethanes, Polyureas, and Polyaspartics - three coating types synonymous with high performance and durability:

- Many similarities between the technologies yet a host of varying properties

- Often used in the Infrastructure segment for steel and concrete protection as well as a variety of other applications

- These coatings have a long term proven history of in-field use and can extend the service life of infrastructure

Summary and Comment

Thank You!

Any Questions

Steven Reinstadtler412.413.2561

[email protected]

Follow me on Twitter:SReinstadtler

and LinkedIn:Steven Reinstadtler

mailto:[email protected]

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A Primer on Polyurethane, Polyurea, and Polyaspartic ... PDA 2018... · 1980s First use of 2K Thick...

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