Polyurea Information & Polyurea Links at HealthHaven.com

Not to be confused with Polyuria.

Structural formula of a polyurea linkage.

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 will 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 will not contain a catalyst(s).

[edit] Market Segments

[edit] The Oil and Gas Industry

Polyurea's strengths are tailored to fill the gaps left by traditional coating products used in the oil and gas industry and is the ideal coating product for the oil and gas industry's many coating needs from pipelines to primary and secondary containment.

Possible Applications- Polyurea's ease of application and ability to be used directly on steel, polyurethane foam, or mineral wool, make it an ideal universal anticorrosion coating product for entire pipelines including trunk and well-flow lines regardless of process temperature.

The fact it can be used above or below ground, or in fresh or salt water regardless of depth, makes it the most versatile coating product available to the oil and gas industry. Nukote is the only company in the world to have coated multiple pipelines with polyurea for multinational petrochemical companies. Currently, Nukote polyurea is the brand of polyurea that is specified by name for pipelines around the world.

It is also ideal for lining primary and secondary containment regardless of the substrate including-steel, geotextile fabric, concrete, or earth.

Seamless Membrane- Polyurea chemically binds to itself producing a seamless membrane after installation for pipelines and other applications. Since a majority of coating failures are at the seams the fact polyurea has no seams greatly reduces the potential for coating failures.

Lathe Application- Developed first for Atlantic Richfield and British Petroleum, our proprie tary lathe application techniques have been honed over the past ten years. Using NCS patented lathes, polyurea can be coated in production quantities regardless of pipe diameter or length.

Field Joining- NCS has also developed a proprietary field joining and repair process that is revolutionizing field joining- even for pipelines that use traditional coatings like FBE.

Polyurea vs. other Pipe Coating Material- Nukote polyurea is the most advanced coating available, and easily surpasses the coating products traditionally used in the oil and gas industry in physical properties, performance, application and installation time, and most importantly cost.

Utilizing NCS lathe technology a complete coating facility can be built quickly at minimal costs in strategic locations-including next to the ROW. Nukote polyurea is also compatible with all other coating products, so it is an ideal option for a better field joining or repair material or the better product to add new sections to an existing trunk or well-flow line, polyurea is the ideal solution. Industry applications

    * Pipelines    * Field joining and pipeline repair    * Tanks, and primary containment    * Secondary containment    * Marine-boats, oil rigs, and platforms    * Equipment abrasion and corrosion protection

Ref: http://www.nukotecoatingsystems.co.uk

[edit] Primary and Secondary Containment

Nukote polyurea is an outstanding coating for primary and secondary containment due to its tensile strength, elongation, and resistance to tears, punctures, and chemicals.

When used as a primary or secondary containment coating, Nukote can be applied over steel, geotextile fabric, concrete, wood, fiberglass, masonry, or even earth.

Nukote and Concrete- Nukote pure polyurea is an ideal choice for coating over concrete because Nukote pure polyurea does not react with the moisture present in concrete that can cause pin holing or blisters with other coatings-especially polyurethane hybrids. Additionally, NCS offers a unique, inexpensive primer called PolyPrime. Nukote PolyPrime is a special primer that penetrates and seals concrete reducing both pinholes and blisters. Additionally, Nukote PolyPrime seals bugholes and other irregularities in concrete reducing the amount of polyurea required to form a seamless membrane.

Nukote and Geotextile Fabrics- NCS has pioneered the use of the polyurea-geotextile fabric application. Using a unique geotextile fabric, Nukote polyurea actually locks itself in place ensuring extremely high adhesion strength. This system performs as well as concrete retention structures or common seamed membranes at a fraction of the cost, and is ideal for large primary or secondary containment uses including: leech ponds, land fills, drain basins, tank farm liners, and other application where concrete or steel would be impractical.

Nukote and Steel- Steel primary containment is often used in large cooling systems for power generation or manufacturing plants. Nukote polyurea provides the required coating with minimum downtime, virtually no on-going maintenance, and absolutely no contamination to the system caused by the coating.

Nukote's abrasion resistance also makes it functional for applications where mechanical agitators or other equipment are present regardless of substrate.

Ultra-High Corrosion and Temperature- Nukote Admetal is the best option for primary containment applications where the corrosion and temperature characteristics are ultra high.

Ref: http://www.nukotecoatingsystems.co.uk

[edit] Industrial Applications

In addition to petrochemical industry and primary and secondary containment applications, polyurea is an ideal choice for a number of industrial waterproofing, abrasion resistance, slip resistance, protection, or other coating applications.

Mining Applications - Multinational mines around the world use Nukote polyurea a number of applications including:

    * Primary and secondary containment    * Abrasion resistance and carry back reduction in trucks and rail cars    * Abrasion resistance for chutes and other equipment    * Roller and belt protection and repair    * Erosion protection and rock stability

Marine Applications- Polyurea coats Naval and industrial ships, piers, offshore oilrigs, and other marine applications around the world. Nukote is an ideal product for these applications because of its ability to both maintain physical characteristics in long-term sun and sea exposure and resist marine borers.

Infrastructure Applications - Bridges, ports, airports, high-speed rails, and other infrastructure projects around the world are designed with polyurea as the primary coating product.

Roof Applications- Nukote can be applied directly to the roof, or if insulation is required over polyurethane foam or any other insulation material, to create a seamless membrane that seals the roof or wall coated. Nukote seals the seams created by pipes, exhaust, or other equipment that protrude from roofs.

Floor Applications- Nukote offers a number of options for industrial floor applications. Our most popular is Nukote PolyKote, which is an inexpensive non-polyurea coating that is an ideal basecoat for large, industrial applications on concrete. Nukote polyurea is sprayed over areas where polyurea's physical characteristics or appearance are required. Nukote functions well as a line striping material for these or other line-striping applications.

Polyurea is also an ideal coating for aesthetic, non-industrial floors including officers, cafeterias, hospitals, airports, train stations, and the like. Nukote is perfect for these applications not only because of its physical properties and appearance, but also its fast return-to-service time. Areas can be coated and put back in service within the hour.

Pipelines - In addition to oil and gas pipelines, Nukote polyurea is a standard against which other coatings are measured for other insulated and non-insulated pipelines including potable water, waste water, cooling systems, steam, and many other interior and exterior pipeline applications. Ref: http://www.nukotecoatingsystems.co.uk

[edit] Practical uses

[edit] Truck bed liners

Polyurea truck bed liners form a durable, water and air-tight, permanent liner for the exterior of pick up trucks, dump trucks and steel containers. These durable, easy to clean and abrasion resistant liners protect utility trucks from their harsh duty environments. They also protect against rust and corrosion from damaging trucks and containers. Polyurea liners can also be applied in varied thickness to meet any specific application demand. Sprayed on truck bed liners are available in many colors and can be wrapped over the top edge of the truck bed to provide added protection from impact and abrasion.

[edit] Pipe and pipeline coatings and linings

Polyurea coatings and linings are increasingly being used to protect steel pipes from corrosion. Polyurea has demonstrated its ability to last longer than paint and maintenance services and costs are reduced. Polyurea is a great protective coating system for pipes that are insulated with polyurethane foam. Polyureas are also being used to line the inside of water and sewer pipes for infrastructure rehabilitation work (Polyurea is not recommended for potable water pipeline). Its stronge adhesion to steel made it a unique coating for barried pipe, as it can protect the pipe against soil and rock, indeed it has high resistance to delamination during cathodic protection.

[edit] Bridge coating

Polyurea's ability to outlast paint and fight off corrosion is a major reason these systems are being specified for bridge deck and structure coating by State DOT's around the nation. The most common applications of polyurea coatings on bridges are over steel and concrete.

[edit] Joint fill / caulk

Polyurea is being successfully used as a multi-purpose joint fill, caulking and sealant material. It can provide a flexible, durable, weather-tight and traffic resistant seal for all types of building joints, such as expansion joints and control joints in masonry floors, perimeter joints, panels and doors, water reservoirs, etc. It has excellent crack-bridging properties with high elongation and tensile strength. The fast cure time and insensitivity to moisture allows for a quicker installation with a wider application window. Proper surface preparation and substrate condition is always necessary.

[edit] Holding tanks

[edit] Tank coatings

Polyurea coatings protect steel tanks from corrosion, chemicals, and other natural weather and jobsite elements. With proper surface preparation, substrate condition, formulation choice, primers, and installation procedures, polyurea goes on fast and stays on long. Polyureas are great for extending the life of older tanks and can offer limited structural characteristics as well. These systems can be applied during primary construction or in a retrofit environment. With their fast cure times they are ideal for retrofit since down time is significantly minimized compared to some competing materials.

[edit] Tank linings

Polyurea linings are resistant to many chemicals and industrial liquids. With their fast application advantages and ability to adhere to properly prepared substrates, polyureas are ideal for new storage tank primary lining and rehabilitation projects.

[edit] Waste water treatment linings

Fast cure, chemical and abrasion resistant, concrete primary and secondary containment linings.

[edit] Aquarium lining

Aquariums have also found benefits with polyurea. The ability to form to properly prepared custom shaped walls and themed ornaments make this system desirable. A spray applied, water resistant liner, available in a variety of colors with rapid return to service installation is why facility owners are turning to polyurea.

[edit] Landscape & water containment

Landscape designers and contractors have found similar benefits with polyurea. Polyurea is often used to contain water for ponds and pool decorations to form a primary containment liner. Use of geotextile material is common when applying polyurea over dirt. Proper surface condition is vital when applying over concrete and most other substrates.

[edit] Marine

Above the water line and below, polyurea can be very effective in protecting steel, aluminum, and fiberglass in a variety of water sport and commercial marine applications. From sound attenuation for fishing canoes, to fish hold liners, to hull protection and bilge liners, polyureas are used in many abrasion, chemical and corrosion resistant marine applications.

[edit] Roof coating

Polyurea coatings make an excellent protective covering for polyurethane foam roofs. Polyurea can be formulated to meet specific performance requirements due the wide range of physical properties that can be formulated. Some systems have the "Cool Roof" ENERGY STAR rating for color and reflectivity. These reflective coatings can help reduce the amount energy consumption buildings use for heating and cooling. The fast cure time and insensitivity to moisture allows for a quicker installation with a wider application window. Proper surface preparation and substrate condition is always necessary.

Polyurea is also an excellent solution for waterproofing leaky metal roofing. The elastomeric nature of the membrane/coating system dictates that a properly processed application should easily absorb the natural expansion and contraction cycles of the metal roof without tearing or fracture. This is critical for long term successful service life. As with any roofing system, proper surface preparation is needed.

[edit] Manhole & sewer linings

Polyurea manhole lining is a rapidly growing market due to polyurea’s ability to solve many current issues with groundwater infiltration and installation speed. Many municipal and private water systems are in great need of lining and structural repair. With proper surface preparation and substrate conditions, primers and Polyurea can be applied fast to return the cavity to service faster than most competitive systems. Polyurea’s ability to form a monolithic, durable liner protects the cavity from sediment and groundwater infiltration into municipal wastewater systems.

[edit] Theme park & decorative design

Theme Parks often use polyurea as a protective coating over foam, EPS and other structures to create ornamental building fascia, themed characters, artificial rocks, pools and environments.

[edit] Flooring and parking decks

Polyurea flooring systems are most popular for their rapid turnaround installation capabilities. Other benefits are available with polyurea flooring systems as well. Polyureas are very durable and great for use in areas of high traffic. They are used in clean/dirty rooms as a waterproofing and protective coating from daily pressure cleaning operations. Polyurea can be formulated to be flexible and resilient allowing the flooring system to protect objects that may fall upon them.

[edit] Architectural design

Polyurea has much the same uses in architectural design as it does in theme park applications. Polyurea is used as a protective coating over foam, EPS and other structures to create ornamental building fascia, themed characters, artificial rocks, pools and environments. There are many uses for movie set and theater stage design as well.

[edit] Automotive fascia OEM molded parts

Polyurea can be spray, open pour or reaction injected into molds. Many automotive fascia parts have been molded from polyurea RIM systems. Now many spray in mold uses are becoming popular in replacing parts commonly made from fiberglass. Water park chutes, plaques, automotive aftermarket fascia and spoilers, architectural decorative molding, and more...

[edit] Water parks & playgrounds

Molded slides, protective coating of seats for wet/dry amusement rides, tank linings, water containment, aquariums, concrete stadium seats are just a few of the many applications polyureas are commonly used for in the amusement and theme park industry. Polyureas usage is rapidly growing in applications to replace paint and fiberglass due its fast cure and ability to reduce maintenance cycles.

[edit] Railcar lining & track containment

Polyureas are commonly used to line liquid containment railcars for their waterproofing and chemical resistance benefits. Hopper style rail cars have benefited from the strength of polyurea and its ability to resist abrasion. These cars often carry coal, sand, and other abrasive materials. Polyurea can be applied quickly and it will last longer than many other conventional systems if properly applied.

[edit] Line striping

Polyurea is a very fast set material, which makes it ideal for use in line striping and pavement marking. It can be returned to service for traffic and pedestrian use in only a few minutes (depends on formulation) after application.

Polyurea is much more durable than paint and typically lasts much longer between maintenance cycles. Polyurea is the clear choice when it comes to cost/performance payback and operation.

[edit] Spray molding

The use of Polyureas for spray in mold processes are gaining momentum with the advent of low output spray guns. Polyureas have very fast reaction times and are meter mixed and dispensed through plural component equipment. These materials are dry to the touch within seconds after application reducing demold time dramatically. Physical properties of these materials can be altered by the system formulator to meet application requirements.

[edit] Armor

In some cases polyurea has been tested for its ability as armor.^[1] With some polyureas reaching strengths of 6000psi tensile and over 500% elongation makes it a very tough coating. With its naturally quick reaction times it can be built up to any thickness.

[edit] Dunnage

Polyurea has become more frequently used in the material handling industry for dunnage. When Polyurea is sprayed over foam, wood, paper, and plastic it will create a returnable dunnage detail with similar strength as an injected molded part. This gives the end user the ability to buy dunnage without expensive tooling costs and long lead times.

[edit] Other applications

• Race car body parts

• Mold making

• Artificial rock

• Racking Dunnage

[edit] Fuel storage & containment

Polyurea is resistant to many fuels and chemicals. It is commonly used in fuel pits and pipeline secondary containment. Polyurea is not resistant to all chemicals and necessary compatibility tests and surface preparation are always required.

Definition per the Polyurea Development Association

[edit] References

^ http://www.ara.com/whatnew/lead/dragonshield/explosive%20resistant%20coating.htm

[http://www.www.versaflex.com/ The Polyurea People
Polyurea products

[edit] External links

[0] ttp://www.ara.com/whatnew/lead/dragonshield/explosive%20resistant%20coating.htm

[1]

Contents