Perfect Performance in Four Seconds

Polyurea reaction (Figure 1), which provides a permanent solution to water insulation problems frequently experienced by all sectors today at 65ºC temperature and 150 bar pressure, will maintain its position as the latest technology on the market until a newer one arrives.

Figure 1. Polyurea reaction [1]

Figure 2. Polyurea water insulation market volume [2]

Although it appears to be an ordinary problem, the cost of solving insulation issues has grown exponentially each year, reaching record levels in 2014 with a budget of USD 950 million for polyurea insulation systems alone. Until a more advanced technology solution finds its place on shelves, it will continue to draw attention in the water insulation market as the most effective solution with an average annual market volume growth of 6% through the end of 2022. (Figure 2) So what is the fundamental factor behind polyurea systems holding such a significant market share? Polyurea Systems essentially involve colliding polyamine molecule groups with isocyanate molecule groups at high pressure (average 150 bar) and temperatures of 60–65ºC, allowing the reaction to occur on the applied surface. The polyurea chain formation shown in Figure 1 cures in just four seconds on the applied surface, serving as a barrier between the contact surface and ambient conditions. This chemical bond structure provides 100% water impermeability along with chemical resistance, hardness, and effective corrosion resistance to the surface. Although polyurea is a highly effective coating technology in terms of performance, it is unfortunately a more expensive solution compared to alternative options in terms of cost. For this reason, companies frequently offering polyurea services in the market also discuss "hybrid polyurea" systems. The fundamental difference of hybrid polyurea systems from pure polyurea systems is that the polyamine reactant here appears as a hybrid compound structure mixed with polyol reactant containing -OH groups. In this case, polyurethane structure also exists on the surface alongside the polyurea structure, and while the polyurethane structure, which is inferior in performance to pure polyurea, provides cost advantages, it reduces water insulation performance and chemical resistance on the surface. Two primary advantages that polyurethane provides in hybrid systems are cost and better appearance of the applied surface. The appearance of the applied surface has fewer waves and provides homogeneous matte performance. As seen in Figure 3, in high humidity, the chemical resistance of polyurethane falls behind that of polyurea, reducing resistance performance. [3-5]

Figure 3. Behavior of index values of pure polyurea and polyurethane at 85% humidity, depending on density changes in the environment

  As Kimteks Polyurethane family, our definitive solution recommendation for water insulation is the KIMcoat PP 001 + Izokim PP 001 system with pure polyurea reaction. In pure polyurea systems, when polyamine and isocyanate components are applied to the surface at a 100:100 volume ratio at 65ºC temperature and average 140 bar (2000 psi) pressure, they expand in 3 seconds and achieve touch-dry in 18 seconds. KIMcoat PP 001 system is particularly recommended for locations requiring water insulation under the most demanding conditions. It is a definitive solution for water insulation on all types of building terraces, floor balconies, underground tunnels, roof and floor coverings, as well as on bridge, road and tunnel bases in construction projects requiring maintenance and repairs where water can be applied directly to the surface without requiring complete water drainage and cleaning, and on all surfaces requiring repair; on concrete or cement-like plaster-based screed surfaces where water insulation is needed. KIMcoat PP 001 can be used in parking lots of buildings and similar shopping centers as a first coat for water insulation purposes before epoxy, polyurethane or acrylic coating applications, while also serving as a primer on the substrate and providing high strength to prepare a flawless base for final coat applications. Our other hybrid polyurea system, KIMcoat HP 001 + Izokim PP 001, whose water insulation performance is not as effective as pure polyurea but offers advantages in terms of cost and appearance, shows effective performance on every surface where polyurethane can be used and provides 100% water insulation when applied in two or three coats. In our hybrid polyurea system, we use the most purified polyether polyol syntheses that the technology permits in modified form, so it is applied to the surface at performance levels close to pure polyurea systems. Application conditions and component ratios are the same as in pure polyurea. The water insulation performance and chemical resistance it provides to the surface are virtually identical, although there are differences between hardness and strength performance.  

Figure 4. Polyurethane reaction chain in hybrid polyurea systems [3-8] Hybrid

  The reason hybrid polyurea systems are more economical in cost is that mixtures of polyamine molecules and polyol molecules form chemical bonds with isocyanate prepolymers during application (Figure 4). Since polyols show less reactive properties compared to polyamine components, the amounts of catalysts used to shorten the reaction profile are proportionally higher than in pure polyurea systems. As long as catalyst amounts remain limited within a specified range, both products comply with both REACH regulations and RoHS certification. Both KIMcoat PP 001 pure polyurea and KIMcoat HP 001 hybrid polyurea systems conform to the conditions specified in VOC regulations.   Dinçer Eker Research and Development Manager Kimpur-Kimteks Poliüretan San. ve Tic. A.Ş  

Table 1. Comparison of polyurea with other systems [9]

Table 2. Physical properties of polyurea coating [10]

References: 1.Primeaux II, D.J. 100% Solids Aliphatic Spray Polyurea Elastomer Systems. In Polyurethanes World Congress 1991, Proceedings of the SPI/ISOPA, Acropolis, Nice, France, September 1991, pp 474-477. 2.Global Markets Insights – Insights to innovation. 3.Primeaux II, D.J. 100% Solids Aliphatic Spray Polyurea Elastomer Systems. Journal of Elastomers and Plastics, Volume 24, October 1992, pp 323 – 336. 4.Primeaux II, D.J. U.S. Patent 5,162,388 (1992). 5.House, D.W. et.al. U.S. Patent 5,312,886 (1994). 6.Primeaux II, D.J. U.S. Patent 5,504,181 (1996). 7.Primeaux II, D.J. et.al. U.S. Patent 5,616,677 (1997). 8.Primeaux II, D.J. et.al. U.S. Patent 6,013,755 (2000). 9.Primeaux II, D. J., (2000). "Polyurea Spray Coating Systems," Primeaux Associates LLC. 10. Copon Hycote 169HB, "Technical Guidance Note: Semi Structural Polymeric Lining System," Company Brochure, E. Woods Company, United Kingdom. <accessed on December 2009>