At MPU Coatings, we pride ourselves on being at the forefront of polyurea technology. Our focus on polyaspartic and amine technologies, along with our extensive research and development efforts, has enabled us to create a range of high-performance polyurea coatings tailored to meet diverse market needs.
The Evolution of Synthetic Coatings
The history of synthetic coatings is a fascinating journey, beginning with Bakelite in 1907 and advancing through the invention of polyurethanes, epoxies, and polyureas. These materials have become the backbone of high-performance coatings, each offering distinct advantages in different applications. In the 1930s, chemists like Pierre Castan and Otto Bayer introduced epoxies and polyurethanes, respectively, which revolutionized various industries. However, it wasn’t until 1988 that polyureas entered the scene, bringing a new level of performance with their rapid curing times, high elongation, excellent abrasion resistance, and outstanding tear strength.
Polyurea Leads the Way
Polyureas quickly gained commercial acceptance despite their initial challenges, such as the need for specialized application equipment due to their fast cure rates. Their superior performance characteristics set them apart from traditional epoxy and urethane systems. As environmental regulations tightened in the late 20th century, the development of polyaspartic resins emerged as a significant advancement in polyurea technology. These resins offered high performance with lower VOC formulations and more manageable reactivity.
MPU’s Innovations in Polyurea Technology
At MPU, we have taken polyurea technology to the next level. Our MPU self-leveling, one-coat polyurea eliminates the need for a topcoat, offering unparalleled performance from the first application. This innovation results from years of dedicated research and development focused on polyaspartic acid and amine technology. Our products are designed to meet the diverse needs of the market, from industrial coatings to residential flooring.
One of the standout features of our MPU polyurea self-leveling coatings is their ability to form a seamless layer in a single application. This simplifies the application process while ensuring exceptional performance. The self-leveling nature of MPU’s polyurea ensures a smooth, bubble-free finish, even when applied at higher film thicknesses. This minimizes common issues like bubble formation and surface imperfections, particularly in high-humidity environments. Moreover, the absence of a topcoat requirement reduces application time and labor costs, making MPU polyurea a cost-effective solution for large-scale projects.
Understanding Polyaspartic Chemistry
Polyaspartic coatings, a subset of polyureas, are formulated through a Michael Addition reaction of di-amines with maleic acid di-esters, resulting in a product that provides:
- One-coat application: Typically applied at thicknesses of 6-8 mils, they can reach up to 16-18 mils in a single coat.
- Rapid curing: Compared to traditional epoxies and urethanes, polyaspartics cure quickly, allowing surfaces to be returned to service within hours.
- Weatherability: UV stable, color-fast, and resistant to yellowing, ensuring long-lasting aesthetics.
- Durability: Superior abrasion resistance and flexibility make polyaspartics perfect for high-traffic areas and suitable for bridging small cracks.
The chemistry of polyaspartics enables a balance of performance and application ease. Unlike conventional polyureas, which can be challenging to apply due to their rapid cure times, polyaspartics allow for a more manageable working time. This means contractors can use standard application methods, such as brushing or rolling, without the fear of the material setting too quickly.
Advantages of Polyaspartic Coatings in Corrosion Protection
Polyaspartic coatings have also revolutionized corrosion protection, especially for steel surfaces. When used alongside a zinc-rich primer, a polyaspartic topcoat provides excellent long-term durability and protection, reducing the need for multiple layers. Traditionally, epoxy protective coatings required two or three coats, but with polyaspartics, the coating scheme is simplified to just a zinc-rich primer followed by a single polyaspartic topcoat. This not only ensures corrosion protection but also maintains the requisite film thickness, making the process more efficient.
Over the past 15 years, polyaspartic coatings have proven their effectiveness in protecting wind turbines, bridges, industrial plants, food processing facilities, and agricultural and construction machinery against corrosion. The high-performance features of polyaspartics, initially developed for corrosion protection, have also led to their widespread use as concrete floor coatings.
Polyaspartics in Floor Coating Applications
The floor coating industry today demands user-friendly, dependable coating systems that can be installed with consistency and speed. Concrete floors, notorious for cracks and joints, present unique challenges for traditional rigid epoxy systems, which often fail under thermal or load-induced movement. These cracks can lead to increased wear, collection of debris, and progressive damage to the flooring system.
Epoxies, while inexpensive and initially effective, suffer from issues like reflective cracking, fading in sunlight, yellowing with age, and hot tire pick-up. They also require long curing times, which delays project completion. Urethanes, although fast-curing, are moisture-sensitive and prone to bubbling. Polyurea, with its rapid cure, tends to follow surface contours, leading to a textured finish rather than a smooth one.
Polyaspartics, however, overcome all these deficiencies. They provide a smooth, aesthetically pleasing finish similar to self-leveling epoxy, while offering three times the abrasion resistance, greater flexibility, and UV stability. Compared to urethanes, polyaspartics are less moisture-sensitive and less likely to bubble, making them a superior choice for high film build applications.
Cost Efficiency and Performance of Polyaspartics
Polyaspartics not only offer superior performance but also deliver significant cost savings. A case study involving a steel bridge highlights these advantages. A three-coat system consisting of a zinc-rich primer, an epoxy base coat, and a urethane topcoat was compared to a two-coat system with a zinc-rich primer and a polyaspartic topcoat. The three-coat system was applied at a rate of 383 square feet per day, while the two-coat system achieved 502 square feet per day, a 31% increase in productivity. The cost of the three-coat system was $100 per square foot, while the two-coat system was $68 per square foot, representing significant savings in both time and money.
This cost efficiency, coupled with the fast return-to-service provided by polyaspartics, makes them a strategic choice for industrial and maintenance coatings worldwide.
Conclusion
MPU Coatings is committed to providing innovative solutions in the coatings industry. Our dedication to research and development has led to the creation of high-performance polyurea and polyaspartic coatings that meet the evolving demands of the market. With our self-leveling polyurea coatings and versatile polyaspartic products, you can expect a solution that simplifies application processes while delivering outstanding performance, durability, and cost savings.
Explore our range of products at MPU Coatings and discover how our cutting-edge solutions can enhance your projects.
Reference Link:
5 Problems With Polyurea And Polyaspartic Concrete Floor Coatings
Adding ‘Polyurea’ To Your Coatings Vocabulary
Epoxy vs Polyaspartic Concrete Coatings: Curing Time and Durability