Editor’s Note: This article, by Dudley Primeaux and his strong
team of co-authors, is part of the series of Top Thinker articles
appearing in JPCL throughout 2012. Mr. Primeaux is one of 24
recipients of JPCL’s 2012 Top Thinkers: The Clive Hare Honors,
given for significant contributions to the protective coatingsindustry over the past decade. The award is named for Clive
Hare, a 20-year contributor to JPCL who shared his encyclopedic knowledge of coatings in many forums. Professional profiles of all of the award winners, as well as an article by Clive
Hare, will appear in a special 13th issue of JPCL, to be published in August 2012.

The Protective
Coatings Specialistand Polyurea:
The Sequenceof Events

afforded me the opportunity to travel thethe polyurea technology was in automotive

world and witness a variety of coating and lin-

Reaction Injection Moulding (RIM) work. By theing application work as well as give numerous

mid-90s, however, the use of certain key raw

presentations on the technology (Fig. 1).

materials in polyurea spray application rose toI am also a firm believer in continuing edu-a point that exceeded the use of the samecation and keeping up with new industry tech-raw materials used in the RIM work, and thatniques and technologies. I have pursued vari-use has continued to grow since. The use ofous certifications relating to protective coat-polyurea coating and lining technology today

ings and linings as well as application equip-

far exceeds that of polyurea RIM, and it has

ment. The major highlight of my career wascome a long way from the initial intended use

not so much the polyurea technology, but myas a high-performance protective coating sys-certification as an SSPC Protective Coatings

tem for spray-applied polyurethane foam.1
More recently, doubt has been cast on theCoating Inspector (CCI). These certifications

suitability of polyurea systems for use inaffirmed my qualifications in this industry andimmersion applications because of failuresin relation to the polyurea technology.

noted in this application area. But much of theWhen the polyurea spray elastomer coatingproblem with these failures can be attributed

technology was first demonstrated in the mid-to improper specification and incorrect materi-80s, some individuals within the development

al selection for the specific application. Evencompany that said this concept, while very

when a proper system is selected and applied,Fig. 1: Construction application in Austria

olyurea elastomer

However, over the years, there has been a

new performance specifications, and you

coating and lining tech-melding of the various technologies, andhave an excellent choice for many application areas.

nology has made some significant

many people have now classified, or implied

inroads since its introduction in thethat, polyureas are the same as urethanelate 1980s. Initially, the polyurea

systems, urethane/urea systems, or both

The Story

technology had set itself in a differ-types of system. But the unique characteris-

Many may not realize this, but I have a uniqueent class of coating/lining systems com-tics of polyureas have shown promise inposition in this polyurea world andpared to conventional urethane coating/liningsome special coating/lining work. These

coatings/linings industry. I have worked onsystems. This was primarily due to thesystems are excellent coating and lining

the pure research and development side,

unique characteristics of the technology,materials when properly used. Couple prop-

technical sales/marketing, material develop-

both in processing and performance.

er use with industry training, standards, andment, supply, and support, as well as inspec-50 JPCL September 2012 / paintsquare.com

interesting, would go nowhere. The future forSpecialist (PCS) and as an SSPC Concrete

By Dudley J. Primeaux II, PCS, CCI

P

tion and training work. This experience hasFig. 2: Grand Isle, LA, beach rehabilitation

paintsquare.com / JPCL May 2012 51

The Protective Coatings Specialist and Polyurea

improper surface preparation, spray applica-

deterioration and puncture damage, as well as

9.6 km (~6 miles) of protective sand dunetion technique, or both can lead to application

seal the woven structure.

coastline area. The geotextile containers werefailures. The same is true for other coating/lin-

Following the devastation from Hurricane

first coated by an experienced and certified

ing technologies. Possessing the proper train-

Katrina in 2005, the coastal city of Grand Isle,

contractor in South Carolina, who used a high-ing, material selection, and guidance can lead

Louisiana, was all but washed away.

performance, aromatic, polyurea spray elas-to a successful application. The bottom line isRebuilding the area also meant rebuilding thetomer system in a sand color. The coatedthat properly formulated polyurea systems areprotective sand dunes along the beachfront.

containers were then placed and filled withthe sand slurry, and the area now has a nice
new coastline of sand dunes for protection(Fig. 2).3
A similar type of installation of the polyureacoated geotextile containers was scheduled
for a new river crossing, bridge construction,and header protection area in S. Honduras.
The geotextile containers were already inplace and filled with sand; they just needed
the polyurea coating application for protection. The procedure for installing the geotextile containers can either be that they are
sprayed first then sand slurry filled, as at
Grand Isle, or sand filled before coating, as at
S. Honduras. The choice depends on the way
the containers will be installed, where they will
be located, and access limitations. Because
the polyurea coating is only applied on the topFig. 3: Honduras geotube coating

performing satisfactorily in immersion applications, including potable water, wastewater,and oil- and gas-related tank lining work.2

Application of the Technology
Outside of the typical application areas that
one might consider for coating and lining
work, there are other interesting applicationsof the technology. One such application is theuse of the polyurea technology as a protective
coating system for geotextile fabrics. This
combination has been used in a variety of secondary and primary liner containment applications with excellent success. One area ofwork in particular is coating a proprietaryFig. 4: Flooded river and collapsed bridge in Honduras

woven polyethylene geotextile container technology used in soil stabilization/infrastructure

Following a specification from the U.S. Armyside of the containers, the contained “water”

rehabilitation. The polyurea spray is applied toCorps of Engineers, sand-filled, polyurea-coat-is able to bleed out from the bottom side of

the surface of the geotextile container to pro-ed geotextile containers (geotubes) were

the tube, in either situation. The presence oftect the thermoplastic system from sunlightplaced along the beachfront to rebuild aboutwater (from the sand slurry) is the main rea-52 JPCL September 2012 / paintsquare.com

The Protective Coatings Specialist and Polyurea

son polyurea is used, because of the lack ofmoisture interaction with the spray system
during installation. A polyurethane or even ahybrid system would have foamed.
The day after completion of the project, amessage was received from Honduras withthe subject line, “Amazing sequence of eventswith the [geotextile containers].” The message
was puzzling until the last picture was viewed.
Unbelievably, the new concrete bridge wasgone! It had rained so much that the area
flooded, and the 100-meter-wide riverbed wasfull of flowing (rushing) water. But the polyureacoated containers were still in place (Figs. 3and 4)!
In the past few years, the recent surge inactivity for domestic oil and gas sources has
contributed significantly to the use of polyurea
Fig. 6: Robotic sprayed-in-place pipelining

Fig. 5: Helicopter ballistic protection

stop projectiles. This protec-pipelining work with the polyurea technology.

tion includes large-caliber

These developments take advantage of therounds up to .50 cal. The

rapid set and cure of the systems for infra-majority of the use of thisstructure rehabilitation, a serious issue, as oftechnology has been retro-late.

fitting various types of heli-

Another unique development related to thecopters, including those used

polyurea technology has been that of robotic

by the 160th Special

sprayed-in-place pipelining. Sure, the polyurea

Operations Aviation Regiment

technology has been used in the past for sim-(‘the Night Stalkers’) such asple robotic lining of pipe where single joints of

the Sikorsky MH 60

pipe are lined either in a shop area or at a field

Blackhawk and the Bell 412installation site: a simple wand or spray headseries (Fig. 5).6

is inserted into the joint section, and either theThe ballistic composite

pipe rotates or the spray head rotates.

technology. This usage includes work in sec-

required the development of a polyurea spray

The new developments are for installed sec-

ondary containment/frac pond liners as wellsystem with some unique features. First, thetions of pipe of up to 600 feet (~180 meters)

as lining for oil and process chemical storage

material itself required high impact strength

in length. And this use is not just for straighttanks.4 As a result, standards that qualify the(though not bullet-proof strength). Otherrun pipe, but can also include various 45-

use of these types of systems were required.

requirements included fire retardance anddegree and 90-degree pipe bends. Unique

The Underwriters Laboratory of Canada (ULC)

antimicrobial resistance to the chemicals andpolyurea systems are formulated to be

recently published the CAN/ULC-S668-12

fuels associated with aircraft use. Most impor-processed in the robotic equipment, which has

standard relating to secondary containment

tantly, the fast-set technology required adhe-the ability to line pipe from a four-inch (10-cm)

work wherein the process for spray-applied lin-sion to the low surface energy composite sub-diameter up to a 96-inch (2.4 meter) largeers, including polyurea systems, is noted.5

strate—not an easy order, but it was done

diameter pipe and corrugated sections. Whileand is performing well.7

the primary use of the technology is for

Polyurea technology is also being utilized toprotect and save lives in our military in theform of special composite panels that actually

There have also been some new developments and involvement related to interior

54 JPCL September 2012 / paintsquare.com

water/wastewater work in our failing infrastructure, the technology is also being performed inThe Protective Coatings Specialist and Polyurea

the industrial and chemical sectors for suc-

The primary focus of this standard is toviable and growing coating and lining technolo-

cessful pipeline rehabilitation (Fig. 6).8

establish minimum surface preparation

gy. This change is evidenced by industry

Evaluations have shown that the applied

requirements as well as types of lining sys-

acceptance, the number of companies supply-

robotic polyurea pipelining system not only

tems for pipelining conditions. Interestingly

ing quality polyurea coating and lining sys-

provides abrasion and corrosion resistance,

enough, there are modified polyurea sys-tems, and the wide range of applications. To

3. D.J. Primeaux II, “The Sequence of Events,” FAPU–European

but also pressure integrity to the pipe system.

tems that achieve the Class IV Structural

further qualify this, SSPC has issued various

Polyurethane Journal, FAPU-69, November/December, 2011,

A three-inch (7.62 cm) diameter hole in a test

designation (used to classify pipe rehabilita-

documents and standards on polyurea technol-

pp. 28–29.

pipe section was masked over with tape andtion systems, and noted in references).

ogy through the C.1.3.D Polyurethane

then a layer of polyurea lining was applied toClass IV designation is the highest, from aCommittee, and has new work from the C.1.9

Liners for High Performance, Rapid Installation Containment

the inside of the host pipe. The mask wasstiffness/flexural modulus consideration, andPolyurea Committee, and in the C.1.13

Applications,” 14th Annual International Aboveground Storage

removed and the pipe sample was then pres-would be such as like a piece of PVC. A

Coatings for Wastewater Facilities Committee.

Tank Conference & Trade Show, National Institute for Storage

sure tested. It was found that 250 mils (6.4

lower class would be a more flexible lining

I am just proud to have been part of polyurea

Tank Management (NISTM), Rosen Shingle Creek, Orlando,mm) of applied polyurea can withstand a pres-system, like a typical sprayed polyurea elas-technology from the start and to have seen

Florida, March28–30, 2012.

sure rating of over 400 psi (27.6 bar). Failuretomer), like those with flexural modulus

the progression.

pressure alone just for a pipe made withgreater than 250,000 psi (1,720 MPa). Thispolyurea (no host metal pipe) is over 250 psi

would basically be a free-standing pipe (nor-References

Liquid Tanks,” Underwriters Laboratory of Canada Standards,(17 bar) at 250 mils (6.4 mm) thickness.9

mally called pipe-in-pipe repair).11,12

1. D.J. Primeaux II, “Spray Polyurea—

April 2012.

To further qualify the use of the technolo-Francisco, California, October, 1989, pp. 126–130.
2. D.J. Primeaux II, “Drinking Down Under: Great Idea, SecondThoughts, the Right Path,” SSPC 2012 featuring GreenCOAT,Tampa, Florida, January 30–February 2, 2012.

4. D.J. Primeaux II and Michael D. Whitener, “Polyurea Composite

5. CAN/ULC-S-668-12, “Standard for Liners Used for Secondary
Containment of Aboveground Flammable and Combustible

Versatile High Performance Elastomer

6. Lifeport Inc., a Sikorsky Aerospace Services Company.
7. United States Patent Application Publication

gy in this application, ASTM International hasConclusion

for the Polyurethane Industry,”a working group developing a standard relat-Polyurea technology is no longer the research

Polyurethanes ’89, the 32nd

ed to spray-in-place pipelining systems.10

lab experiment of the mid-80s, but is instead aTechnical/Marketing Conference, SPI, San

2010/0151181A1, June 17, 2010.
8. Jeff Griffin, “Polyurea Lining Offers Quick-Install, Spray-On
Lining,” Underground Construction, July 2006, p. 35.
9. Erez N. Allouche and Eric J. Steward, “Organic ‘High-Build’
Spray-in-Place Liners–An Emerging Class of Rehabilitation
Methods,” Trenchless Technology Center, Louisiana University,
Underground Construction, June 2009, pp. 28–32.
10. Working Group WK23937, “Standard Practice for Renewal ofPotable Water Pipes by Spray in Place Pipe–Polyurea andPolyurethane,” ASTM International.
11. AWWA M28, Rehabilitation of Water Mains, American Water
Works Association, Denver, CO.
12. Methods for Renewal of Potable Water Pipes, ASCE–Manual ofPractice, American Society of Civil Engineers, current revision.
Dudley J. Primeaux II is a consultant and the owner
Click our Reader e-Card at paintsquare.com/ricof Primeaux Associates LLC (Elgin, TX), a consultant firm for the polyurea industry
Mr. Primeaux is active in SSPC, NACE, and PDA,
where he is a past-president and a member of theBoard of Directors. He has also completed theSSPC PCS Protective Coatings Specialist andSSPC CCI Concrete Coatings Inspector certifications. He is an inventorof 26 U.S. patents and 8 European patents on polyurethane andpolyurea foam applications, as well as polyurea spray elastomer systems and applications. He has authored over 40 technical papers on
polyurea elastomeric coating and lining technology, as well as several
chapters in SSPC book publications. JPCL

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