POLYASPARTICS –
CHANGE THE COATINGS GAME!
POLYISOCYANATES
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PREPOLYMERS
DISPERSIONS
UV SYSTEMS
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INTRODUCTION
Nowadays, machine manufacturers, own-
stadiums, large buildings, flooring or archi-
ers of commercial or industrial premises
tectural elements, polyaspartic coating
and other relevant decision-makers want
technology offers cost savings in applica-
durable coatings that meet scheduling
tion and resumption of normal working
demands and just-in-time delivery require-
as quickly as possible. Based on Bayer
ments while, at the same time, protecting
technology, polyaspartics can change the
their assets. Without sacrificing perform-
coatings game.
ance, 2K polyaspartic coating technology
offers greater productivity and durability for
applications in the industrial maintenance
and OEM markets. Whether for bridges,
OVERVIEW
I N TROD U C TI ON
3
KEY BEN EFI TS
4–5
APPLI C ATI ON S
6–15
C H EM I STRY OF POLY ASPARTI C S
16–17
G LOBAL PARTN ERSH I P
18–19
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KEY BENEFITS
FROM U LTRA HIGH SOLID TO SOL-
Polyaspartic coatings dry significantly
VENT-FREE
faster at room temperature, usually taking
Ever-increasing legislative requirements for
between 1.5 and 4 hours. This allows addi-
a reduction in volatile organic solvents
tional treatment or transport of the coated
demand the use of low-solvent coating
parts to be carried out sooner.
materials. In the case of OEM coatings for
Polyaspartic coatings make much greater
plant and machinery this is particularly rele-
film thicknesses possible, e.g. a dry film
vant when conventional coating materials
thickness of up to 400 μm in a single ope-
have to be replaced. However, many low-
ration. In practice, this means that one less
solvent or solvent-free coating materials
coat is required in the application process.
would require investing in new equipment
The increase in efficiency is particularly
and/or modifications to the production pro-
important if the coating process is part of
cess. Since this is often impossible or too
a process chain since the coating process
expensive, coating materials that can be
often acts as a bottleneck.
processed on existing coating facilities are
Together, the two benefits of rapid drying
of particular interest.
and a reduced number of coats add up to
Low-solvent coating materials, which –
a significant increase in productivity. In
depending on the application – either have
practice, the overall coating process, i.e.
a VOC content of less than 250 g/l or
application of all coats plus drying time,
are virtually solvent-free in their ready-to-
can be two or three times faster than with
use state, can be produced on the basis
conventional coatings.
of polyaspartics that comply with current
requirements, such as the EU VOC Directive
or the South Coast Air Quality Management
District in California.
ENERGY COSTS A N D CO 2 S A VI N GS
The unique reactivity of aspartics with aliphatic polyisocyanates makes their reaction
kinetics somewhat more independent of
INCREASED
PRODUCTIVITY
AND
temperature than is the case with conventi-
COST EFFICIENCY
onal 2K coating technologies. Especially in
The main benefit of polyaspartic coatings is
OEM paint shops, polyaspartic coatings con-
that they significantly increase productivity
tribute significantly to reducing energy costs
in the application process.
and CO2 emissions. It goes without saying
The increase in productivity over conven-
that both aspects will become increas-
tional topcoats is achieved thanks to two
ingly important in the future.
properties of polyaspartic coatings:
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LONG-LASTING PERFORM ANCE
The key benefits determining the success of
In general, the well-known positive attributes
polyaspartic coatings are illustrated in the
of aliphatic 2K PU coatings are also found in
triangular diagram below (see fig. 1).
2K polyaspartic coatings, for example:
High gloss retention during weathering
Adjustable flexibility through choice of
polyisocyanate
Resistance to acids and alkali
High mechanical resistance, e.g. abrasion resistance and impact strength
Ease of repair
EFF
ICIENCY
RAPID CURING/DRYING
FEWER COATS
EASY APPLICATION
QUALIT Y
CUSTOMER AND
END-USER
EN
VIRONMENT
INDUSTRIES
HIGH APPEARANCE
SOLVENT-FREE
AND HIGH SOLID SYSTEMS
LONG-LASTING PERFORMANCE
LOW ENERGY CONSUMPTION
LOW MONOMER
CONTENT
Fig. 1: Key benefits in the success of polyaspartic coatings
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APPLICATIONS
POLYASPARTICS FOR INDUSTRIAL
With metal substrates such as cold rolled
COATINGS/CORROSION PROTECTION
steel or aluminum, on which adhesion is
Thanks to their high productivity, poly-
usually inadequate, the adhesive proper-
aspartics are already being used for a vari-
ties can be improved by using an adequate
ety of metal coatings. One of the main
polyisocyanate (see page 16 “Chemistry of
applications is the OEM coating of steel
Polyaspartics”).
parts for corrosion protection and industrial
coating purposes.
CORROSION PR O TE CTI O N
In the field of heavy-duty corrosion protec-
IND U STRIAL COATINGS
tion, e.g. bridges and wind turbines, three
In the field of industrial coatings, polyaspar-
coats are frequently applied. In such cases,
tics are widely used for coating agricultural
the intermediate coat can be replaced by a
and construction machinery. The size and
polyaspartic topcoat (see fig. 3).
weight of such machines mean they are
The main applications for polyaspartics are
often unsuitable for forced drying at elevat-
in the field of OEM coatings. Numerous
ed temperatures. The two-coat system fre-
practical examples in the past have demon-
quently used at present for such machines
strated the suitability of polyaspartics for
can be replaced by a one-coat polyaspartic
heavy-duty corrosion protection.
topcoat (see fig. 2).
primer
Fig. 2
DTM polyaspartic topcoat
Replacement of the primer by a direct-to-metal polyaspartic topcoat
primer
Fig. 3
2K PU topcoat
intermediate coat
2K PU topcoat
primer
polyaspartic topcoat
Replacement of the intermediate coat by a polyaspartic topcoat
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GEL COATS, PORE FILLERS AND
noted that, through the combination of high
by rapid dry sandability, good adhesion
SURFACERS
flexibility and hardness of these systems,
to different metal substrates and excellent
F O R C E D P L AST IC S
they have good adhesion to the substrate
corrosion protection.
For several years now, polyaspartics-based
and also constitute a good substrate for the
gel coats, pore fillers and fine surfacers
final finish, the 2K PU topcoat.
FOR
FIBER-REIN-
CLEAR COATS
have been used for coating glass fiber-
Very high-solid clear coats based on aspar-
reinforced plastics. This has been particu-
POLYASPARTIC SYSTEMS FOR AUTO -
tics and reactive thinners in combination
larly true of wind turbines, which have to
MOTIVE AND LARGE VEHICLES REPAIRS
with special low viscosity polyisocyanates
resist extremely rugged conditions over
offer the benefits of very fast drying times
long periods. These solvent-free reactive
K NIFING PU TTY
at ambient temperatures, an acceptable
systems can be applied – depending on the
Knifing putties based on highly reactive
pot life, high brilliance and good chemical
viscosity – by rolling (gel coats), brushing
aspartates and low-viscosity polyisocy-
resistance.
(pore fillers) or knifing (surfacers) at high
anates can be formulated with a very short
Structure: Using a repair coating system
film thicknesses. They are mainly used to
pot life, rapid dry sandability and good
consisting of a solvent-free putty or spot
fill pores and holes in glass fiber-reinforced
adhesion to metal.
repair filler, a low-solvent primer surfacer
composites (rotor blades of wind turbines)
and a very high-solid polyaspartic clearP RIM ER SU RFACERS
coat, it is possible not only to reduce sol-
made possible by the rapid dry sandability
Combinations of aspartates with reactive
vent content, save time and cut energy
of filled gel coats (pore fillers and surfac-
thinners (aldemines), low-viscosity polyiso-
consumption, but also to make the whole
ers). In such cases, the high reactivity of
cyanates and a minimum amount of solvent
repair process far more efficient (see fig. 4).
these efficient polyaspartic systems means
for spray application are used to formulate
that an entire paint system can be applied
very high-solid primer surfacers or fillers
in a single working day. It should also be
(250 g/l). Such systems are characterized
45'
EC
O
L
NE BA S
YA
SP
C
A RT I C L E A R
CO
C
‹2
NG
NG
BOR
AT
DI
R
R
SAN
CE
CZ
ERO
VO
VO
TE
PO
IC PRIMER S
UR
A
RT
POL
YA
PA
W
TY
S
S PA RT I C P U T
AT
YA
OL
FA
P
and to smooth surfaces, an application
50
G/L
SAN
DI
VOC
MARKET
1 H 30'
2 H 15'
250 G/L
4H
Fig. 4: Efficiency of polyaspartic systems for automotive and large vehicle repairs
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CONSTRU CTION IND U STRY
hours. Standard 2K PU topcoat technology
Over the past eight years, polyaspartic
can add color stability to the system but
coatings have found their way into many
with a curing time of approx. 8–16 hours the
application areas in the construction indus-
application no longer enjoys the advantage
try. Here are just some of them:
of weather tolerance. Polyaspartic coatings
Topcoats for sprayed polyurea membranes
are a logical supplement to fast-setting poly-
Fast-setting garage coating systems
urea technology. When applied by roller or
(small areas)
1K airless spray equipment, a polyaspartic
Highly decorative photo floorings
topcoat allows a 2-hour curing time with
Concrete sealers for stamped/stained
a potlife of approx. 30 min. Consequently,
concrete
the complete waterproof coating system is
Binders for stone carpets
almost climate-independent.
Pourable joint sealants
Binders for colored quartz sand production
FAST-SETTING GARAGE COATING
Each field of application has its own individ-
SY STEM
ual requirements, but common to them all
is the need for speed to allow resumption
Painting small areas like a private garage
(up to 150 m2) using a conventional coat-
of normal working as quickly as possible.
ing system is a time-consuming and laborintensive project. A curing time of between
TOPCOATS FOR SPRAYED POLYUREA
8–16 hours with the common solventborne
M EM BRANES
2K technology means that contractors can
Sprayed polyurea membranes are widely
only apply one coat per day and have to
used in the waterproofing sector. The main
come to the site at least three times. With
benefit of these coating materials is weath-
polyaspartic coating technology, a 3-coat
er-tolerant application. Thanks to their high
system can be applied with a roller within
reactivity, these membranes cure within
a day, saving significant labor costs and
5 minutes of application. Unfortunately,
hassle for the owner. In addition, VOC and
polyurea membranes are not color-stable,
emission-free polyaspartic coating systems
which means that yellowing can occur within
are now state of the art (see fig. 5).
C O NV EN T IONA L SYST EM
1. primer with chips
> 1 day
2. 1st sealer
> 1 day
3. 2nd sealer
> 1 day
in total
> 4 days
Primer with chips
1st sealer
2nd sealer
P OLYA SPA RT IC SYST EMS
1. primer with chips
> 2 hrs
2. 1st sealer
> 2 hrs
3. 2nd sealer
> 2 hrs
in total
> 6 hrs
Fig. 5: Fast setting garage coating system
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HIGHLY DECORATIVE PHOTO FLOORING
CONCRETE SEALERS FOR STAMPED
In the past, the laying of highly decora-
AND/OR STAINED CONCRETE
tive seamless flooring was a major task.
Stamped and/or stained concrete can be
A great deal of time-consuming preparation
protected by a clear coat to protect from
was needed, followed by artistic painting
soiling and increase abrasion resistance.
with many small paint cans and brushes.
Productivity of 2–4 m2/h for the actual
Conventional sealers are solvent-based or,
picture was normal, which added up to a
longer comply with requirements such as
5–7 day job for the whole floor, even for
durability, abrasion, etc. Polyaspartic clear
small shop-in-shop areas.
coats not only provide long-lasting perform-
Polyaspartic coating photo floor technol-
ance, they are also VOC- and emission-free,
ogy has introduced a kind of “pre-fab”
making them the first choice for indoor
work routine to the world of floor coatings.
applications.
in the case of waterborne 1K paints, no
The floor picture is printed on fabric and
applied in a lamination process on-site.
Normal working can resume on the decorative flooring within eight hours so that a
shop owner, for example, have the work
done overnight (see fig. 6).
Primer
Leveling coat
Base coat
Fixing coat
Fabric
Sealer
Fig. 6: Highly decorative photo flooring (all layers based on polyaspartics)
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BINDERS FOR STONE CARPETS
carpets or colored stone façades. However,
Seamless stone carpets are another deco-
transportation of these stones is expensive
rative flooring alternative. Mosaic or ter-
and their uneven shape is not helpful for
razzo-like decorative flooring can be pro-
smooth application.
duced through a mixture of natural stones
Although round, color-coated quartz sand
or colored quartz sand (see also binders
products have been established on the
colored quartz sand below) and a reactive
market for many years now, the production
binder. The fast curing properties and bril-
process requires a lot of solvent and is fairly
liance of polyaspartic coatings are a major
slow.
advantage in this field.
Polyaspartic coating binders can solve both
problems. VOC-free formulations are possi-
POURABLE JOINT SEALANTS
ble and the production time can be reduced
Joint sealants based on polyaspartic tech-
to approx. 30 min.
nology offer some unique advantages over
other technologies. By choosing the right
CONCLUSION
products, the UV and color stability of the
Concerted efforts to enhance effectiveness
sealant can be dramatically improved.
and efficiency are more important than
Polyaspartic joint sealants also have the
ever while the quality and environmen-
unique ability of curing at low tempera-
tal compatibility of coatings remain crucial
tures. In addition, the use of plasticizers
success factors. Polyaspartic coatings are
can be eliminated in some formulations
fully in line with these market drivers – the
to allow plasticizer-free sealants to be for-
use in different industrial and construc-
mulated. Apart from their good working-
tion applications demonstrating the key
to-curing-time ratio, polyaspartic sealants,
benefits polyaspartic coatings bring. So it
once cured, offer better physical properties
is hardly surprising that they are now being
than conventional pourable sealants.
used in more and more fields of application,
e.g. in-mould or wood coatings.
BINDERS FOR COLORED QUARTZ SAND
PRODUCTION
Natural stones in different colors, e.g.
Atlantic Green granite or New Imperial Red,
are available for the production of stone
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CHEMISTRY OF POLYASPARTICS
Aspartics are sterically hindered secondary diamines (see fig. 7).
O
R
O
H
N
O
O
R
H
N
O
O
X
O
R
R
O
Fig. 7 General structure of aspartics
The reactivity of aspartics with polyisocyanates can be influenced through the choice of the
rest X, enabling the parameters of pot life and drying time to be adjusted specifically in a
broad range (see Table 1 and fig. 8).
Product
Solids content
[%]
Desmophen® NH 1520
Equivalent weight
Viscosity @ 23 °C
[mPa·s]
Reactivity
100
290
approx. 1,500
low
Desmophen NH 1420
100
276
approx. 1,500
moderate
Desmophen® NH 1220
100
234
approx. 100
high
®
Table 1: Aspartics portfolio
9
NH 1520
8
Dry-to-handle* / h
7
6
5
4
3
2
1
0
0.001
NH 1220
0.01
NH 1420
NH 1520 (1 : 1)
NH 1220
NH 1420 (1 : 1)
NH 1420
0.1
1
10
Potlife / h
Fig. 8: Relation of potlife and drying time
on the example of industrial topcoats
Crosslinker: Desmodur® N 3600
NCO: NH ratio: 1 : 1
* at 20 °C/50 % rel. humidity
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Aspartics react with aliphatic polyisocyanates to form polyaspartics (see fig. 9).
O
R
R
O
O
Rµ
N
O
R
H + R³– N=C=O
R
O
Aspartic
O
O
Aliphatic polyisocyanate
Rµ
N
O
C
H
N
R³
O
Polyaspartic
Fig. 9: Reaction of aspartics with aliphatic polyisocyanate to give polyaspartics
The properties of polyaspartics can be influenced by the choice of polyisocyanate.
The choice depends on the
desired VOC content
application
mechanical properties
adhesion to the substrate
Polyisocyanate
Desmodur® N 3900
Solids content
[%]
Viscosity @ 23 °C
[mPa·s]
NCO content
[%]
100
730
23.7
®
100
1,200
23.0
®
Desmodur N 3390
90
500
19.6
Desmodur® N 3800
100
6,000
11.0
Desmodur N 3600
Remark
Flexibility
Table 2: Aliphatic polyisocyanates as co-reactants for aspartics
The wide variety of possible combinations enables the development of customized
polyaspartic-based coating materials to meet different requirements. For experimental
Desmophen NH and Desmodur grades please contact your local sales representative.
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Edition: 2011-02 · Order-No.: MS00051641 · Printed in Germany · D