Protective coatings are required in industries that use pipes for transporting liquids, gases, or chemicals.
Piping is used consistently and exposed to corrosion, chemical attacks, abrasion, and environmental wear and tear. Protective coatings like polyurea have now gained industrial acceptance that reduces such risks and increases the life span of the pipe.
In this article, we will learn about polyurea pipe coatings, their advantages, application process, and use in various fields.
Meaning of Polyurea Pipe Coatings
Polyurea pipe coatings are basically composed of polyurea, which is an elastomer. When applied to surfaces, this elastomer offers a callous protective layer.
The chemical reaction to form polyurea is between a diisocyanate component and a mixture of synthetic resins. It is flexible and swift curing. Once applied to the pipe, a solid protective barrier could shield it from exterior damages like corrosion, chemical exposure, and any kind of weather condition.
Unlike other traditional coatings, such as epoxy or polyurethane, polyurea is unique in several key areas. It cures fast, has better flexibility than epoxy or polyurethane, and has excellent resistance to extreme environmental conditions.
Polyurea can be used for the oil and gas, water treatment, and chemical-processing industries because pipes encounter brutal conditions.
The Advantages of Polyurea Pipe Coatings
Polyurea offers several advantages over other coating materials, making it the primary material used in coating pipes in various environments.
- Probably the most significant advantage of using polyurea is the time it takes to harden. In many traditional coating materials, total hardness may take hours or days. On the other hand, polyurea usually achieves total hardness in a few seconds or, at most, a few minutes. This ensures the project's completion, meaning that any industrial process is returned to normality within a very short time.
- Polyurea pipe coatings are quite strong and elastic, so they can withstand extreme conditions without breaking and flaking. Owing to temperature variation or pressure inside, pipes usually expand and contract. Due to polyurea's flexibility, it follows the movement of a pipe to prevent damage and, hence, long-term protection.
- Polyurea is ideal for service in aggressive chemicals in oil, gas, and other chemical processing applications because it possesses superior resistance to oils, solvents, acids, and many other chemicals that could cause the corroding or degradation of traditional coatings.
- When applied to a pipe, polyurea forms an unbroken seam of a weldless, continuous coating covering the entire pipe surface. Due to the absence of seams and joints, this polymer system exposes no weak points for corrosion or abrasion that may likely start inside the pipe.
- Polyurea pipe coatings are highly moisture-resistant and ideal for pipes exposed to water or humid environments. They also offer excellent UV resistance, preventing corrosion caused by prolonged exposure to sunlight. These properties also make polyurea coatings suitable for pipelines located in outdoor or marine environments where exposure to water and UV radiation is expected.
- Pipes, especially those used in industrial settings, are often subjected to physical impacts and abrasive conditions. Polyurea’s tough and durable nature protects against abrasion, impact, and mechanical wear.
The Polyurea Coating Application Process
Polyurea pipe coatings involve several critical steps that ensure proper adhesion and protection. The process is usually applied through the spray application method, and the general steps involved are outlined below.
- The pipe surface must be cleaned and prepared correctly before polyurea coating. This means removing dirt, rust, grease, or previous coatings that could interfere with adhesion. Standard methods of surface preparation include sandblasting or power washing to provide a clean and rough surface on which the polyurea can bond.
- Sometimes, a primer is applied to the pipe surface before the polyurea application. Primer improves adhesion and thus ensures a strong bond between the pipe and the coating. Not all the polyurea systems require a primer to be applied; however, it is most often used in environments where bonding to the substrate could be particularly challenging.
- Once prepared and primed, the high-pressure spray system applies the polyurea coating. The two components of the polyurea mixed before the isocyanate and the resin- have the properties that allow them to cure rapidly on contact with the pipe surface.
- One of the significant advantages of polyurea is its very short curing time. When the coating emerges from the gun, the film begins setting so that the pipe can be handled or put in service immediately at practically close seconds.
Applications of Polyurea Pipe Coatings
Pipelines in the oil and gas sector are highly exposed to corrosive chemicals and high pressures, under severe conditions of the environment. Therefore, a polyurea coating is critical as it ensures a critical protection against corrosion, chemical exposition, and mechanical wear to ensure long life for the pipelines that carry oil, gas, or other hazardous materials.
Water and wastewater treatment facilities expose pipes to moisture and corrosive chemicals. Polyurea coatings provide waterproof protection and chemical resistance, therefore making them perfect for use as coatings on pipes in this environment.
In the chemical processing industry, the pipelines have a high probability of being subjected to aggressive chemicals and high temperatures. Polyurea, on its part, has an excellent resistance to chemicals that create a powerful protection between the protective coat and pipes containing corrosive materials, thus helping to avoid costly damage.
This is due to exposure to saltwater and UV rays in marine or offshore environments; thus, these pipes continuously undergo harsh weather conditions. Coatings of polyurea, therefore, present excellent resistance to saltwater corrosion and UV degradation with physical wear and tear, making them ideal for pipeline use in challenging environments.
How long does polyurea coating last?
Polyurea coatings can last up to 10 to 20 years, depending on the quality of application, preparation of the surface, and the conditions in the environment.
Indoors or areas with little to no exposure to UV rays and strong chemicals, polyurea pipe coating will last 20 years.
However, in outdoor or industrial situations, where the coating is exposed to extreme temperatures, heavy traffic, or corrosive substances, its lifespan may be slightly reduced, although it still provides excellent long-term protection.
Regular maintenance includes planned cleaning and inspection for damage. Polyurea's major advantage is its ability to resist abrasions, chemical exposure, and wear, which explains why this material is used in flooring, waterproofing, and industrial lining applications, among others.
Polyurea pipe coatings are generally estimated to be long-lived and highly reliable in fulfilling their duties in challenging conditions.
Polyurea pipe coatings are highly resistant to corrosion, chemicals, and environmental damage. They are flexible and tough and may work fast therefore, they can be applied in several industries, including oil and gas, water treatment, and chemical processing. Proper application of polyurea coatings increases pipeline life and significantly reduces maintenance costs.