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ARMORTHANE PROTECTING YOUR WORLD

PROTECTING YOUR WORLD

ARMORTHANE PROTECTING YOUR WORLD

Polyurea Spray:
How Spray-On
Polyurea Works

How spray polyurea is applied: plural-component equipment, heat, pressure and mix ratio, spray technique, common problems, and what it takes to do it safely.
Spray Polyurea

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1:1
Typical mix ratio by volume
Product data sheets
2,000+ psi
Typical high-pressure spray range
Product data sheets
~150–170°F
Typical material heat at the gun
Product data sheets
Seconds
Gel time once A and B meet
Product data sheets

Spray polyurea is applied as two liquids that meet only inside the spray gun. A heated, high-pressure proportioner pumps an isocyanate (A side) and a resin blend (B side) at a fixed ratio through heated hoses to an impingement-mix gun, where they collide, mix and leave the tip already reacting. Within seconds the film gels, and within minutes it can be walked on. Getting that right takes the right equipment, settings and training. Here is how it works.

Quick answer

Polyurea is sprayed with a plural-component proportioner that heats the A and B components (commonly around 150 to 170°F) and pumps them at high pressure (often 2,000 psi or more) at a fixed ratio, usually 1:1 by volume, to an impingement-mix spray gun. The applicator builds the film in multiple overlapping passes to the specified thickness. Results depend on surface prep, correct temperature, pressure and ratio, and safe handling of isocyanates with supplied-air respiratory protection.

What's in this guide
  1. 1The spray system
  2. 2Settings
  3. 3Technique
  4. 4Common problems
  5. 5Safety
  6. 6FAQ
Start here

The spray polyurea system

Proportioner

Heat, pressure, ratio

Pumps A and B at a fixed ratio and heats both to spray temperature. The heart of the system.

Hose

Heated hose

Keeps material at temperature all the way to the gun; long runs need more heat capacity.

Gun

Impingement-mix gun

Mixes the two streams by high-pressure collision in a small chamber and sprays the reacting blend.

ArmorThane builds complete systems and mobile spray rigs. See spray foam rigs for what goes inside a rig.

Dial it in

Temperature, pressure and ratio

SettingWhy it mattersIf it is wrong
Material temperatureLowers viscosity so A and B mix completelyPoor mix, rough texture, soft spots
Spray pressureDrives impingement mixing and atomizationPoor mix, spitting, uneven pattern
RatioSets the chemistry; polyurea is ratio-sensitiveOff-ratio film that is tacky, brittle or weak
Drum temperatureKeeps material in range before it reaches heatersCavitation, pressure imbalance
Mix chamber and tipControls output and patternWrong film build, overspray
Always use the settings on the product data sheet.
Field noteWatch the A and B pressure gauges. If they drift apart, stop and find out why before you put off-ratio material on a customer job.
Spray it

Spray technique

  1. Prep

    Surface clean, profiled and primed. See surface preparation.

  2. Test spray

    Spray a test panel to check pattern, color and cure.

  3. Detail first

    Hit edges, corners, seams and penetrations first.

  4. Cross-hatch passes

    Build the film in overlapping passes at right angles for even thickness.

  5. Check thickness

    Use wet-film checks while spraying and verify after cure.

  6. Inspect

    Look for pinholes, blisters and thin spots; holiday test linings.

Troubleshoot

Common polyurea spray problems

ProblemLikely causeFix
Pinholes and blistersOutgassing from concrete, moisture, spraying on a warming slabPrime, spray when substrate temperature is steady or falling
DelaminationPoor prep, contamination, missed recoat windowRe-prep, prime, respect recoat times
Soft or tacky filmOff-ratio, cold materialCheck ratio and heat; fix the cause before continuing
Brittle filmOff-ratio toward the A sideCheck ratio and pumps
Orange peel or rough textureLow heat or pressure, gun too close or farAdjust settings and technique
Safety

Spraying polyurea safely

Spray polyurea contains isocyanates, which can cause respiratory sensitization. Applicators need training, supplied-air respiratory protection in most spraying situations, skin and eye protection, ventilation and controlled re-entry times for occupied spaces. See OSHA guidance on isocyanates.

Thinking about starting? See opportunities, aromatic vs aliphatic polyurea and polyurea cost.

Spray polyurea

Equipment, coatings and training.

ArmorThane supplies spray polyurea, plural-component equipment and hands-on training, or connects you with a certified applicator.

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Contractors: become an ArmorThane applicator

FAQ

Polyurea spray questions

How is polyurea sprayed?

With a heated plural-component proportioner that pumps the two components at a fixed ratio through heated hoses to an impingement-mix gun, where they mix and spray.

Can you spray polyurea with a regular paint sprayer?

No. Fast-set spray polyurea needs plural-component equipment because it gels within seconds of mixing. Slower hand-applied and roll-on polyurea-type products exist but perform differently.

How thick is spray polyurea applied?

It depends on the job: roughly 20 mils for light-duty coatings to 125 mils or more for heavy linings, built in multiple passes.

How long does spray polyurea take to cure?

It gels in seconds and is typically walkable in minutes, with light service in hours. Full properties develop over a longer period per the product data sheet.

Is spraying polyurea dangerous?

It contains isocyanates and requires training, supplied-air respirators in most spraying situations, protective clothing and ventilation.

AT
Written by the ArmorThane technical team. We have manufactured polyurea, polyurethane and polyaspartic coatings, spray foam and plural-component spray equipment in Springfield, Missouri since 1989. Always follow the product data sheet, safety data sheet and equipment manual.

Sources

  1. OSHA, isocyanates safety and health topic. osha.gov/isocyanates
  2. Polyurea Development Association resources. pda-online.org
  3. American Chemistry Council, Center for the Polyurethanes Industry. americanchemistry.com

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