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ARMORTHANE PROTECTING YOUR WORLD

PROTECTING YOUR WORLD

ARMORTHANE PROTECTING YOUR WORLD

Dunnage Coatings For Tonnage Protection

    DUNNAGE COATINGS
    FOR TONNAGE
    PROTECTION

    Dunnage protects your cargo, but what protects your dunnage? And could protection for your dunnage help protect your cargo too? So many questions, but only one answer: dunnage coatings, polyurea dunnage coatings, to be exact. Just like dunnage, dunnage coatings protect goods during transport, handling, and storage. They impart a tough skin to the surfaces of dunnage so that contact points don’t rub surfaces bare, and to make cleanup and dunnage material management easier. But not every dunnage coating is formulated equally. ArmorThane is the world’s one-stop shop for everything polyurea and polyurethane, and many of our coatings products are used to protect dunnage worldwide. Our high-performance protective coatings bond to almost any substrate, including common dunnage materials like wood and metal. They can be applied in custom colors to communicate information visually, and aggregates can be incorporated to impart textures for better traction. They’re a reliable and cost-effective way of getting more mileage out of your dunnage and better protection for your cargo.
    DUNNAGE COATINGS FOR TONNAGE PROTECTION
    5–10×
    Dunnage Lifespan Increase
    40%
    Reduction in Part Damage
    30 sec
    Gel Time for Polyurea
    20+ yr
    Service Life

    📋 Key Takeaway

    Dunnage coatings are polyurea or polyurethane protective layers applied to dunnage racks, trays, separators, and fixtures used in automotive, aerospace, electronics, and general manufacturing. By shielding contact surfaces from impact, abrasion, and chemical exposure, a dunnage coating extends rack life by 5–10× while reducing part defects, scrap rates, and replacement costs. ArmorThane's spray-applied polyurea systems cure in seconds, bond to wood, metal, plastic, and foam substrates, and deliver the highest impact resistance of any dunnage coating on the market.

    ALL-SURFACE, ANY HARDWARE PROTECTION

    No two operations run the same, and that variance extends to dunnage too. But whatever the dunnage or the tonnage, polyurea is ready to go. For any type of dunnage material, polyurea dunnage coatings can bond to the surface, regardless of whether it’s made of wood or steel, composites or fabrics. This compatibility extends to stainless steel as well, where it can bridge seams that could otherwise snap packaging. Fixtures and carts? No problem. Individual targeting of dunnage components? Absolutely. Inside shipping containers, on trailers or plant floors? We’re sure you get the idea. Our polyurea dunnage coatings are all about versatility, flexibility, and adaptability; it’s a one-size-fits-all solution capable of protecting any dunnage, anywhere.

    ALL-SURFACE, ANY HARDWARE PROTECTION

    LONGER LASTING, FEWER MATERIALS, LOWER COSTS

    A dunnage coating that extends the life of a dunnage rack reduces repairs and scrapped parts. Polyurea spreads impact and resists abrasion, so trays sliding into a dunnage rack don’t chew through rails and carriers don’t mar a body panel. That improves part protection at the point of contact, and because the film builds thin, a coated dunnage rack preserves weight capacity and doesn’t force change to slot size. The elastomer stays intact under high load, and it flexes instead of cracking. Where a factory relies on custom injection nests or water-jet cut foam inserts, coating the contact zones ties the setup together without retooling. That matters when dunnage engineering is trying to control tooling costs for short runs or model changes. Grease and dust wipe off a coated dunnage rack with minimal effort, which shortens changeovers and keeps material handling on schedule. For custom dunnage that follows parts between plants, the same dunnage rack can survive more cycles before its retirement. Compared with conventional epoxy coatings, polyurea returns to service more quickly and better tolerates sudden hits that could chip a rigid film. 
    LONGER LASTING, FEWER MATERIALS, LOWER COSTS

    FOR MUCH MORE THAN DUNNAGE

    Once a team sees the gains on a dunnage rack, it often extends the same polyurea to fixtures and carts, then to returnable bins or pallets. A coated dunnage rack slides quietly in a line-side cart, and the same surface toughens conveyor guides and pallet decks. Polyurea adheres to most materials commonly found on the floor, from carbon steel to plastic and even fabrics. On stainless steel trolleys, it can bridge seams and cover fasteners, and for nests built with custom injection carriers or brackets, a thin layer on touchpoints cushions impacts and adds vibration protection without masking part geometry. Water-jet cut trays and separators can be sealed at edges, which helps them last longer when they move in and out of a dunnage rack all day. Where rigid chemical resistance is the priority, an epoxy coating still has a place on walls or welded stands.

    That’s why many teams choose to combine both materials, using polyurea on the dunnage rack and a rigid film nearby on static surfaces. This gives dunnage engineering options while keeping material handling predictable, as well as scaling well to custom dunnage designs.
    DUNNAGE

    NO MORE
    DUNNAGE-KRUGER

    Dunnage can seem like enough protection for your cargo, but why take the risk? Coating dunnage in polyurea dunnage coatings is an easy, cost-effective way to help ensure your goods survive the journey unscathed. And dunnage doesn’t have to be made of gold to be worth protecting. Dunnage material, whether made of waste or custom components, is always cheaper, easier, and more sustainable to use fewer materials. So no more dunnage-kruger. Don’t overestimate your dunnage and start protecting your dunnage materials with ArmorThane’s high-performance coatings.
    DUNNAGE-KRUGER
    SECTION 3

    TYPES OF DUNNAGE COATINGS

    Not every dunnage coating performs the same way. The chemistry behind the coating determines cure speed, flexibility, chemical resistance, and service life. Understanding the different types helps manufacturers select the right system for their dunnage racks and returnable packaging.

    Polyurea Dunnage Coatings

    Polyurea is the gold standard for dunnage protection in high-volume manufacturing environments. Pure polyurea coatings gel in 5–30 seconds and reach full cure within minutes, meaning coated dunnage can return to service the same day. The resulting film is extremely tough, with elongation values of 300–500% and tensile strength exceeding 3,000 psi. Polyurea bonds to steel, aluminum, wood, HDPE, and foam substrates without primers in most cases, and its seamless, monolithic film bridges cracks and surface imperfections.

    Polyurethane Dunnage Coatings

    Polyurethane coatings offer excellent UV stability and color retention, making them ideal for outdoor dunnage or applications where visual identification matters. Cure times range from 4 to 8 hours, which requires more planning around production schedules. Aliphatic polyurethanes resist chalking and fading, while aromatic formulations deliver higher abrasion resistance at lower cost. Polyurethane dunnage coatings are often specified when aesthetic appearance must be maintained alongside physical protection.

    Hybrid Polyurea-Polyurethane Systems

    Hybrid systems combine the fast cure of polyurea with the UV resistance and self-leveling properties of polyurethane. These coatings are popular for dunnage racks that travel between indoor manufacturing and outdoor staging areas. Gel times typically fall between 30 seconds and several minutes, offering applicators more working time while still achieving same-day return-to-service.

    Epoxy Dunnage Coatings

    Epoxy coatings provide strong chemical resistance and excellent adhesion to metal substrates. However, epoxy films are rigid and brittle compared to polyurea, making them prone to chipping under repeated impact. Epoxies also require 4–12 hours to cure and will chalk when exposed to UV. For indoor dunnage that faces chemical exposure rather than mechanical impact, epoxy can be a cost-effective option, but for most dunnage applications where impact and flexibility matter, polyurea outperforms epoxy on every critical metric.

    SECTION 4

    HOW DUNNAGE COATINGS ARE APPLIED

    Proper application is the difference between a dunnage coating that lasts a decade and one that peels in months. The process involves surface preparation, priming (when needed), spray application, and quality inspection. Here is what a professional dunnage coating application looks like from start to finish.

    01

    Surface Preparation

    All grease, oil, rust, and loose material is removed. Metal dunnage is typically abrasive blasted to SSPC-SP 6 or SP 10 profile. Wood and plastic substrates are cleaned and scuffed to promote adhesion. Surface prep accounts for 60–80% of coating performance.

    02

    Priming (If Required)

    Some substrates benefit from a primer coat to maximize adhesion. ArmorThane polyurea bonds directly to most metals and plastics without a primer, but smooth or non-porous surfaces may require a tie coat for optimum long-term performance.

    03

    Spray Application

    Polyurea dunnage coatings are applied using plural-component spray equipment that heats and pressurizes the A-side (isocyanate) and B-side (resin blend) before mixing at the spray gun. Typical application temperature is 150°F at the gun. Film builds of 40–80 mils are common for dunnage.

    04

    Inspection & Return to Service

    After curing (5–30 seconds for polyurea), the coating is inspected for thickness, adhesion, and coverage uniformity. Dunnage racks can typically return to production within one hour of coating completion, minimizing downtime and maintaining manufacturing throughput.

    SECTION 5

    DUNNAGE COATINGS VS. ALTERNATIVES

    Manufacturers often weigh dunnage coatings against other protection methods. This comparison shows why polyurea dunnage coatings deliver the best total value for dunnage rack and returnable packaging protection.

    Property Polyurea Coating Rubber Liners Foam Inserts Epoxy Paint
    Cure Time5–30 secondsN/A (mechanical)N/A (mechanical)4–12 hours
    Impact ResistanceExcellentGoodModeratePoor (chips)
    Abrasion ResistanceExcellentGoodPoorModerate
    Service Life20+ years3–5 years6–12 months5–10 years
    Custom ColorsYesLimitedLimitedYes
    Chemical ResistanceExcellentGoodPoorGood
    Substrate VersatilityMetal, wood, plastic, foamMust be cut to fitMust be cut to fitMetal, concrete
    Seamless CoverageYesNo (seams/gaps)No (gaps)Yes
    DowntimeUnder 1 hourInstallation timeInstallation time12–24 hours

    📋 Quick Reference: When to Choose Each Dunnage Protection

    High-impact automotive dunnage racks Polyurea (ArmorThane)
    Outdoor staging & UV-exposed dunnage Hybrid Polyurea-Polyurethane
    Chemical-exposure environments Polyurea or Epoxy Phenolic
    Short-term / disposable dunnage Foam Inserts
    Color-coded returnable packaging Polyurea with Custom Pigment

    Need help selecting the right dunnage coating system?

    Get Expert Consultation →
    SECTION 6

    DUNNAGE COATING FAQ

    What Is a Dunnage Coating? ›

    A dunnage coating is a protective layer applied to dunnage racks, trays, separators, and fixtures used in manufacturing, shipping, and warehousing. Typically made from polyurea, polyurethane, or hybrid chemistries, the coating shields contact surfaces from impact, abrasion, chemical exposure, and moisture. The result is longer dunnage life, fewer part defects, and reduced material handling costs.

    How Long Do Dunnage Coatings Last? ›

    Polyurea dunnage coatings from ArmorThane typically last 20 or more years in normal manufacturing environments. Service life depends on the severity of impact, chemical exposure, and temperature cycling. Even under heavy use in automotive assembly plants, ArmorThane polyurea-coated dunnage regularly exceeds 10 years of continuous service without recoating.

    Can Dunnage Coatings Be Applied to Wood and Metal? ›

    Yes. ArmorThane polyurea dunnage coatings bond to virtually any substrate, including steel, aluminum, wood, HDPE plastic, fiberglass, foam, and composite materials. Most substrates require only surface cleaning and light abrasion before application. The coating forms a seamless, monolithic membrane that conforms to complex geometries without seams or gaps.

    How Quickly Can Coated Dunnage Return to Service? ›

    With polyurea coatings, dunnage racks can return to production in under one hour. The coating gels in 5 to 30 seconds and reaches handling strength within minutes. This rapid cure minimizes production downtime compared to epoxy systems that require 12 to 24 hours before the dunnage can be used again.

    How Much Do Dunnage Coatings Cost? ›

    The cost of dunnage coatings varies based on substrate size, complexity, coating thickness, and chemistry selected. While polyurea dunnage coatings have a higher upfront material cost than epoxy or paint, the total lifecycle cost is significantly lower. Extending dunnage life from 2 years to 20 years eliminates multiple replacement cycles, reduces scrap from part damage, and cuts material handling labor. Most operations see full ROI within 12 to 18 months.

    What Industries Use Dunnage Coatings? ›

    Dunnage coatings are widely used in automotive manufacturing, aerospace, electronics, medical device production, glass and ceramics, military logistics, and food processing. Any industry that relies on returnable dunnage racks, trays, or fixtures to transport and protect components during manufacturing and shipping can benefit from dunnage coatings.

    Is Polyurea Better Than Epoxy for Dunnage Coatings? ›

    For most dunnage applications, polyurea significantly outperforms epoxy. Polyurea cures in seconds versus hours for epoxy, has 300 to 500 percent elongation versus 2 to 5 percent for epoxy, and resists impact and vibration far better. Epoxy coatings are rigid and will chip and crack under the repeated loading and unloading that dunnage racks experience daily. Polyurea flexes with the substrate and absorbs energy rather than fracturing.

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