CORROSION PREVENTION COATINGS
High-Performance Polyurea Coatings for Corrosion Resistance
REPAIR DAmaged surfaces
& protect against corrosion
Corrosion is the bane of many home and business owners’ existence. It can turn strong and unblemished surfaces into dangerous eyesores that require constant and expensive maintenance to keep safe and effective. Whether it be metal roofs, large storage tanks, automotive chassis, or anything in between, corrosion is the silent killer feared by the home and the factory alike. But for as much as we hear the term, not everyone understands what corrosion is, its common causes, and most importantly, what you can do to fight against it. So if there’s one thing we hope you take from here today, it’s this: polyurea corrosion prevention coatings are safe, cost-effective, and highly durable materials that can protect surfaces from corrosion and many other physical and chemical risk factors.
WHAT IS CORROSION?
Chemical corrosion, or simply, corrosion, refers to the electrochemical processes that break down materials into their constituent elements, or instead, result in the formation of new compounds. Now, what does this actually mean? It means that some materials, by virtue of their chemical properties, may be damaged or degraded by natural processes that occur when some metals are in the presence of moisture or air, among other chemicals. The most common type of corrosion is rust, which forms via the reaction of iron or iron-containing materials with water or air, producing an iron oxide (a compound made of iron chemically bound with oxygen) on its surface. Corrosion weakens structures to the point of being unsafe or even non operational, and can be expensive to repair or replace. The threat of corrosion is so significant that most homes and businesses go to great lengths to mitigate its effects, and prevent corrosion to begin with. As one of the latest and greatest coating technologies, polyurea is the go-to solution for preventing corrosion and repairing structures that weren’t so fortunate to have their protection in the first place.
CAUSES OF CORROSION & DETERIORATION
Most corrosion is caused by water and moisture, but corrosion can also be the result of exposure to other chemicals like natural or synthetic acids, or by electrical phenomena. Moreover, corrosion can be accelerated by other environmental factors, like temperature and mechanical stress.
oxygen & moisture
Most often, corrosion is caused by direct and prolonged exposure to water or oxygen, creating rust that can quickly spread to degrade entire structures. Polyurea coatings insulate surface materials from their local environments, preventing air and water from causing damaging chemical reactions.
HIGH TEMPERATURES
While not a direct cause of corrosion, higher temperatures can accelerate the rate of corrosion by influencing the speed of chemical reactions. Polyurea corrosion prevention coatings are thermal insulators, and can withstand high temperatures without damage or degradation.
WEATHER CONDITIONS
There’s always oxygen in our air, and at least some moisture to boot, but many climates bring with them extreme weather or harsh ambient conditions that can quickly corrode metallic materials. Polyurea coatings can withstand almost any conditions, including strong winds, large hail, acid rain, UV rays, and anything else mother nature throws at it.
ELECTRIC CURRENT
Corrosion is an electrochemical process – electrons, the same subatomic particles that comprise electricity – move and transfer in complicated chemical reactions that can destroy or create compounds. External electric current, such as those used in many industrial processes, therefore pose a serious risk to materials susceptible to corrosion. Polyurea coatings are electrical insulators, and can protect metal surfaces from electrically induced corrosion.
DIRT AND BACTERIA
Dirt and bacteria are powerful but often overlooked sources of corrosion. Microorganisms can produce corrosive organic acids that degrade metal surfaces, or create corrosive electrochemical environments that are just as dangerous as external electric currents. Polyurea creates a barrier to shield surfaces from dirt and bacteria, and can easily withstand strong acids and organic solvents far stronger than what’s produced by the microscopic world.
MECHANICAL STRESS
Like high temperatures, mechanical stress isn’t a direct cause of corrosion, but can introduce or accelerate corrosion. Mechanical stress can cause materials to crack and fracture, creating highly reactive regions of the material that corrode more quickly. Polyurea coatings are highly durable, and can withstand strong impacts or frequent abrasion to preserve structures and minimize the impact of mechanical stress.
Microorganisms
Polyurea coatings are often used on ships, bridges and other structures exposed to the elements, but they can also be used for smaller applications such as laboratory equipment or medical devices. Polyurea provides excellent adhesion and flexibility which make it an ideal choice for protecting against corrosion caused by bacteria, fungi and algae. It also forms a barrier between the surface and corrosive agents in the environment, preventing them from coming into contact with the substrate material.
Age Deterioration
Polyurea is a popular choice for protecting structures from age deterioration corrosion caused by exposure to the elements. It works by forming a strong, waterproof coating that seals out moisture and helps prevent rusting or other corrosive damage
application of polyurea
corrosion prevention coatings
Almost any surface can be protected with polyurea corrosion prevention coatings. They’ve seen widespread applications across private, commercial, and industrial sectors, and continue to find new applications to protect structures from dangerous and costly corrosion.
WASTE STORAGE TANKS
Waste storage tanks are made of many different materials, and contain an even greater variety of hazardous materials. Being highly durable, chemically inert, and compatible with almost any substrate makes polyurea coatings well-equipped to service waste storage tanks.
MARINE & SHIPPING
Marine vessels are highly susceptible to corrosion, with not even time at port sparing them from the salty water of the seas. Polyurea coatings can help protect ships and boats, from their lower steel hulls all the way to their top decks.
WASTEWATER CORROSION
Complementary to their use in waste storage tanks, polyurea coatings are also well-suited for wastewater protection. They protect container materials while resisting hazardous contaminants, and don’t introduce new sources of pollution into the wastewater treatment process.
FAQ FREQUENTLY ASKED QUESTIONS
Corrosion prevention coatings are chemical shields applied to the surfaces of materials that can degrade through exposure to their local environment. Whether it be industrial chemicals or high humidity, corrosion prevention coatings insulate structures and surfaces from direct contact with corrosive agents, and can themselves withstand harsh physical and chemical environments.
The best corrosion prevent coatings are waterproof, watertight, chemically inert, durable, safe, and cost-effective. Polyurea checks all of these boxes, making it one of the coatings industry’s most versatile and high-performing coating technologies, and among the best choices of corrosion prevention coatings.
Polyurea coatings can be applied to almost any surface, creating a waterproof and airtight barrier between surfaces and their environment. Unlike many substrate materials that are susceptible to chemical corrosion, polyurea is chemically inert, and can withstand high moisture or extended exposure to oxygen without damage or degradation.
This cracking usually occurs in two ways – crazing or micro-fracturing. Crazing refers to the formation of small cracks in the surface of the coating due to shrinkage after application. Micro-fracturing involves deeper cracks caused by increased coating stress due to the expansion or contraction of substrate materials beneath it.
The best way to prevent polyurea coatings cracking is to prepare carefully before application and properly cure afterward. For example, make sure that all surfaces are clear from dirt, dust, grease, oil stains, etc., before applying the coating, as these can cause adhesion failure, which could lead to cracking down the line. Also, be aware that some substrates are prone to absorption when wetted: if dampness has occurred from snow melt or rainfall, for example, then additional time should be taken for adequate drying before application so as not to risk shrinkage during cure time later on, which could again result in craze cracking over time. Finally, ensure that you follow your manufacturer’s instructions and adhere strictly to their recommended drying times for optimal performance; any deviations here will also strain your polyurea.
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ABOUT THE AUTHOR
TYLER GLECKLER
I am a chemist with a specialization in nanotechnology and applied materials chemistry. My work has focused on the characterization of optoelectronic materials, namely including semiconductor nanocrystals.
