VFI®-2538 70 D EPS Form Hard Coat 

VFI®-2538 70 D EPS Form Hard Coat 

VFI-2538 70 D EPS Form Hard Coat is a spray applied, 100% solids, polyurethane coating. It is capable of being sprayed over CNC or hot wire foam cut EPS to create a uniform and releasable surface when casting concrete. A hard polyurethane shell is an alternative to pourable urethane molds or epoxy coatings and allows for faster turnaround times on custom pieces. The form hard coat is easily sandable but does not always require postwork because it creates an extremely smooth finish. Its chemical makeup makes it capable of maintaining a smooth finish while providing square corners. Spraying VFI-2538 allows you to create a variety of shapes with less labor. 

Features & Benefits

  • Great for custom mold-making of a variety of shapes
  • Flat, glass-like texture with reduced need for sanding 
  • Cures to handle in 5 minutes for faster mold turnaround time
  • Saves time by eliminating the need to make a master and a mold box  
  • Comes in an alternative Qwik Spray version that does not need a plural component machine 

Instructions for Use:  

Surface Preparation  

  • EPS – Ensure that the EPS has been aged at least 30 days. Anything between 1 and 3 PCF is acceptable, but for an optimal cost-to-quality ratio, we recommend using 2 PCF foam. Once clean and dry, VFI-2538 can be applied directly to the EPS. 
  • Wood – The wood should be dry and contain less than 11% moisture; otherwise, it should be primed or mist-coated (a light dusting of the coating followed by the main application of the coating). 
  • Urethane or Plastic – First, sand the urethane or plastic and then apply a general urethane primer to ensure good adhesion to the substrate. 


The B side (Poly) must be premixed until uniform before use and continuously mixed throughout the application. The A side (Iso) does not need to be mixed. Mix times will increase if stored for long periods between use. 

When spraying, use a supplied air respirator or a respirator with forced air ventilation in a chemically approved spray booth. 


  • Low Pressure – VFI-2538 requires a low-pressure machine capable of spraying through a static mix tip. The machine needs to have enough pressure to fully clear the tip in 20 seconds, or the material will set up in the static mix tip. Heating the lines and material is recommended for optimal spray pattern and properties but is not required. The recommended temperature for heating the lines and material is between 80°F-100°F.
  • High Pressure – A high-pressure, plural component machine capable of heating the product and providing a minimum 2500 PSI of constant pressure can also be used. The recommended settings are constant pressure between 2300-2500 PSI and line temperatures at 110°F.

Thickness Requirements 

We recommend spraying at a minimum rate of 60 mils or greater to create the best film properties. Multiple passes can be done to increase thickness but must stay within the open window of 30 minutes. If you exceed the open window, we recommend using a suitable primer to create adhesion between layers.  

Post Cure 

The material will need at least 3 hours to cure before heavy movement is allowed, but it is sandable within an hour. Light movement is acceptable sooner than 3 hours if needed. If spraying in thinner passes, it may require a longer post-cure time. Allow a minimum of 24 hours at 77°F for VFI-2538 to cure before casting onto the product.  


The preferred cleanup solvent is xylene or MEK. For cleaning and flushing out lines, it is recommended to use VFI-8005 pump flush to fully clean out the lines. 


*Always read the safety data sheet before working with chemicals   

Use chemicals only as directed and for their intended purpose. Do not dispose of chemicals down the drain. Most chemicals must be disposed of as hazardous waste.   

PPE to avoid all unnecessary exposure:  

  • Eye protection – wear safety glasses and any additional eye protection as necessary 
  • Hand protection – wear chemically resistant protective gloves (nitrile, butyl, or neoprene) 
  • Skin and body protection – wear suitable protective clothing 
  • Respiratory protection – in case of insufficient ventilation, wear suitable respiratory equipment. Respirator selection must be based on known or anticipated exposure levels, the hazards of the product, and the safe working limits of the selected respirator 

Product Limitations  

This product contains isocyanate, which may irritate the skin and is toxic if inhaled as particulate matter. 

  • Incompatible materials – A side: strong bases, acids, alcohols, amines, and water. B side: oxidizers 
  • Conditions to avoid – heat and incompatible materials  
  • Chemical stability – stable under normal storage conditions 
  • Reactivity & hazardous reactions – no dangerous reaction known under normal use 
  • Hazardous decomposition products – may include, but are not limited to, oxides of carbon. Also, oxides of nitrogen and isocyanates for the A side 

Potential Health Hazards  

  • May cause stomach distress, nausea, or vomiting if swallowed. 
  • May cause respiratory tract irritation. A side may also cause allergy or asthma symptoms and breathing difficulties if inhaled.
  • Causes serious eye irritation: discomfort, pain, excess blinking and tear production, marked redness, and swelling of the conjunctiva. 
  • Causes skin irritation and sensitization: redness, edema, drying, defatting, and cracking of the skin. Repeated exposure to the B side material can result in absorption through the skin, causing a significant health hazard.  

*If you are experiencing any of these symptoms, seek medical advice or attention. Call a poison control center or doctor if swallowed. 

Application Methods:

  • Spray Spray

Available Packaging:

  • Drum