VFI®-2538 QS 70 D EPS Form Hard Coat 

VFI®-2538 QS 70 D EPS Form Hard Coat 

VFI-2538 QS 70 D EPS Form Hard Coat is a 100% solids, polyurethane coating using the Qwik Spray System. It is capable of being sprayed over CNC or hot wire foam cut EPS to create a uniform and releasable surface when casting concrete. The Qwik Spray System only requires the VFI-7500 Qwik Spray Gun with an air compressor, allowing for easy equipment startup and low maintenance. It is an alternative to pourable urethane molds or epoxy coatings and allows for faster turnaround times on custom pieces. Its chemical makeup makes it capable of maintaining a smooth finish while providing square corners. Spraying VFI-2538 QS 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 industrial-ready high-pressure spray system 

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 QS 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. 


As a cartridge system, mixing is not required unless the material is visibly separated. If there is visible separation, shake the cartridge until a uniform mix is achieved.  

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

Qwik Spray Coverage Chart

10 sqft15 sqft20 sqft25 sqft30 sqft35 sqft40 sqft45 sqft50 sqft60 sqft
1 tube60 mil
2 tubes120 mil80 mil60 mil
3 tubes120 mil90 mil72 mil60 mil
4 tubes120 mil96 mil80 mil69 mil60 mil
5 tubes120 mil100 mil86 mil75 mil67 mil60 mil
6 tubes120 mil103 mil90 mil80 mil72 mil60 mil


VFI-2538 QS must be used in conjunction with the VFI-7500 Qwik Spray Gun and an air compressor that can provide dry air and a minimum of 10 CFM at 100 PSI of constant pressure. We recommend that you heat the material up to room temperature (77°F) while spraying. Do not heat the material in a microwave. Once you begin spraying, you cannot stop until the cartridge is empty without switching tips. 

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 VFI-1007 Solvent Based Polyurethane 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 QS to cure before casting onto the product.  


One of the great features of the Qwik Spray System is that cleanup is easy. You’ll disconnect the cartridge from the air-atomizing tip, remove it from the applicator frame, and throw it away. If there is residue on the gun, xylene or MEK can be used before it has time to set. Never soak the gun in any cleaning solvent.


*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:

  • Qwick Spray Qwick Spray

Available Packaging:

  • Cartridge