VFI®-6160 60 D Spray Hard Coat

VFI-6160 60 D Spray Hard Coat is a premium, 100% solids, fast setting, spray-applied coating. Once applied, it creates a protective shell over foam and is used for interior or exterior applications when covered with a UV-stable top coat. As a polyurea hybrid, it has high durability, good thermocycling, and strong impact resistance. VFI-6160 can be sanded within an hour of curing and is paintable for theming purposes. It is a fire-retardant material that will meet safety requirements when needed. Its high tensile strength and elongation make it a tough, versatile coating for encapsulating and protecting a piece. 

VFI-6160 60 D Spray Hard Coat from VFI is a premium, fire-retardant coating that creates a highly durable shell over foam for indoor and outdoor use.

Features & Benefits

  • Good for outdoor use when used with a UV-stable top coat
  • Smooth glass-like finish, requiring minimal post work
  • Sandable within an hour of application
  • Similar viscosities allow for easy spraying and staying on ratio
  • Capable of passing ASTM E84 fire testing

Instructions for Use:  

Surface Preparation  

For ensured adhesion, all surfaces must be clean and free of contaminants, including dirt, dust, and debris. Oil and grease must be removed by scrubbing with a cleaning detergent and rinsing with water.  

  • EPS – Ensure that the foam has aged for at least 30 days. Using foam between 1 and 3 PCF is acceptable, but for an optimal cost-to-quality ratio, we recommend 2 PCF foam. Once clean and dry, VFI-6160 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).
  • 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 process with a drum mixer. The A side (Iso) does not need to be mixed. Mix times will increase if the material is stored for long periods between use.  

VFI-6160 60 D Spray Hard Coat requires a plural component machine capable of heating the product and providing at least 2300-2500 PSI of constant pressure. We recommend spraying at a minimum rate of 40 mils to develop a uniform film that protects the piece. The best film properties can be obtained at 60 mils or greater. Multiple passes can be applied to build thickness, but you 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. 

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 longer time to fully cure. 


The preferred cleanup solvent is xylene or MEK. If you are flushing out spray lines, we recommend using VFI-8005 pump flush.  


*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, such as properly fitted dust or splashproof chemical safety goggles and a face shield 
  • Hand protection – wear chemically resistant protective gloves (nitrile, butyl, or neoprene) 
  • Skin and body protection – wear suitable protective clothing 
  • Respiratory protection – wear a supplied air respirator or a respirator with forced air ventilation in a chemically approved spray booth. 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. If you don’t nitrogen purge leftover material, moisture contamination can occur in both sides. The moisture contamination will create a hardened film over and in the A side (Iso) and can cause pinholes and foaming in the B side (Poly) when spraying. We recommend using VFI-8403 Dryer in the B side to reduce the moisture contamination effects. 

VFI-6160 should be able to run behind most polyureas and polyurethanes without issue, but VFI always recommends a test mix before use. The test mix can be taken by combining some of the new material with some material within the spray lines and mixing them to see if there’s a reaction.  

  • Incompatible materials – A side: strong bases, acids, alcohols, amines, and water. B side: strong oxidizers and acids 
  • 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, and are not limited to, oxides of carbon and oxides of nitrogen. Also, isocyanates for the A side   

Potential Health Hazards  

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

*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

Available Packaging:

  • Tote
  • Drum

Physical Properties

  • Hardness Shore D: 60
  • Tensile Strength: 3000 psi
  • Elongation: 380%
  • Tear Strength: 550 pli
  • Specific Volume: 70.70 lb/ft³

Liquid Properties

  • Solids by Volume: 100%
  • Liquid Density A Side: 9.87
  • Liquid Density B Side: 9.03
  • Mixed Liquid Density: 9.45
  • Specific Gravity A Side: 1.18
  • Specific Gravity B Side: 1.08
  • Specific Gravity Mixed: 1.13
  • Ratio by Volume (A:B): 1A:1B
  • Viscosity A Side: 800 cps
  • Viscosity B Side: 800 cps
  • Mixed Viscosity: 800 cps
  • Gel Time: 10 sec
  • Cure to Touch: 30 sec
  • Tack Free: 2 min
  • Cure to Handle: 5 min
  • Recoat Window: 30 min
  • Full Cure: 5 days
  • Flash Point: >200 °F
  • VOC: 0 g/L

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