What Is Polyurea Hybrid?

Polyurea hybrids have been closely confused and mistaken for a polyurea. While they have some components of polyureas, they are vastly different in some major categories, including price, properties, and moisture sensitivity. They are generally two-component systems where a blend of polyols and amines react with an isocyanate.

The chemical backbone of a hybrid is composed of both urethane and urea linkages. These linkages are made of a reaction of amines with isocyanates (urea) and polyol with isocyanates (urethane). However, not all hybrids are equal. Some formulas can be 99% urea linkages to 1% urethane mix, while others can be the complete opposite at 99% urethane to 1% urea. These content variations will change the properties and other features substantially.

Urethane linkages contribute to a more favorable price point compared to polyurea. The amine content, linked to polyurea, makes it less sensitive to moisture compared to urethane, because it does not require catalysts to promote a water reaction. Pure formulations are very limited in the compounds they can use for the B-side. A hybrid’s urethane side allows for more versatility.

They can be specially formulated into tough, elastomeric coatings for industrial and commercial applications. They can handle complex designs over surfaces, such as metal, foam, and concrete when applied by spray. Most are aromatic in nature, which means they do not resist UV rays.

Hybrid vs Polyurea vs Polyurethane

	Hybrid	Polyurea	Polyurethane
Moisture Sensitivity	Lower level of moisture sensitivity compared to urethane due to some amine content	Moisture insensitive; will favor the isocyanate amine reaction over the isocyanate water reaction	Moisture sensitive; reacts with the OH groups in water and has additional likelihood of reacting due to the addition of a catalyst
Cost	Economic option due to polyol content	Higher in cost due to expensive raw materials	Most economic option
Properties	Some high properties (ex. high tensile and tear strength but lower elongation)	Premium combination properties (consistently high tensile strength, tear strength, and elongation)	Not as high of a combination of properties (lower tensile strength, tear strength, and elongation)
Formulation	Isocyanate + Polyol + Polyamine	Isocyanate + Polyamine	Isocyanate + Polyol

Hybrid Advantages

• Their fast-setting ability makes them suitable for spraying on horizontal and vertical surfaces. Some formulas are also capable of being sprayed overhead without sagging. This fast-curing time also provides projects with a quick return to service.
• These coatings are tough and durable, with properties that allow them to resist impact, abrasion, wear, and tear. Other properties that help them resist damage include chemical and corrosion resistance.
• Using a spray-applied method, the material creates a seamless film. Since there are no seams, the coating prevents water penetration that could cause damage to the underlying surface.
• Since these coatings are very versatile, they can be adjusted to fit the needs of the application. Hardness can range from 40 to 75 D on the Shore Hardness scale, which is rubber-like to extremely hard.

How Is It Applied?

Proper preparation of the substrate is important to ensure the coating will perform how it should. Moisture and humidity should be monitored as they could cause issues in the application process.

The two-component materials are typically mixed through a proportioner. With either high-pressure, low-pressure, or cartridge-based spray rigs, the coating is sprayed directly onto the surface to protect it from external damage. Temperatures and pressures of the machines must also be taken into consideration.

• High-pressure spray rigs are the most common application method. They are plural component machines capable of heating the material and maintaining a specified psi. This equipment is best suited for high-volume and continuous coating applications. Vehicle producers, film-set creators, and theme-park sculptors typically benefit from these systems.
• Low-pressure spray rigs are used when coatings have slower gel times and longer cure times. The longer cure time allows easier spraying when going through a machine, using less pressure to push the material. Sometimes, it’s not necessary to have an expensive high-pressure rig, especially if you have flexibility in your project timeline.
• Cartridge-based spray systems offer the benefit of being able to spray while being less of an investment. The cartridges make the application portable and suitable for lower-volume applications. Based on frequency of use, a vehicle repair shop would benefit from cartridge-based coatings, whereas a vehicle manufacturer would probably need a high-pressure system. The maintenance on the machine is also much easier than a high-pressure system and does not require skilled labor to maintain.

Common Polyurea Hybrid Applications

Since hybrid coatings are highly customizable, they are the best choice for a wide range of applications. With a good cost-to-benefit ratio, they’ve been used in the following commercial settings:

• Below-grade waterproofing. The coating creates a seamless, leak-free membrane, which makes it a suitable option for waterproofing surfaces. With fast-curing properties, it is much faster and easier to apply than other materials. The barrier not only protects a building’s foundation against moisture but also against other contaminants in the ground.
• Tank pad coating / secondary containment. Hybrids work to create impermeable barriers in areas where preventing hazardous materials from reaching an environment is critical. These coatings are highly resistant to chemicals and solvents, so in the event of a spill, they keep the material contained. They work great over EPS foam for tank pad coatings.
• Truck bedliner. At a relatively low cost, hybrids form a durable, water, and air-tight barrier for exterior protection of pickup trucks, dump trucks, and utility vehicles. These spray-on coatings are easy to clean and maintain with the bonus of abrasion, scratch, and skid resistance. They are your best bet for vehicle part protection, especially from rust and corrosion.
• Theme park and decorative design. The coatings can form hard shells over EPS foam, wood, and other structures that need long-term protection from abrasion and physical wear. Sculptors and set makers have used them to make characters, artificial rocks, themed environments, and more.
• Joint filler. They also make great materials for filling concrete joints in industrial and commercial settings. Rather than spraying, they are injected into the cracks between concrete panels and cure quickly for a fast return to service. They are excellent at protecting concrete joint edges from damage due to heavy traffic.

VFI High Performance Polymers

VFI manufactures a handful of coatings for industrial and theming projects. From our bedliners (VFI-542, 543, and 544) to our specialty coatings like VFI-206, we have options for any circumstance. Also, ask about our polyurea coatings for other industrial applications. If you don’t see something you’re looking for, contact the VFI team for assistance.