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Because of its versatility, the spread of polyurethane technology into new markets is not a question of if, but when.
August 10, 2005
By: Mike Agosta
Today’s coatings industry can really make your head spin, and we don’t mean from the fumes. The list of coatings choices for end users is seemingly endless, but it is nothing compared to the list of requirements that suppliers and manufacturers must take into account when formulating products. Performance, appearance, protection, cost-effectiveness and environmental compliance are just a few of the factors paint makers and their suppliers must take into consideration. Polyurethane technology is one coatings solution that stacks up well against this long list of demands, and is fast becoming the technology of choice for a number of end markets. According to the Alliance for the Polyurethane Industry, approximately 542 million pounds of polyurethane were used in coatings applications in the U.S. in 2000, an 8.4% increase in the amount of polyurethane used in coatings in 1998. Major benefits What makes polyurethanes so popular? Every coatings maker and raw materials supplier Coatings World spoke with offered different reasons. However, all of their answers can be summed up in one word: versatility. According to industry insiders, polyurethane technology can be used in almost any formulation.
“We believe that polyurethanes are one of the most versatile polymers in the coatings formulations because of their low temperature and fast curing properties, their physical properties and their ease of application,” said Michael Hughes, marketing manager for the adhesives, coatings and elastomers business for the Americas at Huntsman Polyurethanes. “I believe that the range with PU is greater than other methods.” “Polyurethane coatings contain no VOCs or CFs, don’t take a complicated system to apply and have great elastomer qualities,” said Kirk Jeffries, executive director, Rhino Linings USA, Inc., a provider of high-performance sprayed-on polyurethane coatings and linings, such as the coating featured on the truck bed on our cover. “The application and cure times are fast, reducing down time and it is relatively inexpensive and easy to apply.” James McCadden, vice president of sales, U.S. Coatings Company, agreed. “Polyurethane products may be formulated to a wide variety of characteristics thus offering the formulator many options,” he said. “The window of options is larger than other generic classes such as epoxies and alkyds.” According to Mr. McCadden, polyurethane products can be used in numerous formulations, such as winter cure primers, high build 100% solids elastomeric secondary containment linings, high build industrial finishes, satin finish to high gloss finishes and high solids/low VOC finishes. “Today’s polyurethane finishes may be formulated in solvent systems as well as water-based systems,” he added. Another term often heard when discussing polyurethane coatings is high-performance. “Polyurethanes are generally considered high performance coatings, offering excellent color and gloss retention, and good resistance to abrasion and chemicals,” said Mark Thomas, manager of product marketing for Tnemec Company, Inc. “Polyurethanes typically offer better color and gloss retention than other coating types.” John L. Williams, executive vice president, Bayer Corporation and president, coatings and colorants division, agreed, stating, “Polyurethane-based coatings formulations yield high-performance coatings systems with excellent chemical resistance, solvent resistance and outstanding durability, as well as other properties.” “A polyurethane, be it solvent- or water-based, has always been considered a premium coating system,” said Mike O’Shaughnessy, vice president sales and administration, Alberdingk Boley, Inc. “The combination of resistance properties coupled with highly durable films makes this chemistry one of the most used, premium coating systems available.” This durability is one of the major selling points of polyurethane coatings. “Enhanced performance properties are gained by using polyurethane dispersions in coatings as they provide increased durability, abrasion-resistance, scrubability and other strengthening properties to the coatings customer,” said Chuck Reardon, a spokesperson for Dow Polyurethanes. Some of the resilient properties of polyurethane finishes are outstanding weathering characteristics, superior UV and acid-etch resistance and excellent chemical resistance and appearance. It’s this durability that makes them ideal for end markets where protection is of paramount importance. It’s no surprise then, that the construction and transportation markets are the largest users of polyurethane technologies. According to API, construction is the major end-use for polyurethanes. The U.S. construction market consumed 165 million pounds of polyurethane coatings in 2000, mostly for wood and concrete flooring applications. Right behind it is the transportation market, which used 162 million pounds of polyurethane coatings in 2000. In the transportation market, refinish paint is the predominant application area, according to API. “Improved durability properties for construction and transportation coatings provide large growth opportunities for innovative technologies,” said Mr. Reardon. BASF believes that these markets are key to its polyurethanes business and, as a result, concentrates most of its efforts in these areas. “Our focus is to grow in the traditional market segments for polyurethane coatings and continuously bring new technologies that add value to our customers in these areas,” said Brian Searfoss, market development manager, BASF Corporation. “We do not see saturation in any existing or potential end-use market for polyurethane-based high-performance coatings. There is plenty of room for growth in key markets.” API statistics on the construction market back this up. The use of polyurethanes in the market is increasing at an average annual growth rate of 4.3%, due largely to the increasing popularity of wood floors in residential housing. Mr. Hughes of Huntsman Polyurethanes believes that the construction and transportation markets provide the greatest opportunity for suppliers and paint formulators, but also represents a major challenge. “Our belief is that transportation and construction markets offer the greatest opportunity, challenge and reward for the manufacturer due to their overall size and scope along with their demand for continued product improvement,” he said. “Although both can be technically challenging, they develop new solutions that can be applied in other markets as well.” New Markets It is these solutions, according to Mr. Hughes, that provide much of the leverage for companies looking to expand beyond traditional markets for polyurethanes and into new ones. According to API, tanks and pipes, which used 48 million pounds of polyurethane coatings in 2000, are a high growth market for polyurethanes.
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