Introduction
Do you need a durable and adaptable solution for surface protection? Elastomeric coatings, composed of elastic polymers such as silicone and polyurethane, offer superior waterproofing protection, with high resistance to corrosion and environmental effects. They exhibit elastic properties that allow them to adapt to various substrates, ensuring long-lasting protection under extreme operational conditions.
In this paper, the physical properties of elastomers, the various types of elastomeric coatings, and their application in various industrial sectors are explored. It also compares them with other options available in the market to highlight their prevalence, providing a comprehensive view of their functionality and advantages.
What is an elastomeric coating?
It is a thick protective coating composed of elastomeric polymers such as silicones, polyurethane, and other synthetic rubbers. These materials are selected for their elastomeric properties, such as flexibility and strength, being able to expand and contract with temperature changes and under stress without losing their integrity when the force is removed.
They act by forming a continuous waterproof barrier that adheres firmly to the substrate, effectively protecting surfaces exposed to severe weathering conditions. In addition to their waterproofing function, they offer efficient protection against corrosion and wear for a variety of industrial and construction applications.
What are the physical properties of elastomers?
The properties that give these materials high resistance to corrosion and other phenomena are presented below1:
- High flexibility: elastomers have a molecular structure that allows them to deform under stress and recover their original shape, even at low temperatures.
- Weak intermolecular forces: These forces allow the polymer chains to slide over each other, facilitating deformation and stretching of the material.
- Wide working temperature range: Although the specific working temperature varies according to the formulation of the elastomer, in general, these materials can operate in a wide range of temperatures without losing their properties.
- Other relevant characteristics: Hardness, ability to withstand compressive deformation, tensile strength, abrasive wear resistance, tear resistance, chemical resistance, color variability, resistance to aging degradation, gas permeability, and maximum elongation capacity to the breaking point.
Elastomer properties are exceptional, capable of withstanding a wide variety of operational and environmental factors. The choice of the appropriate elastomer will depend on the specific characteristics required for the final coating.
Advantages and disadvantages of elastomeric coatings
These coatings offer numerous advantages. They are notable for their remarkable flexibility and stretchability, qualities attributed to the weak intermolecular bonds that allow the polymer chains to slide past each other with ease. However, it is essential to consider the limitations of these coatings when evaluating their potential use.
Main advantages
- High durability: Their special formulation gives them greater resistance to atmospheric, chemical, and abrasive agents, prolonging the useful life of the surfaces, and reducing the need for frequent repairs and maintenance.
- Flexibility: This characteristic allows them to adapt to the movements of the substrate, avoiding cracks and structural failures.
- Waterproofing: They form a continuous and effective barrier against moisture, protecting structures from leaks, cracks, and corrosion.
- Weather resistance: They withstand sudden changes in temperature, UV rays, rain, and other atmospheric agents without deteriorating.
- Ease of application: They are easy to apply and cure quickly, allowing the treated areas to be quickly put into service.
- Aesthetics: They offer a wide variety of colors and finishes, allowing to customize and improve the appearance of surfaces.
- Energy efficiency: Thermal reflectivity reduces heat absorption,
- benefiting buildings in the construction industry by reducing energy costs.
Main disadvantages
- High costs: Although they offer a long-term return, due to their greater durability and lower maintenance requirements, initial investments are higher than conventional paints.
- Specialized application: They require careful and specialized application to ensure a good result.
- Substrate preparation: Good surface preparation is necessary to ensure effective adhesion.
- Possible limitations in extreme climates: In very cold or very hot weather conditions, the application and curing of the elastomeric coating may be affected
- Maintenance and repairs: They require little maintenance, but when they possess any indication of damage repairs can be complex.
These characteristics highlight the importance of carefully assessing the specific needs and conditions of a project before deciding which elastomeric coating to use, ensuring that the choice aligns with the objectives of durability, efficiency, and cost-effectiveness.
Types of elastomeric coatings
Among the most common are acrylics, silicones, and urethanes, each with their own characteristics and applications2:
Silicones
Silicone elastomers are the most popular type of elastomeric coating in the construction industry. They offer excellent durability; their resistance to standing water, UV rays, and fungal growth makes them ideal for flat, high-humidity areas. Although they are more expensive than acrylics, their long life and high performance justify the investment.
Acrylics
These are known as the “original” elastomeric coating. They are the most economical and easiest to apply. Their water base makes them less aggressive to the environment and easier to clean. However, their resistance to standing water is limited; they are recommended primarily for sloped roofs with drainage. Acrylics offer good UV protection and are ideal for projects on a limited budget.
Urethanes (or Polyurethanes)
They are highly resistant to abrasion and chemicals, with excellent adhesion properties, suitable for industrial floors or other surfaces with severe wear, and are effective in corrosion protection. They are used in both base coats and topcoats, depending on the type of urethane (aliphatic or aromatic). Aliphatic urethanes are excellent for UV resistance, while aromatic urethanes offer superior adhesion.
Butyls
Made primarily from isobutylene rubber, these coatings are impermeable to air and water, providing an excellent barrier. Their high flexibility makes them ideal for applications requiring airtightness, mostly used for sealing.
Elastomeric coatings are selected according to the specific needs of the project, considering factors such as climate, chemical exposure, need for flexibility, and required durability. They are also classified according to their base technology, which can be water-based or solvent-based.
High-performance industrial elastomers
Securit™2 Elastomer
An advanced coating that offers superior corrosion protection in harsh industrial areas such as mining, petrochemical, and marine. They feature high flexibility and durability, suitable for surfaces such as steel, concrete, and non-ferrous metals. Formulated to resist high humidity and contaminants such as SO₂ and CO2; provides a barrier against corrosive agents, extending the useful life of structures and equipment, and reducing maintenance costs3.
TOFF TO-6080
It is a modified polyurea elastomeric coating, resulting from the reaction of two components, the resulting system is 100% solids. The elastomer is manufactured in two components that are mixed at the point of application to create a high-performance elastomer in a few seconds. This process is environmentally friendly, containing no VOC’s (Volatile Organic Compounds), as well as no CFC’s (Chlorofluorocarbons). It is the result of new technological advances that allowed it to be formulated based on polyols of natural origin. The fast reaction allows multiple passes to achieve the desired thickness.
High-thickness anticorrosive elastomeric coating that adheres to multiple substrates such as concrete and metal. It forms a continuous membrane and stands out for its fast drying time, can be touched in only 10 seconds, and withstand pressure in one minute.
GacoFlex A48
In 2023, the GacoTM brand introduced GacoFlex A48, an elastomeric acrylic roof coating. This product is the first single-component, fast-curing, high-build acrylic coating, allowing single-coat applications up to 80 mils wet; it offers extended durability, and excellent reflectivity, reducing energy costs and simplifying application with its ability to cover in a single pass5.
Applications of Elastomeric Coatings by Industry
Elastomeric-based coatings are in high demand for a variety of industrial applications. The following are the industries that commonly take advantage of these materials and their main uses6:
- Building and construction industry: They are widely used to protect the exterior of buildings, roofs, and infrastructure against weathering. These coatings provide an effective barrier against moisture infiltration, UV radiation, and thermal cycling; providing greater energy efficiency in buildings; they are also used in bridges, and tunnels, and for waterproofing reservoirs and swimming pools.
- Oil, gas, and petrochemical industry: In these sectors, they are used to protect equipment, machinery, and other surfaces that require protection against corrosion, abrasion, and exposure to chemical products. They are applied on storage tanks, piping, valves, pumps, pressure vessels, and other infrastructure to prevent leaks and corrosion. They are also used in drilling equipment because of their high resistance to extreme operating conditions.
- Marine industry: In this sector, these coatings are essential to protect ships, barges, offshore platforms, docks, and docks from corrosion and exposure to salt water. They provide a durable, waterproof barrier that withstands the marine environment. In addition, they are applied below the waterline to protect hulls from biofouling and erosion, improving fuel efficiency and reducing maintenance costs.
- Automotive industry: Here they are used to waterproof the underside of vehicles, to provide corrosion protection, and to dampen sound. They can also be used in railway infrastructure and aerospace applications.
- Food industry: They are used to coat containers and surfaces that come into direct contact with food. These coatings are valued for their safety, and resistance to bacteria and other contaminants.
This development reflects how these coatings are leveraged in various industries due to their unique elastomeric properties, with the construction industry-leading in terms of volume and diversity of applications.
Comparison with other coatings
The following table summarizes, and compares the elastomeric coating with other traditional coatings in several aspects:
| Characteristics | Elastomeric coating | Traditional coating (Ex: Acrylic paint) |
| Flexibility | High flexibility, adapts to substrate movements. | Stiffness, may crack with substrate movements. |
| Durability | Increased durability, and resistance to weathering, UV rays, and chemical agents. | Lower durability, they may discolor and degrade over time. |
| Waterproof | Increased durability, and resistance to weathering, UV rays and chemical agents. | Lower impermeability, they can allow the entry of water in small quantities. |
| Abrasion resistance | Excellent waterproofing, protects against moisture and seepage. | Lower abrasion resistance, they wear more easily. |
| Crack bridging | They can bridge small cracks in the substrate, preventing their propagation. | Do not bridge cracks, may crack along with the substrate. |
| Application | High abrasion resistance, ideal for high-traffic areas. | Easier application, less substrate preparation. |
| Cost | More expensive than traditional ones | Less expensive than elastomeric coating. |
| Service life | Requires more careful preparation of the substrate, and more specialized application. | Shorter service life, requires more maintenance. |
Elastomeric Coatings Market: Forecast (2024-2030)7
The elastomeric coatings market is estimated to reach $20.4 billion by 2030, experiencing a compound annual growth of 12.7% during the period 2024-2030. These coatings provide thermal and moisture protection, corrosion control, and overall protection to the building or structure environment. Asia Pacific dominates this market due to increasing commercial and residential activities in developing countries such as India, China, Japan, Indonesia, South Korea, and others.
Conclusions
With continuous advancements in technology and formulations, along with increasing investments in global infrastructure development; elastomeric coating continues to be an indispensable raw material in construction and corrosion protection. Although they present problems such as high initial costs and specific application requirements, their durability and contribution to energy efficiency justify their long-term choice.
These elastomeric coatings meet the demands of performance and cost-effectiveness in projects, maximizing their benefits and overcoming any limitations, as long as the most suitable one is selected according to the application conditions.
References
- BOP. Propiedades de los elastómeros y dónde utilizarlos. Consultado en fecha 13 de agosto 2024 en https://www.bop-products.com/blog/elastomers/elastomer-properties-and-where-to-use-them/#:~:text=Other%20elastomer%20properties%20are%20hardness,permeability%2C%20and%20elongation%20at%20break
- AMERICAN WEAHERSTAN. Elastomeric Coating: The Definitive Guide. Consultado en fecha 16 de agosto 2024 en https://www.americanweatherstar.com/elastomeric-coating-the-definitive-guide/
- TINOCO ANTICORROSAO. Consultado en fecha 16 de agosto 2024 en https://tinocoanticorrosao.com.br/en/
- TOFF. Hoja tecnica TO-6068. Consultado en fecha 16 de agosto 2024 en http://www.toff.com.mx/fichas-tecnicas/06-6080.pdf
- Gaco. Consultado en fecha 18 de agosto 2024 en https://gaco.com/product/gacoflex-a48/
- NUKOTE. Explorando los beneficios de los recubrimientos elastoméricos de película gruesa Consultado en fecha 17 de agosto 2024 en https://www.nukoteglobal.com/benefits-of-elastomeric-thick-film-coatings/
- IDUSTRY ACR. Mercado de recubrimientos elastoméricos: pronóstico (2024-2030). Consultado en fecha 17 de agosto 2024 en https://www.industryarc.com/Report/11714/elastomeric-coatings-market.html
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