MADISON CHEMICAL

INDUSTRIES INC.
BULLETIN

Info Tech Bulletin #3

100% Solids Polyurethane

Vs.
Fusion Bond Epoxy

April 2005

Madison Chemical Industries Inc.

“The World Leader For Infrastructural Coatings”™
490 McGeachie Drive Milton, Ontario, Canada L9T 3Y5
Phone (905) 878-8863 Fax (905) 878-1449
Email: sales@madisonchemical.com Web Site: www.madisonchemical.com
Introduction
This InfoTech Bulletin compares Madison's plural component polyurethane
coatings to fusion bond epoxy (FBE). Specific reference is made to ANSI/AWWA
C213-91, which relates to water transmission pipelines. In addition, the same
comparison is valid when comparing the two technologies for use on oil and gas
pipelines.

Madison’s plural component polyurethanes are solvent-free and very fast setting.
They are self priming and will self-cure at any ambient temperature. The finished
product is completely inert. Polyurethanes come in various formulations and
formats. Please note that rigid or “structural” polyurethanes are the type being
considered here. These values do not apply to polyurethane elastomers, which
perform well on concrete but are not well suited for long term protection of steel.

TABLE 1
PERFORMANCE

100% SOLIDS RIGID FUSION BOND RESULTS

MATERIAL PROPERTIES POLYURETHANE EPOXY INDICATOR
Impact Resistance (ASTM G-14) 60 in/lbs 60 in/lbs Higher is better
Shear Adhesion 3000 psi 3000 psi Higher is better
Hot Water Resistance Pass Pass Pass or fail
(212 °F, 100 °C)
Flexibility 1.0 inch 6.25 inches Lower value is
(size of mandrel to pass) better
Abrasion Resistance 80 mg 300 mg Lower value is
(ASTM D4060) better
Ceramic Modification 20-30 mg N/A
(CM) version*
Surface Resistivity 1.0 x 1014 1.1 x 1015 Lower value is
(ohms per cm2 ) better
Dielectric Strength 200 1000 Higher value is
(volts per mil) better
Freedom from pinholes Pinhole-free when Contains pinholes Pinhole-free is
properly applied even when properly better
applied
Achievable film thickness 14 mils (350 microns) Any desired film Unlimited build
per coat; separate build to suit provides more
second coat possible conditions and versatility.
desired design life
Can be modified with Anti- Yes No AM technology is
Microbial additives for water and proprietary and
wastewater pipe interiors unique to Madison
Can be modified with ceramic Yes No CM technology
nano-spheres for greater improves impact
abrasion resistance and abrasion
resistance
Emission of solvents and toxins None None Both are environ-
mentally friendly
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100% Solids Polyurethane Vs. Fusion Bond Epoxy
April 2005
Mil for mil, structural polyurethanes are equal to or better than FBE, based on
most performance parameters. Of even greater significance is that fact that one
can significantly lengthen the desired design life of a polyurethane system by
selecting any desired thickness. See Madison Design Life Bulletin No. 2,
“Century Pipe”.

On pipe exteriors, the toughness of the protective barrier is very important. Pipe
is typically manufactured and coated at one site and shipped to a distant
installation site. A coating’s impact resistance and flexibility are good indicators
of its ability to resist damage in transit and during installation.. While the fusion
bond epoxy and the polyurethane are equal on impact resistance, the
polyurethane is much better suited for surviving the movement and flexing of the
pipe without being damaged. In addition, the selection of the CM (ceramic
modified) version of the appropriate polyurethane will enhance both abrasion and
impact resistance.

On pipe interiors, polyurethane is much more commonly used than FBE because
of ease of application and cure. Also, the availability of Anti-Microbial technology
is of interest in the water and wastewater markets.

FBE must be cured at high temperature, typically around 2300 C (4500 F). This is
energy intensive and also raises the potential for reduced performance if exact
curing parameters are not met. Madison’s 100% solids rigid polyurethane
systems will self-cure at almost any ambient temperature. Application
0 0
temperatures can range from -40° C to+ 65°C (–40 F to +150 F). Due to the
natural exothermic nature of the polyurethane coating during the initial cure, the
ambient and substrate temperatures are not factors in the complete curing and
full performance of the coating.

TABLE 2
APPLICATION

ACTIVITY 100% SOLIDS RIGID FUSION BOND RESULTS INDICATOR

POLYURETHANE EPOXY
Surface Preparation SSPC SP10 SSPC SP10 Same
Surface Profile 1.5 - 4.0 mils (38 to 1.5 - 4.0 mils (38 to Same
100 microns) 100 microns)
Coating Thickness Any desired thickness 14 mils Polyurethane more
(see Table 1) versatile.
Preheating Not Required 2300C (+/- 100) FBE must have preheat

While repairs of the polyurethane and epoxy systems may appear to be similar, it
is important to keep in mind that the repair material for fusion bond epoxy is a
liquid epoxy that is different in composition and performance from the primary
fusion bond epoxy system. Temperature limitations of a hand applied epoxy
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100% Solids Polyurethane Vs. Fusion Bond Epoxy
April 2005
during cold weather applications (< 100C or about 50 oF) are not feasible without
proper heating and containment. Polyurethanes are touched up with the parent
material or a slow-setting version of the parent material.

Field joints of both FBE and polyurethane can be done with shrink sleeves. An
additional choice with polyurerethane is a similar product in a slower-setting
hand-applied format. Coating field joints with FBE is prohibitive. Liquid-applied
epoxies are sometimes used but are generically different in nature

Madison’s 100% solids, rigid polyurethane coating systems can be used on any
shape of structure, including valves, fitting and other “specials”. It is also
economical for short runs and small projects. FBE can only be used on long runs
of straight pipe.

AWWA and Underwriters’ Laboratories Standards

Madison's 100% solids polyurethane coatings meet and exceed the ANSI/AWWA
C-222 standard for External and Internal Coating of Steel Water Pipe and
Fittings. In addition, Madison has held a number of UL listings dating back to
1975.

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100% Solids Polyurethane Vs. Fusion Bond Epoxy
April 2005