POLYUREA’S PIPELINE TO PIPELINE PROTECTION

Polyurea coatings can be traced back to mid-20th century polymer research. Scientists first noted the remarkable properties of polyurea as far back as 1948, observing its superior thermal stability compared to other polymers. However, these early experiments were confined to laboratories and not yet practical for coating pipelines.

Fast forward to the 1980s, and polyurea technology began to take shape in industry. A key precursor was its use in Reaction Injection Molding (RIM) for automotive parts during the early 1980s, where polyurea provided fast curing body panels and bumpers. This success in rapid molding set the stage for spray-applied coatings, and the breakthrough came in 1988 when Texaco Chemical Co. introduced the first commercial two-component fast-set polyurea coating. The technology was first used commercially as a roofing spray in 1989, and marked the birth of polyurea as a coating/lining solution outside the lab.

Early applications through the 1990s saw polyurea branching into protective linings for concrete, steel tanks, and even truck bed liners. The protective coatings industry was initially skeptical – some saw polyurea as “over-hyped” – but its performance began winning converts. By 1998, even the National Association of Corrosion Engineers (NACE) took notice, issuing a technical report to define and compare polyurea vs. traditional polyurethane coatings. From a few experimental gallons in 1990, polyurea coatings rapidly gained acceptance by pipeline and infrastructure engineers worldwide.

THE CURE FOR AGING PIPELINES

One of the biggest impacts of polyurea coatings has been dramatically improving pipeline longevity. Traditional pipeline coatings (like epoxies or coal tar enamels) often struggled with long-term durability under harsh conditions. Polyurea, by contrast, forms a seamless elastomeric barrier that is extremely resistant to corrosion, moisture, and chemicals. This corrosion resistance means steel pipelines coated with polyurea are far less prone to rust and degradation over time. By sealing out water and oxygen, polyurea coatings effectively halt the electrochemical processes that eat away at unprotected steel, thus prolonging the service life of pipelines by many years.

Beyond corrosion, polyurea’s toughness guards against physical wear. Pipelines (especially for oil, gas, or water) often carry abrasive fluids and suspended solids that scour interior walls, and polyurea’s high abrasion resistance protects against this internal erosion. Equally important is polyurea’s flexibility and adhesion, which help it handle the expansion, contraction, and movement of pipelines. Unlike brittle coatings that might crack under strain, polyurea remains elastomeric and bonded to the substrate, preserving a tight seal even as temperatures or pressures fluctuate. This flexibility translates to fewer coating breakdowns and better protection through the pipeline’s operating cycles.

NOT JUST STRONGER—BUT FASTER

When pipelines do require repair or maintenance, time is money. Extended downtime to recoat or patch a pipeline means lost throughput and revenue—a major concern in industries like oil and gas. Here, polyurea’s ultra-fast curing gives it a decisive edge. Traditional epoxy coatings can take many hours or even days to fully cure before a pipeline can resume operation. Polyurea, by contrast, can set in seconds and reach full cure within minutes. This rapid cure allows pipeline sections to be put back in service almost immediately after coating.

Polyurea’s fast cure also thrives in challenging field conditions. Its reaction is virtually unaffected by ambient humidity—unlike some epoxies that can blush or fail in moisture. This means repairs can proceed in less-than-ideal weather or on damp surfaces without compromising adhesion. Even complex fixes like sealing leaking joints or patching damaged coating wraps can be completed in one short shift. In municipal water systems, crews use spray-applied polyurea liners to rehabilitate old leaky pipes in-place; the rapid set time minimizes water supply interruptions and traffic disruptions compared to lengthy dig-and-replace jobs. All told, polyurea coatings have set new benchmarks for repair efficiency, allowing pipeline maintenance that once took days to be done in mere hours.

INDUSTRIES AND REGIONS EMBRACING POLYUREA PIPELINE COATINGS

Given these performance benefits, it’s no surprise that polyurea coatings have seen widespread adoption across industries and geographies. In the oil and gas industry, polyurea is now used to protect everything from buried transmission pipelines to refinery tanks and offshore platforms. Oil and gas facilities constantly battle corrosive substances and mechanical wear, and polyurea’s ability to form an ultra-strong, elastomeric barrier has proven superior to traditional epoxies or paints​. It bonds well to steel infrastructure (pipes, pump jacks, wellheads, etc.) and stands up to aggressive chemicals, making it an ideal choice for petrochemical pipeline protection​. Major pipeline operators in North America, the Middle East, and Asia have incorporated polyurea for coating field weld joints, internal linings, and external pipeline wraps to extend the life of their assets.

The water and wastewater sector has likewise become a key adopter of polyurea coatings. Municipalities around the world face aging water mains and sewer lines prone to corrosion and leakage. Polyurea offers a cost-effective rehabilitation method: spraying a polyurea liner inside a deteriorated pipe to seal cracks and halt corrosion. Many new wastewater pipelines are factory-coated with polyurea except at the joints, which can then be coated in the field – providing near-complete protection against sewage’s corrosive cocktail. Even in cases where epoxy is initially applied on field welds, operators find it often cannot withstand long-term exposure; by comparison, polyurea joint coatings show far fewer failures. The superior performance has driven cities from North America to Asia to refit their infrastructure with polyurea linings for drinking water and sewer systems.

Other industries have also caught on. The marine and shipping industry values polyurea for protecting ship decks, ballast tanks, and offshore structures from saltwater corrosion – Europe’s marine sector alone contributes a sizable share of polyurea demand. The mining and industrial sectors use polyurea to line slurry pipes, containment areas, and chemical tanks due to its resistance to chemicals and impact. Even the transportation infrastructure arena (roads and bridges) uses polyurea as a fast-curing waterproofing and anti-corrosion coating on concrete and steel surfaces. Geographically, North America led early adoption of polyurea in pipelines and construction (partly due to strict VOC regulations that pushed out solvented coatings). Europe and Asia-Pacific are rapidly growing markets, with Asia’s industrializing countries demanding more high-performance coatings for new infrastructure projects​. In the Middle East, polyurea is sought after for oil & gas pipelines and desalination plants that require durable, long-lasting coatings under extreme conditions. In short, across pipelines carrying oil, gas, water or chemicals – from the deserts of the Middle East to the sewers of Hong Kong – polyurea coatings have proven their worth and gained global acceptance.

THE FUTURE OF POLYUREA PIPELINE COATINGS

Polyurea coating technology continues to evolve, with recent advancements promising even greater impact on pipeline maintenance. One notable trend is the integration of robotics and automation in coating applications. Researchers and specialized contractors have developed robotic spray systems that can travel through pipelines, applying polyurea linings in-situ with precision. Early robotic SIPP trials over 15 years ago showed the feasibility of spraying long pipeline sections, and today’s robots can even navigate bends and smaller diameters. This opens the door for fully automated pipeline rehabilitation, where miles of aging water or gas lines could be relined with minimal human entry, reducing cost and safety risks.

Meanwhile, chemists are refining polyurea formulations to tackle previous limitations. UV-resistant aliphatic polyureas are becoming more common, addressing the issue of aromatic polyurea chalking under sunlight for above-ground pipelines. Innovations in additives are yielding polyurea coatings with special functionalities—for instance, fire-resistant grades for use on oil rigs and refineries, or enhanced thermal resistance for hot pipelines. Research is even underway on self-healing polyurea coatings, which embed microcapsules or dynamic bonds that can autonomously repair small cracks, thus maintaining a continuous barrier over time. While still largely in labs, self-healing and smarter polyurea coatings could significantly reduce inspection and maintenance needs in the future.

The industry is also pushing polyurea into new frontiers of sustainability. Manufacturers are exploring low-VOC and even bio-based raw materials to make polyureas greener, as well as improving recyclability of overspray waste. Given the strong environmental resistance of polyurea, its use in protecting infrastructure aligns with sustainability goals—assets last longer, and leaks (whether oil or water) are prevented, avoiding environmental contamination. In regions facing water scarcity, polyurea-lining water pipelines to prevent losses is an eco-friendly strategy being adopted by utilities. Furthermore, as infrastructure worldwide ages, the demand for reliable rehabilitation methods is rising. Polyurea stands poised to be a linchpin technology in renewing pipelines without the carbon footprint of full replacements.

FOLLOW THE FUTURE WITH ARMORTHANE

Pipeline coatings are only one of many exciting applications of polyurea coatings that are helping protect vital infrastructure for the future. You can keep tabs on new developments by following ArmorThane’s blog series, where we publish regular content to help keep you informed on the latest and greatest in spray elastomer technology. We cover recent advancements, industry trends, business opportunities, and useful information about how our polyurea formulations can help you protect your home or business. We also offer comprehensive startup packages so you can let the technology jump off the page and into your professional life by becoming a certified ArmorThane applicator. Our packages include everything you’ll need to get started, including all-in-one training, high-quality spray equipment, our best coatings formulations, and lifetime technical support and business development assistance. Follow along with us as we follow the future and keep the world up to date with what’s in store for an already incredible materials technology.