Polyurea is a coating technology/product and has been used very successfull for many different applications all around the world. Polyurea technology is not new, it has been around and in use for almost four decades now but in comparison to many other coating systems it is more advanced than some traditional coating systems and offers a whole array of advantages to the owner/contractor that cannot be achieved with other coating systems.

Polyurea is not a specific coating system by name or specification but it is a polymer technology with a wide range of product formulations that are matched to a particular requirement.

There are not many coating systems that can compare to Polyurea when it comes to attainable physical properties e.g. high elongation, superior tensile strengths, excellent abrasion resistance, high impact resistance, excellent chemical resistance.

Polyurea’s major benefit has to be its fast set and return to service characteristics, Tack free within 10 – 60 Seconds and open to traffic within the hour, returning an area to service many times faster than traditional coatings.

Polyurea needs a primer for porous surfaces e.g. concrete, cement, brick etc.

Polyurea has excellent elongation and is ideal for waterproofing the outside of basements and tanks etc. where resistance to high positive pressure and the ability to accommodate building movement is important to the effectiveness of the waterproofing.

For tanking jobs a Polyurea system is highly puncture and abrasion resistant and ideal where backfill and consolidation is part of the project.

Polyurea is sprayed using plural component spray equipment at +70C.

CASE STUDY – Concrete Manholes in Brisbane

Case Study – Concrete Manholes in Brisbane


1 x Concrete Manhole used in Trunk Line Sewer, Size = 1050 dia x 2.7m deep + biscuit


 The manhole was in need of repair due to severe high levels of H2S attack and erosion.


The chamber was vented above and below the chamber on the sewer line and then an air mover was used to increase the ventilation and airflow. A high pressure power wash was followed by acid etch, wash down and then dried using the air mover.
Spray ApplicationSpraying took 1.5 hours including the preparation. 1 coat of Epoxy was applied at 6mm using approx 40 gallons of Epoxy resin


 Redlands Shire Council were impressed with the outcome, more work followed.

Before; – with the temporary pipe to protect the epoxy spray from live sewer.



Condition before spraying



Preparation finished and spraying commences


Complete Spray

CASE STUDY – Concrete Catch Pits

Case Study – London Underground

Substrate Details

2 Concrete Catch Pits approx size 1200x600x1500mm.
The pits are located Approx 100m from the platform station, they are positioned on either side of the track. One is on the north bound side and the second on the south bound

LUL induction certificate was required by all engineers before any work could be carried out including pre inspection. The work could only be carried out between the hours of 1am and 5am and pending any other engineering works. 


Suck out all the water and waste in the sump using gully sucker followed by power wash.
Cracks and holes were repaired using a high build epoxy resin mastic which was applied by hand using a trowel
The concrete surface was then washed using a diluted (max 10%) Sodium Hypochlorite (bleach)
This is applied using a hand held sprayer with Viton seals. Used to remove and kill off any algae or bacterial growth.
Power wash again.  Gully suck water from the wash down.  A diluted Hydrochloride Acid wash (max 10%) using hand held sprayer with Viton seals. This was required to etch the concrete surface to give maximum adhesion and also to remove any surface salts on the concrete structure.
Power wash again.


Epoxy spray applied  with one coat at 6mm.  Once the resin cured the acro props were reinstalled. 






CASE STUDY: Brewery Waste Sump

Case Study – Brewery Waste Sump

Substrate2 sumps
MaterialPrecast Concrete caisson bolted together and sealed with Rubber Gaskets.  The Rubber Gaskets had failed causing infiltration due to poor installation.
Purpose of the sumps Treatment of brewery waste products, including hops, yeast and barley
Significant preparation was required prior to spraying which took 5 days.
Sump 1 Approx size 4m dia x 4m deep
ConditionThe sumps was in reasonable condition with minimal infiltration. The surface had a previous coating which proved extremely difficult to remove.
PreparationHigh pressure power wash. The existing coating was then abraded to provide a suitable key for the epoxy followed by power wash again.
The entire surface was then acid etched and washed down with water prior to spraying.
Spraying1 coat at 6mm thick.
 Sump 2Approx size 7m dia x 5m deep
Condition The sump had extreme infiltration and the surface had a previous coating which proved extremely difficult to remove.
PreparationHigh pressure power wash. The existing coating was then abraded to provide a suitable key for the epoxy followed by power wash again.
Areas of infiltration were then drilled and an injection grout system applied to seal the leakages which included fast setting cement (waterplug).
The entire surface was then acid etched and washed down with water prior to spraying.
Spraying1 coat at 6mm thick.








CASE STUDY: Brick Manhole Chambers

Case Study – Brick Manhole Chambers

Substrate10 x Brick Manhole Chambers
SizeManholes all approx 600mm x 600mm at various depths, ranging from .75m to 2m deep
PurposeDrainage system on chemical plant
ConditionVarious, ranging from a very severe build up of mineral deposits to oil and grease residue and had previously been coated with an unknown material plus minor structural defects.
Repair detailsChemicals were leaking into the water table causing pollution issues with EA. A sealed system was required because the drains had recently been re-lined because a sealed system was required
PreparationWhere required the manhole was isolated using inflatable drain plugs and then high pressure power washed. Previous coating was removed using a scabbler. Mineral build up was removed using a CP9 and scabbler. The oil/grease residue was removed using acetone.
Spray1 coat at 6mm applied
Time Scaleapprox 7 days







CASE STUDY – Pumping Station (Sewerage / Lifting Stations)

Case Study Summary

 Material:Concrete with 4 steel lift screws

Repair Details:

The station had long term H2S damage and required a complete new surface coating. In some areas the damage was intense, especially on the ceiling. There was no previous coating.
Preparation: High Pressure jet was followed by a chlorine wash to remove any algae, fungal growth and bacteria not removed by washing. Rinsed with water and then acid etch to remove any carbonates, sulphate, and chloride.
Spray:1 coat at 6mm thick.