The Challenge

In the roofing industry, application methods are limited for applying rapid-cure materials. To start, rapid-curing sealing membranes are delivered in 200-liter drums. This container volume is often too large for most touch-up and small project applications. In addition, the setup time for the standard rapid-cure material application method – plural-component spray system (hot spray) – is both time consuming and cost prohibitive for smaller projects. Due to high equipment costs and high levels of coating waste, rapid-cure coatings are often not used by applicators. To combat these challenges, roofing companies use polyurethane (PU) coating systems for small and touch-up applications. However, there are issues with using PU coating systems as well.

40 liters is the standard kit size for a PU coating system. Smaller kits for touch-up are often not available. Also, the mixing and metering of the coatings used in a PU coating system are performed at the construction site, which brings a high risk of failure. Since most PU coatings cure in 5-30 seconds, PU touch-up applications usually require the use of a plural-component spray system, which as was mentioned above, features a long setup time and can be expensive.

The Solution

One company, BASF, found themselves facing these challenges. There was simply no easy and cost-effective way to apply rapid-cure sealants for small applications with minimal setup time and very little material waste. BASF then discovered the Sulzer MIXPAC MixCoat system and found that it was the solution the problems plaguing small and touch-up applications in roofing. Christoph Duerst, Area Sales Manager for BASF, said that “The MixCoat System opens new potential markets for the rapid curing technology.”

The MixCoat system checks every box and solves every problem roofing companies face in applying rapid-cure materials. With MixCoat, when applying rapid-cure sealants, only an air compressor and a MixCoat spray system are needed, and preparation time can be reduced from 2-4 hours to 15 minutes. Due to the MixCoat’s use of cartridges, very small areas can be coated while minimizing coating waste, and partially used cartridges can be recapped and reused for the next project. The prefilled cartridges also protect the applicator from direct contact with unmixed material, adding another layer of safety. In addition, the MixCoat system uses low-pressure compressed air, 7 bar (100 psi). Compared to airless or hot-spray equipment, which can utilize 50-300 bar (725-4350 psi), the risk of injury while using the MixCoat system is drastically reduced. MixCoat’s low-pressure air assisted systems also produce far less overspray then the typical airless spray technology, reducing the risk of environmental pollutants and unintentional property damages. Furthermore, MixCoat equipment is affordable and is extremely easy to use. It is a simple and cost-effective method for rapid-cure coating technology.

By Sulzer