Pros and Cons of Polyurethane Topcoat

Polyurethane topcoats are a popular choice for industrial flooring and surface protection, particularly in high-traffic environments like warehouses and factories. These coatings provide a durable, resistant barrier against wear, chemicals, and moisture. 

Here at CustomCrete, we’ve applied over a half million sq. ft of polyurethane topcoat in businesses just like yours. 

This article explores the pros and cons of polyurethane topcoats to help Chicago-based businesses make an informed decision.

What is Polyurethane Topcoat?

A polyurethane topcoat is a protective coating applied to floors, machinery, and industrial surfaces to enhance durability and resistance to environmental damage. It is available in two main types:

• Solvent Based Polyurethane: Known for its high durability but has a longer drying time and strong fumes.
• Water-Based Polyurethane: Offers a faster drying time and lower odor, making it a safer option for indoor applications.
• Aliphatic Moisture Cure Urethane: A preferred polyurethane with low odor and fast cure time.

Common Industrial Uses

• Warehouse and Factory Floors 
• Commercial Spaces 
• Machinery and Equipment 
• Outdoor/agricultural Areas
• Restaurants and Kitchens 

The Pros of a  Polyurethane Topcoat

Polyurethane topcoats offer a range of benefits that make them a popular choice for protecting and enhancing surfaces in commercial settings.

1. Exceptional Durability

Polyurethane topcoats create a tough protective layer that withstands heavy machinery, foot traffic, and abrasions, making them ideal for industrial environments. These coatings are designed to protect floors and equipment from daily wear and tear, preventing costly repairs or replacements. With proper application, polyurethane can extend the lifespan of surfaces significantly, reducing long-term maintenance expenses. 

2. Chemical Resistance

These coatings resist harsh chemicals, oils, and solvents commonly found in industrial settings, protecting surfaces from spills and corrosion. It is important to discus the types of coating available with a concrete flooring specialist to determine the proper flooring based of for the chemicals your company uses.  

In areas where exposure to aggressive substances is frequent, polyurethane serves as a reliable barrier, ensuring that floors and machinery remain intact despite repeated contact with harmful chemicals. This resistance makes polyurethane a superior choice for factory floors, laboratories, and warehouses handling industrial fluids. 

3. Moisture and Stain Resistance

Polyurethane forms a barrier that prevents moisture infiltration and staining, extending the life of floors and equipment. This quality is especially beneficial in environments where liquid spills and humidity fluctuations are common. By repelling water and other fluids, polyurethane coatings help maintain the integrity of surfaces while making them easier to clean and maintain, ultimately enhancing workplace safety and cleanliness.

Note that the surface needs to be dry before applying polyurethane topcoat. This is an additional coating that is applied over another coating to add strength, uv stability or texture.

4. Easy to Clean and Maintain

The smooth finish of polyurethane-coated surfaces makes them easy to clean, reducing maintenance costs and downtime. Unlike untreated concrete or metal, polyurethane’s non-porous surface prevents dirt and grime from embedding deeply. Routine cleaning with standard industrial cleaning solutions is usually sufficient to keep polyurethane-coated surfaces looking polished and professional. 

5. Aesthetic Flexibility

Available in different finishes, from glossy to matte, polyurethane topcoats allow businesses to maintain both durability and an appealing workspace. 

Additionally, color variations and decorative options allow customization to fit the branding or specific aesthetic requirements of industrial and commercial environments. 

6. Low Maintenance Costs

With a long lifespan, polyurethane coatings require fewer repairs or reapplications, leading to lower long-term costs. Facilities can save on labor and material expenses over time, making polyurethane an economically sound investment. 

Properly applied polyurethane topcoats can last several years without the need for frequent touch-ups or replacements, providing continuous protection with minimal upkeep. An additional benefit is to add a high-wear additive that extends the lifespan of your floors and creates a preferred texture. 

7. UV Stability and Color Retention

Unlike some coatings that degrade or yellow over time, high-quality polyurethane topcoats are designed to be UV stable. This means they maintain their color and clarity even in areas exposed to direct sunlight or harsh industrial lighting. This makes polyurethane an excellent choice for outdoor applications or facilities with large windows and bright lighting conditions. 

The Cons of Polyurethane Topcoat

While polyurethane topcoats provide excellent protection and durability, they also come with some drawbacks that are important to consider before application.

1. Long Drying Time

Moisture cure polyurethane takes longer to dry, which can cause downtime in industrial operations. Large-scale facilities that require quick turnaround times may find this a disadvantage, as floors and machinery coated with polyurethane must be left undisturbed for extended periods. This delay can impact productivity, making scheduling and strategic planning essential during application. 

2. Slight Odor

Solvent-based polyurethane emits strong odors, requiring proper ventilation and safety precautions during application. Industrial settings must ensure adequate airflow and may need to halt operations temporarily for about 12 to 24 hours to avoid exposing workers to hazardous fumes.

Businesses should also invest in protective equipment for applicators to minimize health risks associated with prolonged exposure. At CustomCrete, we often use moisture cure polyurethane that only has a slight odor.

3. Application Complexity

Achieving a smooth, even finish requires careful preparation and professional application, especially on large surfaces. Improper application can lead to bubbling, streaking, or uneven coverage, which reduces the effectiveness of the coating. 

Surface preparation, including cleaning and sanding, is crucial to ensure proper adhesion, and multiple layers may be required for optimal performance. 

4. Slipperiness When Wet

While polyurethane provides a durable surface, it can become slippery when wet, increasing the risk of workplace accidents. In high-traffic areas or environments where spills are frequent, businesses should consider incorporating anti-slip additives or textured finishes to enhance safety. 

Where should you go from here?

Polyurethane topcoats provide exceptional durability, chemical resistance, UV stability and long-term cost savings for industrial settings. However, considerations like curing time and surface suitability should be factored into the decision. You should evaluate your facility’s needs to determine whether polyurethane topcoats is the right investment.

Now that you understand the pros and cons of polyurethane topcoat, your next step is to request a quote to see if polyurethane is the right choice for you.