Thursday, May 20, 2021

The Ultimate Guide To Purchasing A Mobile Spray Rig

This article will provide a better understanding of Spray Foam Equipment & Polyurea Coating Equipment. These components make up a turnkey rig that allows you to maximize profits and a positive return on Investment.

HIGH-QUALITY EQUIPMENT installed correctly leads to PROFITS. While LOW-QUALITY EQUIPMENT installed Improperly results in LOSSES.

Hopefully, with the information you take from this article, you will be better equipped, keep crews spraying materials, minimize downtime, and increase profits. You do not want to train crews to be equipment mechanics, wasting time, losing money, and creating a bad reputation. Selecting PROPER SPRAY FOAM EQUIPMENT is extremely important for Maximum Yield and Producing a Quality Product.

 Each component of a Spray System relies on the other to Produce Maximum Yield and Quality Spray Products. Many low-quality rig builders UNDER-SIZE components to win the battle of the lowest price. This is a huge mistake and will be covered, in much detail, below.


  • The REACTOR (Proportioner) Heats, Pressurizes and Dispenses the A & B Materials to produce the Spray Foam or Coating Product. Certain models of Reactors have larger preheaters, longer hose capabilities, various pressure ratings, different output abilities, and functioning power requirements.
  • A Reactor Package consists of The Reactor, Transfer Pumps, Transfer & Re-circulation Lines, Heated Hoses, and Gun.
  • Under sizing the Reactor will result in damaged equipment, downtime, and repair cost. Preventing efficient processing for producing a quality product.
  • It is important to know the market segment that will be Targeted. (Residential, Commercial, Roofing, Slab Jacking, Secondary Containment, Bed-liners, etc.…. A turnkey Spray Foam Rig or Coatings Rig will be built custom for the applications the investor purchases it for.
  • Investing in a larger reactor setup will tackle both Low-Volume and High-Volume Productions. However, the difference in price for the entire rig package can be $20K to $50K. So, choosing the correct Reactor is key to prevent overspending without under-sizing.
  • Since Rigs are built custom with components to support specific Spray Foam Reactor Packages, they are not always up-gradable. This means if a rig is built to target residential work, the makeup of the Rig's components will be sized for that specific Reactor.
  • For Example, a Residential Spray Foam Setup with a Graco E20 Reactor can be 210 Ft. hose length and Sprays 20 Lbs./ Min. The Generator that powers this Rig is 22 KW, Compressor 3 HP, and the System is built on a 16 Ft 10,000 Lb. GVWR Trailer Platform. This Rig is not powerful or large enough to host a Higher Volume Reactor. A whole new rig would need to be purchased for the upgrade. So, it is important to work with an equipment specialist to select the best possible Reactor Package.


  • Selecting the Proper Spray Rig Compressor is vital to operate efficiently. The Compressor supplies air to many components. First, it supplies air to the Pneumatic Transfer Pumps, Approx. 5 CFM x 2 = 10CFM. Another 5CFM to Activate an Air Purge Spray Foam Gun.
  • Many 0.50Lb. Open Cell Spray Foams and Polyurea Coatings will need to be mixed continuously. An Agitator or Mixer Demand 5 to 15CFM. With foam, selecting a product that needs no mixing will bypass this process. With Polyurea, this is not an option; a mixer will be required.
  • Some sprayers prefer High-Pressure Breathing Systems. The compressed air is filtered from the Compressor and delivers clean, breathable air to the applicator's mask. These systems demand at least 15 to 30 CFM. Low-Pressure Separate Fresh Air Pumps eliminate the high demand for CFMs.    
  • An UNDERSIZED Compressor will not supply enough air for the Pumps, Gun, Mixer, and Breathing System. This will result in insufficient material supply, improper mixing, gun failure, and shortage of supplied air to the sprayer. Ultimately poor material processing reducing yield and return on Investment. 
  • Refrigerated Air Dryers are used to remove water vapor created by the Compressor. Refrigerating the air before feeding the spray foam component eliminates condensation deliver by the air hoses to the rig components. Removing unwanted moisture is important to protect Equipment and prevent moisture from mixing with ISO or A-Side Material. Guns with moisture will clog easier and create more downtime. Moisture will also contaminate the processing, reducing yield and producing a Less Quality Product. Like every other component, it is Important to size the Air Dryer handle the CFM being used by the System.
  • If using a Screw Compressor, a Coalescent Filter is a must. It stops oil from contaminating the Dryer and Air Lines. This should be standard in all quality screw compressor installs. These filters need to be changed as the manufacturer recommends in the systems manual.


  • Spray Foam Rigs require Massive Amounts of Power to run all the System's Components. The REACTOR "Proportioner" utilizes Primary Pre-Heaters ranging from 6 KW on the Low End to 20 KW on the High End.
  • Spray Machines also have Heated Hoses to keep the materials warm as they pass through, maintaining desired processing temperatures. An Electric motor operates either Electric or Hydraulic Displacement Pumps and Pressurize the A&B Materials. In addition to the REACTOR, Compressors, Air Dryers, Lights, Outlets, Fresh Air Pumps, Interior Heaters, Air Conditioners, and other Auxiliary Tools will need Power. Total system requirements will range from 20 KW to 50KW in most spray rigs and up to 100KW (+) in Dual REACTOR Rigs.
  • Selecting a Generator Manufacturer who honors Warranty and Supports their product locally is key! Our Generators can be repaired all over the Nation with no problems.
  • We recommend using a diesel generator. They are more fuel-efficient, run cooler, have 20 times the longevity, and way fewer overall issues.
  • Many companies will build cheaper rigs with gas generators to keep their cost down. The load demand of the Spray Foam System is extremely high. Gas generators will be pushed to the max and fail to deliver the on-demand continuous, Power needed for maximum production. This will result in blown engines and burnt-up Equipment. In hot weather, gas generators overheat often. I run inside a trailer that can catch fire and create a dangerous work environment if not cooled properly.
  • We are an official Dealer of the Generator we use in our designs, and the manufacturers are aware of how the units are used. Winco and Morse have both designed their products specifically for this type of application.
  • The Generator needs to be Properly Ventilated and Exhausted. Not properly venting the Generator will result in OVERHEATING. Not exhausting the Generator correctly could result in carbon monoxide poisoning and even death.
  •  GENERATOR SIZE MATTERS- Under sizing, a Generator will shorten its life and the components it powers. This will prevent spray equipment from delivering the proper air, heat, and pressure: Down Time, Poor Product Yield, and Fried Equipment.


  • A Trailer built on an Under-Rated GVWR will deteriorate quickly.
  • Spray Foam and Coatings Rigs haul heavy loads daily. Make Sure the Axles are sized to handle the loads being hauled daily. Normal GVWR will Range From 10,000 Lbs. to 16,000 Lbs. Torsion Axles will provide a smoother ride and maintenance-free, more rigid, and better handling control in crosswinds and rough roads than Spring Axles. 
  • It is imperative to have an equal balance Spray Foam Trailer. If the Tongue Weight is TOO HEAVY (Weight>15% of Load) or TOO LIGHT (Weight<9% of Load), resulting in tires, broken axles, bent frame, and broken welds.
  • An Unbalanced Trailer will result in Dangerous and Uncontrollable Swaying and Pulling from the trailer and Lethal to the Driver and Others on the Road. This is also not healthy for the Tow Vehicle.
  • Selection of Barn-door or Ramp door will be important for loading the 55 Gallon Drums by either Forklift or Drum Dolly.

 *Structure of the Trailer is also important and is one of the first things a cheap rig builder cut prices with. We use complete box tube framing and space out the beam the proper distance for maximum overall strength. *

 *Material weight is plus or minus 3000 to 5000 lbs. on the trailer at any given time. So, the Barrel weight needs to be over the axles so that the trailer always has a consistent tongue weight. *

 *If GVW is rated too high, a CDL will be needed. This is just something that Dual Reactor Spray Rigs will need to pay attention to. Most single proportioner rigs will not come close to this. Total Rating must be under 26,000 combined Truck and Trailer in most states. *

 The Equation for Success





The Equation for Failure






Questions Before Buying a Rig

  • How often do you intend on spraying?
  • What type of applications will the Equipment Perform?
  • Will you be spraying open cell or closed cell?
  • Will you perform High-Volume Applications like Roofing and Trench Breakers?
  • Do you intend on Slab Jacking? 
  • What environment will you be working in?

Budget and Goals

The budget will largely affect the Investment. Back to the second question above, "What application will the Equipment perform?

If the budget does not line up with the business goals, maybe change the goals and start smaller and aim higher. Otherwise, wait till the good Investment can be made.

Why Graco?

No other Pump Manufacturer has the Advanced Product Development and Technology like GRACO, Established in 1926. The closest competitor Falls Short 9 Decades.

Why ArmorThane?

ArmorThane understands that HIGH-QUALITY EQUIPMENT installed correctly leads to PROFITS. While LOW-QUALITY EQUIPMENT installed Improperly results in LOSSES. They pride themselves on building the highest quality rigs to provide the GREATEST RETURN ON INVESTMENT

ArmorThane combines Graco's Top Quality Reactors with leading manufacturers of generators, compressors, air dryers, trailers, and other components to produce a superior custom-built spray rig. With over 30 years of rig engineering, ArmorThane pioneers the Spray Foam and Coating Industry's Rig Market. They Educate, Train, and Support all Produced Products!

Where Not to Purchase Equipment

Do not buy your Equipment from a Non-Graco Distributor, and steer clear of used Equipment from private sellers and on eBay!!!!!!!!

These companies advertise prices lower than Distributors, and that is Impossible. Resellers buy their Equipment from a Licensed Distributor. This leads to deceptive practices that will almost always VOID the Equipment Warranty. Warranties can also only be processed by a Distributor, NOT a RESELLER!

*Remember you want to be a Spray Foam Applicator, not a Spray Foam Mechanic. *

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Let ArmorThane Build It Right

We want to make your coating jobs as convenient and fast as possible. That's why we design the trailer to your request or we'll help guide you through the layout and equipment choices based on your business plans. Options range from a smaller, low pressure configuration to a longer, two-room version that's fully outfitted with a high volume system.

Example Trailers

Industries and projects have difference requirements. Ask us for more details on these custom built examples:

  • Primary and Secondary Containment Unit – 36 Ft Gooseneck Trailer with resting berths and large chemical storage
  • Mining and Heavy Industry Unit – 30 Ft Gooseneck Trailer with multiple air tools from one large compressor
  • Residential and Commercial Coatings – 20 Ft Bumper Pull Trailer designed for easy-to-reach projects such as decks, animal enclosures
  • Foam-Focused Unit – 20 Ft Bumper Pull Trailer with long line sets reaching from the trailer
Each Mobile Coatings Unit comes complete with everything you need to get started AND keep going. Everything is included up front…

Projects are different from one applicator to the next. So, why buy a trailer designed for someone else? Instead, we customize the design of a trailer to fit your projects.

Our Coatings Units take power and equipment to any industrial, commercial or residential jobsite. Customers look to us for guidance, but the final choice of equipment and layout is yours. Options vary from a smaller, high or low pressure configuration to a longer, two-compartment version that’s fully outfitted with a high pressure system. Sizes typically range from 16' up to 36'.

MCU are Built to Take the Coatings Business Directly to the Job Site

Whether you decide to run completely mobile or simply add flexibility to a workshop business, ArmorThane helps you select the materials and application equipment that fits your plans.

Trailers are specifically designed for easy access with all of the tools needed to produce high-quality ArmorThane coatings. A gas generator even allows you to bring power to any site.

Image result for mobile coating units

While No Two Trailers are Alike, Here are Some Features of One-Compartment and Two-Compartment MCUs:

  • Rear Ramp Entry Door
  • Optional Separated Equipment Room
  • Exhaust Fans for Equipment Room
  • Spray Gun Access Door
  • Ventilated Generator System
  • Multiple Regulated Air Drops
  • Multiple 110V and 230V Power Connects
  • Propane or Electric Trailer/Material Heat
  • Coated Interior for Scratch Protection
  • Shore Power Switch
  • Outside Fill Fuel Tank
  • Refrigerated Dry Air
  • Side Entrance Door into Optional Equipment Room
  • Optional Internal Wall for Sound Reduction, Insulation
  • Propane Travel Racks for Propane Heat
  • Reinforced Hose Hangers
  • Hose Connection Impact Guard
  • Proportioner Impact Guard
  • Wall-Mounted Tool Cabinets
  • Work Bench with Gun Vise
  • Eye Wash Station
  • First Aid Kit
  • Fire Extinguisher
  • Optional Exterior Graphics

Secondary containment pit coating

Plus we provide all of the polyurethane, polyurea and hybrid coating products, primers, sealers, topcoats, spray guns, tools and supplies you need.

Several Questions Help Us Make Key Design Recommendations

We want to help you make the right decisions. When you talk with us, we’ll ask questions regarding:

  • Type of Spraying Projects
  • Spraying Environment (Temperature, Humidity)
  • Spraying Distance from the Trailer
  • Tools and Equipment Used
  • Access to Power, Cost of Power
  • Equipment Noise, Heat
  • Ventilation Required
  • Site-to-Site or Fixed Locations

You get:
Industry Leading Components
• Turn Key Generator Powered Unit
• Open and Closed Cell Spray Foam
• Fresh Air and Safety Systems
• Climate Controlled Mobile Storage

Heated Hose Rack
Holds up to 410 ft. of hose. Designed with no sharp edges to tear or fray protective scuff jacket. Includes mounting bracket for heated hose circulation manifold.
Fit and Finish
Interior of trailer is lined with a white laminated plywood (not just painted). White aluminum trim in corners keeps the fluid and air hoses concealed for a clean and professional look.
Fully Insulated
ArmorThane Mobile Rigs are fully insulated with sprayed polyurethane foam for the best insulation while adding structural strength to the trailer.
Trailer Specs
Trailer manufactured by United Trailers with 7.5 ft. tall interior height, double I-beam construction with support studs on 16 inch centers. Includes rear bogey wheels, and is backed with a 5 year warranty.
Work Bench and Cabinet
Galvanized steel work bench with vise, grinder and overhead white aluminum locking cabinet.
Barrel Braces
Engineered to hold two or three sets of material securely for a mobile application.
Generator/Air Compressor All rigs come with generators and air compressors from leading manufacturers and are approved installations backed by warranty.
Separated Utility Room
Generator is installed in separate utility compartment, sealed from the spray/work space — reducing noise and exposure to emissions.


Image result for mobile coating unit
  • ft (8.5m) gooseneck trailer (8 ft / 2.4m height)
  • 20 ft (6m) tag-along trailer (8 ft / 2.4m height)
  • 16 ft (5m) tag-along trailer (7 ft / 2.1m height)
  • Box truck
  • Sea containers
  • 53 ft (16m) trailers for roofing and Xtreme Mix
    All trailers and box trucks include:

  • Proper ventilation. Engineered louver system designed to keep the generator from overheating
  • Color-coded drum restraints
  • Insulated partition wall between utilities and cabin. This separates the generator from the proportioner – reducing noise during operation
  • Electrical system with control panel
  • Hose hanger (up to 410 ft /125m capacity)
  • 1/4 in (.635cm) plywood walls, double 3⁄4 in (1.9 cm) plywood flooring (trailers only)
  • Heavy-duty 8 in (20.3 cm) main beam construction (trailers only)
  • Custom barrel brace set
  • Two ABC approved fire extinguishers
  • Deluxe first aid kit



  • Reactor® H-40
  • Reactor H-25
  • Reactor E-30
  • Reactor E-20
  • Reactor H-XP2
  • Reactor E-XP2
  • Reactor A-20
  • Xtreme Mix™
    Gun Package:

  • Fusion® Air Purge
  • Fusion Mechanical Purge
  • Gusmer® GX-7
  • GX-8
  • GX-DI
  • Gap Pro
  • D-Gun
  • XTR Gun
  • Flex Plus™ Gun

  • 2000 psi
  • 3500 psi
  • 5000 psi
  • 7250 psi (Water-jacketed hose available)


  • 40 KW diesel
  • 60 KW diesel
    Generator packages include:

  • Installation and wiring
  • E-stop
  • Hardware
  • Shut down alarms
  • Correct sizing for application


  • Rotary screw compressor (40 cfm) integrated with generator saves valuable floor space (60 cfm model is optional)
  • 5 hp Champion compressor (17.5 cfm)
  • 5 hp Champion compressor (Vertical) (17.5 cfm)
  • 10 hp Champion compressor (35 cfm)
    All air systems include:

  • Installation and plumbing
  • Refrigerated dryer – 225°F (107°C) inlet temperature ensures proper air drying in any climate
  • Filtration
  • Regulators
  • Quick disconnects
  • Correct sizing for application