Water and polyurethanes, and even more specifically isocyanates, do not get along.
Worse yet, the isocyanate has now been reduced to an amine which then reacts with the isocyanate to make a polyurea. And since we know from Newton's Third Law of Isocyanate Chemistry that "For every urethane reaction, there is an equal but faster urea reaction", the isocyanate is now foamy and partially polymerized.
Our isocyanate and polyols were in sealed bottles and were fine, but the additives to the coating seem to have absorbed far more moisture than we ever thought possible. So we're firing up the vacuum oven to dry everything out. But just like how your clothing can get wet in a downpour in just a few seconds but need the better part of an hour to dry out in a dryer, so it is with drying our materials. There is no indicator that they are dry enough. We go for a while and run a test sample. Go for a while longer and run another test sample. Go for a while longer...
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