Polyfusion

Polyfusion is a coating providing an anti-osmotic barrier used to insulate porous substrates against the external agents the coating is exposed to. Generally speaking, the substrates to be protected are porous materials such as concrete, fiberglass, etc.

Steel Industry

The Flame Spray Technology is particularly suitable for coating metal substrates, since it provides the following benefits:

No need for a primer; powders adhere directly to the prepared substrate
Anti-osmotic barrier for outdoor surfaces such as buildings/construction, bridges, off shore sector, nautical applications
Continuous dialectical insulation; protective coating against stray currents for articles to be buried; electrical and marine corrosion protection
Abrasion resistant coatings, high mechanical strength; Coatings for ducts to discharge mineral waste, process water etc.
Chemical resistance; anti-acid coating for tanks, containers, fittings, industrial plants etc.

Application on Metal

The substrate must be cleaned. Sandblasting is the preferred pre-treatment method, using a grain size which provides a 40-50 microns profile and SA 2.5 cleaning standard.
The substrate is preheated to approximately 100C-150C (normally the melting point of the thermoplastic coating powder used) using the gun of the flame spray coater (flame only, no powder).
The powder flow is started by turning on a switch located on the gun itself or by pressing the gun trigger. Now the powder is propelled through the gun by dry compressed air and hits the preheated substrate and immediately melts adhering to the substrate.
Coating thickness is dependent on the number of passes. The minimum recommended coating thickness is 300 microns.
Additional coating or repairing will always be possible in time: while coating, after coating is complete, after some time or later.
The flame spray cycle is now complete.
Usually the substrate is air cooled. If needed, you can water quench the coated substrate.

Concrete Industry

Concrete is a composite material that deteriorates when exposed to normal environmental conditions. At the casting stage, concrete is sensitive to climatic changes and absorbs gases present in the atmosphere. We should not overlook the fact that concrete “breathes”, so it expands and shrinks with seasonable moisture and temperature variations, and this often causes cracking problems. Other peculiar and negative characteristics of concrete are a non-uniform, changing surface morphology as well as the typical porosity of the finished body.

Application on Concrete

Removal of existing coating
Surface preparation: Inspect the surface for any delamination or hallow spots. If hallow spots are found they must be chopped out and repaired.
Sand or smooth existing surface to a flat finish with a sanding disc or cement based product
Blast to clean the surface
Apply a first layer of the bi-component sealing primer Polyres A+B
Apply a second layer of Polyres and wait until it dries
Apply Polyfusion System through the Spartacus Flame Spray System

Applied through Flame Spray using special coating applicators such as the IBIX SPARTACUS Flame-Spray Powder Coating System.

Three different Application Guns

Centurion Flame Spray Application
Medium Flame Spray Application
Standard Flame Spray Application

IBIX Spartacus and Centurion Application Guns

Color Charts:

Polyfusion Used for Concrete and
Steel in Basic, Solid Colors.

The colors below are representations of the standard color range of U-Poly-Con & Steel.

Because of the limitations of color presentation on websites the colors should be used for guidance only and not as a true representation of the colors of the finished products.

Color	U-P Number	RAL Number	Color	U-P Number	RAL Number
Beige	222	RAL1015	Red	233	RAL3020
Yellow	344	RAL1021	Green	475	RAL6005
Blue	536		Blue	542	RAL5015
Grey	613	RAL7035	Silver	654	RAL7001
Grey	695		Grey	640	RAL7016
Brown	838	RAL8019	Brown	813	RAL3009
Black	700	RAL9005	White	110	RAL9016