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
Concrete Coating Process

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. 

ColorU-P NumberRAL NumberColorU-P NumberRAL Number
Grey613RAL7035Silver 654RAL7001

Polyfusion Used for Concrete Flooring
in a Variety of Colors.