Intercure 99: High-Performance Polyaspartic Coating

Discover the advanced direct-to-metal coating designed for industrial durability

industrial facility with metal structures

Highlights

Single-Coat Efficiency: Rapid one-coat application that saves time and reduces labor costs.
Rapid Cure and Durability: Cures in 1.5 hours at 25°C, providing fast handling and long-term aesthetics.
Advanced Polyaspartic Technology: Excellent anticorrosive protection and color stability suitable for industrial applications.

Overview of Intercure 99

Intercure 99 is a sophisticated two-component polyaspartic coating that represents an innovative solution in protective metal coatings. Formulated as a low volatile organic compounds (VOC) system, it is designed to serve as both a primer and finish in a single application. This unique approach not only streamlines the coating process but also minimizes resource usage and labor while meeting high performance and environmental standards. It is especially popular in environments where moderate corrosivity is present, such as those categorized under ISO 12944 C3.

Technical Specifications and Characteristics

Composition and Application

Intercure 99 is built upon advanced polyaspartic chemistry, where the fast cationic polymerization reaction allows the coating to cure rapidly even at standard ambient temperatures. It is a two-component system that combines a resin and curing element, producing a robust polymer network once applied. The product is commonly applied as a direct-to-metal system, meaning that with the correct surface preparation, it can be used as a combined primer/finish coating, thereby eliminating the need for multiple coats.

Application Method

The single-coat nature of Intercure 99 is a particularly advantageous feature. It is applied at film thicknesses typically ranging between 150 and 250 microns (6 to 10 mils). Airless spray techniques are advised for achieving uniform coverage and the best possible performance. Alternatively, conventional air spraying with a cross-spray technique may be employed, ensuring that the coating is distributed evenly across all substrate surfaces. Rapid cure properties allow the coated metal to dry hard within 1.5 hours at 25°C (77°F), reducing downtime in industrial settings.

Surface Preparation

Proper surface preparation is paramount for achieving optimal performance with Intercure 99. Prior to application, the substrate should be thoroughly cleaned and abraded to remove contaminants such as rust, scale, and old coatings. Abrasive blasting to standards such as ISO 8501 Sa2½ or SSPC-SP6 is highly recommended. Failure to prepare the surface adequately can reduce the adhesion properties of the coating and compromise its longevity.

Performance Attributes

The performance of Intercure 99 is defined by several key attributes that contribute to its popularity in industrial applications:

Characteristic	Description
Application	Single-coat direct-to-metal primer/finish
Film Thickness	150-250 microns (6-10 mils)
Cure Time	1.5 hours at 25°C (77°F)
VOC Levels	Low VOC, complying with environmental regulations
Corrosivity Category	Suitable for ISO 12944 C3 environments
Durability	Long-term color and gloss retention coupled with excellent anticorrosive protection

Key Features and Benefits

Time and Cost Efficiency

One of the most notable advantages of Intercure 99 is its single-coat application capability. Traditional coating systems often require a two-layer process—typically a primer followed by a finish coat. By merging these functionalities into one, Intercure 99 significantly reduces the overall application time and the associated labor costs. Fast curing in just 1.5 hours means that production lines can move forward with minimal downtime, thereby improving throughput in manufacturing and maintenance cycles. This efficiency is especially valuable in large-scale industrial operations where time is directly linked to productivity.

Durability and Aesthetic Retention

Intercure 99 is engineered to provide not only protective barrier properties but also long-lasting visual appeal. The coating maintains its color and gloss over extended periods under exposure to varying weather conditions and industrial environments. This dual performance ensures that structures such as wind towers, structural steel, and transformers maintain an attractive appearance while being protected from corrosion. The durable finish minimizes the frequency of maintenance schedules and reduces overall lifecycle costs.

Environmental Considerations

With increasing regulatory pressures and environmental concerns about VOC emissions, Intercure 99 stands out due to its low VOC formulation. This environmentally friendly aspect makes it compliant with stringent international environmental standards while still delivering high levels of performance. Its HAPS-free formulation ensures that hazardous air pollutants are minimized, making it a safer option for both applicators and the environment. Additionally, its capability to cure quickly reduces the amount of time the finished coating is exposed to potential environmental degradation during the curing phase.

Versatile Industrial Applications

The versatility of Intercure 99 is one of its core strengths. While primarily used on metal substrates, its robust anticorrosive properties and resilient finish allow it to be employed in a wide range of scenarios:

Structural Steel and Industrial Equipment

In industrial environments, structural steel requires protective coatings that can withstand mechanical wear and harsh weather conditions. Intercure 99 is ideally suited for this application due to its durability and rapid curing characteristics, making it a reliable option for bridges, warehouses, and heavy industrial frameworks.

Wind Towers and Transformers

Applications in the energy sector, such as wind towers and transformers, benefit from the robust anticorrosion properties of Intercure 99. The coating provides long-lasting aesthetics and effective protection against environmental exposure, ensuring that the metal components remain operational and visually appealing over a prolonged period.

Mining and Heavy Machinery

In mining operations, the exposure to abrasive materials and corrosive elements can accelerate degradation of equipment. Intercure 99 offers a tough barrier that not only simplifies maintenance but also extends the lifecycle of components such as conveyors, pumps, and other mining machinery.

Performance in Different Environments

It is important to note that while Intercure 99 excels in environments classified under ISO 12944 C3, it is not designed for continuous water immersion scenarios. The product’s formulation is optimized for moderate corrosivity settings where periodic contact with water or moisture occurs but is not constant. In situations demanding resistance in highly corrosive (C4 or C5) or continuously immersed water environments, it may require additional protective systems or a different formulation altogether.

Detailed Analysis: Technology and Performance

Polyaspartic Technology

At the heart of Intercure 99 is its polyaspartic formulation, a technology that has revolutionized the coatings industry by enabling faster curing times without sacrificing performance. Polyaspartics are known for their ability to form robust cross-linked polymer matrices which impart high levels of mechanical strength and chemical resistance. This technology not only speeds up the cure—minimizing downtime—but also offers excellent thermal stability and flexibility. Moreover, polyaspartic coatings provide resistance to a range of chemicals, making them ideal for industrial settings where exposure to aggressive substances can be expected.

Low VOC and Environmental Compliance

The formulation of Intercure 99 emphasizes a low VOC profile, making it compliant with various environmental regulations and reducing the impact on air quality. In regions where stringent emission standards apply, using a low VOC coating improves sustainability and safety. The environmental profile of the coating further enhances its marketability in industries that are increasingly adopting green initiatives. In many cases, choosing a coating with low VOC emissions is not only a regulatory necessity but also a corporate responsibility measure.

Anticorrosive Performance and Aesthetic Longevity

One of the primary functions of any protective coating on metal substrates is to prevent or dramatically slow down corrosion. Intercure 99 accomplishes this by creating a durable barrier against moisture, oxygen, and other corrosive agents. Over time, its ability to maintain color and gloss ensures that the metallic substrate retains an appealing appearance, reducing the need for frequent repainting or maintenance interventions. Its robust chemical resistance also contributes to its longevity, maintaining structural integrity and aesthetic quality even in challenging environmental conditions.

Application Best Practices

Preparation and Safety Guidelines

The success of any coating application rests heavily on proper surface preparation and adherence to recommended safety protocols. Intercure 99 requires that the substrate be free from contaminants and adequately abrasive blasted to achieve optimum adhesion. Following standards such as ISO 8501 Sa2½ or SSPC-SP6 is essential.

Surface Cleaning and Blasting

Prior to application, surfaces must be meticulously cleaned of oil, grease, rust, and old coatings. Abrasive blasting not only removes these contaminants but also roughens the surface to provide a mechanical bond for the coating. This process should be performed in accordance with the relevant industry standards to ensure the best possible outcome.

Personal Safety and Equipment

When handling Intercure 99, it is crucial to consider that the product contains components that require careful handling. Isocyanates, present in some two-component systems, necessitate the use of personal protective equipment (PPE) including respiratory protection, gloves, and protective eyewear. Additionally, application areas should be well-ventilated to mitigate exposure to any potentially harmful vapors. Following all prescribed safety guidelines not only protects users but also ensures consistent application quality.

Application Techniques

Optimal application of Intercure 99 can be achieved through a variety of methods. Airless spraying is generally considered the most efficient due to its ability to atomize the coating finely, creating an even and uniform film. However, traditional air spray systems can also be used provided a proper cross-spray technique is employed to maintain consistency in film thickness and coverage.

Economic and Industrial Impact

Reduced Downtime and Increased Productivity

Industrial operations thrive on efficiency and minimal downtime. With its rapid cure time of 1.5 hours at 25°C, Intercure 99 allows for rapid return-to-service of treated components. This is especially crucial in sectors such as mining, power generation, and manufacturing where time is a critical element. The reduction in labor hours and material waste translates directly into cost savings, bolstering the economic value of this coating system.

Maintenance and Lifecycle Cost Savings

The longevity and durable finish of Intercure 99 mean that assets require less frequent maintenance and repainting. Over the lifecycle of an industrial installation, such cost savings can be substantial. The enhanced durability also contributes to overall asset reliability, reducing the risk of unplanned downtime caused by corrosion-related failures. This improvement in maintenance cycles and lifecycle cost benefits further justifies the initial investment in this high-performance coating.

Case Studies and Practical Applications

Industrial Installations

Numerous industrial installations have adopted Intercure 99 in environments where fast turnaround times and high protective standards are paramount. For example, structural steel in large industrial buildings and bridges has been effectively treated with this coating, providing a long-lasting finish with minimal maintenance requirements. The single-coat method has allowed maintenance teams to achieve significant savings in both time and labor, enhanced by the product’s rapid cure and exceptional adhesion qualities.

Energy Sector Applications

In the energy sector, components such as wind towers and transformers face unique challenges including exposure to harsh weather and corrosive environments. Intercure 99’s ability to form a robust anticorrosive barrier has proven especially valuable in such settings, safeguarding equipment from premature degradation while maintaining an appealing finish. The product's reliability under sporadic extreme conditions reinforces its suitability for mission-critical applications.

Heavy Machinery and Mining Equipment

Mining operations, which subject equipment to a demanding blend of mechanical stress, chemical exposure, and abrasive environments, rely on coatings that can endure these conditions. By applying Intercure 99, machinery such as conveyors, pumps, and other industrial mechanisms benefit from a protective coat that drastically extends their service life. Its successful application in these scenarios highlights its robustness and operational efficiency, even under severe conditions.

Comparative Advantages

Single-Coat vs. Traditional Multi-Coat Systems

Compared to traditional multi-layer coating systems that require a separate primer and finish, Intercure 99’s single-coat formulation presents several clear advantages. Not only does it reduce the number of application steps, but it also minimizes the chance of application errors that may occur when aligning multiple layers. This streamlined process is particularly beneficial in applications where downtime is critical and labor costs must be controlled.

Environmental and Regulatory Compliance

With industry trends moving towards reduced environmental impact and enhanced safety standards, the low VOC composition of Intercure 99 positions it as an attractive alternative. The product meets rigorous environmental regulations and offers a sustainable option for companies aiming to reduce their carbon footprint. Further, its HAPS-free formulation minimizes the impact on both indoor and outdoor air quality, reinforcing its value in sustainable industrial practices.

Additional Considerations and Limitations

Handling and Overcoating

Despite its numerous advantages, certain practical considerations must be observed when working with Intercure 99. For instance, it is recommended that overcoating be performed within a 24-hour interval from the initial application, ensuring that the protective properties of the initial layer are not compromised. Additionally, while highly resistant to corrosion, it is not designed for continuous water immersion. In such cases, specialized coatings may be more appropriate.

Temperature Sensitivity and Field Conditions

Although the product is designed to cure rapidly at standard temperatures, field conditions such as lower ambient temperatures (down to 5°C or 41°F) have been managed effectively due to the inherent properties of polyaspartic chemistry. However, it remains essential to monitor environmental conditions closely to ensure optimal performance during application. The rapid cure and robust performance can vary if not applied under the recommended conditions or if surface preparation standards are not rigorously met.

Conclusion and Final Thoughts

Intercure 99 stands as a paradigm of modern industrial coating technology, combining the advantages of polyaspartic formulations with a streamlined single-coat application process. With its rapid cure time, exceptional anticorrosive performance, and low VOC profile, it represents an ideal solution for applications ranging from structural steel and wind towers to heavy mining equipment. Its ability to provide lasting color and gloss retention not only improves aesthetic outcomes but also significantly reduces maintenance intervals. While the coating demonstrates clear advantages in moderately corrosive environments up to ISO 12944 C3, its application should be managed carefully in scenarios involving continuous water immersion.

In essence, Intercure 99 is a cutting-edge coating system that has been engineered to meet the demands of modern industrial operations. Its rapid cure properties and single-coat efficiency reduce downtime and labor costs, while its robust performance under diverse environmental conditions ensures longevity and durability. By meeting both economic and environmental targets, it continues to be a leading choice for industries seeking reliable, efficient, and sustainable protective coatings.