Performance (back to top)
Zero Rust has exceeded 2000 hours at 3.5 mils d.f.t. (dry film thickness) in the ASTM-Bll7 salt spray tests. This was previously unheard of in an air-dried coating.

The effectiveness of Zero Rust on bare steel surfaces is optimized at 3.0 to 3.5 mils d.f.t. over profile. This should provide at least five years of protection with minimal prep work. Longer performance is attainable with additional prep work and cleaning.  Eliminating air entrapment on the substrate and removal of contaminants (oil, grease, dirt) will improve overall performance and maximize bonding of Zero Rust with the substrate.

Note: On exterior applications there is a possibility of color chalking or fading. If gloss and long-term color retention are important, we recommend top coating with our Crystal Coat™.

Coverage (back to top)
288 square feet per gallon for recommended 3 mils (.003 inch) dry film thickness (866 square feet per gallon per dry mil.)

Surface Preparation (back to top)
Thoroughly clean all surfaces of any dirt, oil, grease, silicone, and any other contaminants.  Remove all loose rust. Zero Rust's Prep-Step™ is very effective in helping to remove all of these contaminants plus providing additional benefits.
As with any paint product, a direct relationship exists between surface preparation and product performance.
See our Prep-Step page for more information.

New steel (mill scale):
Mill scale should be removed prior to coating with Zero Rust. If left intact, any mill scale will become the weak link in the chain.  Then, in any area where the Zero Rust film breaks, rust will develop and spread sideways between the mill scale and the steel.

Rusty Surfaces:
When working down rusty surfaces, proceed with two goals in mind: (1) Remove all loose scale and powdery rust. Minimizing air entrapment is the key. Leave no oxygen behind in the substrate to continue the rusting process. Heavy rust scale can be softened for easier removal with the use of our Prep-Step. (2) Remove as much pitting as possible. The smoother the surface and the tighter the remaining rust, the less product you will need o span the highs and lows to achieve the 3.0 to 3.5 mil coverage.  

Partially rusted, partially painted surfaces:
When repairing a deteriorated painted surface, total removal of old paint is preferred. When this is not feasible, treat as you would mill scale from the standpoint that the old paint becomes the weak link in the chain. The cleaner and tighter the surface, the better the resultant job. Pay particular attention to paint edges that may lift and curl. For best results, use a rotary sander to feather out exposed steel to adhering paint edges.

Galvanized Steel Surfaces:
On aged, rough galvanized steel, Zero Rust will bond with the addition of either one tablespoon of dry Portland cement or half a tablespoon of high calcium hydrated lime per gallon of Zero Rust. Mix thoroughly. 

On new galvanized steel, use a vinyl wash primer before applying Zero Rust.

Thinning (back to top)
Application with airless spray equipment requires no thinning and can be done directly from the can. 

Because of its high-solids content, Zero Rust will require thinning for most siphon gun and gravity-feed applications. A reduction of 15-20% with xylene is typical. Recommended thinners are xylene, lacquer thinner, acetone, and acrylic enamel reducer. Do not use mineral spirits or VMP Naphtha for thinning. When using a brush or roller, thin to suit.

If the container is open for an extended time, Zero Rust may start to thicken due to solvent evaporation. To maintain the desired consistency, add more thinner and mix well.

NOTE: Zero Rust meets the current Volatile Organic Compound (VOC) limits for Architectural Coatings (AIM) as published by the US Environmental Protection Agency on 9/11/98.  For those customers who fall under the AIM category, thinning must be done with an EPA-approved exempt solvent such as Acetone or Oxsol 100.

Application (back to top)
Mix well before using. Apply with spray, brush, or roller. Zero Rust is a high solids product with 54% solids by volume. For practical purposes, 2 mils of wet film yields one mil of dry film after solvent evaporation. If Zero Rust is thinned prior to application, additional wet film thickness must be applied to reach the same desired millage.

For best results apply a minimum of two coats, using a crisscross pattern from one coat to the next to help preclude holidays (pin holes) and thin spots. To assure adequate coverage, an easy visual barometer is to use two different colors for the first and second coats; i.e., a coat of red oxide followed by enough of the final color to hide the red oxide.  This two-coat, two-color method will preclude putting on too much product.  For maximum protection, red oxide and black are the best  for sealing, and we recommend using either of these colors as the first coat.

Do not apply too heavily and allow adequate time for flash off between coats (20 to 30 minutes is the minimum flash off time between coats).  This is extremely important! Because Zero Rust is designed for impermeability, the surface of the film starts closing as solvents start flashing off.  This in turn impedes the migration of solvents from the interior of the film. When a thick coat is applied or if adequate time is not allowed between coats, the paint takes much longer to dry thoroughly.

When closing bulk containers for subsequent use, pour a 1/4 inch layer of thinner on top of the remaining Zero Rust before closing the lid. This will stop skin from forming during storage and lengthen the life of your unused Zero Rust.

There is a possibility of color chalking or fading on exterior applications. If gloss and long-term color retention are important, we recommend top coating with Crystal Coat™, which is a non-yellowing clear acrylic topcoat that has been formulated as a color stabilizing, high gloss coating to be used over Zero Rust.

Note: Zero Rust is not recommended for submersion applications

Drying Time (back to top)
Zero Rust dries to touch in 30 minutes and is tack-free within one hour, depending on the relative humidity and temperature. Drying time can also be affected by film thickness, flash off time between coats, amount of thinning, air movement, and temperature.

Topcoats (back to top)
Normally, commercial topcoats may be applied within 24 hours or after solvents have evaporated. Zero Rust is compatible with a wide variety of commercial topcoats. As it is impossible to cover all topcoats or topcoat combinations here, you will need to do test panels to determine compatibility and dry time window for your selected topcoat/topcoats.  For particular applications, contact your technical representative.

High-solids, acetone-free, two-component automotive urethanes can be used successfully as topcoats. Urethanes containing acetone, however, make top coating air-dry finishes more difficult. As acetone is now Volatile Organic Compounds (VOC) exempt, it is increasingly being used in urethanes. Our testing shows that, because acetone is an aggressive paint stripper, it can soften and wrinkle or lift the undercoat, thus shortening the lift-free window. It requires more precise timing when top coating with low viscosity urethanes that contain acetone or that are thinned with acetone. 

A 4 mil wet film of Zero Rust can be top coated within 3 to 6 hours with minimal solvent trap problems. If you are unable to apply the topcoat within this time frame, it is advisable to wait 24 hours before top coating. Additionally, applying a light bridge coat of the urethane before the flood coat will help stop solvent dive-in, which can cause lifting and wrinkling of the Zero Rust.

Temperature Range    (back to top)
Zero Rust can withstand intermittent temperatures of 250-300 degrees before the resin starts baking out. Heat resistance will vary by color.

Cleanup and Waste Disposal...(back to top)
Use methyl ethyl ketone (MEK), xylene or lacquer thinner for cleanup. Dispose of wastes and residue in accordance with regulations applicable to the area of use.

Benefits of Using Zero Rust (back to top)
Surface tolerant -- Zero Rust is formulated to be applied over existing rust with minimal preparation. Just follow the instructions under Surface Preparation.

No sandblasting required -- Environmental considerations are making sandblasting less viable due to waste disposal and containment.

Protection at the metal level -- Most primers are merely a "fuzzy" coat onto which paint will hang. Any protection offered by the topcoat is then one step removed from the steel. Zero Rust will truly protect, isolate, and insulate the steel.

Recoatable -- Just scuff sand to recoat or repair. Most catalyzed systems do not allow repairs without extensive surface preparation. 

Colors Available (back to top)
Stock colors are Black, White, Gray, Red Oxide, "Cat" Yellow, Tide Green, Tan, Safety Yellow, Safety Blue, and Safety Red. Color matching is available subject to price and quantity quotation.

For a visual reference, please check our Color Chart page.

Sizes Available (back to top)
Available in 12 oz. aerosols, quarts, gallons, 5 gallon pails, and 50 gallon drums. 

Crystal Coat (back to top)
Crystal Coat is a single package, high solids, high gloss, clear acrylic top coat for use over Zero Rust. It is specifically formulated to provide optimum ultraviolet (UV) screening, superior gloss retention with exceptional film clarity and will not yellow with age. Crystal Coat can also be used to brighten aged finishes that have been properly dechalked or to provide oxidation protection for non-ferrous metals, i.e., brass, bronze, aluminum. Two coats are recommended for enhanced gloss and UV protection.

Crystal Coat is available in the same container sizes as Zero Rust.

Zero Rust Prep-Step (back to top)
Prep-Step is not an acid, i.e., not a converter.  Prep-Step is a totally biodegradable, environmentally friendly product that is helping solve many long term protection problems.
Click here to read more about Prep-Step.