Zero-Rust is a direct-to-metal, phenolic modified alkyd coating, that controls rust and corrosion by putting down an impermeable barrier at the steel level. Zero-Rust has two superior traits: (1) It provides maximum adhesion to steel.  This is called chemical affinity. (2) Its dielectric ability is extraordinary. It isolates steel from the electrolysis process which converts steel to rust. In laymen's terms, this means that if you can starve the oxygen from the substrate, oxidation cannot occur.

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

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.

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.

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 colours for the first and second coats; i.e., a coat of red oxide followed by enough of the final colour to hide the red oxide.  This two-coat, two-colour 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 colours 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 colour chalking or fading on exterior applications. If gloss and long-term colour retention are important, we recommend top coating with Crystal Coat™, which is a non-yellowing clear acrylic topcoat that has been formulated as a colour stabilizing, high gloss coating to be used over Zero-Rust.

Note: Zero-Rust is not recommended for submersion applications.

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