COLD GALVANIZING
CATHODIC PROTECTION

Excellentes mechanical structures

Perfectly resistant to fresh water

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Allows the support to expand
Highly resistant to climate changes
Does not crack or peel off
Very high resistance to impact and abrasion
Resistant to saline environments

RUST-ANODE PRIMER® acts as an active couple with the steel surface

RUST-ANODE PRIMER® can be used as a single layer. It • Allows cold galvanising on the majority of metals

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Prolongs the life span of bridge and footbridge structures that have been treated by hot-dip galvanisation

RUST-ANODE® technology is an anti-corrosion treatment where zinc acts as an active couple with the surface of the steel. The product instantly generates new cathodic protection by galvanic anode which founds perfectly with the old galvanisation layer. Cold galvanising works on the majority of metals and alloys.

Cathodic protection that is more profitable than hot-dip galvanising.

In the case of hot-dip galvanisation, each element in the metallic structure has to be treated separately in a zinc bath to reinforce their cathodic protection potential.
RUST-ANODE PRIMER® is ready for use, and can be applied directly to the steel as a mono component paint. The advantage is that the metallic structure of the bridge does not need to be dismantled and can be ‘reinforced’ to maintain the cathodic protection for many years.

 

Anti-corrosion product for cold galvanizing
Cold galvanizing for the treatment of rust and corrosion

COMPLETE COLD GALVANIZING
RUST-PROOFING TREATMENT
PUR ZINC BASE
READY TO USE - SINGLE-COMPONENT

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TS RUST-ANODE PRIMER en
General information

RUST-ANODE PRIMER® is a cathodic protection applied as one component cold zinc coating, ensuring excellent protection from CORROSION.
RUST-ANODE PRIMER® provides a zinc-rich one-component process.
RUST-ANODE PRIMER® is ready to use.
RUST-ANODE PRIMER® has been developed to withstand scratches, corrosion, hydrocarbons, waste and severe conditions.
RUST-ANODE PRIMER® can be used without a top/decorative coat.
RUST-ANODE PRIMER® may also be used as a primer in a duplex system with a compatible top coat (active + passive).
RUST-ANODE PRIMER® can be applied by a brush, roller, spray gun or electrostatic .
RUST-ANODE PRIMER® can be used to restore cathodic protection on previously hot-dip galvanized or metallized film or to restore existing RUST-ANODE PRIMER®.
Can be covered with paint products.
Bonds well with existing paint.
Very resistant to corrosion and impact.
Provides excellent protection against salt damage.
Equal expected lifetime to hot-dipped galvanizing and/or metalization at equal zinc thickness.
Can be applied to all types of metal.

Characteritics

 

  • Zinc quantity: 87% ± 5% (by weight) DFT (dry film thickness)
  • Zinc purity: approx. 99.995%
  • Ready to use: one component coating
  • Colour: Mat light grey RAL #7005
  • Safety: Non-toxic and non-flammable when dry
  • Specific gravity (density): 2,45 Kg/dm3 ± 5 %
  • VOC (solvents): 285 grams/litre ± 10 %
  • Apply to: Steel or, aluminium or cast aluminium, copper, cast iron...
  • Flashpoint: 52°C
  • Diluent: RUSTASOLV PRIM

 

Application domains

Marine environments (boats, barges, gangways, quays, piles, etc.)
Bridges – dams
Various structures
Tanks, silos
Factories
Transport
Buildings
and more

Properties
Can be used as a primer or top coat over existing coats of RUST-ANODE PRIMER®.
Can be used to restore cathodic protection to existing galvanized coatings or to restore existing RUST-ANODE PRIMER® coatings.
Very resistant to corrosion, scratches impact and abrasion.
Multi-coat (duplex) system: RUST-ANODE PRIMER® can be covered with a compatible paint.
Applications As a primer, 40 to 80 μm (dry) DFT or in two (2) coats up to 160 μm DFT (thickness to be adapted per Galvanising Standard ASTM A123).
Withstands variations in temperature De –80°F to + 200/250°F (-60°C à +120°C).
Application temperature –10 °C to +40 °C (curing times vary) Curing times vary depending on temperature (temperature of substrate should be at least 3 °C above dew point)
stimated coverage 6,55 m2/kg at 40 μm DFT (152 g/m2).
Practical coverage
 5,70 m2/kg per 40 μm DFT coat (175 g/m2).
Resistance to marin environment Exceptionnally good; a duplex system is recommended.
Résistance to acids / alkalis May be applied in a pH is between 5.5 ans 12.5.
High plasticity No cracking – Allows tfor expansion and bending of metal substrate.
Weldability A coat of up to 40 μm thick can be welded without affecting weld joints (x-ray).
Expected lifetime Similar to hot-dip galvanizing (depending on thickness of dry film).
Estimated product life cycle in duplex form Similar to hot-dip galvanizing with duplex.
Conductivity Dry film has a good conductivity.
UV ASTM G154-12a. Little impact.
Salt spray ASTM B117/ISO 12944-6/7253. Excellent.
Bending ASTM D-522.
Flexibility CAN/CGSB-1-GP-71 Method 119.5
Organic zinc-rich coating CAN/CGSB -1.181.
Resistance to solvents – hydrocarbons – waste Excellent.
Implementation - Surface preparation
  • Clean in accordance with standard practice;
  • Degreasing by steam-cleaning recommended with appropriate degreaser (140 bar at 80 °C)
  • Some roughness is required, Ra 12.5 μm (dry or wet shot-blasting);
  • Surface should be free of rust dust (uncontaminated compressed air), friable material, oil, grease or other chemical contamination;
  • Cleaning solutions should be residue-free;
  • Maximum salt tolerance is 7 μgr/cm² on the. Please contact technical support
  • Surface moisture: no moisture should be present (droplets or condensation);
  • Ambient humidity: a minimum humidity of 25% is required to activate curing (moisture cure):
  • Normal application temperature is between -5 °C and +40 °C;
  • The substrate temperature should be at least 3 °C above dew point;
  • Sharp edges and drilled holes must be rounded;
  • Continuous weld runs are recommended;
  • Weld joints must be cleaned;
  • Apply RUST-ANODE PRIMER® as soon as possible to prepared surface (4 hours max. waiting time). In the event of contamination before application, surface should be re-cleaned per above instructions.
  1. Preferred: Shot-blasting, sand-blasting, slurry blasting, vapour blasting, intensive brushing or cleaning with ultra-high pressure water (with rotary nozzle). Standard level of cleanliness and degree of roughness equal to Ra 12.5 μm + two (2) coats of RUST-ANODE PRIMER® 40 to 60 μm (DFT) each.
  2. Mill scale: Surfaces should be clean, dry and grease-free. Over time, mill scale may flake and lift the coating. To prevent this, surface should be shot-blasted or cleaned with ultra-high-pressure water (with shot).
  3. Cold-rolled steel: Poor bonding due to high zinc powder content. It is necessary to degrease or shot-blast (or clean with ultra-high-pressure water plus shot), leaving the metal to oxidise slightly in the open air to remove the shine and obtain a surface with good adhesion. A coarse-grained buffing wheel at low speed can also be used to score surface.
  4. Partially rusted iron: Brush thoroughly to eliminate loose particles and apply a water or steam wash to remove dust.
  5. Existing paint: Use RUST-ANODE PRIMER® to touch up rusted areas (never use on surfaces covered with bituminous coating or on products containing aluminium). RUST-ANODE PRIMER® provides a cathodic protection which is only effective when in direct contact with the steel surface. On existing paint, RUST-ANODE PRIMER® acts like ordinary paint and will not provide cathodic protection.
  6. New or existing galvanizing (or metallizing): RUST-ANODE PRIMER® may be applied directly without mechanically preparing the surface. However, existing galvanizing or metallizing should be washed to remove surface contamination (zinc chloride). RUST-ANODE PRIMER® will restore existing zinc coating and enable full cathodic protection to be restored.
    New galvanizing or metallizing damaged by drilling, flame-cutting or welding will have restored cathodic protection after a coat of RUST-ANODE PRIMER® is applied. Stripe coating RUST-ANODE PRIMER® is ideal for galvanized surfaces with new welds (Recommended: 2-3 coats, 40-60 μm (DFT)). All surfaces should be free of grease, oil or other contamination before application.
  7. Aluminium: Surface should be free from white rust dust, friable material, oil (cutting and drilling oil) grease or other chemical contamination. Mechanical cleaning is not normally necessary if aluminium is bare and clean. Apply directly after cleaning.elds (Recommended: 2-3 coats, 40-60 μm (DFT)). All surfaces should be free of grease, oil or other contamination before application.
  8. Copper: Surface should be free from verdigris (a bright bluish-green encrustation), dust, friable material, oil (cutting and drilling oil) grease or other chemical contamination. Apply directly after cleaning.
  9. Cast iron and cast aluminium: Surface should be free from rust dust, friable material, oil (cutting and drilling oil) grease or other chemical contamination. Abrade surface (SSPC-SP6), (SSPC-SP3 small areas) to remove mould residue. Clean with compressed air. Apply directly after cleaning.
  10. On concrete: Before applying galvanized steel to concrete, apply a generous coat of RUST-ANODE PRIMER® to the clean concrete.
Application

IMPORTANT NOTES:

  • The product is ready to use by brush or roller.
  • The zinc content in RUST-ANODE PRIMER® requires the product to be mixed for 2-3 minutes; use of a spiral paint mixer is highly recommended.
  • Gloves and safety glasses are recommended.
  1. Exercise caution when opening container.
    If the lid is bulging, this may indicate that the product has separated and the container should be opened with caution to allow any hydrogen to escape.
    The formation of hydrogen does not affect the quality of the product and it may be used after it has been properly mixed.

     

  2. The product is ready to be applied by brush or roller.
    It is recommended to apply 2 coats, waiting 1 to 24 hours between coats (depending on ambient humidity and outside temperature) to obtain a minimum thickness of 80 μm to 130 µm for dry film (DFT).

    Brush / Roller
    • Ready to use after mixing properly.
    • Pratical coverage 6.20 m²/kg per 40 mm coat (measured dry = DFT) or 162 g/m²
    • Can be recoated two (2) hours after dry to the touch
    • Dilution is not normally necessary; however it can be diluted with a small amount of
    • RUSTASOLV PRIM to facilitate application (up to a maximum of ½ litre per 12 kg container).
    • Mix well.
    • Industrial round brush/short pile roller (mohair)


    Spraying
    • Dilute by 4 to 10% with RUSTASOLV PRIM (test in advance)
    • For gravity spray guns and pressurised containers use 1.8 to 2.2 mm nozzles. Pressure 3 to 4 bar.
    • Conventional suction guns are not recommended.
    • Mix well.
    • Can be applied using an electrostatic spray gun.
    • Estimated coverage: 7.05 m²/kg at 40 μm (dry = DFT) (142 g/m²)
    • Pratical coverage: 6.20 m²/kg per 40 mm DFT coat (162 g/m²)
    • Successive coats may be applied (wet-on-wet)


    Airless spray
    • Dilute by 4 to 5% with RUSTASOLV PRIM (test in advance)
    • Dilution with a pump ratio of not less than 40:1 is recommended
    • Recommended nozzles: 0.015 – 0.020” (0.38 to 0.51 mm)
    • Mix well.
    • Low-pressure application is recommended (approx. 100 to 150 bar)

    TIPS:

    • It is recommended that corners, edges, bolts and screws be stripe coated in advance, before applying a uniform coat.
    • Due to the rough texture, never apply the first coat with a roller; use a brush to fill in gaps and to better cover the surface.
    • For spray gun application:
      • It is recommended that all filters should be removed from the spray gun to prevent blockage;
      • Use short tubes;
      • the product should be continuously mixed while spraying;
      • continuous circulation of the product using a (bypass) connector at the spray gun outlet is recommended;
      • spray equipment should be flushed before and after cleaning with RUSTASOLV PRIM.

     

  3. Drying and curing time:
    • Drying time for a wet film with a thickness of 150 microns = 6.0 mil (1.0 thousandth of an inch total dry film thickness (DFT) = 25 microns):
    • Drying times vary according to the thickness of the wet film, ambient temperature and humidity level
    • To touch: approx. 3 hours
    • To handle: approx. 5 hours
    • Apply two coats using a spray gun: No waiting time between coats
    • Apply with a brush/paintbrush/roller: Waiting time between coats as needed (minimum of two (2) hours after dry to the touch).
    • Ambient temperature may effect waiting time
    • Excessive thickness may increase drying time
    • Full curing: 15 days (estimated)
      • To use: Next day
      • To immerse: minimum 2 hours
    • Dust-free after 30 minutes (depending on temperature and film thickness)

     

  4. Second coat:
    • You can apply a 2nd coat of RUST-ANODE PRIMER® two (2) hours after dry to the touch (depending on ambient humidity and temperature) if applied using a brush; immediately if applied with a spray gun;

     

    NOTE
    RUST-ANODE PRIMER® is not designed to be applied in excess thickness, in one wet film dot not exceed 150 μm (6mil), if you require a 375 μm DFT, 4-5 coats will be required to achieve this DFT.

  5.  Recoating RUST-ANODE PRIMER® with paint (test in advance):

    RUST-ANODE PRIMER® can be used as a single coat (single system) as well as a base coat/primer (duplex system) with a compatible top/decorative coat of paint (duplex system)
    Compatible paint (sealer and/or top coat) should be applied within 24 hours and within a maximum window of 50 hours.
    If the maximum re-coating time has been exceeded, apply a mist coat of Rustasolv-Primer, and apply a top coat of paint once the primer has dried.
    > Single system (active protection):
    RUST-ANODE PRIMER® is used as a two-coat single system, to obtain a total DFT (dry film thickness) of 120 to 180 μm.
    This system is easy to maintain.
    RUST-ANODE PRIMER® coating will eventually lose thickness as zinc is sacrificed to provide cathodic protection.
    A new coat of RUST-ANODE PRIMER ® can be applied to restore an existing coat of RUST-ANODE PRIMER®.
    > Duplex system (passive protection):
    RUST-ANODE PRIMER® can be used in a duplex system, by spraying.
    This duplex system significantly increases the estimated product life cycle.
    > Compatible paints:
    RUST-ANODE PRIMER® can be recoated using a wide range of compatible paints, however testing in advance is recommended.
    To prevent bubbles, pitting or other imperfections when re-coating (which impedes the RUST-ANODE® process), it is recommended to use a misting technique: the initial application of a thin, continuous film allowing bubbles to pass through the film.
    This film will form a barrier against aggressive diluents in the paint.

    • Misting technique:
      • Apply at least 12 hours after RUST-ANODE PRIMER® is dry to the touch.
      • 25 to 30 μm DFT (continuous coat). –
      • Normal dilution according to the paint’s technical specifications.
    • Full coat:
      • Apply at least two (2) hours after first coat is dry to the touch.
      • Minimum specific thickness 25 to 30 μm DFT (of the first coat).
      • Normal dilution in accordance with technical specifications.

     

    NOTE
    Compatible paints: please refer to the technical department
    Top coat paints should not contain organic solvents such as xylene, toluene or butyl acetate. Testing in advance is recommended.

  6. Estimated usage table:

    RUST-ANODE epstimated usage table

    RUST-ANODE minimum recommended tickness zinc steel

  7. Recommendations:
    • We recommend using the mist coat technique (minimum of 2.0 mil = 50 microns wet) before applying the total desired thickness.
    • If a container is partly used, the surface of the remaining RUST-ANODE PRIMER® should be covered with a thin film of Rustasolv-Prim.
    • Do not mix the product and close lid completely.
    • The equipment used in the application process can be cleaned using solvents such as paint thinners, MEK, acetone, or Rustasolv-Prim or others.
    • Hoses should be cleaned with RUSTASOLV PRIM before reusing RUST-ANODE PRIMER®.