COLD GALVANIZING
CATHODIC PROTECTION

The cold galvanizing that challenges

rust and turns back the clock

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Easy to apply under any weather condition
Minimum time before ready to use
Excellent result for an optimal productivity
Surface uniformity
Allows the substrate dilatation

RUST-ANODE® restore the cathodic protection of the massive metal structures

It is possible to give a new life to your old hot dip galvanized steel pylons and towers.
The application of the RUST-ANODE® technology doesn’t need to dismantle your structure ; the apllication takes places on site.

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An anticorrosion coating easier to apply than a hot dip galvanization

Hot dip galvanization needs every part of the metal structure to be separately treated in a zinc bath to reload the cathodic protection.
The RUST-ANODE® technology applied on the substrate provides a new cathodic protection. The new galvanization fully binds to an existing hot dip galvanization coat and protects for years pylons, communication towers and other metal structures

Restoration of pylons and other metal structures

The RUST-ANODE® technology is at the same time an active cathodic protection and a passive paint protection ready to use
Cold galvanization can be applied with the same equipment as any classical anti rust paint.

 

Product for cold galvanizing against rust
Cold galvanizing against corrosion

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

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TECHNICAL SHEET OF RUST-ANODE®

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General information

RUST-ANODE® is a cathodic protection applied as cold galvanizing, ensuring excellent protection from CORROSION.
RUST-ANODE® is a single-component zinc-rich treatment which contains approximately 96% zinc in the dry film.
RUST-ANODE® is ready to use.
RUST-ANODE® can be applied by brush, roll or any spraying technique.
RUST-ANODE® can be used to restore cathodic protection on existing hot-dip galvanized or metallized film or to restore existing RUST-ANODE® under any conditions and without sand-blasting.
Very resistant to corrosion and impact
Provides excellent protection against salt damage
Lifetime expectation il equal to the lifetime expectation of the hot dip galvanizing
Application on steel or steel casting
List of references since to 1954.

Characteritics
  • Zinc quantity: approx. 96% (by weight) DFT (thickness of dry film)
  • Zinc purity: approx. 99.995% purity
  • Ready to use: one component coating
  • Colour: Mat light grey RAL #7001
  • Safety: Non-toxic and non-flammable when dry
  • Specific gravity (density): 3,15 Kg/dm3 (26.26 bbs/g) ± 2 %
  • VOC (solvents): 340 grams/litre (2.50bbs/g)
  • Solvent: Dearomatised citrus peel-based solvent
  • Apply to: Steel or cast iron
  • Flashpoint: 29°C
  • Diluent: SUSPENSION FLUIDE

 

Application domains
  • Electrical and telecommunications towers
  • Metal structures
  • Beams
  • Etc.
Properties
Can be used to restore cathodic protection to existing galvanized coating or to restore existing RUST-ANODE® coatings.
Very resistant to corrosion, scratches and impact.
Multi-coat (duplex) system RUST-ANODE® can be covered with a compatible paint.
Applications Ideally in two (2) 80 μm DFT coats up to 160 μm DFT (thickness to be adapted per Galvanising Standard ASTM A123).
Resistance to cold/heat 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).
Theroretical coverage 4,35 m2/kg at 40 μm DFT (230 g/m2).
Practical coverage
 3,82 m2/kg per 40 μm DFT coat (261 g/m2).
Resistance to marin environment Exceptionnally good.
Résistance to acids / alkalis Can be applied in a pH atmosphere range from 5.5 up to 9.
High plasticity No cracking – Allows the dilatation and bending of metal support.
Weldability A coat of up to 40 μm thick can be welded without affecting the weld (x-ray).
Lifetime expectation Similar to hot-dip galvanizing (depending on thickness of dry film).
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.
Solvent resistance Poor – use RUST ANODE PRIMER for excellent resistance to solvents and hydrocarbons.
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; In case of salt contamination, salts should be removed. Salt levels should not exceed 7 μg/cm². Please contact technical support
  • Maximum surface humidity is 90%, no moisture should be present (droplets, condensation);
  • 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 line is recommended;
  • Weld must be cleaned;
  • Apply RUST-ANODE® as soon as possible to the prepared surface (4 hours max. waiting time). In the event of contamination before application, surface should be recleaned per above instructions.
  1. Preferred: Shot-blasting, sand-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 + 2 coats of RUST-ANODE® 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 can also be used at low speed 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® to touch up rusted areas (never use on surfaces covered with bituminous coating or on products containing aluminium). RUST-ANODE® provides a cathodic protection which is only effective when in direct contact with the steel surface. On existing paint, RUST-ANODE® acts like ordinary paint and will not provide cathodic protection.
  6. New or existing galvanizing (or metallizing): RUST-ANODE® may be applied directly without mechanically preparing surface. However, existing galvanizing or metallizing should be washed to remove surface contamination (zinc chloride). RUST-ANODE® 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® is applied. Stripe coating RUST-ANODE® is ideal for galvanized surfaces with new welds (Recommended: 2 coats, 40-60 μm (DFT)). All surfaces should be free of grease, oil or other contamination before application.
  7. Cast iron: Surface should be free from rust dust, friable material, oil (cutting and drilling oil) grease or other chemical contamination. Abrade surfaces (SSPC-SP6), (SSPC-SP3 small areas) to remove mould residue. Clean with compressed air. Apply directly after cleaning.
Application

IMPORTANT NOTES:

  • The product is ready to use by brush or roller.
  • The zinc content in RUST-ANODE® requires the product to be mixed; use of a mixer is 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 for dry film (DFT) or follow ASTM A123.

    Brush / Roller
    • Ready to use after mixing properly.
    • Serviceable coverage 3.82 m²/kg per 40 mm coat (measured dry = DFT) or 261 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
      SUSPENSION FLUIDE to facilitate application (up to a maximum of ½ litre per 12 kg container). If windy mix additional SUSPENSION FLUIDE
    • Mix well.
    • Industrial round brush/short pile roller (mohair)


    Spraying
    • Dilute by 4 to 10% with SUSPENSION FLUIDE (test before)
    • 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.
    • Theoretical coverage: 4.35 m2/kg at 40 μm (dry = DFT) (230 g/m2)
    • Pratical coverage: 3.82 m2/kg per 40 mm DFT coat (261 g/m2)
    • Successive coats may be applied (wet-on-wet)


    Airless spray
    • Dilute by 4 to 5 % with SUSPENSION FLUIDE (test before)
    • Dilution with a pump ratio 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 to stripe coat corners, edges, bolts and screws 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 cover the surface ideally.
    • For spray gun application:
      • we recommend to remove all filters from the spray gun to prevent blockage;
      • 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 SUSPENSION FLUIDE.

     

  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 of film)

     

  4. Second coat:
    • You can apply a 2nd coat of RUST-ANODE® 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;
    • Compatible paint (sealer and/or top coat) should be applied within 24 hours (recommended) depending on ventilation, temperature and humidity levels or prior testing.
    • Each new coat of RUST-ANODE® rewets the previous one and forms a single uniform coat. Because of the Cathodic protection the structures protected with RUST-ANODE® can be restored after their zinc layer has been destroyed.

     

    NOTE
    RUST-ANODE® is not designed to be applied excessively thick, do not exceed 400 μm (16.0 mil) DFT.

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

    RUST-ANODE® can be used as a single coat as well as a base coat (primer) with a compatible top/decorative coat paint (duplex system).
    > Single system (active protection):
    RUST-ANODE® 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® coating will gradually lose thickness over time as zinc is sacrificed to provide cathodic protection.
    A new coat of RUST-ANODE® can be applied to a clean surface and, it will re-liquefy and restore the previous RUST-ANODE® coat. The RUST-ANODE® DFT to be applied depends on the residual coat of RUST-ANODE®.
    > Duplex system (passive protection): please refer to the technical department
    When using a duplex system, it is recommended to apply the rust-Anode RUST-ANODE® be applied in a single application, by spraying to obtain a dry film thickness of between 60 and 80 μm, up to a maximum of 100 μm DFT.
    This duplex system significantly increases the estimated product life cycle.
    However, this top coat of paint will prevent the cathodic protection from being restored and/or repairs being applied directly to the existing coat of RUST-ANODE®.

     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:
    • In general, we advise to use RUST-ANODE® without a top coat (as a single system) to restore cathodic protection or directly repair the existing coat of RUST-ANODE®; wash with water to remove salts and zinc chlorites. Existing and new coats will merge to ensure that cathodic protection is restored. This also applies to restored existing galvanizing.
    • We recommend to use a misting technic (minimum of 2.0 mil = 50 microns wet) before applying the total desired thickness.
    • Brushes and equipment should be cleaned with “RUST-ANODE® SUSPENSION FLUIDE” or white spirit.
Estimated usage table

Coverage of the RUST-ANODE®

Theoretical figure:

\[
\text {Number m² / liter} = \frac{\text{Volume % dry extract x 10}}{\text{Dry film thickness in micron (µm)}}
\]\[
\text {Number m² / Kg} = \frac{\text{Volume % extrait sec x 10}}{\text{Dry film thickness in micron (µm)}} \times \frac{1}{\text{density}}
\]

RUST-ANODE®

dry extract 54.8% (in volume)
density 3,15 kg/ dm3

Practical figure

The practical figure depends on several factors, among others : the shape and the roughness of the part, the real thickness, the application method, etc…
The practical efficiency for an application by low pressure gun is often estimated to 75% of the theoretical figure.

Practical figures for the covering and consumption at different thickness

RUST ANODE cold galvanising coverage

The thickness of a the wet fil can be measured by a wet film comb.
The thickness of the dft is to be measured by a thickness gauge.

Test reports
  • Report dated 19/09/2016 by CoRI (Coating Research Institute – Belgium)
    – ES-160909.c Standard ASTM D6450 Flash Point – Falsh point testing
    – ES-170412.a Standard ASTM D5441 – ISO 4624 – Pull off - Pull-off test for adhesion
    – Report MW16AN12– Spectre Infrared spectrum
    – Report DW/06an017 Norme ISO 3251 teneur en matière sèche
  • Report ref 123-P017476-0501-CR-0001-00 de LVM Technisol (Canada)
    – Adhesion test to standard ASTM D3359 – ASTM D3330 showing that RUST-ANODE® and RUST-ANODE PRIMER® products applied to existing hot-dip galvanizing WITHOUT major surface preparation (apart from using water by hand + degreasing) provide excellent adhesion.
    – Report ref 123-P017476-0500-CR-0001-00 de LVM Technisol (Canada) dated July 2008 on 112 samples … comparison of RUST-ANODE® and RUST-ANODE PRIMER® products (3 different degrees of preparation) /HOT-DIP GALVANISING – Salt spray (ASTM B117) – salt spray with scoring – 733 & 1032 hours – bending to assess adhesion and resistance to cracking (ASTM D522) – stamping to assess adhesion and stretching.
  • Rapport PO-4482 by Scrooby’s Laboratory Service (South Africa) showing the zinc “concentration” of RUST-ANODE® and RUST-ANODE PRIMER® products.
  • Metalogic report (Metalogic is a spin-off company of University Leuven) - measurements of the cathodic protection of the RUST-ANODE® product.
  • Numerous additional quality and efficiency certificates available upon request.
Packaging and storage

6-kg and 12-kg containers | 1.5 kg: Upon request only

Storage:

Keep containers completely closed in a dry store, between 5 °C and 20 °C in the original unopened container.
Shelf pot lifetime (unopened container) 2 years minimum.