ZR PREP.
Phosphate System.
ZR Prep is a biodegradable surface conditioner for rusty steel or freshly prepared steel that has been dipped, stripped or sand blasted. It is a combination of complex phosphate salts, esters and wetting agents.
Product Uses
1. Rusted Surfaces: ZR Prep will soften and help remove loose rust particles, while solidifying the tight rust left behind. ZR Prep also phosphates the surface and adjusts its pH to 6, both of which are ideal conditions for paint adhesion.
2. Freshly Prepared Steel: ZR Prep adjusts the pH and phosphates the surface, thus forestalling flash rust. So if you have a project that has been dipped, stripped or sandblasted and you can't get it painted for a period of time, ZR Prep powder that has been dissolved in water, sprayed on, and allowed to dry will give you a holding period before coating.
3. General Cleaning: ZR Prep will help you remove dirt, grime, greases, oils, and silicone from steel surfaces. It is not harmful to sound painted surfaces.
Mix two ounces (2 heaped tablespoons) of ZR Prep per gallon of water, stirring until all crystals have dissolved. Apply with spray bottle or pump up tank sprayer.
On raw non-rusted steel, simply allow the solution to dry. On rusted steel, allow full soaking of the rust. Work the entire surface with a wire brush to loosen rust and then allow the surface to dry. Pressure wash to remove all residues, then reapply ZR Prep solution and allow the surface to dry thoroughly before painting.
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ZR is a phenolic modified alkyd coating that controls rust and corrosion by putting down an impermeable barrier at the steel level.
ZR has two superior traits:
A - It provides maximum adhesion to steel. This is called chemical affinity.
B - 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).
Performance
ZR is an air dried coating and has exceeded 2400 hours at 4.0 mils dft. (dry film thickness) in the ASTM-Bll7 salt spray tests.
The effectiveness of ZR on bare steel surfaces is optimized at 3.0 to 4.0 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™.
Temperature
Zero Rust can withstand intermittent temperatures of 250-300 degrees before the resin starts baking out. Heat resistance will vary by color.
Benefits of Using Zero Rust
Surface tolerant -- ZR 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. ZR will truly protect, isolate, and insulate the steel.
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Crystal Coat
Crystal Coat is a single package, high solids, high gloss, clear acrylic top coat for use over ZR Paint. 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 de-chalked or to provide oxidation protection for non-ferrous metals, i.e., brass, bronze, aluminum. Two coats are recommended for enhanced gloss and UV protection.
Description.
Crystal Coat is a high solids, clear acrylic blend lacquer for use as a high-gloss color stabilizer over ZR. It has been specifically formulated for optimum ultraviolet screening and superior gloss retention with exceptional film clarity. Cured films have excellent resistance to mineral acids and alkaline materials.
Testing experience has shown that 1.5 mils dry film thickness of Crystal Coat over ZR exhibits gloss and color retention far superior to air dry enamels. Exceptionally quick dry rates allow multi coat applications with as little as 15 minutes between coats. The finish has excellent flexibility and resistance to surface marring.
Uses.
Specifically designed as color stabilizing gloss surface coating for ZR when a gloss finish is required. Secondary uses may include resurfacing and brightening of properly de-chalked but otherwise sound aged finishes. A light sanding or buffing may be required for proper adhesion, providing the surface is lift resistant to Crystal Coat. Other uses may include oxidation protection for non-ferrous metals, i.e., brass, bronze, aluminum, copper and chrome.
Applications.
Conventional spray application may be accomplished with siphon, pot, and airless, electrostatic or high volume, low pressure equipment. Thinning with xylene, toluene, aromatic 100 or lacquer thinner @ 10% to 25% may be necessary for some equipment. Viscosity, as supplied, is adequate for airless and pressure pot sprayers. Tip sizes in the range of .010 to .014 help reduce over application to protect from runs.
Application over Zero Rust.
Apply ZR as directed. For optimum protection, a 1.5 mil dry film of Crystal Coat should be applied over ZR. Apply Crystal Coat when ZR is dry-to-touch-- i.e., when film is dry enough that light pressure with a finger doesn't leave a print. Dry-to-touch time will vary depending on the ZR film thickness and on curing conditions, but is usually between 30 minutes and four hours. Apply Crystal Coat as supplied two coats at three to 4 mils wet, or three light coats at two to 3 mils wet when applying thinned materials. One gallon of Crystal Coat, as supplied, will cover 250 to 275 sq ft at 1.5 mils dry film. A 12-ounce aerosol can covers 9 to 10 sq ft at this same thickness.
Note:
If Zero Rust is allowed to dry too long after the dry-to-touch stage, wrinkling may result. If this occurs, ZR needs to cure 6 to 7 days before application of Crystal Coat.
At that time a very light burnishing of the Zero Rust is recommended for maximum adhesion.
