SURFACE PREPARATION WITHOUT PREP STEP
Ideally, for best performance, metal surfaces should be prepared using Prep
Step. If this is not possible, surfaces must be thoroughly cleaned of any dirt,
oil, grease, silicone or any other contaminants. As with any paint product,
a straight line relationship exists between surface preparation and product
(1) New Steel (mill scale) – It is recommended that mill scale be removed
prior to coating with Zero Rust. If left intact, any mill scale will become
the weak link in the system; where the Zero Rust film may become broken, rust
will move sideways between the mill scale and the substrate.
(2) Rusty Surfaces – When working down rusty surfaces,
proceed with two goals in mind:
(a) Remove loose scale and powdery rust and minimize pits. Minimizing air
entrapment in the substrate is key. Leave no oxygen behind in the substrate
to continue the rusting process.
(b) The smoother the surface and the tighter the resultant rust, the less
product will be needed to span the highs and lows to achieve the 3.0 to 3.5
(3) 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 system. The cleaner, tougher and
tighter the old paint can be prepared, the better the resultant job. Pay particular
attention to paint edges that lift and curl. For best results, use a rotary
sander to feather out exposed steel to adhering paint edges.
(4) Aluminum – For corrosion protection on aluminum, follow industry
preparation standards for cleaning, etching, etc. CAUTION: If aluminum is cleaned
with Prep Step, hydrogen gas may be produced. Take proper ventilation and flammability
(5) Aged, Rough Galvanized Steel – Zero Rust will bond to galvanized
steel with the addition of one tablespoon of dry Portland cement per gallon
Zero Rust. Half a tablespoon of high calcium hydrated lime may be used in lieu
of the Portland cement. Mix thoroughly. Follow general instructions for cleaning.
(6) New galvanized steel – For new galvanized steel, use a vinyl wash
primer before applying Zero Rust. The dry mil thickness of the primer should
not exceed ½ mil.