ZINCFIX®
ZincDust 90
ZINCFIX® ZincDust 90 is a one-component, organic-bound zinc-rich cathodic protection coating containing 96% zinc in the dry film. Applied directly to properly prepared steel and hot-dip galvanized surfaces, it forms a strongly adherent cold galvanic coating designed to provide long-term corrosion protection.
The coating combines cathodic, galvanic and sacrificial protection with passive barrier protection, offering protective characteristics comparable with hot-dip galvanizing in a liquid-applied system. It is particularly suited to repairing damaged galvanizing, protecting exposed steel, use as a weldable shop primer and protecting reinforcing steel in concrete.
Performance Characteristics
- 96% zinc in the dry film
Provides an exceptionally high concentration of zinc for active corrosion protection. - Cathodic protection
The zinc becomes the anode while the steel substrate acts as the cathode, allowing the zinc coating to sacrifice itself preferentially to protect the steel. - Galvanic protection
Direct contact between the zinc-rich coating and steel enables electrochemical corrosion protection. - Sacrificial protection
Zinc corrodes preferentially before the underlying steel. - Barrier protection
Formation of a zinc oxide layer provides an additional passive barrier against corrosion. - Comparable characteristics to hot-dip galvanizing
Provides cold-applied corrosion protection without requiring immersion in molten zinc. - Excellent corrosion resistance
The datasheet states corrosion performance equivalent to hot-dip galvanizing. - Ideal for galvanizing repairs
Restores protection where galvanized steel has been cut, drilled, welded or mechanically damaged. - One-component formulation
No separate hardener or activator is required. - Unlimited pot life
Material remains usable when correctly stored and maintained. - Infinitely overcoatable
Additional coats chemically bond with the underlying coating to form a homogeneous film and renew cathodic protection. - Weldable
Can be used as a weldable shop primer at reduced film thickness. - Excellent adhesion
Adheres well to correctly abraded steel and galvanized surfaces. - Versatile topcoat compatibility
Can be overcoated with acrylic, epoxy, polyurethane and vinyl coatings. - High-temperature resistance
Withstands 150°C dry continuous and 200°C intermittent exposure. - Touch-up capability
Suitable for repairing inorganic zinc primers. - Aerosol option
Available as AEROCOAT® ZINC 90 for localized repairs. - Recognised zinc pigment specification
Zinc dust pigment conforms to ISO 3549 and ASTM D520. - SSPC compliance
Conforms to SSPC-Paint 20 Type 2 Level 1.
Intended Uses
ZINCFIX® ZincDust 90 is designed for long-term corrosion protection of steel and hot-dip galvanized surfaces, particularly where the protective zinc layer has been damaged or where a cold-applied alternative to conventional galvanizing is required.
Hot-dip galvanizing protects steel through both a physical barrier and sacrificial zinc protection. When galvanized steel is cut, welded, drilled or mechanically damaged, the underlying steel may become exposed. The surrounding zinc then begins sacrificing itself to protect that exposed area, potentially consuming the adjacent galvanized coating prematurely.
Applying ZINCFIX® ZincDust 90 to the prepared damaged area restores a zinc-rich protective layer and helps prevent this localized loss of corrosion protection.
The product also has two notable specialist applications identified in the datasheet. At 30–40 µm DFT, it can be used as a weldable shop primer, while application to reinforcing steel in concrete can help protect rebar against corrosion and subsequent concrete spalling.
Typical Applications:
- Hot-dip galvanized steel repair
- Mild steel
- Structural steel
- Welded galvanized components
- Site-cut galvanized steel
- Drill holes in galvanized steel
- Mechanically damaged galvanizing
- Steel fabrication
- Weldable shop priming
- Reinforcing steel / rebar
- Inorganic zinc primer touch-ups
- Structural steel connections
- Galvanized frames
- Handrails and balustrades
- Fencing and gates
- Galvanized pipes and fittings
- Steel brackets and supports
- Transmission structures
- Utility infrastructure
- Industrial equipment
- Machinery
- Construction steelwork
- Coastal steel structures
- Industrial structures
- Maintenance and refurbishment
- Workshop repairs
- Field-applied galvanizing repairs
The product can be used either as a stand-alone protective system, as part of a duplex coating system, or specifically for repairing damaged galvanizing, with system film thickness determined by the corrosivity category and required durability.
Technical Information:
- Product Type: Zinc-rich organic-bound cathodic protection coating
- Technology: One-component zinc-rich coating
- Zinc Content: 96% zinc in the dry film
- Colour: Medium grey metallic – darkens after prolonged exposure
- Finish: Smooth
- Gloss Level: Matt
- Density: Approximately 2.50 kg/L
- Mass Solids: 83%
- Volume Solids: 66%
- Theoretical Coverage at 60 µm DFT: 11 m²/L or 4.4 m²/kg, before loss factors
- Theoretical Coverage at 90 µm DFT: 7.33 m²/L or 2.93 m²/kg, before loss factors
- Application Methods: Brush, spray or aerosol
- Number of Coats: Dependent on coating system and application method
- Flash Point: 25°C
- Dry Continuous Temperature Resistance: 150°C
- Intermittent Temperature Resistance: 200°C
- Touch Dry at 25°C: 20 minutes
- Hard Dry at 25°C: 4 hours
- Full Cure at 25°C: 24 hours
- Minimum Self-Overcoating at 25°C: 4 hours without abrasion
- Other Topcoats: Allow 24 hours
- After 24 Hours: Light abrasion with sandpaper required before overcoating
- Pot Life: Unlimited
- Air Spray: Solvent XL; 1.8–2.5 mm needle size
- Airless Spray: Solvent XL; 15–23 thou tip
- Minimum Airless Pressure: 180 bar
- Thinner: Solvent XL
- Minimum Surface Temperature: 5°C or 3°C above dew point
- Maximum Surface Temperature: 40°C
- Minimum Ambient Temperature: 7°C
- Maximum Ambient Temperature: 45°C
- Maximum Relative Humidity: 95%
- Pack Sizes: 1 kg, 2 kg, 10 kg and 30 kg
- Aerosol Pack Size: 400 ml
- Shelf Life: Unlimited at 25°C when stored and maintained according to the datasheet
- Storage Temperature: 5–35°C
Active/Cathodic/Galvanic Protection
When two different metals come into contact with each other in the presence of an electrolye (e.g water), they form a galvanic cell in which the lesser noble metal (e.g zinc) corrodes in favour of the more noble metal (e.g steel).
This electrochemical reaction is the base for the complex field that is cathodic protection. Galvanic, cathodic, or active protection arises from zinc (the anode) sacrificing itself in favour of the base metal – steel (the cathode) with the resulting flow of electrons preventing steel corrosion. In this way the protection of the metal is guaranteed, even when the zinc layer is slightly damaged.
Passive/Barrier Protection
Barrier protection is the most widely used method of corrosion protection and barrier protection properties act by isolating the base metal from the environment and are highly effective in keeping moisture and corrosive agents from reaching the surface. A coating with only barrier protection properties will protect the surface as long as the coating is in tact. In order for the coating to protect as effectively as possible it should have very good adhesion and mechanical resistant properties.
With ZINCFIX® cold galvanizing systems, there are 2 ways in which the barrier/passive protection occurs; the first is from the binder that adds additional protection to the zinc and is effective in creating a barrier to moisture & the second is the layer of zinc oxide protecting the steel surface & any surface exposed from mechanical damage thus preventing any rust creep under the paint film.
Inhibition/Sacrificial Protection
Inhibition/sacrificial corrosion protection is the process of zinc oxidising to form a moisture impervious layer of zinc oxide / zinc salts. As zinc is exposed to the elements, the zinc layers corrode and wear away, as it wears away more zinc oxide layers take formation (sacrificial). Zinc is naturally porous and when the zinc oxide layers form, the porosity of the zinc is filled with zinc oxides / zinc salts.
This process of filling the porosity dramatically reduces the rate at which the layer sacrifices itself. In addition to the formation of zinc oxide layers; ZINCFIX® coatings contain high performance binders which add additional protection to the zinc particles within the zinc oxide / zinc salts layer. These high performance binders act as corrosion inhibitors to the zinc. This inhibition/sacrificial protection system essentially blocks/inhibits the corrosive agents from reaching the steel.
Colours & Finishes
Please Note: Colour swatches and illustrations displayed are only to be used as a guide and can vary from the original.
