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AEROCOAT ZINCFIX® 90
Cold galvanizing & galvanized steel repair


ZINCFIX Galvanized Steel Repair
Corrosion Protection Aerosol image

AEROCOAT ZINCFIX® 90 is an organic bound zinc rich coating containing more than 96% zinc in the dry film. It is applied to clean steel and hot dip galvanized surfaces to form an adherent anti-corrosive cold galvanic coating.

AEROCOAT ZINCFIX® 90 is used as a protective coating on steel & for repairs on galvanized steel. Without a topcoat AEROCOAT ZINCFIX® 90 will provide active/cathodic/galvanic protection, passive/barrier protection & inhibition/sacrificial protection comparative to hot dip galvanizing in the form of a cold liquid coating.

What Can AEROCOAT ZINCFIX® 90 Be Used For?


Repair Of Hot Dip Galvanized Steel
AEROCOAT ZINCFIX® 90 works great as a repair system on welds, drill holes and damages on hot dipped galvanized steel.

Protective Coating For Steel
AEROCOAT ZINCFIX® 90 can also be used as a protective coating as it provides galvanic, inhibitor & barrier performance properties that are comparative to hot dip galvanizing.

Re-galvanizing Layer
Hot dip galvanized structures on site that are unable to be re-galvanized can now be re-galvanized using AEROCOAT ZINCFIX® 90.

Weldable Shop Primer
At low film thicknesses of 30 - 40µm, AEROCOAT ZINCFIX® 90 can be used as a weldable shop primer after blast cleaning thus allowing for the application of more AEROCOAT ZINCFIX® 90 or other paints on site without the need for re-blasting.

For Use On Rebar
AEROCOAT ZINCFIX® 90 can be used as a protective film on steel rebar. Thus preventing concrete spalling.

AEROCOAT ZINCFIX Protective Coating for Steel
Re-Galvanizing Layer
Repair of Hot Dip Galvanizing

Examples of AEROCOAT ZINCFIX® 90 Systems


System 1

Aerocoat ZincFix 90 System 1 Diagram

System 2

Aerocoat ZincFix 90 System 2 Diagram

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

Cathodic Protection Diagram

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 AEROCOAT 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.

Passive Protection diagram

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; AEROCOAT 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.

Inhibitor Protection diagram
Galvanic Protection diagram

Performance Characteristics


  • Easy to use, one component product aerosol.
  • Can be overcoated by a range of topcoats such as epoxies, polyurethanes, acrylics & vinyl's.
  • High temperature resistance of 150°C.
  • Zinc dust pigment conforms to ISO 3549 & ASTM – D 520.
  • Adheres well to abraded steel & galvanizing.
  • Can be used as a touch up primer for inorganic primers.
  • Excellent corrosion protection, exhibits corrosion protection equivalent to hot dip galvanizing.
  • Unlimited pot life & unlimited shelf life.
  • Infinitely overcoatable, each new layer of AEROCOAT ZINCFIX® 90 chemically bonds with the underlying layer to form a homogenous film thus providing a rejuvenated layer of active cathodic protection.
  • Conforms to SSPC-Paint 20 Type 2 Level 1.
  • Film hardness improves with exposure.
  • Will never peel or flake (Will not be compressed or squashed & will not crack due to flexibility).
  • Quick drying time.
    1. Touch dry in 10 min (20°C).
    2. Overcoating after 1 hour with AEROCOAT ZINCFIX® 90.
    3. Overcoat with other topcoats 6 – 24 hours.
  • Easily repair mechanical damage due to transports or impact.
  • Galvanized structures can be “re-loaded” using AEROCOAT ZINCFIX® 90.
  • Formulated with a high-performance UV stable binder (Provides additional protection to zinc and better weathering resistance).
  • AEROCOAT ZINCFIX® 90 used specialized atomized zinc (Ultra high purity & very high amount of metallic zinc).