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AEROCOAT ZINCFIX® ZincFlake
Cold galvanizing & galvanized steel repair


ZINCFIX Galvanized Steel Repair
Metal Corrosion Protection Aerosol image

AEROCOAT ZINCFIX® ZincFlake is a one component zinc rich cathodic protection primer that contains more than 50% lameller zinc & aluminium particles 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® ZincFlake is used as a protective coating on steel & for repairs on galvanized steel. Without a topcoat AEROCOAT ZINCFIX® ZincFlake 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. Due to the plate like structure, flakes have a larger surface area than spherical zinc dust; this means a lower film thickness can be applied and will give equivalent protection to thicker applied conventional coatings.

What Can AEROCOAT ZINCFIX® ZincFlake Be Used For?


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

Protective Coating For Steel
AEROCOAT ZINCFIX® ZincFlake 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® ZincFlake.

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

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

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

Examples of AEROCOAT ZINCFIX® ZincFlake Systems


System 1

ZincFix ZincFlake System 1 Diagram

System 2

ZincDek ZincFlake 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 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; 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.
  • Excellent flexibility and metallic appearance.
  • AEROCOAT ZINCFIX® ZincFlake can be over-coated by a range of topcoats such as acrylics, epoxies, polyurethanes & vinyls.
  • High temperature resistance of 150°C.
  • Adheres well to abraded steel and galvanizing and has excellent intercoat adhesion.
  • Can be used as a touch-up primer for inorganic primers and can be applied to rusty surfaces.
  • Available in aerosols (AEROCOAT AEROCOAT ZINCFIX® ZincFlake).
  • Excellent corrosion protection.
  • Low porosity and permeability.
  • Resistance to many “mild” chemicals and solvents including petrol and brake fluids.
  • Offers galvanic protection.
  • Hydrophobic, weather resistant and spot weldable.