ZINCFIX®
ZincFlake Zinc-Alu Air Dry
ZINCFIX® ZincFlake Zinc-Alu Air Dry is a one-component, organic-bound zinc-rich cathodic protection primer containing more than 50% lamellar zinc and aluminium particles in the dry film. Applied directly to properly prepared steel and hot-dip galvanized surfaces, it forms a strongly adherent anti-corrosive coating designed for long-term protection.
Its plate-like zinc flakes provide both active cathodic protection and an additional passive barrier against corrosion. The larger surface area of the lamellar particles allows effective protection at lower film thicknesses than conventional spherical zinc coatings, while providing low porosity, excellent adhesion, flexibility and weather resistance.
Performance Characteristics
- Dual corrosion protection
Combines active cathodic protection with passive barrier protection. - Lamellar zinc and aluminium technology
Contains more than 50% zinc and aluminium flakes in the dry film. - Enhanced barrier effect
The plate-like particles create an overlapping protective structure that reduces penetration of corrosive elements. - Efficient at lower film thicknesses
The larger surface area of the flakes allows lower film builds to provide corrosion protection comparable with thicker conventional zinc coatings. - One-component convenience
No separate hardener or activator is required. - Excellent corrosion protection
Designed for long-term protection of steel and galvanized substrates. - Excellent adhesion
Adheres strongly to correctly prepared steel and galvanizing. - Excellent intercoat adhesion
Provides a suitable foundation for compatible protective coating systems. - Low porosity and permeability
Helps restrict moisture and contaminant penetration. - Hydrophobic and weather resistant
Provides additional resistance to moisture and atmospheric exposure. - Excellent flexibility
Helps the coating accommodate normal substrate movement. - Metallic appearance
Produces a brilliant zinc metallic finish. - Versatile topcoat compatibility
Can be overcoated with acrylic, epoxy, polyurethane and vinyl coatings. - Chemical and solvent resistance
Resistant to many mild chemicals and solvents, including petrol and brake fluids. - High-temperature resistance
Withstands dry continuous temperatures up to 150°C. - Suitable for inorganic zinc repairs
Can be used as a touch-up primer over inorganic primers. - Suitable for appropriately prepared rusty surfaces
Extends its usefulness in maintenance applications. - Spot weldable
Suitable for selected fabrication processes. - Aerosol option available
AEROCOAT® Zinc Flake provides convenient application for smaller repairs and touch-ups.
Intended Uses
ZINCFIX® ZincFlake Zinc-Alu Air Dry is intended for the long-term corrosion protection of clean steel and hot-dip galvanized surfaces, where a combination of cathodic and barrier protection is required.
Its corrosion protection works through two complementary mechanisms:
Cathodic Protection – Direct contact between the zinc particles and the steel substrate allows the zinc to provide active galvanic protection.
Barrier Protection – The plate-like zinc flakes overlap within the coating film, creating a more difficult pathway for moisture and corrosive contaminants to penetrate towards the substrate.
Because lamellar flakes have a larger surface area than conventional spherical zinc dust, the coating can use a lower zinc concentration and lower film thickness while still providing effective corrosion protection. The datasheet states that a lower film thickness can provide equivalent protection to thicker conventional zinc coatings.
The product is suitable for:
- New steel protection
- Hot-dip galvanized steel
- Galvanizing repairs
- Corrosion maintenance
- Inorganic zinc primer touch-ups
- Appropriately prepared rusty steel
- Steel subsequently receiving compatible topcoats
Typical Applications:
- Mild steel
- Hot-dip galvanized steel
- Galvanized steel repairs
- Structural steel
- Steel fabrication
- Welded galvanized components
- Site-cut galvanized steel
- Inorganic zinc primer repairs
- Steel maintenance
- Industrial machinery
- Industrial equipment
- Steel frames and structures
- Pipes and fittings
- Brackets and supports
- Handrails and balustrades
- Fencing and gates
- Utility structures
- Construction steelwork
- Infrastructure steelwork
- Workshop fabrication
- Field maintenance
- Localized corrosion repairs
- Components requiring compatible topcoat systems
- High-temperature steel applications within the specified temperature limit
For smaller localized repairs and difficult-to-access areas, the product is also available in aerosol form as AEROCOAT® Zinc Flake.
Technical Information:
- Product Type: Zinc-rich cathodic protection primer
- Technology: One-component, organic-bound lamellar zinc and aluminium coating
- Zinc / Aluminium Content: More than 50% lamellar zinc and aluminium particles in the dry film
- Protection Mechanism: Cathodic / galvanic protection combined with passive barrier protection
- Colour: Zinc, brilliant
- Finish: Smooth
- Density: Approximately 1.1 kg/L
- Volume Solids: 50%
- Typical Dry Film Thickness: 50 µm DFT
- Theoretical Coverage: Approximately 10 m²/L at 50 µm DFT, before allowance for loss factors
- Application Methods: Brush, spray or aerosol
- Number of Coats – Brush / Spray: 1 coat
- Number of Coats – Aerosol: 1–2 coats to achieve the specified DFT
- Dry Continuous Temperature Resistance: 150°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 before application
- Overcoating After 24 Hours: Light abrasion with sandpaper required
- Pot Life: No limitation
- Brush Application: Recommended
- Thinner for Brush Application: Not required
- Thinner for Spray Application: Up to 25% Solvent XL
- Cleaner: SA65 Thinner for dry paint and equipment
- Minimum Surface Temperature: 5°C or 3°C above dew point
- Maximum Surface Temperature: 40°C
- Minimum Ambient Temperature: 10°C
- Maximum Ambient Temperature: 45°C
- Maximum Relative Humidity: 85%
- Tin Pack Sizes: 1 L and 5 L
- Aerosol Pack Size: 400 ml
- Shelf Life: 12 months at 25°C from date of manufacture, subject to inspection thereafter
- 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.
