Feronite Rusty metal primer is the absolute method of choice when steel or iron must be prevented from further corroding and it is not possible to clean the whole item to a bright (class 2.5) surface and apply a zinc rich coating.  It has been extensively used where sand blasting is not possible or desireable or the effort to acheive a surface suitable for a zinc rich coating is great.  It is completely acceptable (in fact it is desireable) to leave a coating of tightly adherent rust on the surface to be protected, only the loose crumbly, or dusty rust must be removed prior to application. 

Feronite Rusty Metal Primer is frequently applied to objects which are difficult to sand blast such as vehicles, trailers, fences, iron railings, sheet metal, and the outside of storage tanks. It may also be used to restore and preserve iron-based items of historical importance. 

Feronite Rusty Metal Primer works by excluding nearly all oxygen and moisture from the surface being protected. To prevent corrosion being initiated by moisture and oxygen that has penetrated through the barrier, it also contains a good rust inhibitor.  In addition to this, it converts the residual rust on the metal surface to a dense, impermable, tightly adherent ferric tannate layer which further protects the metal and inhibits ongoing rusting. 

The primer component is a vinyl/acrylic copolymer emulsion. This emulsion is an excellent moisture and oxygen barrier, it displays excellent metal adhesion and good adhesion to a wide range of other substrates, has excellent durability, toughness and corrosion resistance.  It is a single pack coating.  It displays remarkably low moisture, oxygen and carbon dioxide permeability.  (It is necessary to use 2 pack epoxies to get lower permeability.) It has flame retardent properties.

Feronite Rusty metal primer incoporates Zinc Phosphate as a rust inhibiting pigment.   It reacts to form zinc ions and phosphate ions.  The phosphate ions phosphate the steel which makes the surface passive.  The zinc ions act as cathodic inhibitors, in a manner not dissimilar to how a zinc rich coating works.

The residual rust of the steel or iron surface is reacted by the tannin polyphenols in the Feronite Rusty Metal Primer to convert them to a chelated form of iron tannate.  This become tightly adherent to the steel and impermeable to moisture thus providing a further measure of protection to the surface.



Instructions

Feronite Rusty Metal Primer
Use Feronite Rusty Metal Primer unless service temperatures will exceed 70ºC.

Planning.

  1. Coverage is 7 to 10 square metres per litre depending on the rust thickness.

  2. Shelf life is approximately 12 months at 20ºC.  Avoid storage above 30ºC.

Preparation

  1. Remove oil or grease with solvent and then detergent and water.

  2. Remove loose or flaky rust and paint by scraper, wire brush or wet sand blast.

  3. Wash surface with clean water and leave damp.

  4. An ideal surface has an overall covering of firmly attached rust.

Application

  1. Mix Feronite Rusty Metal Primer thoroughly by shaking or stiring.  Up to 10% water may be added if thinning is desired.

  2. Only pour out as much Feronite Rusty Metal Primer as needed for the job. Do not return primer to the bottle to avoid contamination with rust particles.

  3. Apply Feronite Rusty Metal Primer onto a dampened surface preferably with a stiff bristle brush to assist penetration.  May also be applied by spray, roller or immersion.

  4. Re wet the surface with a fine light spray of water after 10-20 minutes, especially if the surface is drying quickly or in warm weather.

  5. Surface turns blue black as Feronite Rusty Metal Primer reacts with the surface rust.  Reaction is completed in 3 to 4 hours.

  6. For best results apply a second light coat of Feronite Rusty Metal Primer when the first coat is just touch dry.

  7. If any rust is still visible on a heavily rusted surface, abrade the primed surface, wash down and re-apply Feronite Rusty Metal Primer.

Finishing

  1. Feronite Rusty Metal Primer may be top coated after only 2 to 4 hours drying time.

  2. Feronite Rusty Metal Primer will protect the surface for up to 12 months before painting and it is compatible with all paints.

  3. Apply paint directly to Feronite Rusty Metal Primer.  For best results, two coats of oil based paint are recommended.  Some acrylic paints are unsuitable for steel.

  4. Clean up equipment with water.

Feronite Rust Converter
Best for when service temperatures exceed 70ºC

Planning.

  1. Suitable for hot surfaces to 250ºC.

  2. Coverage is 10 to 15 square metres per litre depending on the rust thickness.

  3. Shelf life is unlimited.

Preparation

  1. Remove oil or grease with solvent and then detergent and water.

  2. Remove loose or flaky rust and paint by scraper, wire brush or wet sand blast.

  3. Wash surface with clean water and leave damp.

  4. An ideal surface has an overall covering of firmly attached rust.

Application

  1. Mix Feronite Rust Converter thoroughly by shaking or stiring.  Up to 10% water may be added if thinning is desired.

  2. Apply Feronite  Rust Converter onto a dampened surface preferably with a stiff bristle brush to assist penetration.  May also be applied by spray, roller or immersion.

  3. Re-wet the surface with a fine light spray of water after 1/2-1 hour, especially if the surface is drying quickly or in warm weather.

  4. Surface turns blue black as Feronite  Rust Converter reacts with the surface rust.  Allow 24 hours for the reaction to be completed.

  5. On heavy rust, if any rust is still visible, wash down and repeat the Feronite Rust Converter treatment.

Finishing

  1. Feronite  Rust Converter will protect the surface for up to 12 weeks before painting.

  2. Remove any residual black dust by wiping with a wet cloth or by hosing.

  3. Allow surface to dry thoroughly.

  4. Apply first paint coat of zinc chromate or zinc phosphate or equivalent metal primer, followed by undercoat and top coat.

  5. Clean up equipment with water.