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Zapping Corrosion

Finishing Today Magazine
by Col. Ron Savin
May 9, 2008

PROBLEM: Conventional zinc-rich coatings based on zinc dust have been limited to maintenance primer applications that require a blasted substrate for effective performance.

SOLUTION: Advanced coatings containing a low-cost, highly conductive zinc flake material can galvanize heavy rust, thereby eliminating the need for costly sandblasting and a conventional coat of zinc-rich primer. Anti-Corrosion CoatingThe coatings also can be used to prevent fouling in marine applications.

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We have developed a method for producing zinc rich, zinc flake primers without the addition of solvent during manufacturing. The quality of corrosion resistance provides outstanding protection to all steel substrates. This development is of considerable importance to the coatings industry for the following reasons.

  1. Production time is reduced by 75%.
  2. All paints shipped dry provide an indefinite shelf and pot life.
  3. The volume of material shipped is reduced by approximately two thirds, which is a considerable saving on freight.
  4. An appropriate solvent blend need only be added during application.
  5. There are numerous advantages concerning safety, reduced solvent utilization and a considerable reduction in the cost per gallon.
  6. An important application of Hyperzinc® is the tenacious adhesion to virtually all substrates including cold rolled steel, galvanized, rust, baked enamels, powdered metals, most plastics etc. This quality of adhesion is an effective method of reducing or eliminating costly sandblasting at tens of thousands of body shops and is an excellent primer over bed liners, railroad rolling stock, sea containers, and many other substrates where sandblasting is the conventional method of surface preparation,
  7. It is easily sanded for any top coat.





Hyperzinc® is made with zinc flakes instead of zinc dust. Unlike zinc dust, zinc flakes inter-lock to create a durable, laminar coating.

Hyperzinc® doesn’t just inhibit rust – it completely galvanizes it.
  • Lightweight
  • Extremely durable
  • More surface area
  • Eliminates most sandblasting
  • Safe for the Environment
  • Can be easily sanded


Zinc flakes provide 400% more surface area to make contact with rust than traditional round zinc powder. Zinc powder is an average of 80 microns in diameter, while zinc dust is an average of 4 to 6 microns around.
  • Corrosion protection of Zinc with the aesthetic qualities of a bright attractive platelet.
  • Appropriate for applications that currently use the less effective zinc dust.
  • Lighter weight by volume than powder.
  • Versatility that includes organic and inorganic binders, improved welding properties, superior cathodic qualities, and soft sedimentation.
 
Areas of Application

Hyperzinc® coating is superior to conventional industrial coatings for use on:

  • Rust Corrosion ProtectionRailroad rolling stock
  • Dams & Bridges
  • Storage Tanks
  • Shops and Port Facilities
  • Guardrails
  • Transmission Towers
  • Trucks, Automotive Parts, Chassis, etc.
  • Light Poles
  • Gutters and Down Spouts
  • Air Conditioning Equipment
  • Wire Fencing, etc.
  • Ducting
  • Passivation of Rust
  • Pipe, Plumbing and Tubing
  • Fasteners and Powdered Metal Products
  • Steel Reinforced Bars
  • Off Shore Drilling Platforms
  • Construction Equipment
  • Cathodic Electrostatic Zinc Flake Powder for numerous applications
 
 
 
 
Tech Specs
In addition to the data provided below, a technology update is now available.
Typical Physical Properties of Hyperzinc® Flake
  • Average Flake Size: 25 - 35 microns
  • Average Flake Thickness: 1 micron