Frequently asked
questions about Core Products
APPLICATION REQUIREMENTS
- Do I need to dilute
the Core Products or use other materials with
your products?
- Do I need to sandblast the
surfaces prior to using the Core Products, and
apply primers and sealers as well?
- What if there is a huge buildup
of rust, do I need to sandblast in this case?
- If a surface has already
been coated or primed before and the original coating doesn't
have good adhesion, will the Core Products loosen
and fall off the original coating?
- What should we do with chloride, old
coatings etc. on surfaces before applying your products?
- When applying your products
on smooth metallic surfaces, do these surfaces need to be
dry prior to application?
- If there is existing red lead-based
paint on steel structures, do we have to remove the lead
prior to using your products?
- Can we use your products on walkways
and areas of high traffic?
APPLICATION METHOD
- How many coats should
I apply to achieve a 3- to 6-mil DFT?
COMPARISON WITH EPOXY
- How are your products
compared with epoxy in terms of price and life expectancy?
- Once your products
are applied on a surface with a 3mil/6mil DFT, how long
will the products last before another application is needed,
say in a saline atmosphere or a chemical environment? Also,
under similar conditions, if epoxy paint is used, what is
its re-coating cycle compared to your products?
- All of your test results are
based on 6-mil DFT, which is as good as a double layer coating,
and also equivalent to a cumulative single layer coating
of primer and a single layer of epoxy. Hence, your product
appears to be more costly than epoxy. Please advice what
difference it is going to make in the case of 3-mil DFT
and 6-mil DFT.
COMPATIBILITY OF CORE PRODUCTS WITH OTHER PRODUCTS
- What's the compatibility
between the Core Products and other coatings?
COMPETITORS
- Who are your closest competitors
and how do you compare your Core Products with
theirs in terms of quality and price?
CONVERSION OF MEASUREMENTS FOR USERS OUTSIDE THE US
- How thick is 6-mil DFT?
DIFFERENCE BETWEEN RUSTCOAT™ AND
RUSTGUARD™
- What's the difference
between Rustcoat™ and Rustguard™, besides the colors? Do
we need to apply Rustguard™ in conjunction with Rustonic™?
HOW OUR PRODUCTS WORK
- How do the Core Products work?
ELEMENTS OF CORE PRODUCTS
- What are the elements
of the Core Products? And what are the causes
of rust formation?
- How do the Core Products work?
LIFESPAN OF CORE PRODUCTS
& SHELF LIFE
- Your brochures mention
that your products provide long-term protection against
rust. Please explain.
- What is the guaranteed life
for Rustonic™ on 3-mil/6-mil layers of coating when it is
applied in ship interiors, ballast tanks, bridges and offshore
structures?
- What is the shelf
life of your products?
OFFSHORE PLATFORMS
- For offshore platforms,
can we apply your products in underwater, splash zones and
above-the-deck areas?
OTHER APPLICATIONS FOR CORE PRODUCTS
- What is the purpose of
applying the Core Products on concrete and wooden
structures?
PIPELINES
- Do we need to plastic-wrap
underground pipelines for protection after applying your
products?
- Which of your products
should we use for sewerage and drainage pipelines?
STEEL REINFORCEMENT BARS
- Can any of your Core Products be used for steel reinforcement
bars and if yes, what would be the lifespan of such an application?
SHIPPING INDUSTRY USAGE
- Can any of your
Core Products be used underwater
and on the exterior of ships?
APPLICATION
REQUIREMENTS
1. Do I need to dilute the Core Products or
use other materials with your products?
A. We designed the products in our Core Products to be
used in its entirety so as to save the end-user time and money.
Therefore, diluting our products or using them with other
materials is not necessary. Our Core Products are
really three in one: they act as a primer, sealer and finishing
coat, all in a one-step application process.
2. Do I need to sandblast
the surfaces prior to using the Core Products,
and apply primers and sealers as well?
A. Our Core Products may
be applied directly to surfaces, even corroded ones, without
the need for sandblasting, priming or sealing. For best results,
just remove any loose surface rust, dirt or oil before coating.
3. What if there is a huge buildup
of rust, do I need to sandblast in this case?
A. No, sandblasting is not necessary. If there is a huge
buildup of heavy-scale or loose rust over a large surface
area, and you wish to obtain a smooth surface after applying
our products, we would recommend cleaning and removing the
rust prior to coating. Note, however, that this is NOT a requirement.
4. If a surface has already
been coated or primed before and the original coating doesn't
have good adhesion, will the Core Products loosen
and fall off the original coating?
A. As long as the primer or the old/original coating is
not loose, our products will bond to it and will not chip
or fall off.
5. What should we do with chloride,
old coatings etc. on surfaces before applying your products?
A. We recommend you water-wash any loose chloride, old
coating, oil, dirt and grease off the surface. As long as
the old coating is still intact, you do not have to remove
it.
6. When applying your
products on smooth metallic surfaces, do these surfaces need
to be dry prior to application?
A. On bare metallic surfaces, our products act as both
rust-preventive agents and water-repellents by removing and
displacing moisture from these surfaces. Note that surfaces
do not have to be dry before applying our products. In high-humidity
conditions where the surfaces are moist, you can apply our
products without drying the surfaces. However,
this does not mean that you can apply our products on surfaces
in rainy conditions where there is water buildup on the surfaces.
7. If there is existing red
lead-based paint on steel structures, do we have to remove
the lead prior to using your products?
A. No, you do not have to remove the lead in this case.
In many countries, companies are still using red lead-based
paint despite its health hazards because of its relatively
economical cost. However, such paints have been found to poison
waterways and rivers, causing cancer and other illnesses.
Our products will bond perfectly to steel structures with
red lead-based paint, and prevent the lead from falling off.
However, for safety's sake, prior to coating, we recommend
gathering any existing loose or broken-off red lead-based
paints from the structures in a net to avoid scattering of
lead pieces in the waterways.
8. Can we use your products on walkways
and areas of high traffic?
A. No, our products are NOT intended for use in areas
to be walked on or where there is any kind of traffic or abrasion
as this may cause damage to the products.
APPLICATION
METHOD
1. How many coats should I apply to achieve a 3 - 6 mil DFT?
A. You can apply one coat to achieve 3 – 6 mil DFT (dry
film thickness).
The recommended method of use is Graco's Xtreme King 244478
or equivalent for Rustonic-Mastic™, Rustcoat-Mastic™,
and Rustguard-Mastic™.
Check recommended nozzle tip size with local Graco representative.
Set pump for 56:1. Hose diameter: ½ inch; hose length:
25 - 50 ft. Contact local Graco representative for any clarifications.
For Rustonic™, Rustcoat™,
and Rustguard™ use Graco's Xtreme Bulldog 244458 or equivalent. Again, check
recommended nozzle tip size with local Graco representative.
Set pump for 33:1. Hose diameter: ½ inch; hose length:
25 - 50 ft. Contact local Graco representative for any clarifications.
Please check with your local Graco distributor for the
necessary airless gun equipment. Or visit their web site at www.graco.com
COMPARISON
WITH EPOXY
1. How are your products compared with epoxy in terms of
price and life expectancy?
A. Epoxy is more expensive because you first need to use
zinc as a primer, then epoxy as a top coat, and finish off
with moisture-cure urethane as a sealer and protective coating.
Again, you will need to sandblast the surfaces before you
apply these products, which would not be necessary if you
are using our products. Our products are really three in one
- they act as a primer, sealer and finishing coat in a one-step
application.
2. Once your products
are applied on a surface with a 3-mil/6-mil DFT, how long
will the products last before another application is needed,
say in a saline atmosphere or a chemical environment? Also,
under similar conditions, if epoxy paint is used, what is
its re-coating cycle compared to your products.
A. Rustonic-Mastic™ is especially designed for use in highly-corrosive environments
like that of a chemical plant. With a recommended application
of 21-mil DFT, it provides superior resistance to caustic
fumes like ammonia, bleach, acid, chlorine and sulfur. It
is difficult to provide exact figures in terms of years for
field applications, re-coating cycle etc. because it depends
on the level of corrosion in the environment. What we can
guarantee is that most of our products have passed 2200 hours per ASTM B117 salt spray tests,
4000 hours per ASTM G154 QUV Weather-O-Meter and 4000 hours per ASTM
G155 Xenon Arc Weather-O-Meter tests.
3. All of your test results are
based on 6-mil DFT, which is as good as a double layer coating,
and also equivalent to a cumulative single layer coating of
primer and a single layer of epoxy. Hence, your product appears
to be more costly than epoxy. Please advice what difference
it is going to make in the case of 3-mil DFT and 6-mil DFT.
A. The thickness (3-mil vs. 6-mil) of the applications
depends on the level of corrosion in the usage environment.
We have listed 3-mil and 6-mil because these are the most
commonly used levels of application thickness in the industry.
You do not have to apply all our products at 6-mil DFT; in
less corrosive environments, go with 3-mil and in more corrosive
environments, use 6-mil DFT. The only exception is Rustonic-Mastic™,
which is designed to be used in chemical plants and should
be applied at 12- or 21-mil DFT, based on the severity of
the corrosive environment.
COMPATIBILITY
OF CORE PRODUCTS WITH OTHER PRODUCTS
1. What's the compatibility between the Core Products
and other coatings?
A. All our products can be sprayed over any other coatings.
However, we do recommend you conduct a pretest on a patch
area before applying our products on the entire surface. This
is standard practice before you use any new coating over the
existing paint or coating. You may also apply other products,
like calcium alkyd-sulfonate paint, enamel, solvent- or water-based
epoxies etc., over our products. Again, we recommend a pretest
on a patch area prior to actual application.
COMPETITORS
1. Who are your closest competitors and how do you compare
your Core Products
with theirs in terms of quality and price?
A. Our products are exceptional because there are no rust-preventive
products in the market which contain asphalt, microcrystalline
wax, aluminum- and metallic-pigmented colors in a single product.
Note
that both lines are based on the same formulation, offer the
same protection against rust, and contain less than 500 grams/liter
of VOC, which are in full compliance with the regulations
stipulated by the EPA and CARB for metallic-pigmented coatings.
The closest to our product is alkyd-sulfonate paint, which
does not even come close in performance. It costs twice as
much as our products, and preparation costs in using alkyd-sulfonate
paint are going to be substantial because of the need for
priming and sealing.
CONVERSION OF MEASUREMENTS FOR USERS OUTSIDE THE US
1. How thick is 6-mil DFT?
A. Please note that the measurements provided in this catalogue are based on the
U.S. system of measurement (mass units). Users outside of the United States may need
to convert the measurements to SI, “Système Internationale” (Metric System), for their
purposes. For example: 6-mil DFT = 152.4 microns DFT.
Useful Conversions
- One mil is one thousandth of an inch.
- One micron is one thousandth of a millimeter.
- One inch is 25.4 millimeters.
Going back to our example, if one mil is 25.4 microns, 6 mil is 152.4 microns.
DIFFERENCE
BETWEEN RUSTCOAT™ AND RUSTGUARD™
1. What's the difference between Rustcoat™ and Rustguard™,
besides the colors? Do we need to apply Rustguard™ in conjunction with Rustonic™?
A. Both Rustcoat™ and Rustguard™ have the same base formulation. The only difference is that Rustguard™ has added surfactants and UV- and corrosion-resistant pigmented
colors. And no, you do not have to use Rustguard™ with Rustonic™.
Just remember to use Rustonic™-Classic on areas not exposed to UV light. Use Rustcoat™ and Rustguard™ separately and in areas exposed to UV light. Use Rustguard™ in interior or exterior areas where colors are required.
HOW OUR PRODUCTS WORK
1. How do the Core Products work?
A. These products penetrate inside the old coating to shield and protect the
rusted surfaces to prevent any water penetration and rust formation. While they do
not change the chemistry of the rust, like Rust-Converto™ they do shield the surfaces from further rust formation and growth.
ELEMENTS
OF CORE PRODUCTS
1. What are the elements of the Core Products?
And what are the causes of rust formation?
A. Our Core Products contains asphalt, microcrystalline wax, marine oil, mineral
spirit, lubricants and other rubberized raw materials. Each Core Product contain less than 500 grams/liter of VOC,
which are in full compliance with the regulations stipulated
by the EPA and CARB for metallic-pigmented coatings. Since
all our products are wax-based and contain lubricants and
corrosion inhibitors, they will seal the surfaces and stop
water and oxygen penetration. Without these two elements,
rust will not form.
2. How do the Core Products work?
A. These products penetrate inside the old coating and
shield to shield and protect the rusted surfaces to prevent
from water penetration, thus preventing further rust formation.
While they do not change the chemistry of the rust like Rust-Converto™,
they do shield the surfaces from further rust formation and
growth.
LIFESPAN
OF CORE PRODUCTS & SHELF LIFE
1. Your brochures mention that your products provide long-term
protection against rust. Please explain.
A. Compared to other coatings, our products provide long-term
protection against rust and corrosion in the sense that you
do not have to keep reapplying our products. Because of its
100% sealing ability, it is able to stop oxygen penetration,
which is one of the causes of rust and corrosion. Once they
are coated on the surfaces, they should last a minimum of
5 - 10 years with the proper care and maintenance of the structures,
and depending on the actual environment.
2. What is the guaranteed
life for Rustonic™ on 3-mil/6-mil layers of coating when it is applied in ship
interiors, ballast tanks, bridges and offshore structures?
A. Based on US standards, we guarantee that most of our products
have passed 2200 hours per ASTM
B117 salt spray tests and 4000 hours per ASTM
G154 QUV Weather-O-Meter and 4000 hours per ASTM
G155 Xenon Arc Weather-O-Meter tests. Please note that it is
difficult to equate or compare the number of hours of salt
spray tests and UV tests with actual years of the application
in the field.
3. What is the shelf
life of your products?
A. The shelf life of our products is about five years,
if left unopened in their cans. Once they are coated on the
surfaces, they should last a minimum of 5 - 10 years, depending
on the actual environment and with the proper care and maintenance
of the structures.
OFFSHORE
PLATFORMS
1. For offshore platforms, can we apply the Core Products in
underwater, splash zones and above-the-deck areas?
A. All our products can be applied on splash zones. For under-the-water
structures and areas exposed to high-levels of corrosion,
we recommend Rustonic-Mastic™.
For any areas above the deck, you may use either Rustcoat™ or Rustguard™.
While our products can be used underwater, note, however,
that they CANNOT BE APPLIED UNDERWATER. If there are any under-the-water
structures which need coating, you should remove them out
of the water (e.g. onto a dry surface) for application.
OTHER
APPLICATIONS FOR CORE PRODUCTS
1. What is the purpose of applying the Core Products on
concrete and wooden structures?
A. In some highly-corrosive environments, like detergent
and chlorine manufacturing plants for example, the fumes actually
"eat away" at the surrounding wooden and concrete
structures. Also, in ocean spray environments, the concrete
structures contain internal steel bars which could corrode,
if left unprotected. This would then weaken the structures
and when this happens, rust would bleed to the outside surfaces
of the concrete. In such cases, our products may be used to
protect these concrete and wooden structures.
PIPELINES
1. Do we need to plastic-wrap underground pipelines for protection
after applying your products?
A. If you are using our products on the external surfaces
of the pipelines and steel structures, you do not need to
use the plastic wrap for coverage. However, if you are using
our products for underground or underwater pipelines, we would
recommend wrapping a layer of heavy-duty plastic over our
products. The reason for this is to avoid abrasion from underwater
or underground conditions. You may use our products in the
internal of these pipelines only if the pipelines are NOT
intended to store or transport drinking water, food items
and any kinds of solvent because the solvents can destroy
our products.
2. Which of your products
should we use for sewerage and drainage pipelines?
A. We would recommend Rustonic-Mastic™ for sewage and drainage pipelines. This is a superior, industrial-strength
product designed for use in extremely corrosive environments
where bleach, soda ash, sulfur, chlorine, acid, and caustic
soda fumes are present. And these fumes typically exist in
a sewerage plant environment.
STEEL
REINFORCEMENT BARS
1. Can any of your Core Products be used
for steel reinforcement bars and if yes, what would be the
lifespan of such an application?
A. Yes, Rustonic™, Rustcoat™ and Rustonic-Mastic™ can be used for reinforcing steel coatings. Since they are
covered with concrete, steel coatings can last a minimum of
10 - 15 years (theoretically) if they are applied with our
products. Again, there is no way to measure the number of
years of protection versus the salt spray tests. We can only
guarantee that all our products have passed 2200 hours of ASTM B117 salt spray tests.
As you know, in any steel structure repairs, 25% of total
repair costs are material costs and 75% is labor and preparation
costs. Using our products would cut down the total costs for
you or your clients tremendously since our products offer
a one-step application system which would save on labor and
preparation costs (e.g. sandblasting, removing poisonous old
lead paint, priming and sealing).
SHIPPING
INDUSTRY USAGE
1. Can any of your Core Products be used
underwater and on the exterior of ships?
A. Our products are not designed for coating the exterior
of ships or any surfaces exposed to high levels of abrasion
like the bottom of a ship's hull. However, Rustonic™ is an excellent product to use in the ballast tanks of ships
and submarines, and is the only product in the world which
can be used with the fill-and-drain system. You may use Rustcoat™, Rustguard™, Rustcoat-Mastic™ and Rustguard-Mastic™ on railings and walls of ship decks NOT exposed to abrasion.
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