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ZERO RUST

Zero Rust

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SKU:
AR-05
MPN:
AR-05
Condition:
New
Availability:
Usually Ships Same Day
Weight:
1.00 LBS
Width:
2.50 (in)
Height:
8.00 (in)
Depth:
2.50 (in)
  • Zero Rust
  • White Zero Rust
  • Red Oxide
  • Gray
  • Black
Frequently bought together:

Description

ZERO RUST® PRIMER
Direct-To-Metal Rust Control with Tremendous Adhesion

Zero Rust® is a phenolic-modified alkyd coating designed to form a tight barrier that keeps oxygen and water away from steel. When oxygen and water can’t reach the substrate, corrosion can’t feed. Add the missing ingredient most “metal primers” don’t have: Outstanding adhesion.

DTM (Direct-To-Metal)
Barrier vs. Oxygen/Water
Single-Pack Air Dry
High Solids / Low VOC
Isocyanate Free
 
 
 

The Big Advantage: Adhesion That Bites into Metal

In the refinishing world, the failure doesn’t start on the surface, it starts underneath. When a chip, scratch, or worn edge exposes steel, corrosion creeps laterally under weak films. Zero Rust® is built to bond hard and create a tight shell that helps starve corrosion of what it needs to grow.

Refinisher takeaway: If a chip repair exposes metal, you want a primer that locks down steel — not just “covers” it.

Performance Highlights

  • Direct-to-metal corrosion control (DTM barrier)
  • Outstanding adhesion to steel and rusted steel
  • Designed to block oxygen and moisture
  • Single-package air dry workflow
  • High solids film build
  • Topcoat recommended for UV / color / gloss retention outdoors
Target film build (max protection on bare steel):
3.0 – 3.5 mils DFT over profile (commonly achieved with two coats at proper WFT).

2000+ Hours Salt Spray — What That Means

Zero Rust® is commonly cited at ~2,000 hours in ASTM B117 salt spray at about 3.5 mils dry film. Salt spray testing is an accelerated corrosion chamber — it’s harsh and continuous. This level of performance indicates a strong protective film and adhesion under extreme corrosion stress.

Important:  Zero Rust® Is recommended for submersion ONLY when Top-coated and cured. 
Where Tub/Tile/Countertop Refinishers Use Zero Rust®
Because exposed steel and cast iron is where failures start.

In real service work, you don’t just refinish “surfaces” — you run into damaged edges, chips, drains, Overflows, brackets, rails, steel tub chips, Cast Iron Tub and Sink Rust, Especially Cast-Iron Over-Flows on Sinks and metal fixtures. Zero Rust® is for stabilizing metal, so your system has a strong foundation.

Best Use Cases (Refinishing)
  • Steel tubs where chips expose bare metal
  • Rusted Cast Iron Tubs - Great for Clawfoot Tub Feet
  • Rust-spot stabilization before refinishing systems
  • Metal trim / brackets / rails in service areas
  • Repairs where sandblasting is not practical
What Makes It Different
  • Designed for new steel, rusty, and partially rusted surfaces
  • Works best on solid, cleaned, decontaminated substrates
  • Creates a tight barrier that helps stop corrosion from moving sideways

Zero Rust® Application Guide (Refinisher-Friendly)

1) Surface Preparation
  • Clean thoroughly: remove dirt, oil, grease, silicone, and contaminants.
  • Remove loose rust/scale (solid foundation only).
  • New steel: remove any mill scale — it can be the weak link.
  • Polished/smooth metal: abrade (e.g., 220–320 grit) to promote adhesion.
  • Partially painted surfaces: total paint removal is preferred; otherwise remove all loose paint and feather edges.
  • Galvanized Metal: Etch with Scumbuster or Safet-Etch
2) Thinning & Equipment
  • Airless: typically, no thinning — can spray from the can.
  • Siphon/Gravity guns: product is heavy-bodied; reduce ~10–20% by volume as needed.
  • VOC-exempt solvents: acetone, methyl acetate, and PCBTF are commonly used for thinning/cleanup.
  • Brush/Roller: thin to suit for workable flow.
Pro tip: Spray in thin coats, air dry between coats with Turbine Air or blow dryer for maximum speed. Your wet film thickness must increase to achieve the same dry film.
3) Film Build & Two-Coat Method
  • Target DFT: 3.0 – 3.5 mils dry on bare steel (max protection).
  • Typical build: 2 coats using a crisscross pattern to reduce pinholes and improve uniformity.
  • Wet film example: apply ~3.5 mils wet per coat (commonly ~1.5 mils dry per coat), totaling ~3.0–3.5 mils DFT.
  • Use a wet film gauge to verify you’re not under/over applying.
Don’t over-apply excess film dramatically extends dry times and wastes material with no added corrosion benefit.
4) Flash, Recoat & Drying
  • Apply when surface temp is roughly 50° – 95°F.
  • Coat 1: allow adequate flash before Coat 2.
  • Typical recoat window: set-to-touch and ready in about 20–30 minutes (varies by conditions).
  • At ~70°F / 50% RH: often dry to touch ~30 min, tack free ~1 hour when properly applied.
Dry time depends on film thickness, reduction, air movement, humidity, and temperature. The #1 cause of slow dry is over-application.

Topcoats & Compatibility (Read This)

  • Zero Rust® may chalk and colors may fade in exterior exposure (does not necessarily reduce corrosion resistance).
  • If gloss and long-term color retention are important, use a durable topcoat.
  • Topcoats are often applied when the second coat is set-to-touch or re-coat after 24 hours (when applied at recommended film build).
  • If top-coating after 24+ hours, scuff sanding is recommended. 
  • Solvent sensitivity note: some strong-solvent topcoats can lift/wrinkle Zero Rust® (risk decreases as it cures). Always test topcoat suitability.

  • Pro-Tip Prevent wrinkling & Solvent Attack or Reactions:

  • When applying your topcoat over Zero Rust or any existing coatings spray light mist coats
  • Let each coat air-flash
  • Force dry by turbine air or a blow dryer to gently drive off solvents between passes
  • Then build coverage gradually
  • This locks the primer in place and prevents solvent lift.
  • It's the hot solvents in your topcoat or reducer applied wet and heavy that saturate and cause wrinkling.
  • Zero Rust® is not recommended for galvanized steel unless etched.
  • Service temperature: can tolerate intermittent heat (often cited in the ~250–300°F range) before breakdown; heat resistance varies by color (black commonly strongest).

Cleanup & Waste Disposal

Clean equipment with VOC-exempt solvents (commonly acetone or similar). Dispose of waste/residue according to local, state, and federal regulations.

Coverage

Typical coverage is often stated around ~250–300 sq ft per gallon at ~3.0 mils DFT (varies by version and transfer efficiency). Aerosols are often cited around ~10 sq ft per can.

Build Your Rust Repair Kit with the Below Products
Suggested Companion Products (Refinishing Workflow)
These are the “next step” items customers ask for when fixing chips, edges, and blend repairs.
SharkThane QD 4 Hour Dry (Quick Dry Aerosol)
SharkThane Quick Dry Aerosol

Great for fast service work when you need a quick topcoat solution in a can. Ideal for small repairs and touch-ups. Most Standard Color including Clear Coat. Custom Colors available upon request. 

Melt Down Urethane Repair Blender
Melt Down Urethane Repair Blender

Avoid Dry Edges on Repairs. The product that helps you BURN THAT HALO and soften dry edges on spot repairs cleaner blends, less “hard edge” drama. No Return Trips for Buffing and Polishing. 

Bull Shark Adhesion Promoter (Aerosol)
Bull Shark Adhesion Promoter

For composites & plastics: fiberglass, ABS/plastic, cultured marble, Formica, and other “problem surfaces.” Use Bull Shark when the substrate is not porcelain/ceramic.

Power Bond (Bonding Agent / Wipe-On Primer)
Power Bond Wipe On Primer

For porcelain & ceramic (think tubs, tile, and certain hard surfaces). Commonly discussed as a “bonding agent” in our market — built for serious adhesion where typical primers fail.

Quick selection rule: Steel/rust = Zero Rust® • Composites/plastics = Bull Shark • Porcelain/ceramic = Power Bond • Blend repairs = Melt Down (to BURN THAT HALO) • Fast topcoat touch-ups = SharkThane QD

Adhesion First. Rust Stopped at the Steel Level.

For chip repair, exposed metal, and rust-spot stabilization, Zero Rust® Primer is built to do what most coatings don’t: bond aggressively, form a tight barrier, and help keep corrosion from moving under your work.

Always follow the official Product Data Sheet / Application Guide for full preparation, film build, and topcoat compatibility details.

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