RUST BULLET INDUSTRIAL FAQs

1. Is Rust Bullet® appropriate for Industrial and Commercial projects?

Yes. Rust Bullet will provide superior protection even under the harsh conditions common in industrial and commercial environments. It protects surfaces with an impenetrable, nonporous, armor-like shield that repairs, defends and maintains surface integrity. Rust Bullet’s Patented Technology is UV resistant, scratch, chip and chemical resistant and provides outstanding protection from abrasives and corrosives that damage and destroy surfaces.
 
Rust Bullet is a one part multiple coat urethane that can be applied with little or no surface preparation, reducing the high cost of product, labor and the containment of waste. Rust Bullet requires little or no maintenance, consequently saving money and minimizing down time. If surface preparation is necessary, Rust Bullet Metal Blast can be used to dissolve rust and properly etch the metal prior to the application of Rust Bullet. Always allow the surface to completely dry before applying Rust Bullet. Although it is not always necessary to blast surfaces prior to a Rust Bullet application, Soda Blasting, Dry Ice Blasting and Hydro-Blasting are three methods of media blasting that are effective, clean and environmentally safe. All media are sound options and clean up will be relatively minor. Surface Prep on industrial and commercial projects may vary dependent upon the condition of the substrate.
 
Rust Bullet Standard Formula (Gold Label) is appropriate for most industrial or commercial type projects. A minimum dry film thickness (dft) of 12 - 15 mils is recommended for most industrial and commercial applications.
 
Rust Bullet is available at quantity discount pricing in Pints, Quarts, Gallons, 5 Gallon Pails and 55 Gallon Drums.

2. What is Dry Film Thickness (dft)?

Dry Film Thickness (dft) is the thickness of a coating when dry, expressed in mils. One mil is equal to one thousandth of an inch. 1 mil = .001 inch (1/1000).

For comparison purposes, 4 mils is approximately the thickness of one sheet of standard paper. Most black plastic trash bags have a thickness of about 1.5 mil although heavy duty bags may be about 3.0 mils.

3. How do I know what the recommended dry film thickness (dft) is for my project?

The higher the mil measurement of Rust Bullet's dry film thickness (dft), the greater the protection provided. Generally industrial or commercial type projects require a minimum dft of 12 - 15 mils; however, many variables should be considered when determining the desired dft for any project. Some of these variables to consider are:

The existing condition of the surface being coated
The surface’s exposure to:

Moisture
Harsh chemicals
Abrasive objects

The damaging effects the surface must endure from environmental conditions and exposures

4. Once I have determined the desired dry film thickness (dft) for my project, how do I ensure the finished project has sufficient mil coverage?

The most accurate way to measure dry film thickness is to use a mil gauge.  Apply an appropriate number of coats to achieve the desired dft for the appropriate protection for your project. Refer to the chart below to determine the theoretical coverage of Rust Bullet Coatings (70% solids by volume). This theoretical coverage does not take into account transfer efficiency which will vary dependent upon application equipment, applicator and atmospheric conditions during application.  The number of coats needed to achieve the appropriate dft will depend on the chosen method of application: brush, roller, HVLP Spray System or Airless Spray System.

mil dft

SF/Gal

6

187.13

7

160.40

8

140.35

9

124.76

10

112.28

11

102.07

12

93.57

13

86.37

14

80.20

15

74.85

16

70.18

17

66.05

18

62.38

5. What are the appropriate Stirring & Mixing methods for Rust Bullet Coatings?

STIRRING and MIXING
 
Do not open and stir a Rust Bullet Coating when the temperature is below the dew point.

Rust Bullet Coatings should be stirred thoroughly for at least 3 minutes or until completely uniform and homogenous (avoid whipping air into product). Shaking the container prior to application may cause the formation of bubbles in the finish of the coating. Never stir the product by mechanical means; this will trap air molecules containing moisture between the coating and the surface causing improper curing and possible coating failure.

Rust Bullet Products that have been sitting for six months or longer may develop settling. Follow the same stirring instructions, but increase the stir time and be sure to incorporate any settled thick product on the bottom of the container.

The exact balance of viscosity, solvent, and active ingredients must be maintained; therefore, Rust Bullet Coatings must only be thinned with Rust Bullet Solvent . Thinning or adding any other product to a Rust Bullet Coating will compromise the performance and quality of the finished product. Use Rust Bullet Solvent at an approximate ratio of 3% - 5% by volume (i.e. 1.0 to 1.5 oz solvent per quart of coating).

7. How does Rust Bullet compare to an Epoxy Primer?

An Epoxy Primer is not an anti-corrosive coating and will not furnish the protection provided by urethanes such as Rust Bullet Coatings. Urethane coatings provide a high degree of chemical and moisture resistance as well as excellent adhesive properties. Additionally Rust Bullet Products have demonstrated a high competition with epoxy coatings due to the ease of application, one-component product and ease of repair, when necessary. A properly applied and cured Rust Bullet Coating will not break like the epoxy and powder coatings. Although Rust Bullet Coatings do not require a catalyst for curing like the Epoxy coatings, using the Rust Bullet Rapid Fire Accelerator will decrease the curing time by up to 80%.

If an epoxy finish is desired, and the existing surface is an epoxy finish, scrape off any loose rust and epoxy coating, rough-up the remaining tight epoxy with 100 grit sandpaper prior to applying Rust Bullet then re-apply the epoxy coating over the final coat of Rust Bullet. Please note: For best results, the surface should be prepared down to bare metal, removing as much of the existing failing coating as possible. Rust Bullet works best when it is in direct contact with rusted or clean metal.

9. Will Rust Bullet protect my Galvanized Metal Roof?

Yes. Rust Bullet is the ideal coating for protecting galvanized metal buildings and roofs. It not only provides protection from rust and corrosion, but will actually make your metal roof stronger and more weather resistant. Following the application guidelines, application of Rust Bullet Coatings to a clean galvanized surface will exhibit no issues with adhesion or compatibility. Rust Bullet applies easily and quickly by brush, roller or an airless spray system. Costly roof and building replacements can be avoided by simply applying Rust Bullet.

10. What is the recommended application method for Galvanized Corrugated Roofs?

The recommended application method for Rust Bullet on Galvanized Corrugated Roof projects is an airless spray system with a 517 to 523 tip at approximately 3000 PSI. Multiple coats should be applied to achieve the recommended dft (dry film thickness); each coat of Rust Bullet will add strength and durability, increasing the life of the roof.

11. Will Rust Bullet protect Concrete?

Yes. Rust Bullet, with its Superior Patented Technology for rust and corrosion control provides outstanding protection to many surfaces, including concrete. The most common polyurethane sealer is a one-component, moisture-cured urethane such as Rust Bullet. Rust Bullet reacts with moisture to form a polyurethane coating that is both aliphatic and aromatic, exhibiting excellent adhesion to the substrate, impact resistance and UV resistance. Rust Bullet not only improves the appearance of concrete, it provides an impervious shield allowing easy clean up of oil, grease, and chemical spills along with strong protection against impact and abrasives. Concrete has been a reliable and versatile product for centuries. Chosen for its strength and durability, concrete is expected to withstand the most abusive conditions. It is subjected to the destructive effects from harsh chemical spills, abrasive objects, moisture, and the impact from heavy tools and machinery often resulting in an unsightly appearance and damage requiring costly repairs or replacement. Dependent upon the condition of the concrete, you may choose to use a non-silicone concrete sealer, seam sealer and crack repair prior to the application of Rust Bullet Coatings to a concrete surface.

Rust Bullet protective coating will:
Provide excellent chemical resistance
Provide protection from abrasives
Seal a surface from moisture
Allow easy clean up of spills
Prevent concrete from sweating
Reduce dust
Fill cracks, gaps, and chips up to 1/4 of an inch
Enhance appearance
Add years of life to concrete surfaces

Power wash or simply rinse off dirt and debris and let the surface dry completely before applying Rust Bullet. Two to three coats of Rust Bullet is usually sufficient for most concrete applications depending on the concrete's condition and existing damage. Porous concrete and heavy traffic areas may require additional coats. Rust Bullet is self leveling and can fill in cracks, gaps and chips up to 1/4 inch. If a slip resistant surface is desired, sprinkle silica or similar fine sand over a tacky coat of Rust Bullet, allow just enough time for the sand to adhere and then apply the final coat of Rust Bullet.

13. Is Rust Bullet recommended for use on a Chain-Link Fence?

Yes. Rust Bullet Standard Formula (Gold Label) will provide superior protection from corrosion and abrasives to chain-link fencing adding years of life to the integrity of the steel.

Chain-Link, known for its strength and durability, is perhaps the most economical type of fencing available. Commercial chain-link fence systems have been preferred for decades to define property lines and enclose government and business facilities, adding protection, security and value to commercial property. Fence manufacturers make products for many different uses including lightweight, temporary needs. The application of Inferior coatings may allow the components to rust prematurely. The result is a permanent installation made from materials that weren't designed for longevity. The protective coating will fail much sooner than loss of steel integrity. Many manufacturers offer warranties that apply only to the loss of structural integrity of the steel, meaning the product has rusted to the point that the strength of the steel is no longer there.

Prior to applying Rust Bullet, simply wire brush the rusted areas to remove loose or flaking rust; wash off dirt and dust and let fence dry completely. Rust Bullet Metal Blast can also be used to dissolve rust and properly etch the metal prior to the application of Rust Bullet. Always allow the surface to completely dry before applying Rust Bullet. The best tool for application to the chain mesh is a long-nap paint roller with a 1 1/2-inch nap; the longer the nap the better because the roller's fibers will reach through and around the fence material. Ideally both sides of the fence can be coated at the same time with the assistance of a coworker. A brush should be used on the fence rails, posts, hardware and horizontal supports. If an airless spray system is used a primer size tip is recommended. It is important that the area behind the fence be protected from overspray.

14. Will Rust Bullet protect metal and concrete from Magnesium Chloride?

Yes. Rust Bullet will perform well to protect metal and concrete from direct contact with magnesium chloride. Magnesium chloride is used as a de-icer or anti-icer on road surfaces in many states. Magnesium chloride is available in dry or liquid form; either form is very effective in melting ice. It has been confirmed that magnesium chloride will cause significant damage to concrete and metal. Magnesium chloride is very corrosive and will stick to any surface when dry and react with moisture or water to corrode metal and concrete. It will affect concrete in two ways, either by a slow rate or a fast attack depending on the concentration and the conditions and circumstances. A very high concentration of magnesium chloride on a frequent basis will reduce the protective properties of any corrosion control coating, including Rust Bullet. Rust Bullet with its armor tuff coating will last longer and provide better protection than any other product available. A dry film thickness (dft) of 12 -15 mils is recommended for surface that will come into contact with magnesium chloride. Regular inspection of the surface to identify any breaches in the coating for immediate and easy repair is always recommended.
 
It is important to remove embedded chlorides from the surface prior to the application of a new coating system, as embedded salts are a major cause of surface corrosion.

15. Is Rust Bullet an appropriate coating for use on an Air Duct?

Yes. Rust Bullet will provide excellent protection for an Air Duct System. We recommend not running air through the system for at least 72 hours after the final coat of Rust Bullet has been applied. Rust Bullet will encapsulate the rusted areas adding strength to the coated surfaces.

17. Does Rust Bullet contain Lead or Chromates?

No. Rust Bullet Products are environmentally friendly as they contain No Lead, No Zinc, No Chromates, No Acids and No Heavy Metals. Our Products comply with Volatile Organic Compound (VOC) limits regulated by The Environmental Protection Agency and the more stringent regulations of the State of California.

18. Will Fertilizer and Lime effect Rust Bullet?

No. A properly applied and cured Rust Bullet Coating will hold up extremely well to fertilizer and lime. For best results apply thin even coats of Rust Bullet to achieve a minimum dry film thickness (dft) of 12 - 15 mils. A regularly schedule inspection and maintenance program is recommended for all harsh environments, allowing for immediate identification and repair of any breaches or imperfections in the coating.

19. What are the effects of Fuels on a cured Rust Bullet Coating?

Fossil fuels, such as refined oils (gasoline, diesel, jet fuels and kerosene) will not affect the integrity of the cured Rust Bullet Coating. Additionally, renewable fuels such as Biodiesel and Ethanol will have no adverse affect on substrates coated with Rust Bullet Products. As with any harsh environment, a regularly scheduled inspection and maintenance program is recommended to immediately identify and repair any breaches or imperfections in the coating surface.

20. Can a surface coated with Rust Bullet be Welded?

To ensure the welded metals are properly bonded, the Rust Bullet coating should be removed to expose the bare metal. It is possible to join two Rust Bullet coated metals by welding without removing Rust Bullet; the metal will join together but may not achieve the strong bond expected by the welding process. If metal coated with Rust Bullet, or another coating, is welded without removing the existing coating, the extreme heat involved in the welding process will disintegrate the coating possibly releasing harmful gases; therefore, the appropriate safety precautions, such as wearing a gas mask and safety goggles, must be followed. After welding, Rust Bullet must be reapplied over the welded area to ensure complete protection of the entire surface.
 

Ø Laser Beam Welding

o   The  LBW heat-affected zones of a Rust Bullet Coating may require additional coating after the weld. Dependent upon the use of Milliseconds long pulses or continuous laser systems, the depth of the weld may penetrate and degrade the coating affecting integrity through to the substrate. If a shallow weld is applicable, the coating may be applied at a dft that will allow the unaffected coating to retain integrity and continued protection of the substrate. A required dft in this scenario would be the minimum of 9mil dft remaining unaffected from the welding

21. Is Rust Bullet compatible with Cadmium?

Yes, Rust Bullet is compatible with Cadmium. Cadmium is mostly used in the electroplating of metal and steel. It is used as a form of corrosion protection. Before applying Rust Bullet on electroplated surfaces, the surface must be clean and free of grease and wax. We recommend cleaning and etching the electroplated surface with Rust Bullet Metal Blast to ensure proper adhesion.

23. What if my project requires a faster recoat time? Is it possible to decrease the drying time between coats?

Rust Bullet Rapid Fire Accelerator was designed to be added to all Rust Bullet Coatings to decrease the normal recoat time of 2 to 4 hrs to approximately 30 to 40 minutes per coat. Rapid Fire makes it possible to apply multiple coats of Rust Bullet in a single day and reduces project completion time by as much as 80%. Rust Bullet Rapid Fire Accelerator is designed for spray applications. A Rust Bullet coating accelerated with Rapid Fire can be applied with either an HVLP Spray System or an Airless Spray System.

IMPORTANT: Rapid Fire is to be added to the Rust Bullet coating at the job site; it cannot be added until you are ready for application. As soon as Rapid Fire has been added, the curing process begins. Pot life is approximately 4 - 6 hours. Rapid Fire is not to be used on first coat of Rust Bullet; only on second and subsequent coats. Only mix Rapid Fire Accelerator into the quantity of Rust Bullet that will be used within a 4 - 6 hour period.

24. Can Rust Bullet be Top Coated?

Yes. Rust Bullet is metallic gray in color, UV resistant and requires no topcoat. If a finished color other than metallic gray is desired, Rust Bullet can be top coated between 24 to 48 hours after the final coat has been applied with no additional preparation. Rust Bullet is compatible with most conventional top coat paints. Rust Bullet BlackShell, WhiteShell, ColorShells and Clear Shot are formulated specifically as the optimum topcoat for both Rust Bullet Standard and Rust Bullet Automotive Formulas if a smooth glossy  finish is desired. Rust Bullet Topcoats are scratch and chip resistant, UV resistant, as well as, resistant to Acid Splash and Chemical Solvents and are an excellent protective stand alone coating, requiring no basecoat or topcoat. Rust Bullet Topcoats will easily outperform other protective coatings; however, the unbeatable combination of these topcoats over Rust Bullet Standard or Rust Bullet Automotive will provide the absolute best protection against rust and corrosion available today. Rust Bullet ColorShells are ANSI Z535 Compliant with OSHA Safety Colors.

25. When can I apply a Topcoat if I have coated my project with a Rust Bullet coating that has been accelerated with Rust Bullet Rapid Fire?

Wait approximately 1 hour before applying a topcoat over the final coat of Rust Bullet Standard or Rust Bullet Automotive that has been accelerated with Rapid Fire. The previous coat should be tack free.

IMPORTANT: A Rust Bullet coating that has not been accelerated by adding Rapid Fire can be top coated between 24 and 48 hours after the application of the final coat of Rust Bullet with no additional preparation.

26. Will I have problems with the application of Rust Bullet if I am located in an area with High Humidity?

If humidity is too high (80% +), it will adversely affect the curing and adhesion process. A couple of things can be done to minimize the adverse affects of high humidity, if necessary:
For the best possible adhesion in high humidity areas, etch the metal surface with Rust Bullet Metal Blast prior to applying Rust Bullet.

Provide air circulation or an air flow that vents the air away from the coated surface. This may assist in reducing the humidity, but may also circulate particles and debris that may become embedded in the wet paint.

Apply Rust Bullet by brush. A brush application tends to trap less air and moisture and is therefore the best application method in a high humidity zone. Apply additional, thinner coats rather than fewer, thicker coats. This will help eliminate the formation of bubbles or blisters on the coating surface which can occur if the solvents cannot be expelled. The formation of humidity bubbles or blisters can result in poor adhesion, which in turn, may need re-sanding and a touch up.

27. Can Rust Bullet be used instead of Standard Military Paint?

Yes. Rust Bullet is currently used by many divisions of the United States Military. Rust Bullet has strong resistance to chemicals and abrasives in addition to its superior patented technologies for controlling rust and corrosion. Based upon the attributes of a properly applied and cured Rust Bullet Coating, it may be used as a chemical agent resistant paint system. Rust Bullet can be easily top coated with the Rust Bullet BlackShell, WhiteShell, and ColorShells which are ANSI Compliant OSHA Safety Colors, as well as other standard military topcoat paints. Rust Bullet has been awarded a Schedule Contract with the General Services Administration (GSA), allowing qualifying entities to purchase from the GSA Schedule.

Rust Bullet GSA Contract Number: GS-06F-0050R
GSA Schedule Number: 51V
Rust Bullet Cage Code: 3E9H7
Special Item Number (SIN): 834-100
Some of the United States Government Military and Non Military Agencies currently using Rust Bullet:
Federal Aviation Administration, (FAA)
United States Department of Transportation, (DOT)
United States Army
United States Navy (USN)
United States Air Force (USAF) - Spacelift Range Systems Contract (SLRSC)
United States Marine Corps (USMC)
United States Naval Undersea Warfare Centers (NUWC)
United States Coast Guard (USCG)
United States Army Corp of Engineers (USACE)
The National Radio Astronomy Observatory's Very Large Array (VLA)

28. Can Rust Bullet® Topcoats provide protection for Industrial and Commercial Projects?

Yes. Rust Bullet BlackShell, WhiteShell, ColorShells and Clear Shot are scratch and chip resistant, UV resistant as well as resistant to Acid Splash and Chemical Solvents. Rust Bullet Topcoats are excellent protective stand alone coating, requiring no basecoat or topcoat and can be used on bare steel providing very strong protection. The Rust Bullet Topcoats are formulated with specialized resins and anticorrosive agents and can be used as a stand alone anticorrosive coating that will protect iron and steel. Although Rust Bullet Topcoats will easily out-perform other coatings on bare steel it will not produce the level of protection of the patented Rust Bullet standard or Rust Bullet Automotive formulas for fighting rust and corrosion. For the absolute best rust and corrosion protection available, apply Rust Bullet Topcoats over Rust Bullet Standard or Rust Bullet Automotive. The Rust Bullet BlackShell, WhiteShell and ColorShells are ANSI Z535 Compliant OSHA Safety Colors.
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