Product Detail
ROCEpoxy Direct-To-Metal Epoxy Mastic 9100 by Rust-Oleum is a two-component high solids epoxy coating that provides a durable surface that can hold up in most industrial environments. This abrasion and chemical resistant coating creates a protective, gloss finish that can be applied directly onto sound rusted steel, galvanized metal, clean steel, concrete, and even slightly damp surfaces.
Features and Benefits of ROCEpoxy Direct-to-Metal Epoxy Mastic 9100 Coating:
- Extremely versatile, durable, solvent-based epoxy
- Direct-to-metal and self-priming on a variety of substrates
- Ultra-smooth finish with high build capacity on edges and welds
- Superior resistance to solvents, chemicals, abrasion, and impact
- Pot life of a minimum of two hours
- Five year rust-proof guarantee*
- Easy to use - convenient 1:1 mixing ratio
*Contact Rust-Oleum Technical Services directly to apply for the guarantee
Specifications
| Usage Interior/Exterior: | Interior and Exterior |
| Suitable For: | Specifically designed for application directly on sound rusted steel with minimum surface prep. Can also be used on clean steel, galvanized metal, concrete (including floors), previously coated and slightly damp surfaces. |
| Finish: | Gloss |
| Primer Suggestions: | Not required in mild to moderate exposures. Primer is required in severe exposures and on heavily rusted surfaces. |
| Coverage: | 130-220sq. ft./gal. at recommended DFT (assumes 15% material loss) |
| Pot Life: | 2.5-3 hours at 75°F |
| Cure Time: | Tack free in 6-8 hours at 70°F |
| Recoat Time: | 16 hours to 30 days at 70°F |
How to Apply
Surface Preparation
All Surfaces: Remove all dirt, grease, oil, salt and chemical contaminants by washing the surface with Krud Kutter PRO Cleaner & Degreaser. Rinse thoroughly with fresh water and allow to dry. All surfaces must be dry at time of application.
Steel: Hand tool (SSPC-SP-2) or power tool (SSPC-SP-3) clean to remove loose rust, scale, and deteriorated previous coatings to obtain a sound rusted surface. For optimum corrosion resistance, abrasive blast to commercial grade SSPCSP-6, with a blast profile of 1-2 mils (25-50 μ).
Previously Coated: Previously coated surfaces must be sound and in good condition. Smooth, hard, or glossy finishes should be scarified by sanding or sweep blasting to create a surface profile. The ROCEpoxy DTM Epoxy Mastic 9100 is compatible with most coatings, but a test patch is suggested.
Galvanized Metal: Remove oil, dirt, grease and other chemical deposits with a cleaner & degreaser. Remove loose rust, white rust or deteriorated old coatings by hand or power tool cleaning or brush off blasting. Rinse thoroughly with fresh water and allow to fully dry.
Concrete or Masonry: New concrete or masonry must cure 30 days before coating. Any concrete surface must be protected from moisture transmission from uncoated areas. Remove all loose, unsound concrete.
Concrete Floors: Remove laitance and create a surface profile by either acid etching with Cemtetch Self Etching Cleaner, or by grinding. If etching, consult with Cemtetch Technical Data Sheet for complete application instructions. Rinse thoroughly and allow to dry. The concrete must be fully dry prior to coating application. After etching, the concrete should have a texture, which resembles fine grit sandpaper. Repeat the process if necessary. Surface sealers and curing agents must be removed by grinding. Vacuum to remove fine dust and debris. The floor should be dry and dust free prior to application. Previously coated floors need to be in good condition with proper adhesion to the concrete substrate.
Application
Airless spray is the preferred method of application. However, brush, roller, or air-atomized spray may also be used. Refer to table for thinning recommendations. For proper performance, a dry film thickness of 5-8 mils per coat is required. Excessive brushing or rolling may reduce film thickness. Apply a second coat if necessary to achieve the recommended film thickness.
Use at air temperatures between 50-120°F (10-49°C) and when the surface temperature is at least 5°F (3°C) above the dew point and less than 120°F (49°C). Low curing temperatures and/or condensation on the film while curing can affect appearance in the form of an amine blush. This can generally be removed with soap and water; however, in a case of extreme blushing, the performance of the coating may be slightly affected.
Equipment Recommendations
(Comparable equipment also suitable)
Brush: Use a good quality natural or synthetic bristle brush.
Roller: Use a good quality roller cover (3/8 – ½” nap).
Air-Atomized Spray:
| Method | Fluid Tip | Fluid Delivery | Atomized Pressure | |
|---|---|---|---|---|
| Pressure | 0.055-0.070 | 10-16 oz./min | 25-60 psi | |
| Siphon | 0.055-0.070 | -- | 25-60 psi | |
| HVLP (var.) | 0.043-0.070 | 8-10 oz./min | 10 psi (at tip) |
Airless Spray:
| Fluid Pressure | Fluid Tip | Filter Mesh |
|---|---|---|
| 1,800-3,000 psi | 0.013-0.017 | 100 |
Thinning
Thinning is normally not required, except for air-atomized spray. For air-atomized spray application, thin only up to 10% by volume with thinner after the components have been mixed.
Note: Addition of more than 10% of thinner will cause VOC to exceed 340 g/l.
Mixing
Both the base and activator components are highly pigmented. Mix each component thoroughly to ensure any settled pigment is re-dispersed before combining the components together. Combine at a 1:1 ratio by volume in a container large enough to hold the total volume. Mix thoroughly for 2-3 minutes. Power mixing is preferred. Do not mix more material than you plan to use within the listed pot life.
Clean-Up
Use an Epoxy thinner.
Data Sheet
ROCEpoxy Direct-To-Metal Epoxy Mastic 9100 by Rust-Oleum is a two-component high solids epoxy coating that provides a durable surface that can hold up in most industrial environments. This abrasion and chemical resistant coating creates a protective, gloss finish that can be applied directly onto sound rusted steel, galvanized metal, clean steel, concrete, and even slightly damp surfaces.
Features and Benefits of ROCEpoxy Direct-to-Metal Epoxy Mastic 9100 Coating:
- Extremely versatile, durable, solvent-based epoxy
- Direct-to-metal and self-priming on a variety of substrates
- Ultra-smooth finish with high build capacity on edges and welds
- Superior resistance to solvents, chemicals, abrasion, and impact
- Pot life of a minimum of two hours
- Five year rust-proof guarantee*
- Easy to use - convenient 1:1 mixing ratio
*Contact Rust-Oleum Technical Services directly to apply for the guarantee
| Usage Interior/Exterior: | Interior and Exterior |
| Suitable For: | Specifically designed for application directly on sound rusted steel with minimum surface prep. Can also be used on clean steel, galvanized metal, concrete (including floors), previously coated and slightly damp surfaces. |
| Finish: | Gloss |
| Primer Suggestions: | Not required in mild to moderate exposures. Primer is required in severe exposures and on heavily rusted surfaces. |
| Coverage: | 130-220sq. ft./gal. at recommended DFT (assumes 15% material loss) |
| Pot Life: | 2.5-3 hours at 75°F |
| Cure Time: | Tack free in 6-8 hours at 70°F |
| Recoat Time: | 16 hours to 30 days at 70°F |
Surface Preparation
All Surfaces: Remove all dirt, grease, oil, salt and chemical contaminants by washing the surface with Krud Kutter PRO Cleaner & Degreaser. Rinse thoroughly with fresh water and allow to dry. All surfaces must be dry at time of application.
Steel: Hand tool (SSPC-SP-2) or power tool (SSPC-SP-3) clean to remove loose rust, scale, and deteriorated previous coatings to obtain a sound rusted surface. For optimum corrosion resistance, abrasive blast to commercial grade SSPCSP-6, with a blast profile of 1-2 mils (25-50 μ).
Previously Coated: Previously coated surfaces must be sound and in good condition. Smooth, hard, or glossy finishes should be scarified by sanding or sweep blasting to create a surface profile. The ROCEpoxy DTM Epoxy Mastic 9100 is compatible with most coatings, but a test patch is suggested.
Galvanized Metal: Remove oil, dirt, grease and other chemical deposits with a cleaner & degreaser. Remove loose rust, white rust or deteriorated old coatings by hand or power tool cleaning or brush off blasting. Rinse thoroughly with fresh water and allow to fully dry.
Concrete or Masonry: New concrete or masonry must cure 30 days before coating. Any concrete surface must be protected from moisture transmission from uncoated areas. Remove all loose, unsound concrete.
Concrete Floors: Remove laitance and create a surface profile by either acid etching with Cemtetch Self Etching Cleaner, or by grinding. If etching, consult with Cemtetch Technical Data Sheet for complete application instructions. Rinse thoroughly and allow to dry. The concrete must be fully dry prior to coating application. After etching, the concrete should have a texture, which resembles fine grit sandpaper. Repeat the process if necessary. Surface sealers and curing agents must be removed by grinding. Vacuum to remove fine dust and debris. The floor should be dry and dust free prior to application. Previously coated floors need to be in good condition with proper adhesion to the concrete substrate.
Application
Airless spray is the preferred method of application. However, brush, roller, or air-atomized spray may also be used. Refer to table for thinning recommendations. For proper performance, a dry film thickness of 5-8 mils per coat is required. Excessive brushing or rolling may reduce film thickness. Apply a second coat if necessary to achieve the recommended film thickness.
Use at air temperatures between 50-120°F (10-49°C) and when the surface temperature is at least 5°F (3°C) above the dew point and less than 120°F (49°C). Low curing temperatures and/or condensation on the film while curing can affect appearance in the form of an amine blush. This can generally be removed with soap and water; however, in a case of extreme blushing, the performance of the coating may be slightly affected.
Equipment Recommendations
(Comparable equipment also suitable)
Brush: Use a good quality natural or synthetic bristle brush.
Roller: Use a good quality roller cover (3/8 – ½” nap).
Air-Atomized Spray:
| Method | Fluid Tip | Fluid Delivery | Atomized Pressure | |
|---|---|---|---|---|
| Pressure | 0.055-0.070 | 10-16 oz./min | 25-60 psi | |
| Siphon | 0.055-0.070 | -- | 25-60 psi | |
| HVLP (var.) | 0.043-0.070 | 8-10 oz./min | 10 psi (at tip) |
Airless Spray:
| Fluid Pressure | Fluid Tip | Filter Mesh |
|---|---|---|
| 1,800-3,000 psi | 0.013-0.017 | 100 |
Thinning
Thinning is normally not required, except for air-atomized spray. For air-atomized spray application, thin only up to 10% by volume with thinner after the components have been mixed.
Note: Addition of more than 10% of thinner will cause VOC to exceed 340 g/l.
Mixing
Both the base and activator components are highly pigmented. Mix each component thoroughly to ensure any settled pigment is re-dispersed before combining the components together. Combine at a 1:1 ratio by volume in a container large enough to hold the total volume. Mix thoroughly for 2-3 minutes. Power mixing is preferred. Do not mix more material than you plan to use within the listed pot life.
Clean-Up
Use an Epoxy thinner.
