RUST PROTECT // ANTI-RUST COATING

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• Focus on safe, waterborne low VOC coatings

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Rust Protect is a direct-to-rust (DTR), dual-component, surface applied universal substrate that protects a wide variety of ferrous materials, including hard rust metal surfaces from continued deterioration due to naturally occurring threats. Rust Protect dries smooth, creating a strong bridge between rusted metal surfaces and application-specific top coats.

• This low-VOC anti-corrosion solution is made up of 25% cementitious material allowing for adhesion to cement while the proprietary technology also allows for adhesion direct-to-rust and direct-to-metal surfaces.

• Environmentally Stable: Temperature resistance (-80ºF to +500ºF) and maintains flexibility without cracking or peeling, allowing for expansion and contraction of a substrate due to internal pressure changes or external influences.

Uses include:

• Concrete encased metal• Metal stairs and ramps• Corrosion Under Insulation (CUI)• Exhaust systems• Corrugated metal roofs• Rebar• Steel structures• Boilers & Furnaces• Metal doors• Pipe exteriors

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Rust Protect has been tested to the following standards:

• ISO12944• ASTM B117-11• ASTM D1654• ASTM D3359• ASTM D4060• ASTM D4541

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Superior technology that yields greater returns on your investment

DryWired™ Rust Protect combines two unique performance characteristics, previously thought impossible for a cementitious product:

1. Cement Bonding to MetalRust Protect is 25% cement yet bonds aggressively with nearly all metal surfaces. Adhesion characteristics are maintained even on surfaces that are highly corroded with rust. Rust Protect fulfills the age old desire to coat metal surfaces with an inexpensive yet extremely durable product like cement.

2. FlexibilityFlexible cement? That’s correct. Rust Protect can bend as much as 90 degrees without cracking or lifting when properly applied. This characteristic allows Rust Protect to be applied to “live” surfaces that expand and contract due to internal pressure changes or external influences such as freezing/thawing.

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no abrasive blasting is required

DryWired™ Rust Protect’s advanced formula is designed for application directly over hard rust surfaces while maintaining superior adhesion characteristics that are two to three times industry standards.1

The surface only needs to be power washed and degreased prior to application.

This unique performance characteristic results in: • Less prep time• Fewer containment issues• Lower disposal costs• Increased profitability• Greater bid conversion

(1) 2012 pull tests performed by a NACE Certified Engineer, Level 2, demonstrated minimum failure points of 750 psi

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No more grinding

The ability to apply Rust Protect directly to hard metal surfaces results in significantly less preparation time and lower labor costs without sacrificing performance.

This reduction in labor costs allows contractors to submit bids that are up to 50% lower than bids using blasting or grinding.

Despite the additional materials expense of purchasing Rust Protect, the much greater offset in labor charges allows the contractor to generate greater profit per job, even when the total bid calculation is lower than a bid using blasting or grinding.

TEST TEST TYPE COATING RESULT/RATING

ISO 1519:2002 Bend Rust Protect Cracking, no detachment

ASTM B117-11 (96 hours) Salt Fog Rust Protect + Top Coat 9

ASTM B117-11 (96 hours) Salt Fog Rust Protect + No Top Coat 8 and 9

ASTM B117-11 (192 hours) Salt Fog Rust Protect + No Top Coat 7 and 8

ASTM B117-11 (96 hours) Salt Fog Rust Protect + Top Coat 10

ASTM B117-11 (192 hours) Salt Fog Rust Protect + Top Coat 9

ASTM D1654 (96 hours) Salt Fog (scribe) Rust Protect + No Top Coat 9

ASTM D1654 (192 hours) Salt Fog (scribe) Rust Protect + No Top Coat 9

ASTM B117-D1654 (96 hours) Salt Spray (scribe) Rust Protect + Top Coat 9

ASTM B117-D1654 (192 hours) Salt Spray (scribe) Rust Protect + Top Coat 9

ASTM D3359 Pull Rust Protect + No Top Coat 5B – no paint removed

ASTM D3359 Pull Rust Protect + Top Coat 5B – no paint removed

ASTM D4060 Abrasion Rust Protect + No Top Coat 113.7 - 118.4mg loss

ASTM D4060 Abrasion Rust Protect + Top Coat 42.0mg loss

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DryWired has conducted extensive testing on Rust Protect dating as far back as 2010 using ASTM testing standards. The table below lists the results of these tests.

Sample Cure Time Bond Strength (psi)

Bond Strength (kg/cm2)

Bond Strength (bar)

Mode of failure (% of coating)

A 28 days 1,047 73.6 72.2 95%

B 21 days 875 61.5 60.3 50%

C 14 days 722 50.8 49.8 40%

D 14 days 693 48.7 47.8 80%

E 5 days 289 20.3 19.9 35%

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In 2015, DryWired conducted additional pull testing according to ASTM D 4541 standards on non-profiled cold rolled steel. As shown in the table and graph below, DryWired reached a level exceeding 1,000 psi when fully cured after 28 days. Industry standards are 200 psi, which Rust Protect exceeded after only 5 days cure time.

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In 2015, DryWired conducted salt spray testing at Exova Labs, one of the world’s largest independent testing companies, on non-profiled cold rolled steel according to ISO standards 12944. This test places a scribe down the center of a 120cm x 90cm coated panel to expose the underlying substrate. The panel is then placed in a chamber where it is continuously in contact with a salt spray solution for 240 hours and 480 hours in salt fog environment. A passing grade results when the coating prevents rust

migration from the scribed area into the area that remains covered by the coating being tested.

The panels coated with Rust Protect passed level “C3-HIGH” for corrosion resistance, thereby making Rust Protect available for use within the European Union as a direct to metal corrosion inhibitor.

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Date: June 18, 2012Client: ExxonMobil Asset: HVAC Rooftop PipeSubstrate: Hard rust under insulation corrosionTesting process: • Surface Prep – loose rust removal,

power wash and degreasing• Rust Protect applied to clean and dry

hard rust surface• Multiple different top coats were

applied the same day after Rust Protect curing

• Tests conducted 5 days later

Industry Standard: 250 psiClient Standard: 350 psi

Results: 750– over 1,000 psi

Test Performed

Product Tested Requirements Failure Point Failure

Element Rust Protect Failure

Pull Test Rust Protect D-4541 825 psi Underlying rust No

Pull Test Rust Protect with Top Coat D-4541 800 psi Topcoat No

Pull Test Rust Protect with Top Coat D-4541 1,000+ psi Pull kit No

Pull Test Rust Protect with Top Coat D-4541 750+ psi Pull kit No

Pull Test Rust Protect with Top Coat D-4541 750 psi Topcoat No

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case study: CTS testing

INdustry standard: 200 psi | client standard: 200 psi | results: 370-431 pSI

Date: May 31,2016

Client: CTS Cement

Asset: None (Lab test)

Substrate: 3 types of textured and smooth cement

Testing process:

1. Pour cement into forms and allow for two cure periods of 48 hours and 168

hours.

2. Rust Protect applied to clean and dry surface at time intervals indicated

above.

3. Rust Protect allowed to dry 24 hours.

4. Pull tests conducted using ISO block forms and testing equipment.

CTS Product Surface Coating Cure Tension

(psi) Failure point # of tests

V/OR.M.

TEXTURED NONE 48-HR 128.7 BOND LINE 2

TEXTURED RUST PROTECT 48-HR 400.7 BOND LINE 2

TEXTURED NONE 168-HR 151.9 BOND LINE 2

TEXTURE RUST PROTECT 168-HR 370.2 PRODUCT 2

CEMENT ALL

TEXTURED NONE 48-HR 76.8 BOND LINE 2

TEXTURED RUST PROTECT 48-HR 393.1 BOND LINE 2

TEXTURED NONE 168-HR 76.7 BOND LINE 2

TEXTURED RUST PROTECT 168-HR 410.2 BOND LINE 2

TRUTEXTURED RUST

PROTECT - 406.0 SUBSTRATE 4

SMOOTH RUST PROTECT - 431.0 SUBSTRATE 3

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Drywired’s protective coatings can offer significant competitive advantages across much of a company’s entire asset platform:

Low Total Cost of Ownership• Equal or greater long term maintenance of the asset• Much lower upfront labor requirements• Reduced service and production interruption• Minimal technical training required• No proprietary equipment required• Ease of repair/patching, reducing future maintenance costs

Low Toxicity• Extremely low toxicity and VOC levels• Virtually odorless• Although recommended, gloves, face-masks and eye protection are

not required

Product Flexibility• Can be used independently or in conjunction with many other

DryWired products, as well as third-party products from Simpson Strong Tie, Sherman Williams, Carboline, PPG, 3M and AkzoNobel.

• Received approval letters stating continued warranty coverage for use with Sherman Williams and Carboline top coats.

• Field proven with PPG Amaron440 (epoxy) and Carboline Carbo-lace119 (PUD).

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case study: fiber reinforced polymer

before after

Problem: A potash mine head frame had structurally degraded from excessive

weathering, UV and wind related abrasion damage.

Previous Solution: None. Traditional repairs would fail within 5 years.

DryWired Solution: Rust Protect on exposed rebar to bond with shotcrete, FRP

wrap for structural repair and top-coated to create a comprehensive finish.

Result: Savings of over $30,000 and 2 weeks time.

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case study: PUMP STATION

Problem: The coating on a coastal pump station located on Terminal Island in

Long Beach, CA had degraded from challenging environmental issues.

Previous Solution: A major paint manufacturer’s OEM coating system had

failed faster than expected, resulting in clear-disbonding and corrosion.

DryWired Solution: Rust Protect to coat the completed structure, including

areas with exposed corrosion, and top coated with a proprietary urethane.

Result: Savings of over $8,000 and 4 days time.

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case study: MARINE VESSEL

Problem: The 30-year old service vessel’s deck regularly required new plating at

great expense to the owner due to cancerous rust in areas that receive constant

abuse.

DryWired Solution: Rust Protect was sprayed directly onto the heavily rusted

(but cleaned) deck and then top coated with PPG Tide Guard 171. This saved

time and money associated with having to sandblast and re-plate the corroded

deck.

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Project example

Coating example: 20,000 square foot tank

Problem: Costly to sandblast and apply

traditional 3-coat system using Zinc Rich

Primer/Epoxy/Urethane.

DryWired Solution: Power wash rusted

surface, degrease and apply Rust Protect

and proprietary top coat.

Savings: 32.9% of total project costs as

illustrated below.

Traditional DryWired VarianceLabor $91,709 $58,109 $33,600Fringes - - -Substrate $27,044 $17,135 $9,909Equipment $23,907 $15,825 $8,082Material $28,858 $37,169 $8,311Abrasive $21,846 - $21,846Subcontract - - -Misc $4,796 $4,796 -

TOTAL $198,160 $133,034 $65,126PROJECT SAVINGS 32.9%

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Project example

Problem: Costly to sandblast and apply

traditional 3-coat system using Zinc Rich

Primer/Epoxy/Urethane.

DryWired Solution: Power wash rusted

surface, degrease and apply Rust Protect

and proprietary top coat.

Savings: 40.6 % of total project costs as

illustrated below.

Coating example: 1 mile pipeline (24” pipe)

Traditional DryWired VarianceLabor $156,113 $87,038 $69,075Fringes - - -Substrate $75,754 $34,841 $40,913Equipment $63,477 $40,482 $22,995Material $44,820 $64,485 $19,665Abrasive $45,753 - $45,753Subcontract - - -Misc $5,995 $5,995 -

TOTAL $391,912 $232,841 $159,071PROJECT SAVINGS 40.6%

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Rust Protect solves the age olD problems caused by spalled rebar

Problem: Spalled rebar creates 2 specific repair

problems

1. Repair cement will not adhere to

rusted rebar, thereby rendering it

structurally useless.

2. Repair cement creates a cold joint

with the old cement that will fail

rapidly.

Solution: Rust Protect solves these issues by

adhering aggresively to both the rusted

rebar and the original cement work. Please

refer to pages 5-9 for pull test data on

both corroded metal and slab concrete.

1. Spalled beam and rusted rebar2. Coated beam and rebar3. Coated beam and rebar4. Patched concrete on coated beam5. Finished beam

1.

2.

4.

5.

3.

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Rust Protect’s extremely strong adhesion properties have led to unique applications in the fiber Reinforced polymer (FRP) industry.

Problem: Although incredibly strong and functional,

finished FRP solutions are aesthetically

unpleasing. And due to the surface

profile and characteristics of the epoxy

resins used, it is extremely difficult to

cover FRP with a coating that remains

adhered.

Solution: Rust Protect has been proven to adhere

aggressively to finished FRP solutions; and

because of its cementitious nature, Rust

Protect provides a cement-like surface that

(a) can be painted over directly and (b)

creates and ideal substrate for troweling

cement.

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rust protect cured frp

elastomeric paint

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Iso 12944 Paints & Varnishes - Corrosion Protection Of Steel Structures By Protective Paint Systems: Part 2

For this test, a substrate coated with DryWired Rust Protect is scribed, exposing a 120cm x 90cm section of the bare underlying substrate. The substrate with a section exposed is then placed in a chamber where it is sprayed with a salt solution for 240 hours. It is then exposed to a salt fog chamber for 480 hours. The rating the coating is given is determined by rust mitigation from the exposed area to the coated area. DryWired Rust Protect received a “C3-Medium” rating, meaning this coating is in compliance with ISO Standard 12944 Paints & Varnishes - Corrosion Protection of Steel Structures by protective paint systems for the listed exterior and interior application areas for ratings of C3, C2, and C1.

Corrosivity category and risk

Low-carbon steel Thickness loss (µm)a

Examples of typical environments in a temperate climate (informative only)

Exterior Interior

C1Very low < 1.3 -

Heated buildings with clean atmospheres, e.g. offices, shops, schools, hotels

C2 Low > 1.3 to 25Atmospheres with low level of pollution. Mostly rural areas

Unheated buildings where condensation may occur, e.g. depots, sports halls

C3 medium > 25 to 50

Urban and industrial atmospheres, moderate sulphur dioxide pollution. Coastal area with low salinity.

Production rooms with high humidity and some air pollution e.g. food-processing plants, laundries, breweries, dairies

C4 high > 50 to 80Industrial areas and coastal areas with moderate salinity.

Chemical plants, swimming pools, coastal, ship and boatyards

C5-I very high (industrial) > 80 to 200Industrial areas with high humidity and aggressive atmosphere

Buildings or areas with almost permanent condensation and high pollution

C5-M very high (marine) > 80 to 200 Coastal and offshore areas with high salinity

Buildings or areas with almost permanent condensation and high pollution

All statements, technical information and recommendations contained in this document are based upon tests or experience that DryWired believes are reliable. However, many factors beyond DryWired’s control can affect the use and performance of a DryWired product in a particular application, including the conditions under which the product is stored or used and the time and environmental conditions in which the product is expected to perform. Since these factors are uniquely within the user’s knowledge and control, it is essential that the user evaluate the DryWired product to determine whether it is fit for a particular purpose and suitable for the user’s method of application. No warranty or condition, expressed or implied, is given regarding the accuracy of the statements, technical information or recommendations contained in this document. Except to the extent prohibited by law, DryWired will not be liable for any losses or damages arising in any way from the DryWired product including, without limitation, any direct, indirect, special, incidental or consequential damages, regardless of the legal theory asserted, including warranty, contract, negligence or strict liability.

FOR ADDITIONAL INFORMATION PLEASE CONTACT :

Office: +1-323-581-8181 • Fax: +1-310-855-1208 • Email: sales@drywired.com

5524 Alcoa avenue Vernon, CA 90058

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