RustSeal Application Directions - RustSeal TDS

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RustSeal is applied in three steps: degrease with KBS Klean, etch and prep with RustBlast, then brush or spray two coats of RustSeal at 2 mils each. Apply between 55 and 82 degrees F and allow 2 to 6 hours between coats. RustSeal cures by absorbing moisture from the air and forms a rock-hard, non-porous shell directly over rust.

Importance Of Surface Preparation:

Despite what others may lead you to believe, it does not matter how good the rust prevention product is if the surface is not prepared properly. Corrosion and organic contamination will block and inhibit any coating from deeply penetrating and permanently adhering to the surface. Even new metals have protective surface oils applied that will interfere with adhesion. The cleaner the surface using KBS Klean, the more effective RustBlast will work, and the deeper RustSeal will penetrate into the pores to permanently seal and protect the surface.

Apply RustSeal to clean, dry bare metal with a good porous surface profile, such as tightly rusted, sandblasted, or other abraded surfaces RustSeal can bite into.

Sandblasted Surfaces: newly sandblasted metal (fresh, not recycled sand) that has been handled with gloved hands is the ideal choice for a direct RustSeal application, requiring no preparation other than blowing off loose dust (proceed to Step #3). Always wear gloves when handling sandblasted items to avoid contaminating the surface with oily fingerprints.

Plastic media, bead, or soda-blasted surfaces do not provide adequate abrasion for a direct RustSeal application and require Step #2 RustBlast for further etching. For all other applications, follow the KBS 3-Step System below. Always allow products and surfaces to reach room temperature before prepping and painting.

Step #1 - KBS Klean Directions:

After removing any loose, flaky rust by sanding with 320 grit sandpaper, wire brushing, or wire wheeling to achieve a solid surface profile, remove all surface contamination. Slight residues of grease, oil, or fingerprints can ruin a good paint job. Avoid solvent-based cleaners, which leave residues.

Dilute KBS Klean concentrate with water; warmer water gives more effective, powerful cleaning action. Effective dilution rates vary by contaminant type and surface material. KBS Klean may be used in power washing equipment. For general cleaning, apply liberally and scrub for 5 to 10 minutes; for heavy-duty cleaning, extended soaking up to 24 hours or more may be necessary. Use a bristle brush or scouring pad on heavily soiled surfaces and retreat as needed. Do not allow KBS Klean to dry before rinsing thoroughly with water, then let dry. Metal surfaces cleaned with KBS Klean should always be treated with RustBlast before painting to ensure proper adhesion.

For alloys and non-ferrous metals, keep KBS Klean application times and dilution rates to a minimum due to material variation. Follow with RustBlast to remove surface rust, etch the metal, and leave a zinc phosphate coating for superior RustSeal adhesion. For new, smooth, or shiny metal, lightly scuff with 400 grit sandpaper before KBS Klean and RustBlast. For previously painted surfaces, remove all paint by chemical stripping before KBS Klean and RustBlast; if paint cannot be fully removed, lightly scuff with 400 grit sandpaper followed by KBS Klean. Note: if RustSeal is applied over an existing painted coating rather than bare metal, it may not permanently seal rust but will provide a durable, moisture-resistant coating.

Step #2 - RustBlast Directions:

Ideal application temperature range is 55 to 82 degrees F. For best results, the surface should be free of dirt, oil, grease, and other contaminants; scrape off loose rust, mill scale, or paint, and clean with KBS Klean before using RustBlast.

Apply RustBlast full-strength to a clean, dry surface using a spray bottle, brush, roller, or backpack sprayer for larger areas. Re-apply often to keep the surface wet for a minimum of 10 minutes on smooth or lightly rusted surfaces, 20 to 40 minutes on moderately rusted surfaces, and 1 to 2 hours on heavily rusted or corroded surfaces. Use a scouring pad as needed. Do not let RustBlast dry on the surface before rinsing, to avoid a heavy zinc phosphate buildup that can affect sealing. Rinse thoroughly with water and allow the surface to dry completely. For light corrosion or etching non-ferrous metals such as aluminum, brass, or copper, apply RustBlast for 10 to 20 minutes, then rinse and dry.

It is not necessary to remove every trace of rust before applying RustSeal; RustSeal bonds to and permanently seals remaining flash rust or corrosion. A slight white powder residue after RustBlast treatment is a zinc phosphate coating that aids RustSeal adhesion. Some flash rust or orange staining can occur if the surface was soaked, rinsed, and not dried immediately; this is not a problem and the surface is ready for RustSeal.

Step #3 - RustSeal Directions:

Ideal RustSeal application temperature range is 55 to 82 degrees F (13 to 28 degrees C). RustSeal is moisture-cured, so use only in moderate to dry atmospheric conditions. Avoid applying RustSeal in rainy or humid conditions when the surface cannot be kept dry; damp surfaces can bubble and cause improper adhesion. Humid conditions shorten cure time; low humidity lengthens it. Always work in a well-ventilated area, wear protective eyewear, and wear gloves to avoid skin contact and temporary staining. RustSeal must be cleaned up before it dries, since it cannot be removed by any solvent once cured.

Opening the Can and Stirring

Because paint can shift between the can and lid during shipping, the lid can be harder to remove than usual. If the lid has a plastic ring, remove it. Use a paint can opener with a curved or "L" shaped end rather than a flat head screwdriver, which tends to warp the lid. Lift the lid gently in one section, rotate the can about 10 degrees, lift again, and repeat all the way around; go around a second time lifting a bit more each pass until the lid comes off.

Stir RustSeal thoroughly for several minutes to get an even mixture, repeatedly touching the bottom of the can and lifting to disperse settled pigments or matting agents. Turning the can upside down briefly before opening, or gently shaking it, aids mixing; avoid violent shaking, which produces air bubbles that affect the seal and finish. Continue stirring often during painting. For spray applications, thin 5 to 10% if needed using only KBS #1 Thinner, a slow-evaporating solvent; do not reduce with lacquer thinner.

Do not paint directly out of the can. After stirring, dispense a working amount into a separate steel or glass container and reseal the original can immediately. Never return unused paint to the can; it shortens shelf life and can build pressure that pops the lid. Keep the can groove clean using a scoop or KBS Paint Spout, and use plastic wrap between the lid and can rim to prevent RustSeal from permanently sealing the lid. If the lid will not reseal tightly, transfer and store RustSeal in another properly sized can or glass jar. Store in a cool, dry place; RustSeal may be refrigerated but should reach room temperature before reuse.

Applying Matte Sheens

RustSeal is heavily pigmented, so it is critical to remix all matting agents into suspension using a mechanical mixer on a drill (like the KBS Hurricane Paint Mixer) or at least a paint stir stick, repeatedly touching the bottom of the can and lifting. Apply RustSeal in thin coats only for a clean matte finish; for a more matte result, reduce RustSeal 20% with KBS #1 Thinner or Xylene.

Spraying RustSeal

Follow all caution and warning notices when spraying, and always wear an air-supplied, NIOSH/MSHA approved organic vapor particulate respirator. Thinning is not generally required, but if needed, 5 to 10% with KBS #1 Thinner or Xylene is normally adequate; do not reduce with lacquer thinner. After thinning and stirring well, strain through a 100 micron filter, and use an air line dryer filter to remove moisture from the air line. Clean the spray gun immediately after use.

Recoating

Recoat once the previous coat is dry to the touch and leaves no fingerprint, typically within 2 to 6 hours depending on temperature and humidity. If spraying, clean the gun immediately after each use. If more than 8 hours pass, wait 24 hours and lightly scuff the cured coat with a 320 grit green scotch-brite pad. Apply a minimum of 2 thin covering coats (2 mils each) for general applications, and a minimum of 3 thin covering coats for marine or industrial applications. Use a KBS Preval Sprayer for hard-to-reach areas.

When brushing RustSeal, avoid overworking the brush, which can cause the coating to cure too quickly and leave visible brush marks; brush an area once and move on rather than going back over it repeatedly.

RustSeal Storage: to store leftover RustSeal, hold the lid and plastic wrap closely above the can and spray KBS Paint Saver toward the side of the can to avoid splashing: 2 seconds for quarts or less, 4 seconds for gallons. KBS Paint Saver prevents oxygen and moisture damage and extends storage time.

(Optional) Topcoating RustSeal:

RustSeal is not intended as a final finish on surfaces consistently exposed to direct sunlight; repeated or prolonged UV exposure will cosmetically alter its color and sheen, though its rust protection will not degrade. In areas not exposed to direct UV light, such as the underside of a car, RustSeal seals as well as it serves as a good-looking final finish. To protect against cosmetic change, topcoat RustSeal with any opaque paint system; a clear topcoat like DiamondFinish Clear or KBS MAXX Clear cannot provide the needed UV protection.

BlackTop, KBS Top Coater, and KBS MAXX are high-performance protective coatings and ideal UV-exposed topcoats for RustSeal. There are three effective ways to topcoat RustSeal so the coatings bond and fuse together:

• Apply the topcoat once the final coat of RustSeal is dry-to-the-touch, usually 3 to 6 hours depending on temperature and humidity.
• Let the final coat of RustSeal fully cure (at least 24 hours), scuff with 320 grit, then apply the topcoat.
• Let the final coat fully cure (at least 24 hours), dust with Fusion Self-Etching Primer, let it cure 30 minutes, then apply the topcoat.

Clean Up:

Use KBS #1 Thinner or lacquer thinner for immediate clean up, including the spray gun. RustSeal must be cleaned up before it dries; it cannot be removed by any solvent once cured. Always wear protective gloves. If skin contact occurs, immediately remove RustSeal with #1 Thinner or lacquer thinner followed by soap and water. If RustSeal stains skin, only time will remove it.

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Frequently Asked Questions: RustSeal

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