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The Rustbullet Advantage


How Rust Bullet® Coatings Works

Rust has historically been known as "the cancer of iron and steel" and yet, only short-term fixes have been available. To amplify the problem, the application of these "short-term" temporary products requires the removal of existing rust, and/or extensive, time consuming, and often complicated preparation of the surface before applying the "temporary fix."

It has long been a truism that painting over rust is worse than leaving the rusty surface uncoated. This is because most paints or coatings form a film over the rust, forming a barrier. This barrier traps moisture, the enemy of iron and steel, against the metal surface allowing continued destruction of the metal underneath.

Rust Bullet® is not a paint in the ordinary sense of the word. Rust Bullet® requires no preparation, except the removal of large flakes of loose rust by light scraping or brushing. When applied, Rust Bullet® does not form a film immediately, but rather it penetrates the porous rust reaching the metal underneath. Our exclusive method of protection* dehydrates, or dries out the rust by a chemical activity, allowing the resin to solidify into a tough coating with phenomenal adhesion. The rust becomes intertwined in the resin matrix and remains a permanent part of the coating. The second coat of Rust Bullet® fills any pinholes in the first coat and forms a nearly impenetrable coating that protects the metal. The exclusive method for excellent UV resistance* adds to the protection, and although it requires no topcoat, any conventional paint can be applied over the second coat for decorative purposes. Rust Bullet® has by far the best abrasion resistance of any of the tested products, and is therefore quite difficult to scratch. If a scratch or chip in the coating does occur, it will rust in the breached area because it cannot protect what it does not coat, but rust will not proceed beyond the breach. Rust Bullet® will not lift, blister, or peel away from its leading edge in any significant degree. Simply reapplying Rust Bullet® over the scratch or chip reseals the coating, providing easy, low cost maintenance.

Click Here to See Why Rust Bullet Out Performs Competitor Coatings

Rust Bullet is an Environmentally Friendly Product.  Rust Bullet Coatings contain no lead, no zinc, no chromates, and no heavy metals

Target  Rust Bullet Coatings meet and exceed the EPA Standards for Potable Water
Target  Rust Bullet Coatings are a mould encapsulate
Target  Rust Bullet Coatings outperform most fire-retardant coatings
Target  Rust Bullet Coatings are UV Resistant, chip resistant, scratch resistant & chemical resistant
Target  Rust Bullet Coatings are a one-step, multiple coat process
Target  Rust Bullet Coatings properly applied & cured will provide years of unparalleled protection

Satisfied Customers Continuing to use Rust Bullet Products Today

Target  Federal Aviation Administration, (FAA)
Target  United States Department of Transportation, (DOT)
Target  United States Army
Target  United States Navy (USN)
Target  United States Air Force (USAF) - Spacelift Range Systems Contract (SLRSC)
Target  United States Marine Corps (USMC)
Target  United States Naval Undersea Warfare Centers (NUWC)
Target  United States Coast Guard (USCG)
Target  The National Radio Astronomy Observatory’s Very Large Array (VLA)(One of the world’s premier astronomical radio observatories)

Rust Bullet is a Moisture Cure Urethane

Moisture cured means using the natural elements of the atmosphere for curing. This means no artificial heat source is required, no additional activator or component required. Although Rust Bullet Products contain isocyanates, they are not free isocyanates, but rather are safely bound in the polymer chain and pose no health or environmental risk when Rust Bullet is applied according to guidelines as set forth by Rust Bullet, LLC. Rust Bullet is an Aromatic Urethane with Aliphatic Properties

Aliphatic and aromatic coatings differ in the types of polyols and isocyanates used in the formulation, hence their stability in atmospheric conditions differ significantly. Aliphatic coatings are the superior choice for exterior protection because they are very stable when exposed to ultraviolet light, weathering, and hydrolysis. The raw materials used in formulating aliphatic systems are generally more expensive and have higher viscosities than their aromatic counterparts. Aromatic coatings are more heat and chemical resistant than the aliphatic coatings. Aromatic coatings do not stand up as well against atmospheric exposure since the UV light causes yellowing and chalking.

Because of Rust Bullet’s unique formulation, it is both Aromatic and Aliphatic.

Target  AROMATIC – Strong, Abrasive resistant, Chemical Resistant, Flexible
Target  ALIPHATIC - UV Resistant – will not yellow or chalk

Rust Bullet is a Polyurethane Coating Exhibiting Higher Performance Value than an Elastomeric Coating – with Outstanding Flexible Properties

Due to the cross-linking density of a polyurethane coating (short chains and branching) it shows a high degree of chemical and moisture resistance, as well as excellent adhesive properties. These qualities position polyurethane coatings as the best choice in protecting metals from corrosion. As elastomeric coatings do not perform as well in such areas, they are superior in terms of abrasion and impact resistance as well as protection for substrates that demonstrate more movement than metals (such as concrete). Rust Bullet Products have demonstrated a high competition with the elastomeric coatings in that they exhibit an exceptional abrasion resistance (ASTM D-4060 Abrasion Resistance), Impact Resistance (ASTM D2444) and flexibility (ASTM D-522 Mandrel Bend.

Rust Bullet Coatings Allow for all Exposure Elements

There are three main types of exposure to which coatings are subjected: atmospheric exposure, immersion, and underground exposure. The main difference between atmospheric exposure, immersion, and underground exposure is weather resistance. A coating under atmospheric exposure must endure a variety of conditions, including heating and cooling, oxidation and wetting and drying. Immersion coatings are primarily subjected to water solutions ranging from pure water to high concentrations of various chemicals. Coatings used in underground applications must be resistant to groundwater and soil forces, so they are generally applied thicker than atmospheric or immersion coatings.

Rust Bullet Coatings Provide Optimum Performance in all Three Environments

Target  Atmospheric – Thermal Stability, UV Resistance, Waterproof, Flexibility
Target  Immersion – Water Proof, Chemical Resistance
Target  Underground – Water Proof, Impact Resistance

Rust Bullet is a 70% (+/- 2%) Solids Product

The high solids in Rust Bullet Coatings means a low content of solvents, which evaporate during curing, therefore more than 70% (+/- 2%) of the product applied to the surface will remain on the surface. This is a more environmentally friendly and safer to use product, with decreased levels of flammability and health risk. Additionally this is a more cost-effective coating with the advantage of additional thickness which helps increase physical properties and chemical resistance.

Rust Bullet’s Unique Formula is Stronger than other Aluminum Coatings

Overlapping aluminum flakes add strength and durability as opposed to aluminum powders.

Rust Bullet has Advantages Over and Will Outperform Epoxy Coatings

Rust Bullet is a one part process and the initial coat of Rust Bullet is ready for the second and any required subsequent coats within 2 to 6 hours. Although Rust Bullet does not require a catalyst for curing, Rust Bullet coatings can be made to cure up to 80% faster by using the Rust Bullet Rapid Fire Accelerator. A topcoat may be applied within 12 hours after the final coat of Rust Bullet. Rust Bullet does continue to cure for approximately 3-5 days. Epoxy coatings generally take 7 – 10 days to fully cure and allow the solvents to evaporate, some even require force curing. 

Due to the exothermic (heat releasing) nature of the reaction during curing of polyurethanes, these coatings can cure at almost any ambient temperature, even during the cold months of the year. Epoxy coatings require temperatures above 50°F.

Rust Bullet Coatings feature a unique “self-inspecting” property in that they fail almost immediately if they are incorrectly applied or if there is a problem with the surface preparation. Thus polyurethane coatings can be inspected immediately after application and any defects in the coating will be visible and can be readily remedied. This is not the case with an epoxy coating that requires an extended curing time and multiple step process for remedy. Breaches in an epoxy coating are labor intensive and will involve a large area outside the breach to be included in the repair. Rust Bullet Coatings rarely experience a breach, but when they do occur, are easily repaired with simple scuffing and application of additional Rust Bullet Product.

The plural components of epoxy coatings require precise mixing ratios be obtained at the point of application to avoid coating defects and failures. This is not an issue with Rust Bullet Coatings as they are a one-part, multiple coat process.

Rust Bullet vs. Polyethylene Coatings

A polymer is a large molecule ( macromolecule ) composed of repeating structural units connected by covalent chemical bonds . Polyethylene coatings are produced by filling a pipe with beads of polyethylene and heating until the polyethylene melts and adheres to the pipe interior. Polyethylene is a thermoplastic material which may tend to degrade and become soft when exposed to heat, hence the name thermoplastic. Rust Bullet Products thermal stability is a great asset; 314°F sustained, up to 662°F for up to 72 hours with no visible coating degradation. Additionally the surface burning characteristics of Rust Bullet have proven Rust Bullet will outperform most fire-retardant coatings. Rust Bullet Coatings exhibited a smoke index at 5% and flame spread index at 0% based on the ASTM E84 Surface Burning Characteristics Test.

Rust Bullet Coatings have Superior Adhesive Qualities

Adheres to polished chrome, galvanized surfaces, stainless steel, cold rolled steel, hot rolled steel, fiberglass, to name a just a few.

How Rust Bullet Protects Surfaces

The three recognized methods of protection that coatings provide are; barrier protection, inhibition, and sacrificial action. Barrier Protection blocks moisture, oxygen and other chemicals from the substrate. All coatings are permeable to some degree, but barrier coatings have relatively low moisture permeability. Inhibitive coatings contain special pigments to inhibit or interfere with the corrosion reactions on the substrate. As moisture passes through the coating film, the anti-corrosive pigments slowly dissolve and aid in stopping corrosion. Sacrificial action is the method used by zinc- and aluminum rich coatings. 

Target  Rust Bullet provides a barrier coating that is non-porous and impermeable
Target  Rust Bullet contains special pigments that inhibit corrosion
Target  Rust Bullet is an aluminum rich coating which will “sacrifice” surface integrity over time saving the substrate to which it has been applied

Rust Bullet is the Premium Coating Solution for Asset Protection. For more information about Rust Bullet products, please explore the rest of this website.