Soudal Alu-Zinc Spray - Shiny Finish

Health & Safety Recommendations

Take the usual labour hygiene into account and consult the packaging label and safety data sheet before use. Apply Soudal Alu-Zinc Spray only in well-ventilated areas and keep away from ignition sources, hot surfaces and open flames.

Avoid inhalation of spray or vapour and avoid contact with skin and eyes. Wear suitable gloves and eye protection, particularly when working overhead or inside enclosures. In case of contact with eyes, rinse immediately with plenty of clean water and seek medical advice if irritation persists. Do not smoke during application.

Store and transport the aerosol upright where possible and do not expose the can to temperatures above 50°C. Respect all precautions for use printed on the packaging.

Substrate Suitability

This product is intended for metals and metal assemblies including damaged steel and zinc surfaces. Substrates should be rigid, clean, dry and free of dust and grease so the coating can achieve a reliable key. It is not suitable for low-surface-energy plastics such as PE, PP, PTFE or EVA where adhesion will be poor.

Where mixed materials are present or the substrate history is unknown, carry out a preliminary adhesion test on an inconspicuous area. Alu-Zinc Spray can be used on rust provided all loose material is removed first and a sound surface is presented.

Surface Preparation

Ensure the work area and substrate are dry. Remove all loose rust, mill scale and old, flaking coatings by wire brushing, scraping or abrasive preparation to expose sound metal.

Degrease thoroughly to eliminate oil and contaminants that could interfere with adhesion and galvanic action. Feather firm surrounding paint to a smooth edge and vacuum or wipe away dust. Mask adjacent areas that do not require treatment. Application should not proceed if condensation, rain or surface moisture is present.

Application Method

After loosening the mixing ball, shake the can vigorously for 30 seconds to re-disperse the metallic pigments. Hold the nozzle approximately 20cm from the surface and apply smooth, overlapping passes to produce an even film without runs.

Shake the canister thoroughly before applying each layer to maintain pigment suspension. Always apply Soudal Alu-Zinc Spray in two coats with a minimum interval of 2 hours between coats. Application must take place on a dry, grease-free substrate and in dry ambient conditions.

Angle the spray to ensure complete coverage of edges, drilled holes and welds so the alu-zinc-rich layer is continuous. After the final coat, allow adequate drying before handling or overcoating. The coating is repaintable after 24 hours with a compatible finishing coat.

Coverage

On smooth, non-absorbent steel, a 400ml aerosol typically yields around 1.5m² at standard film builds. Actual coverage will vary with surface profile, application technique, film thickness, edge concentration and overspray.

As the system requires two coats, allow sufficient material to achieve a continuous alu-zinc-rich film across all faces, edges, cut ends and welds.

Drying Time

At approximately 23°C and 50%RH the coating is dust-dry after 10–15min and tack-free after 20–30min. Full cure and repaintability are typically achieved after 24 hours.

Drying depends on temperature, airflow, humidity and applied film thickness; cooler or more humid conditions extend times, while warmer, well-ventilated conditions shorten them.

Cleaning

On completion of spraying, invert the can and discharge for about 3 seconds until only propellant emerges. This clears the valve and actuator and helps prevent blockage by zinc residues.

Remove overspray from adjacent surfaces promptly with a suitable solvent wipe. Clean masking while the coating is just tack-free to minimise edge lift. Dispose of used wipes and empty cans in accordance with local regulations.

Limitations

Do not apply to wet, greasy, dusty or unstable substrates. Do not apply to low-surface-energy plastics where adhesion cannot be assured. Avoid application in rain, fog, active condensation or when the substrate is colder than the surrounding air.

The coating provides sacrificial and barrier protection but is not a structural repair; severely corroded or perforated sections require proper fabrication repair. Where long-term exposure or immersion is expected, confirm whether a compatible finishing system is required. Do not spray into live electrical equipment and do not use near ignition sources.

Other Information

Basis is a mixture of aluminium-zinc compound with epoxy ester. Consistency is fluid. Curing system is physical drying with typical cure and repaintability after 24 hours.

Total solid content is about 24% and VOC content is about 76%. At 23°C and 50%RH the coating is dust-dry after 10–15min and tack-free after 20–30min. Temperature resistance of the cured film is approximately −30°C→250°C. Recommended application temperature is 5°C→35°C. Typical yield is about 1.5m² per can.

Values are indicative and based on controlled conditions; always verify suitability on site and follow good coating practice to ensure a continuous zinc-rich film for effective cathodic protection.

Q) What is Soudal Alu-Zinc Spray and what problem does it solve?

A) Soudal Alu-Zinc Spray is a high-grade, zinc-rich protective coating supplied in a 400 ml aerosol for fast, precise corrosion control on steel and zinc surfaces. With 98% zinc content in the dry film and added aluminium for appearance and barrier density, it delivers an immediate cold-galvanising action that protects unprocessed iron and steel while restoring defence at cut edges, drilled holes and damaged galvanised areas. The coating cures to a bright, shiny, conductive film that adheres strongly to properly prepared metal and withstands handling, rubbing and erosion in service. Because it provides both sacrificial (cathodic) and barrier protection, it is ideal for touch-up after cutting and welding, for priming bare steel to prevent flash rusting, and for quick, long-lasting treatment on items such as coachwork, gutter braces, weld joints and general steel fabrications. In short, Soudal Alu-Zinc Spray offers a portable, economical alternative to full re-galvanising when on-site speed and dependable protection are required.

Q) How does Soudal Alu-Zinc Spray provide galvanising (cathodic) protection on steel?

A) Soudal Alu-Zinc Spray contains a very high loading of pure zinc particles that pack densely within the cured film and make intimate electrical contact with the underlying steel. This contact creates a galvanic couple in which zinc acts as the sacrificial anode, corroding in preference to the steel when moisture and salts are present. The result is true cathodic protection that continues even if the coating is scratched, arresting corrosion creep at edges and defects. The aluminium enrichment contributes a bright, shiny finish and a compact, adherent matrix that sheds moisture and contaminants, adding barrier performance on top of sacrificial behaviour. Crucially, the film remains electrically conductive when dry, ensuring the galvanic pathway is maintained and allowing processes such as spot welding or weld-through without complete coating removal. Together, these features replicate the protective behaviour of hot-dip galvanising in a fast, easy-to-apply aerosol format suited to fabrication, installation and maintenance.

Q) When should Soudal Alu-Zinc Spray be used and which jobs benefit most?

A) Soudal Alu-Zinc Spray is the go-to choice whenever freshly exposed steel needs immediate, durable protection without access to a galvanising bath. Use it to touch in galvanised fabrications after cutting or drilling, to reinstate protection on welds and heat-affected zones, and to prime bare steel brackets, fixings and frames before exposure or transport. It is equally effective during automotive and trailer repairs for treated edges and patched sections, on gutter braces and roofing accessories exposed to weather, and on structural and architectural details where both corrosion resistance and a neat, shiny appearance are expected. Because the film is conductive after drying, it can remain in place for spot welding and weld-through operations, saving time on masking and clean-back. The precise aerosol pattern makes it practical for edges, fasteners and complex geometries, enabling quick, professional touch-ups on site and in the workshop.

Q) Which substrates are suitable for Soudal Alu-Zinc Spray and which should be avoided?

A) Soudal Alu-Zinc Spray is intended for rigid, metallic substrates; clean, dry, grease-free steel, iron and zinc surfaces that can provide a reliable mechanical key. On these materials the zinc-rich film bonds tenaciously and establishes the electrical contact needed for cathodic protection. It is not suitable for low-surface-energy plastics such as PE, PP, PTFE or EVA, nor for elastomeric and bituminous materials where adhesion is poor. Where mixed assemblies are present or the substrate history is unknown, perform a small adhesion test on an inconspicuous area before full application. The product can be used on rusted steel only after all loose, flaky corrosion has been removed to reveal a sound surface. Do not apply to wet, greasy, dusty or unstable substrates, and avoid flexible materials that move significantly in service, as movement will undermine film integrity over time.

Q) How should I prepare metalwork before applying Soudal Alu-Zinc Spray?

A) Proper preparation is essential for adhesion and galvanic effectiveness. Ensure the work area and substrate are dry. Mechanically remove loose rust, mill scale, oxide bloom and failing paint by wire brushing, scraping or abrasive methods until sound metal is exposed at the repair. Feather firm surrounding paint to a smooth edge so the new coating laps neatly without a ridge. Degrease thoroughly to eliminate oils and contaminants that would block zinc-to-steel contact. Vacuum or wipe away dust, then mask adjacent areas that do not require treatment. Only proceed if there is no condensation or surface moisture, trapped water will compromise adhesion and cathodic behaviour. Good preparation ensures the zinc particles can make intimate contact with the steel, forming the continuous galvanic pathway that underpins the product’s long-term protective action.

Q) What is the correct application method for Soudal Alu-Zinc Spray to ensure full protection?

A) After freeing the mixing ball, shake the can vigorously for at least 30 seconds to re-disperse the metallic pigments, and re-shake before each coat. Hold the nozzle about 20cm from the surface and apply smooth, overlapping passes to achieve an even film without runs. Always apply Soudal Alu-Zinc Spray in two coats, allowing a minimum interval of approximately two hours between coats under normal conditions; this staged build reduces pinholes and ensures a continuous zinc network. Angle the spray to fully cover edges, drilled holes and welds, as these are the primary corrosion sites. Work on a dry, grease-free substrate in dry ambient conditions within the recommended temperature range. After the final coat, allow adequate drying before handling or overcoating. Clearing the valve by inverting the can for a brief burst at the end of the job helps maintain a clean, consistent spray pattern for next use.

Q) How long does Soudal Alu-Zinc Spray take to dry, cure and become repaintable?

A) At around 23°C and 50% RH, Soudal Alu-Zinc Spray is typically dust-dry after 10–15 minutes and tack-free after 20–30 minutes, enabling careful handling. Full cure and repaintability are usually achieved after approximately 24 hours. Drying time depends on film thickness, airflow and humidity: cooler or more humid conditions will extend intervals, while warmer, well-ventilated conditions will shorten them. If masking was used, remove it when the coating is just tack-free to minimise edge lift. When overcoating with a compatible finishing system, ensure the zinc-rich layer has fully cured so adhesion is secure and sacrificial protection is not impeded. As with any zinc-rich primer, a short wait for complete solvent release pays dividends in long-term performance and appearance.

Q) Can Soudal Alu-Zinc Spray be spot welded or welded through after it has dried?

A) Yes. Once dry, the Soudal Alu-Zinc Spray film remains electrically conductive, allowing spot welding and weld-through operations without completely stripping the coating. This saves time during assembly and repair. For consistent results, ensure the coating at the weld area is even and not excessively thick so clamping pressure and electrical contact are reliable. It is sensible to perform a quick trial on scrap to confirm nugget quality and refine settings if required. After welding, clean the area and reapply Soudal Alu-Zinc Spray to reinstate sacrificial protection at the heat-affected zone and any freshly exposed steel. Always follow standard welding safety and fume extraction practices, as conductive coatings do not negate the need for appropriate controls.

Q) Can Soudal Alu-Zinc Spray be used on rusted steel and what are the practical limits?

A) Soudal Alu-Zinc Spray can be used on lightly rusted steel as a rapid protective measure provided all loose, flaky corrosion is removed and a sound, stable surface is presented. The zinc-rich film will stabilise the area and limit further oxidation until full refurbishment can be scheduled. However, it is not a structural repair and should not be applied over heavy, active corrosion, perforation or delaminated steel, such defects require proper fabrication repair. For best long-term outcomes, clean back to bright metal wherever possible, apply two coats as specified, and consider a compatible finishing coat in aggressive environments. Always assess the condition of the substrate honestly; sacrificial coatings protect steel, but they cannot rebuild lost section or restore mechanical integrity.

Q) What finish and appearance does Soudal Alu-Zinc Spray leave on the metal?

A) Soudal Alu-Zinc Spray cures to a bright, shiny aluminium-zinc finish that blends well with many galvanised surfaces, providing a professional touch-in rather than a dull patch. The sheen helps repaired areas look clean and consistent on visible items such as handrails, brackets, coachwork and architectural details. The finish is not purely cosmetic: the aluminium enrichment contributes to a dense, adherent film that sheds moisture and contaminants, complementing the sacrificial action of the zinc. Because the coating is conductive, it retains practical utility in fabrication settings where spot welding or electrical continuity is needed. If a different colour or gloss level is required for design reasons, the cured film can be repainted with a compatible finishing system after roughly 24 hours.

Q) How much coverage will I get from a can of Soudal Alu-Zinc Spray and how do I maximise yield?

A) On smooth, non-absorbent steel, a 400 ml aerosol of Soudal Alu-Zinc Spray typically yields about 1.5 m² at standard maintenance film builds. Actual coverage varies with surface profile, application technique, film thickness, edge concentration and overspray. To maximise yield without compromising protection, prepare the surface thoroughly for excellent adhesion, spray at the recommended 20 cm distance with steady, overlapping passes, and focus effort on edges, holes and welds where zinc density is most critical. Two lighter coats with the specified interval outperform a single heavy pass, reducing runs and solvent entrapment. Mask neighbouring areas to reduce waste and achieve a neat edge, and keep the nozzle clean so the spray pattern remains tight and accurate.

Q) What key technical data define Soudal Alu-Zinc Spray’s performance envelope?

A) Soudal Alu-Zinc Spray is based on an aluminium-zinc compound in an epoxy-ester binder, supplied as a fluid aerosol coating that cures by physical drying. The dry film contains 98% zinc for robust sacrificial behaviour. Typical drying at 23°C/50% RH is 10–15 minutes to dust-dry and 20–30 minutes to tack-free, with full cure and repaintability after about 24 hours. Recommended application temperature is 5°C to 35°C, and the cured film exhibits temperature resistance of approximately −30°C to 250°C. Indicative total solids are around 24% with VOC content about 76%. A single can yields roughly 1.5 m² depending on profile and build. These parameters guide planning for application, drying windows and service conditions, ensuring the coating delivers the intended combination of cathodic protection, barrier performance and attractive shiny finish.

Q) What practical hints and tips will improve results with Soudal Alu-Zinc Spray?

A) Shake frequently to maintain pigment suspension and always apply two coats with at least a two-hour interval to minimise pinholes and ensure a continuous zinc network. Prioritise bright, grease-free metal at repair sites; zinc must touch steel to protect it sacrificially. Approach edges, drilled holes and welds from multiple angles so coverage is complete, and keep the can moving to avoid sags. Work only in dry conditions within 5–35°C and avoid substrates colder than the ambient air, which can cause condensation. Feather surrounding paint, remove masking while the film is just tack-free, and allow around 24 hours before overcoating. Invert the can for a few seconds after use to clear the valve, preventing blockages. For aggressive environments or immersion-like exposure, plan a compatible finishing coat over the cured zinc layer to boost barrier performance.

Q) What are the limitations of Soudal Alu-Zinc Spray and when is a finishing system advisable?

A) Soudal Alu-Zinc Spray provides sacrificial and barrier protection but is not a remedy for severe corrosion, perforation or structural damage; such defects demand cut-out and proper repair. The product is unsuitable for low-surface-energy plastics, elastomeric or bituminous substrates, and must not be applied to wet, greasy, dusty or unstable surfaces. Avoid application in rain, fog, active condensation or when the substrate is colder than the air. In harsh environments with long-term exposure or frequent wetting, a compatible finishing coat over the fully cured Alu-Zinc layer is often advisable to reinforce barrier protection while allowing the zinc beneath to defend at defects. Do not spray into live electrical equipment and keep away from ignition sources. Where appearance or durability is critical, validate the whole system with a small on-site trial before large-scale use.

Q) How should Soudal Alu-Zinc Spray be stored, handled and cleaned up for safe, consistent use?

A) Store Soudal Alu-Zinc Spray upright in a cool, dry place away from direct sunlight and heat sources, and never expose aerosols to temperatures above 50°C. Use only in well-ventilated areas, keep away from ignition sources and do not smoke during application. Wear suitable gloves and eye protection, particularly when working overhead or inside enclosures, and avoid inhalation of spray or vapour. In case of eye contact, rinse immediately with plenty of clean water and seek medical advice if irritation persists. After spraying, invert the can and discharge for about 3 seconds until only propellant emerges to clear the valve and actuator. Remove overspray promptly with a suitable solvent wipe, and dispose of used wipes and empty cans in accordance with local regulations. Sensible storage, PPE and housekeeping ensure repeatable, professional results every time.

Q) Can Soudal Alu-Zinc Spray be overcoated and what should I check before painting?

A) Yes, Soudal Alu-Zinc Spray can be repainted after approximately 24 hours of curing under normal conditions. Overcoating with a compatible finishing system can enhance colour match, gloss and cleanability, and can further strengthen barrier protection in demanding service. Before painting, confirm the zinc-rich layer is fully cured, clean and lightly abraded if the finishing product requires a key. Always check compatibility and adhesion with a small on-site test, especially where appearance and long-term durability are critical. Maintain continuity of the underlying zinc network at edges and defects so sacrificial protection remains effective beneath the finish. Proper sequencing, prepare, apply Alu-Zinc in two coats, allow full cure, then overcoat, delivers a robust, attractive, long-lasting result.

Q) Why choose Soudal Alu-Zinc Spray instead of a standard grey zinc spray for visible repairs?

A) Soudal Alu-Zinc Spray combines the proven cathodic protection of a 98% zinc dry film with an aluminium-enriched, bright, shiny appearance that blends more sympathetically with many galvanised surfaces than a dull grey. This means edges, holes and weld touch-ins are protected sacrificially while looking clean and consistent on visible fabrications, coachwork and architectural details. The dense, adherent film resists handling and abrasion, and its conductivity supports spot welding and weld-through once dry. Where aesthetics matter alongside performance, handrails, balustrades, exterior brackets and frames, Soudal Alu-Zinc Spray offers a professional-looking finish without sacrificing genuine galvanising action. For areas where a matt look is preferred, a compatible finish coat can be applied after cure, maintaining the zinc protection beneath.

Technical Data Sheet

Safety Data Sheet

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