Soudal Zinc Spray - Matt Finish

Health & Safety Recommendations

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

Avoid inhaling spray or vapour and avoid contact with skin and eyes. Wear suitable gloves and eye protection, especially when working overhead or in confined locations. 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.

Substrate Suitability

Soudal Zinc Spray is intended for rigid, metallic substrates and is compatible with properly prepared steel, iron and zinc surfaces. It is not suitable for low surface energy substrates such as PE, PP, PTFE or EVA and will show poor adhesion on such materials.

Where mixed assemblies are present or the substrate history is unknown, perform a preliminary compatibility test on an inconspicuous area. For best results, apply only to dry, clean and grease-free metal that can provide a sound key for the coating.

Surface Preparation

Ensure the surface is rigid, clean, dry and free of dust, grease and contaminants. Remove rust, mill scale, oxide bloom and old loose paint by wire brushing, abrasive paper or blasting to expose bright metal.

Degrease thoroughly so that the zinc-rich coating can make direct contact with the substrate. Feather firm surrounding paint to a smooth edge and vacuum away dust. Mask adjacent areas that do not require treatment. Application should be carried out on a dry substrate in dry conditions to prevent moisture entrapment under the coating.

Application Method

Shake the can thoroughly before use and again before applying each layer to re-disperse the zinc content. Hold the nozzle approximately 20cm from the surface and apply in smooth, overlapping passes to achieve an even film.

Always apply Soudal Zinc Spray in two layers with a minimum interval of 2 hours between coats. Maintain the can in motion to avoid local over-build and potential runs. For edges, drilled holes and welds, angle the spray to ensure complete coverage and continuity of the zinc film. Application should take place on a dry substrate in dry ambient conditions.

The product is suitable for conductive touch-in and can be used where spot welding through the coating is required once dry. After the final coat, allow adequate drying before handling or overcoating.

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 zinc-rich film across all faces, edges, cut ends and welds.

Drying Time

At normal room conditions the coating is dust-dry after approximately 10 to 15min and tack-free after about 20 to 30min. Full cure and repaintability are typically achieved after 24 hours.

Drying times depend on film thickness, temperature, airflow and humidity; cooler or more humid conditions will extend the intervals, while warmer, well-ventilated conditions will 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 at the next use.

Remove overspray from adjacent surfaces promptly with a suitable solvent wipe. Clean masking while the coating is still tack-free to reduce 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, bituminous coatings or elastomeric materials where adhesion cannot be assured.

Avoid application in rain, fog, condensation or when the substrate is colder than the surrounding air, as this can lead to moisture entrapment and reduced adhesion. The coating provides sacrificial and barrier protection but is not a structural repair; severely corroded sections and perforations must be cut out and repaired appropriately.

Where long-term exposure or immersion is expected, consult the specification to determine whether a compatible finishing coat is required. Do not use near energised ignition sources and do not spray into live electrical equipment.

Other Information

Base is a mixture of zinc compound with epoxy-ester. Curing system is physical drying with typical repaintability after 24 hours. Application temperature should be between 5°C and 35°C. Temperature resistance of the cured film is approximately −30°C to 350°C.

Typical yield per can is about 1.5m² depending on profile and film thickness. Solid content is around 46% and VOC content is about 54%. Soudal Zinc Spray is suitable as a cold galvanising repair coating and conforms to ASTM 780-93 guidance for the repair of galvanised coatings.

Always verify suitability through site trials where conditions are variable and follow good coating practice to ensure continuity of the zinc-rich film for effective cathodic protection.

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

A) Soudal Zinc Spray is a high-grade, zinc-rich protective coating supplied in a convenient 400ml aerosol for fast, precise corrosion protection on steel and zinc surfaces. With a 98% zinc content in the dry film, it delivers an immediate “cold galvanising” action to shield unprocessed iron and steel from rust while restoring protection to cut edges, drilled holes and damaged galvanised areas. Once applied, the coating cures to a conductive, matt finish that adheres strongly to properly prepared metal and resists mechanical shocks, rubbing and erosion. This combination of barrier protection and sacrificial behaviour prevents corrosion creep at vulnerable details during fabrication, installation and maintenance. Because it can be applied on site without tanks or special equipment, Soudal Zinc Spray is ideal for touch-in after cutting and welding, for priming bare steel to prevent flash rusting, and for extending service life where the original galvanised layer has been compromised but full re-galvanising is impractical.

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

A) Soudal Zinc Spray contains an exceptionally high loading of pure zinc particles that pack densely in the cured film and make intimate contact with the underlying steel. This close electrical contact allows the zinc to act as a sacrificial anode: in the presence of moisture and salts, zinc preferentially corrodes in place of the steel, maintaining a galvanic pathway that protects even if the coating is scratched. The film’s electrical conductivity is central to this mechanism, as it enables current flow between the zinc and the steel substrate. In practice, this cathodic action arrests rust formation at cut edges, drilled holes and weld zones where corrosion typically begins, while the physical film also acts as a barrier to water and contaminants. The result is a twofold defence, sacrificial and barrier, that replicates the protective behaviour of hot-dip galvanising in a portable, easy-to-apply aerosol format suited to workshop and on-site tasks.

Q) What key technical characteristics define Soudal Zinc Spray’s performance?

A) Soudal Zinc Spray lays down a conductive, matt finish coating with 98% zinc content in the dry film, formulated on a zinc compound with an epoxy-ester base. It cures by physical drying to a robust film that is dust-dry in roughly 10–15 minutes, tack-free in about 20–30 minutes and typically ready for repainting after 24 hours under normal conditions. The cured coating resists mechanical shocks, rubbing and erosion, and it remains suitable for spot welding and weld-through operations thanks to its electrical conductivity. Recommended application temperatures are between 5°C and 35°C; the finished film tolerates service temperatures of approximately -30°C to 350°C. A typical 400 ml can yields around 1.5 m² depending on profile and target film build. Solids content is about 46% with a VOC content of roughly 54%. These attributes combine to deliver fast, durable, zinc-rich protection with a clean, low-gloss aesthetic that blends discreetly with galvanised fabrications.

Q) Where and when should Soudal Zinc Spray be used for best results?

A) Soudal Zinc Spray excels wherever steel is cut, drilled or welded and immediate corrosion protection is required without the infrastructure of a galvanising plant. Typical uses include touching in galvanised handrails and brackets after fabrication, protecting bare steel fixings and edges on site before exposure, stabilising welds and heat-affected zones, and priming small components during maintenance. It is equally useful for machinery guards, frames and repairs that will be handled or transported before final finishing. In construction, it protects bolted connections, lighting brackets, balustrade details and sign supports; in automotive and bodywork it helps defend patched sections, drilled panels and brackets prone to stone-chip and water exposure. Because the coating is conductive, it can be left in place where spot welding or weld-through operations are required once dry, reducing masking and rework. Apply only to dry, clean, grease-free metal prepared to provide a sound key.

Q) Is Soudal Zinc Spray suitable for touching in damaged galvanised coatings and cut edges?

A) Yes. Soudal Zinc Spray is designed precisely for touch-in of galvanised steel where the protective layer has been removed by cutting, drilling, grinding or minor damage. The 98% zinc content enables effective cathodic protection at vulnerable details such as edges, holes and welds, limiting the risk of corrosion creep beneath adjacent coatings. After thorough surface preparation to bright, grease-free metal and careful masking of surrounding areas, apply in two coats as directed to build a continuous zinc network at the interface. The matt finish blends discreetly with most factory galvanised appearances, avoiding the gloss mismatch that can highlight repairs. For long-term exposure or aggressive environments, a compatible finishing coat may be specified over the cured zinc-rich layer to increase barrier performance while preserving sacrificial protection at defects. Always verify system compatibility on a small area where appearance and durability are critical.

Q) Can Soudal Zinc Spray be spot welded or welded through, and what should I consider?

A) The cured film of Soudal Zinc Spray remains electrically conductive, allowing spot welding and weld-through where appropriate once the coating is dry. This saves time during assembly by reducing the need to strip back to bare metal at every contact point. For best results, ensure the coating is fully dry, applied evenly and not excessively thick at the weld site so electrical contact and clamping pressure are reliable. Adjust weld parameters if required and perform a brief trial on scrap to confirm nugget quality. After welding, clean the affected area and re-apply Soudal Zinc Spray to restore sacrificial protection at the heat-affected zone and adjacent cut edges. Observe normal welding safety protocols and ventilation; although the product facilitates weld-through, correct fume extraction and personal protection remain essential in any fabrication environment.

Q) Which substrates are compatible with Soudal Zinc Spray and which are not recommended?

A) Soudal Zinc Spray is intended for rigid metallic substrates, properly prepared steel, iron and zinc surfaces that can provide a sound mechanical key. When applied to clean, dry, degreased metal, the epoxy-ester zinc-rich film adheres strongly and delivers both barrier and cathodic protection. It is not suitable for low surface energy plastics such as PE, PP, PTFE or EVA, and adhesion to elastomeric or bituminous materials is poor and not recommended. Where mixed assemblies are present or the substrate history is uncertain, conduct a small compatibility test on an inconspicuous area. Avoid application to unstable, greasy or dusty surfaces, and do not expect reliable performance on flexible substrates that move significantly in service. For complex assemblies, mask off adjacent materials that do not require treatment to maintain neat edges and avoid unwanted overspray.

Q) How should I prepare the metal before applying Soudal Zinc Spray?

A) Effective surface preparation is vital to achieve galvanic contact and long-term adhesion. Begin by ensuring the substrate is rigid, dry and free from oil, grease and contaminants. Mechanically remove rust, mill scale, oxide bloom and any loose or flaking paint using wire brushing, abrasive paper or blasting until bright metal is exposed at the repair area. Feather back sound surrounding coatings to a smooth edge so the new film can be lapped neatly. Vacuum or wipe away dust and thoroughly degrease the cleaned metal with an appropriate solvent to promote direct zinc-to-steel contact. Mask adjacent areas to protect finishes that do not require treatment. Only apply Soudal Zinc Spray in dry conditions to a dry substrate; moisture trapped beneath the film will undermine adhesion and galvanic performance. Correct preparation is the single biggest factor in ensuring the coating provides the sacrificial protection it is designed to deliver.

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

A) Shake the can thoroughly before use, and re-shake between coats to keep zinc uniformly suspended. Hold the nozzle about 20 cm from the surface and apply smooth, overlapping passes to achieve even coverage without runs. Angle the spray to reach edges, drilled holes and welds so zinc particles build a continuous network at all vulnerable details. Always apply two coats, allowing a minimum interval of roughly 2 hours between applications under normal conditions; this staged build delivers a robust zinc-rich film and minimises pinholes. Maintain the can in motion to avoid local over-build. Application should be carried out on a dry substrate in dry ambient conditions within the recommended temperature range. After the final coat, allow adequate drying before handling or overcoating. For small fasteners and brackets, a focused spray pattern helps minimise overspray while ensuring target film build where protection is most needed.

Q) How long does Soudal Zinc Spray take to dry and when can it be overcoated or handled?

A) Under typical room conditions, Soudal Zinc Spray becomes dust-dry after about 10–15 minutes and tack-free after roughly 20–30 minutes, permitting light handling with care. Full cure and repaintability are typically achieved after 24 hours, at which point compatible finishing coats can be applied if specified. Drying times depend on film thickness, temperature, airflow and humidity: cooler, still or humid conditions extend intervals, while warmer, well-ventilated environments shorten them. As with any zinc-rich system, allow the film to stabilise before heavy handling or overcoating so adhesion and galvanic performance are not compromised. If masking has been used, remove it while the coating is just tack-free to reduce the risk of edge lift. Always check a small area before proceeding with full overcoat applications, especially where appearance standards are high.

Q) Can Soudal Zinc Spray be painted over and when is a finishing coat advisable?

A) Yes, Soudal Zinc Spray is typically ready for repainting after approximately 24 hours of curing in normal conditions. Overcoating with a compatible finishing system can improve barrier protection, colour match and cleanability in service, while the underlying zinc continues to offer sacrificial defence at defects. A finishing coat is often advisable in aggressive environments or where long-term exposure and frequent wetting are expected; it can also provide UV uniformity on visually exposed steelwork. Always confirm compatibility and adhesion with a small on-site test, and follow the finishing paint manufacturer’s guidelines for preparation over zinc-rich primers. For immersion or highly corrosive conditions, consult the specification to determine whether a multi-coat system is required. Regardless of the overcoat, ensure the zinc layer is continuous and fully cured so cathodic protection can function as intended.

Q) How much coverage can I expect from a 400ml can of Soudal Zinc Spray and how can I maximise yield?

A) A typical 400ml can of Soudal Zinc Spray yields about 1.5 m², although actual coverage varies with surface profile, application technique and target film thickness. To maximise yield without compromising protection, prepare the metal thoroughly so adhesion is excellent and unnecessary rework is avoided, spray at the recommended distance with smooth, overlapping passes, and focus on edges, holes and welds where zinc density is most critical. Avoid heavy, localised build that can run or trap solvent; two lighter coats with the correct interval deliver a more uniform, effective film than a single heavy pass. On complex details and fasteners, use short bursts and adjust the angle to minimise overspray while ensuring continuity of the zinc network. Proper masking of adjacent areas also reduces waste and produces a cleaner, more professional result.

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

A) Shake thoroughly and often to keep zinc dispersed, and always apply two coats with the recommended interval to reduce pinholes and ensure a continuous galvanic pathway. Prioritise bright, grease-free metal at repairs; zinc needs direct contact with steel to work sacrificially. Spray edges and drilled holes from multiple angles to guarantee complete coverage, and maintain a moving, even pass to avoid sags. Work in dry conditions within 5–35°C, and do not apply if the substrate is colder than the air or if condensation is present. For neat repairs, feather surrounding paint and remove masking while the film is just tack-free. After use, invert the can and clear the nozzle for a few seconds so the valve stays clean for the next job. Finally, if the item will face harsh exposure, plan a compatible finishing coat once the zinc-rich layer has cured to 24 hours.

Q) What are the limitations of Soudal Zinc Spray and when is another approach required?

A) Soudal Zinc Spray provides barrier and sacrificial protection but it is not a structural repair; severely corroded or perforated steel must be cut out and replaced, not coated over. The product is intended for rigid metals and will not adhere reliably to low surface energy plastics, elastomers, bituminous coatings or unstable, greasy or wet substrates. Avoid application in rain, fog or condensation, or when the substrate is colder than the air, as moisture entrapment reduces adhesion and galvanic performance. For prolonged immersion or very aggressive atmospheres, a specified multi-coat system may be required over the zinc-rich layer. The aerosol must not be used near ignition sources or sprayed into live electrical equipment. Where cleanliness, colour match or gloss uniformity are paramount, plan an appropriate finishing coat after full cure and verify appearance on a small test area.

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

A) Store Soudal Zinc Spray upright in a cool, dry place away from direct sunlight and sources of heat, and never expose aerosols to temperatures above 50°C. Use only in well-ventilated areas and keep away from ignition sources, hot surfaces and open flames. Wear suitable gloves and eye protection, especially when working overhead or in confined locations, and avoid inhaling 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 three seconds until only propellant emerges to clear the valve and actuator. Remove overspray from adjacent surfaces 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 the product delivers reliable protection every time.

Q) Does Soudal Zinc Spray align with recognised guidance for galvanised repair work?

A) Soudal Zinc Spray is intended as a cold galvanising repair coating and is suitable for touching in galvanised steel where factory coatings have been cut or lightly damaged, consistent with recognised guidance for repair of galvanised coatings such as ASTM 780-93. While such documents outline good practice for surface preparation, application and performance expectations, conditions vary from site to site. For critical work, confirm suitability through on-site trials, adhere strictly to preparation and application recommendations, and, where needed, incorporate compatible finishing coats to meet the service environment. By combining high zinc loading, strong adhesion and a conductive matt film, Soudal Zinc Spray offers a practical, standards-aware route to restoring sacrificial protection quickly and cleanly in both workshop and field applications.

Technical Data Sheet

Safety Data Sheet

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