PRODUCT DESCRIPTION

High Ratio Calcium Sulfonate Alkyd Coating

One-Coat Active Corrosion Protection

Single-pack direct-to-metal (DTM) one-coat system that actively bonds and neutralizes structural surfaces, formulated to substitute primer, intermediate and topcoat configurations adhering to international environmental protection policies.

Riveted steel truss bridge with grey-coated beams

Recognized as a top-performing system in Federal Highway Administration (FHWA) tests since the 1980s, HRCSA was introduced as an encapsulating coating system as an alternative to traditional primer, intermediate and topcoat configurations eliminating the need for sweep or grit blasting. The technology cuts project overheads, reduces surface preparation and product application time and preserves site conditions resulting in minimal environmental pollution.

Active Interfacial Neutralization

RUSTOPAK® High Ratio Calcium Sulfonate Coating is a highly engineered, single-component polymer architecture that chemically alters the interfacial environment to actively inhibit corrosion as an Over-Based Sulfonate-Carbonate Complex widely recognised as a maintenance over-coat direct to metal (DTM) onto zinc bearing steel (Hot Dip Galvanizing), un-galvanised metal that is not corroding or with tightly adherent corrosion and tightly adherent weathered coatings as a One-Coat high performance solution.

Active Interfacial Neutralization

RUSTOPAK® High Ratio Calcium Sulfonate Coating is a highly engineered, single-component polymer architecture that chemically alters the interfacial environment to actively inhibit corrosion as an Over-Based Sulfonate-Carbonate Complex widely recognised as a maintenance over-coat direct to metal (DTM) onto zinc bearing steel (Hot Dip Galvanizing), un-galvanised metal that is not corroding or with tightly adherent corrosion and tightly adherent weathered coatings as a One-Coat high performance solution.

Zoomed view of RUSTOPAK® coating on a Transnet crane structure.
STOP RUST HERE

RUSTOPAK®

Applied onto low traffic surfaces, HRCSA bonds and neutralizes the following substrates.

Zinc-coated (hot-dip galvanised) structural components

Direct-to-metal application to smooth or weathered hot-dip galvanised surfaces.

Learn more

Bonding to the surface

HRCSA bonds through a coordinating mechanism using electrostatic attraction, allowing direct-to-metal application to smooth or weathered zinc-coated (hot-dip galvanised) substrates.

Hydrophobic protection

The overbased calcium sulfonate matrix forms a thixotropic, overlapping lattice of crystalline calcite (CaCO₃) platelets. The hydrophobic, self-healing matrix seals the treated surface from moisture, inhibiting sacrificial zinc consumption.

Active neutralisation

The supplied formulation description identifies an alkaline sulfonate-carbonate complex that raises the surface pH to ≥ 10.1 and actively neutralizes the treated surface.

Electroplated metal components

Included among the substrates listed for low-traffic applications.

Learn more

Application scope

Electroplated metal components are included in the supplied list of substrates to which RUSTOPAK® neutralizes and bonds when applied onto low traffic surfaces.

Ungalvanised steel, rust-free

Direct-to-metal protection for ungalvanised steel without corrosion.

Learn more

Suitable substrate

The supplied Top Coat description includes direct-to-metal application onto ungalvanised metal that is not corroding.

Surface condition

Surfaces must be completely dry and free of contaminants, including oil, grease, salt and dirt, prior to application.

Ungalvanised steel with tightly adherent rust

Treatment of steel where corrosion remains tightly attached.

Learn more

Tightly adherent corrosion

The supplied Top Coat description states that total removal of tightly adherent corrosion is not required. Tightly adherent rust on structural steel must be completely dry and free of contaminants, including oil, grease, salt and dirt, prior to application.

Hard-to-reach areas

RUSTOPAK® Penetrant (Aerosol) is designed for wetting into hard-to-reach areas. Capillary action enables the product to wick into crevices without dismantling structures. The supplied system instructions pair the Penetrant with RUSTOPAK® Top Coat.

Firmly adherent coatings

Overcoating of compatible, tightly adherent weathered coatings.

Learn more

Coating compatibility

The supplied Top Coat instructions allow direct application over compatible, tightly adherent weathered coatings and refer to a specific approved coating list.

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KEY FEATURES

How HRCSA Delivers Active Protection

Direct-to-Metal Bonding

Direct-to-metal application to smooth or weathered zinc-coated substrates.

Learn more

HRCSA bonds through a strong coordinating mechanism, using electrostatic attraction, allowing direct-to-metal (DTM) application to smooth or weathered zinc-coated (hot-dip galvanized) substrates, also adhering to metals, oxides and compounds on weathered structures unlike conventional primer, intermediate and topcoat systems, which rely on hydroxyl bonding and sweep or grit blasting to create a profile for primer coat mechanical interlocking.

Surface Encapsulation

Encapsulation of weathered substrates, metals, oxides and compounds.

Learn more

HRCSA encapsulates smooth or weathered zinc-coated (hot-dip galvanized) substrates, metals, oxides and compounds present on weathered structures, preserving site conditions while saving time and reducing overheads.

Hydrophobic, Self-Healing Matrix

A permanently hydrophobic and self-healing calcite matrix.

Learn more

The overbased calcium sulfonate matrix forms a thixotropic, overlapping lattice of crystalline calcite (CaCO3) platelets. The permanently hydrophobic and self-healing matrix seals smooth or weathered zinc-coated (hot-dip galvanized) substrates from moisture, inhibiting sacrificial zinc consumption and further oxidation of metals.

Active Surface Neutralisation

An alkaline core designed to raise surface pH to ≥ 10.1.

Learn more

HRCSA stops corrosion cell formation through an active sulfonate-carbonate complex. Its dense, alkaline core continuously raises the surface pH to ≥ 10.1, actively neutralizing both metal and zinc-coated (hot-dip galvanized) substrates, preventing further oxidation.

Hybrid Duplex Protection

An organic-inorganic duplex coating for zinc-coated substrates.

Learn more

HRCSA, an organic-inorganic hybrid, comprising a sulfonate organic and calcium inorganic complex, is a duplex coating for zinc-coated (hot-dip galvanized) substrates that actively delivers extended asset protection.

Integrated UV Protection

Integrated UV technology for long-term outdoor and solar exposure.

Learn more

HRCSA’s integrated proprietary UV protection technology is formulated to help mitigate the adverse effects of prolonged ultraviolet (UV) radiation on the coating film, including UV-induced degradation, surface deterioration, loss of protective properties and premature coating ageing.


By supporting the integrity of the coating’s protective film, HRCSA’s integrated proprietary UV protection technology contributes to the sustained performance of the corrosion protection system throughout its intended service life, particularly where infrastructure is subjected to elevated solar radiation, temperature fluctuations and outdoor weathering, such as utility-scale solar park mounting racks.

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ACTIVE PROTECTION

Active Protection at Work

  • Stops iron and zinc oxidation
  • Adheres & spreads onto surfaces
  • Continuously buffers the surface to alkaline range pH 10.1 (basic)
  • Forms impermeable Calcite crystals
  • Remains hydrophobic (water fearing)
  • Remains firm when cured

REAL-WORLD APPLICATIONS

Protection across industrial environments

Explore the assets, structures and surfaces where corrosion control matters.

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RUSTOPAK® Penetrant (Aerosol)

Overview

Rustopak® Penetrant (Aerosol) is a low-VOC, single-component penetrating liquid designed for superior wetting into hard-to-reach areas.

Used in conjunction with Rustopak® Top Coat, it eliminates the need to dismantle and reassemble components during treatment.

Wetting & penetration

Reaches deep into tight crevices where zinc corrosion is accelerated and where joints are corroding.

Access without dismantling

Treats hard-to-reach areas directly, saving labour and time.

Used with Top Coat

Used in conjunction with Rustopak® Top Coat to treat inaccessible areas.

Select a heading to explore the technical detail.

Penetration & corrosion-prone areas

Specially formulated to treat inaccessible areas prone to differential aeration, bimetallic and crevice corrosion through its polar formulation and neutralization to pH 10.1.

Capillary action enables the product to wick deep into areas that are hard to reach without dismantling structures, displacing moisture and oxygen and encapsulating the treated micro-environment.

At the same time, it neutralizes the interfacial surfaces where zinc (hot-dip galvanizing) depletion is accelerated and rust causes damage to critical sections of structures.

Solar mounting structures

Utility-scale solar mounting racking is an example where active protection is needed before the application of Rustopak® Top Coat to stop accelerated corrosion of zinc.

Engineers are recommended to look for the areas on structures where corrosion starts first.

Crevice application

Spray applied directly into hard-to-reach crevices over tightly adherent pack rust (exfoliation corrosion).

RUSTOPAK®Top Coat

Overview

Rustopak® Top Coat is a single-component, specially formulated active sealant system designed as a high-performance, direct-to-metal (DTM), one-coat anti-corrosion coating.

It features low volatile organic compound (VOC) emissions.

Hot-dip galvanizing

Direct-to-metal (DTM) application onto zinc-bearing steel.

Ungalvanized metal

No need for total removal of tightly adherent corrosion.

Weathered coatings

Direct application over compatible, tightly adherent weathered coatings. Refer to the specific approved coating list.

Select a heading to view preparation and application details.

Surface preparation

Tightly adhered rust on structural steel must be completely dry and free of contaminants, including oil, grease, salt and dirt, prior to application.

Application method

System pair: Overcoat directly onto Rustopak® Penetrant (Aerosol).

Technique: Apply using a wet-on-wet application method.

Application & Quality Control

Application Conditions

Select a heading to view the application requirements.

Rain

When there is no rain anticipated for the day of application. Apply when surfaces are totally dry.

Wind

The wind velocity must be low when spray applying. If the velocity of the wind is too high, switch to roller or brush application. Overspray must be contained with suitable protection such as wind fencing, tarps and drop out sheeting. If there is any overspray on equipment not specified to be coated, it is the applicator’s responsibility to remove all overspray. If this occurs, use mineral turpentine and clean cloth.

Temperature & climatic checks

Surface temperatures between -7° C and 54° C can be coated and the dew point may not be less than 3° C differences between the ambient and the surfaces temperatures. If it is less than 3° C, condensation will form on the surface of the substrate. For the application of the coating the surfaces must be totally dry. Climatic reading is a hold point that must be inspected by a qualified coating Inspector or Supervisor using appropriate equipment such as a Dew Point Meter. Readings of climatic conditions submitted on www.rustopak.com.

Top Coat Application Requirements

Application details

Select a heading to view the application instructions.

Application method & film thickness

Apply by brush when spray application would pose site challenges due to equipment set up, overspray or other indeterminate reasons.

The recommended application method for Rustopak® Top Coat is a single application system applied at recommended 600 µm wet film thickness (WFT) or as specified by DFT requirements. WFT reading is a hold point that must be inspected by a qualified coating inspector or supervisor using WFT combs. Readings submitted on www.rustopak.com.

Temperature fluctuations & wet-on-wet application

It is pertinent for Technicians to account for surface temperature fluctuations with the guideline that the application window between 11:00 and 15:00 may not be optimal to achieve the One-Coat process requiring the instructions to move over to the wet-on-wet application procedure.

Where two coats of the Rustopak® Top Coat are required to achieve the specified WFT / DFT, it is important to apply both coats wet-on-wet i.e. apply the first coat and the second coat within a 2 to 4 hour window at 25 °C using approved synthetic long bristle application brushes or airless spraying equipment.

Jointed areas & brush technique

Apply the Rustopak® Top Coat to jointed areas first using clean/new approved synthetic long bristle application brushes. The correct technique of application is to fully saturate the brushes with the thixotropic product, apply the product with the bristles facing downwards, transferring the product onto the surface/s from the side of the brush face. This method allows maximum product discharge onto the surfaces with one pass of the brush.

Airless spray equipment

Airless Spray: 30:1 Graco Bulldog with 9.5 mm ID high pressure line and a Graco Silver Gun with a 0.43 to 0.53 mm spray tip or similar. Note: Brush or roller application is recommended for jointed areas and ease of application.

Application & material temperatures

May be applied to surfaces and in ambient temperatures down to -17.7 °C provided there is no visible condensation or ice present.

The material temperature prior to being applied must be elevated to achieve a workable viscosity. This temperature may be higher than the minimum recommendations of 1.6 to 7.2 °C based on equipment, desired working times and ambient conditions.

Dew point, humidity & surface readings

Ambient temperatures must remain at least 3 °C above the Dew Point and rising during application.

Material should not be applied when the relative humidity exceeds 90% (RH > 90%) or the substrate temperature is higher than 53 °C. Surface particle reading must be between 1 and 3.

Maximum surface salt level must be less than 70 mg/m².

CORROSION

CORROSION BEGINS AT
THE METAL INTERFACE.

Moisture, oxygen, salts and electrical potential can create corrosion cells at joints, fasteners, crevices and weathered steel surfaces. Visible rust is often only the final sign of activity that began beneath or between connected surfaces.

CREVICES & JOINTS

Water and contaminants can remain trapped where surfaces meet, creating a concentrated local environment for corrosion.

GALVANIC CONTACT

Electrical connection between dissimilar metals can accelerate local corrosion where moisture completes the circuit.

WEATHERED STEEL

Damaged coatings and tightly adherent corrosion create difficult maintenance conditions that require a considered protection strategy.

TECHNICAL GUIDANCE AVAILABLE ON REQUEST

TECHNOLOGY

A COATING SYSTEM DESIGNED
TO CHANGE THE INTERFACE.

RUSTOPAK® High Ratio Calcium Sulfonate Alkyd technology is designed to bond directly to metal and create a high-film-build, hydrophobic and alkaline interfacial environment that helps inhibit the conditions required for corrosion to continue.

BOND

Polar chemistry supports metal wetting, moisture displacement and direct-to-metal adhesion.

SEAL

A high-film-build coating creates a hydrophobic barrier against moisture, oxygen and contaminants.

MODIFY

An alkaline reserve supports an interfacial environment less favourable to ongoing corrosion activity.

EXPLORE THE SIX INTEGRATED PROTECTION FEATURES
Zoomed view of RUSTOPAK® coating on a Transnet crane structure.
Riveted steel truss bridge with grey-coated beams
Technicians reviewing course materials and inspection equipment during HRCSA theoretical training.



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Technicians reviewing course materials and inspection equipment during HRCSA theoretical training.

TECHNICAL TRAINING

Technician Training
& Accreditation

Build the knowledge and practical skills to apply Rustopak® with care, consistency and accurate project records.

The programme prepares technicians to work with Rustopak® ISO 9001:2015 aligned Quality Management Instructions (QMI) across industrial coating projects.

Explore the programme
08Training sessions
5h 40mScheduled presentations & theory examination*
On-sitePractical demonstration & trainee practice

*Approximate total for sessions 1–7, excluding breaks. Practical duration depends on site requirements.

PURPOSE

Competence at every project phase

The objective is to deploy trained, authorised and accredited Rustopak® technicians with the knowledge to follow the QMI, carry out project tasks and maintain the required records.

WHO SHOULD ATTEND

Maintenance contractor teams

Maintenance contractors arrange theoretical and practical training for eligible technicians.

  • Able to read, speak and write in English.
  • Physically fit and able and permitted to work at heights.

CORE COMPETENCIES

What technicians will learn

01

Storage & handling

Follow product handling guidelines from receipt through to disposal.

02

Climatic conditions

Assess dew point, relative humidity and surface temperature.

03

Surface checks

Evaluate coating adhesion, surface cleanliness, surface temperature and chloride levels using the applicable inspection and testing requirements.

04

Application skills

Handle products and materials correctly, operate equipment safely and apply the specified wet film thickness (WFT).

05

Product calculations

Calculate product consumption throughout the application process.

06

Quality records

Maintain precise, comprehensive records for the manufacturer, Rustopak and asset owners, following the applicable TDS and QMI requirements.

YOUR TRAINING PATH

From understanding to application

Select a session to see its topics and hold points.

01Corrosion & the Rustopak coating system± 60 min
  • Corrosion explained.
  • Rustopak High Ratio Calcium Sulfonate Coating Service.
02People, toolbox & sample application± 40 min
  • Staff details and qualifications — Hold Point 01.
  • Toolbox — Hold Point 02.
  • Sample application — Hold Point 03.
03Climatic conditions± 35 min

Climatic Conditions — Hold Point 04.

Assessing dew point, relative humidity and surface temperature forms part of the programme’s climatic competency requirements.

04Surface conditions± 60 min

Surface Conditions — Hold Point 05.

  • Visual inspection of existing coating adhesion.
  • Visual standard for surface cleanliness of prepared surfaces (particles).
  • Test for chlorides.
  • Surface temperature measurement.
05Application & film thickness± 65 min

Application — Hold Point 06.

  • Wet Film Thickness Gauge.
  • Dry Film Thickness: Non-destructive Test.
06Storage, handling & waste disposal± 35 min
  • Storage & Handling — Hold Point 07.
  • Waste Disposal — Hold Point 07.
07Theory examination± 45 min

Examination of theory by the trainer.

08On-site practicalSite dependent

Site arrangements are coordinated before and after the practical, covering equipment, toolbox, product and the structure.

  • Practical demonstration by the trainer.
  • Trainee practical.

The duration is determined by site information.

ASSESSMENT & RECORDS

Demonstrate competence.
Record successful completion.

The programme includes a theory examination and an on-site practical. Following successful course completion, accredited technician details are processed onto the Rustopak database.

Supporting instructions

Training works with the Rustopak ISO 9001:2015 aligned Technical Data Sheet and Quality Management Instructions.

TDS-RSP.HRCSA.TC.TDS.26.01
RSP-QMI-26-04

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TESTING & ANALYSIS

Electrochemical Impedance Spectroscopy

Understanding the EIS measurement method and how its data is interpreted.

Measurement method

Electrochemical Impedance Spectroscopy (EIS) is a non-destructive, in-situ technique used to characterize corrosion by measuring the electrical impedance of a system across a wide frequency range, typically 100,000 to 0.01 Hz. The method applies a small alternating voltage and measures the resulting current to determine parameters such as polarization resistance, charge transfer resistance, and double-layer capacitance, which are used to calculate corrosion rates and analyze coating degradation.

Reading the data

Data is visualized using Nyquist or Bode plots and interpreted by fitting the spectra to Equivalent Electrical Circuits (EEC). These models separate different electrochemical processes, such as fast electron transfer at high frequencies and slow ion diffusion at low frequencies, allowing for the identification of mechanisms like pitting, passivation, and the effectiveness of protective coatings.

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We launched!

Here's the low-down on our launch in Product Hunt...

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Our first customer

A significant milestone - our very first MRR dollar.

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Stable version 1.0 release!

Our stable release is finally here.

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Hit $100k MRR

Here's what we did to grow so fast!

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Acquired by Acme

We're acquired for $100M!

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Independent evidence library

Testing & Performance Reports

Access the original laboratory, field exposure and technical evaluation reports referenced in the RUSTOPAK® Top Coat Technical Data Sheet.

ACC

HERTG 201-16048

American Chemistry Council

Petroleum Additives Panel, High Production Volume Challenge Programme

Environmental and toxicology assessment of the petroleum additive alkaryl sulfonate category.

View original report
KYTC
USACE

ERDC/CERL TR-03-33

Kentucky Transportation Cabinet / US Corps of Engineers

Accelerated coating performance and calcium sulfonate overcoat evaluation

Two supporting documents cover the 5,000-hour Category II performance evaluation and the ERDC/CERL technical report.

5,000-hour reportERDC/CERL report
FHWA

FHWA-HRT-11-046

Federal Highway Administration

Performance Evaluation of One-Coat Systems for New Steel Bridges

Accelerated cyclic weathering and natural exposure evaluations across multiple environments.

View original report
METLAB

SANAS approved report 848-001

METLAB Germiston

ASTM B117 Salt Fog Test, 1,500 hours

Reported excellent corrosion protection with scribe creep below 1 mm for the tested period.

View original report
ESKOM

KIPTS natural weathering

Eskom

Severe marine exposure, 24 months

Performance evaluation on new and weathered samples with varying surface preparation procedures.

View original report
ABB

CCRP ZA 903175

ABB South Africa

Transformer coating performance, 3-year report

Natural C5 marine exposure assessment of HRCSA protection on transformer crevices and coated components.

View original report

Document integrity: Reports are presented in their original issued format and open in a separate browser tab.

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