UNIGALV
The Film Galvanising System UNIGALV is a one-component coating that contains 96% zinc in the dry film and provides cathodic protection of ferrous metals. It can be used as a unique system as an alternative to hot-dip galvanisation or metallisation, as a primer in a duplex system (active + passive), or as a recharging system for hot-dip galvanisation, metallisation, or previously UNIGALV-coated surfaces. It can be applied by brushing, rolling, or spraying on a clean and rough substrate in a wide range of atmospheric conditions.
PHYSICAL DATA AND TECHNICAL INFORMATION
WET PRODUCT
Components:
- Zinc powder
- Aromatic hydrocarbons
- Binder
Density: 2.67 kg/dm³ (±0.06 kg/dm³)
Solid Content:
- 80% by weight (±2%)
- 58% by volume (±2%)
Type of thinner: Unisolv
Flash Point: 47°C
VOC: 474 g/L (EPA Method 24) (=178 g/kg)
DRY FILM
Colour: Grey (colour changes depending on environment – Patination)
Gloss: Matt
Zinc Content: 96% (±1%) by weight, with a purity of 99.995%.
UNIGALV provides full cathodic protection and conforms to standard ISO 3549 regarding its zinc purity and to standard ASTM A780 regarding its use as a repair coating for hot-dip galvanisation.
Special Characteristics:
- Atmospheric temperature resistance of dry film:
- Minimum: -40°C
- Maximum: 120°C with peaks up to 150°C
- pH resistance in immersion: 5.5 pH to 9.5 pH
- pH resistance in atmospheric conditions: 3.5 pH to 12.5 pH
- Excellent UV resistance
Non-toxicity: A dry layer of UNIGALV is not toxic. It has been tested according to standard AS/NSZ 4020.
CONSERVATION
Shelf Life: Unlimited. In case of long-term storage, it is recommended to shake the unopened tin in an automatic shaker at least once every 3 years.
Storage: Store in a cool and dry place at temperatures between 5°C and +25°C.
Pot Life: If closed correctly after usage, UNIGALV will remain applicable.
SURFACE PREPARATION
Cleanliness:
- The metal substrate should first be degreased, preferably by steam-cleaning at 140 bar at 80°C.
- After degreasing, it should be blasted to a cleanliness degree SA 2.5 according to ISO 8501-1:2007 or SSPC-SP10/NACE No. 2.
- Once blasting is completed, the surface should be de-dusted with non-contaminated compressed air or, in the case of wet blasting, rinsed off with clean water and dried with non-contaminated compressed air.
Roughness:
- It is recommended to apply UNIGALV on a metal substrate that has a roughness grade of medium G according to ISO 8503-1:2012.
- This level of roughness is not needed when UNIGALV is applied on a hot-dip galvanisation or a metallisation layer or when applied on top of an existing UNIGALV.
ENVIRONMENTAL CONDITIONS DURING APPLICATION
Ambient Temperature:
- Minimum: -15°C
- Maximum: 50°C
Relative Humidity:
- Maximum: 95%
- Do not apply on a damp or wet surface
Surface Temperature:
- Minimum: 3°C above the dew point
- Maximum: 60°C
Product Temperature: During application, the temperature of UNIGALV liquid should remain between 5°C and 25°C.
APPLICATION INSTRUCTIONS
Application Methods:
- UNIGALV can be applied by brush, roller, conventional spray gun, or airless spraying.
Stirring: UNIGALV must be thoroughly mechanically stirred before application. Re-mixing is necessary every 20 minutes.
Cleaning: Before and after use, all equipment should be rinsed with fresh Unisolv. Never use White Spirit.
DILUTION TABLE
| Application Method | Dilution with Unisolv |
| Brush or roller | Up to 5% |
| Conventional spray | Up to 15% |
| Airless spray | Up to 7% |
COVERAGE AND CONSUMPTION
Theoretical Coverage:
- For 60 μm DFT: 3.62 m²/kg
- For 120 μm DFT: 1.81 m²/kg
Practical Coverage: Depends on the roughness profile of the substrate and the application method.
DRYING PROCESS AND OVERCOATING
Drying Time at 20°C:
- Dust dry: 15-20 minutes
- Touch dry: 30-45 minutes
- Dry to handle: 90 minutes
- Fully cured: 24 hours
Overcoating with UNIGALV:
- By brush: 1 hour after touch dry
- By spray gun: 30 min after touch dry
Overcoating with a Compatible Paint:
- Mist coat: Applied at least 4 hours after UNIGALV is touch-dry.
- Full coat: Applied at least 2 hours after the mist coat is touch-dry.
RECOMMENDED SYSTEM
Stand-alone System
- UNIGALV is used as a stand-alone system, applied in a maximum of 2 layers to achieve up to 150 μm DFT.
- It should not be applied at DFTs higher than 250 μm.
- Easy maintenance: a new layer can be directly applied once the surface has been properly prepared.
Duplex System
- In a duplex system, UNIGALV should be applied in one single application to obtain a DFT of 60 with a maximum of 100 μm.