ZRC Superior Zinc Coating


  • Galvilite Range
    Designed specifically for field and shop repair of hot dip galvanizing
  • Silver finish closely blends in with the color of new hot dip galvanizing
  • Meets and exceeds galvanizing repair specifications ASTM Des. A 780, SSPC-Paint 20 and DOD-P-21035A
  • Industry-leading 95% zinc in the dried film
  • Single-component
  • Apply by brush, roller or spray
  • Meets USA VOC standards
  • Available in clog-free aerosol form


TYPE: Single pack, premixed, ready-to-apply, liquid organic zinc compound with a shiny finish to closely approximate the color of hot-dip galvanizing

GENERAL PROPERTIES: Galvilite® is a high-quality cold galvanizing compound based on a trade secret organic binder which affords true galvanic anti-corrosion protection to metals. The dried film of GALVILITE is 95% metallic zinc. Because of the uniqueness of the formulation, GALVILITE is the only coating of its type to be recognized under the Component Program of Underwriter's Laboratories, Inc.

RECOMMENDED USES: Galvilite is widely used without topcoat in place of hot-dip galvanizing. Specially formulated for repair of damaged hot-dip galvanizing Galvalume® and zinc metallizing, regalvanizing worn hot-dip galvanizing, repair of weldments, and repair of damaged inorganic zinc coatings. Excellent for long-term protection of structural steel, water and waste facilities, power plants, transmission towers and antennae, steel decking and bridges, and numerous OEM uses.

SUBSTRATES: Apply to properly prepared carbon steel, cast iron, hot-dip galvanized, and aluminum surfaces.

NOT RECOMMENDED FOR: Contact with potable water, strong acids or strong alkalis

Continuous: 350°F max/177°C max
Non-Continuous: 750°F max/399°C max

SALT FOG EXPOSURE: 2,852 Hours (ASTM B117)


VOC: 3.3 Lbs/gal (385 gms/Ltr) (ASTM D3960)


SOLIDS CONTENT: % Solids of Liquid Coating — 86% (by weight)/52% (by volume)

METALLIC ZINC CONTENT: 95% by weight in dry film. Zinc Dust used specified as ASTM D 520 Type III.

Wet: 3.0 mils (76 µ) Dry: 1.5 mils (38 µ)

400 Ft ²/Gal @ 1.5 mil dry film thickness
3.4 M ² /Kg @ 38 µ dry film thickness

Liquid — 3 Years 
Aerosol — 1 Year

FINISH: Shiny, silvery gray

FLASH POINT: 111°F (43°C) (SETA method, ASTM D3278)


MASS DENSITY: 2.797 gms/cm³

VISCOSITY: 2500 cps. Brookfield RVT spindle #5 @ 100 RPM, 25°C


IMPACT RESISTANCE: Greater than 30 inch lbs.
(Extrusion) (per ASTM-D2794)

ELECTRICAL CONDUCTIVITY: 73 million ohms per square @ 3 mils dry (resistivity).

ABRASION RESISTANCE: 11.5 liters per dry mil (tested at 3 dry mils) (per ASTM-D968-51)


POT LIFE: At least 24 hours @ 77°F (25°C)


SURFACE PREPARATION: Dependent upon surface conditions and intended service. Typical examples are as follows:

Grease & Oils Solvent to clean SSPC-SP1
Rust Scale Power tool clean to SSPC-SP3 or SSPC-SP11 (SIS St 2 or 3)
Mill Scale, Paint or Heavy Rust Sandblast to SSPC-SP6 (commercial)
(SIS Sa 2)
Water Immersion (100°F (38°C) Maximum) Sandblast to SSPC-SP10(near white)
(SIS Sa 2.5)


BRUSH/ROLLER/AEROSOL: Apply as received in container.

SPRAY (low pressure compressor type):
Atomized Air Pressure 50 Lbs (1.3 kg/cm²)
Fluid Pressure 15 to 20 Lbs (0.4-0.6 kg/cm²)
Orifice of Tip 0.080 inches (0.20 cm)
Viscosity Reduction 4:1 ZRC:XXX Thinner -OR- 16:1 ZRC:Xylol/Xylene

SPRAY (airless type):
Pump 30:1 Ratio
Hose 1/2" (1.3 cm)(I.D.) Airless Type
Orifice of Tip 60 ° - .026 in. (0.07 cm)
Type of Tip Tungsten carbide, reversing
Filter Screens Complete removal is recommended. However, if screens are employed, use no less than 30 mesh.
Viscosity No reduction required.
Recommended Procedure Connect hose directly to pump ensuring a hose length of 50 ft. max. Use least procedure possible. Start at 1500 lbs. (680 kg) and increase as required for good spraying.

CLEAN UP: ZRC XXX Thinner or Xylol/Xylene

DRY TIME (set to touch): When ambient air dried, 20-30 minutes @ 1.5 mil (38 µ) thickness

RECOAT TIME (2nd coat of ZRC): 12 hours. Under certain conditions, recoat time can be reduced. Please contact manufacturer for specifics.

TOPCOATING: After 24-48 hours, Galvilite may be topcoated with acrylic, chlorinated rubber, epoxy, urethane or vinyl type products. DO NOT TOPCOAT WITH ALKYD, ALKYD-MODIFIED ACRYLIC, OR LACQUER TYPE PRODUCTS.

The ZRC Difference

The ZRC difference is made possible by ZRC’s high zinc content (95% by weight in the dried film) of “ultra-pure” zinc dust (ASTM D520 Type III) and proprietary, non-encapsulating binder. This unique combination provides a self healing galvanic film that is impossible for others to match. The proof is in the photos – the performance of ZRC and GALVILITE is clearly superior!