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Anti-Corrosion Coating

No Zinc, No Chromate, No Lead, Anti-Corrosive, Heavy-Duty

AnCatt has successfully developed the national award-winning heavy-metal free (green) heavy-duty anticorrosion coating platform for metals with both unprecedented performance and sustainability. 

 

AnCatt coating technology have been proven with hundreds of independent & field tests, and have been vetted and awarded by the top scientific and industrial organizations such as:  the American Chemical Society, the National Innovation Summit, the RICE Alliances, the National Science foundation, NASA, U.S. Department of State, USAID, & NIKE.

 

AnCatt coating consists of a unique conducting polymer nano dispersion (CPND) based primer, a top layer, and an optional interlayer. The polymer ennobles the surface of metals. It transforms the surface of the metal to be protected into a thin but dense metal oxide layer. This system functions as an effective barrier that protects metals from corrosion without using any heavy-metal pigment such as chromate, lead, or zinc.  It has proven to be the next-generation anti-corrosion coating technology that can significantly outperformane current anti-corrsoion coating products on the market by a whopping 3-6X in longevity while also been the first-ever heavy-metal free (green) high performance anti-corrosion technology.

 

Coating Features

  • Heavy-Duty Anti-Corrosion Protections: Over 13,000 hours of Salt Fog (ASTM B 117) with no rusting or blistering. Also, the panels had no visible changes in appearance, no cracking, flaking, or chalking (click here for pictures and details)
  • Environmentally Friendly: The primer contains no heavy-metal pigments such as Zinc, Chromate, or Lead
  • Very Good Adhesion: Tensile adhesion (pull-off strength) on samples was 700-800 psi  following 1,100 hours cyclic weathering exposure. Tape adhesion tests on samples received perfect score of 5A for each replicates following 8,300 hours of salt fog exposure(click here for more data and detailed pictures)
  • Scratch and Pinhole Tolerant/Self-Healing
  • Protects Many Metals besides Iron/steel, for example, Zinc, Aluminum, Magnesium, Copper , Silver, Titanium, etc.
  • Surface Tolerant
  • Two-Component aliphatic urethane is used as the topcoat resin that provides
    • Exceptional gloss retention
    • Excellent abrasion resistance
    • Excellent chemical resistance
  • Thin & Light Weight: Less than 1/2 current coating thickness
  • Low Raw Materials Costs
  • Easy to Manufacture: manufactured with traditional equipments
  • Easy to Apply:  Applicable with current paint application equipments &
Our accelerated corrosion  tests were conducted by the well-known USA-based third party independent corrosion test laboratory KTA.  The top row of comparison photos are the front of the steel (crs) panels coated with AnCatt CPND coating; the bottom row is the back side of the panels coated with acrylic coatings by KTA. 5,000 hrs is the maximum test hour according to salt fog test (ASTM B 117) international standard.  When 5,000 hrs of testing was reached, coating was still intact, which has been recognized by the industry experts as the best result ever been seen.  After 8,372 hrs of testing, the coating still can provide excellent pull-off adhesion and perfect tape adhesion results. Notice that the coating sealed iteslf from further rust expansion at the scribelines. We waited until 13,000 hrs, and amazingly, the rusting and blistering remained the perfect score of 10.   Please see the corrosion test page or the full lab report for more details.

Typical Uses

Our coating system could be used in severe conditions to protect structural steel, pipelines, tanks, bridges, offshore platforms, wind farms, nuclear power plants, marine hulls, ports,  superstructures, decks, airplane, automobiles, agriculture equipments, etc.  Current target market: Energy, Oil/Gas, Power, Mining, Machineries, Automobile, & Aerospace

Our primer serves as an excellent heavy-metal free replacement for existing heavy-metal based coatings with even stronger anti-corrosion abilities. Our current formulation is vinyl wash primers and epoxy primers; other products are still underway. We also have a low VOC and a water-borne anti-corrosion system.

 

Technical Datasheet

Properties Color Solid Content

Thickness
(µm)

Coverage
(g/m2)
Surface Drying
(hrs)
Drying
(hrs)
Shelf Life
(month)
Mixing Ratio
Primer

Light Blue

~40% ~20 180 0.5 4 6-9 1/0.40
Inter-Layer

White
/Ivory

~79% 50% 250 2 16 6-9 1/0.16
Topcoat Many ~83% ~50 240 3 16 6-9 1/0.15

Application Equipment

Brush, roller, or spray

 

To Learn more about AnCatt coating, please see the slides:  http://www.slideshare.net/SueWang1/an-catt-investordeck-22408427

 

Anti-Corrosion Market

Worldwide, trillions of dollars are lost to corrosion annually. In fact recent studies estimate the direct cost of corrosion in the United States to be nearly $300 billion dollars per year.

Hexavalent Chromate is a well-known carcinogen and is highly toxic to the environment. The regulations are tightening on its usage. The toxic effect became very well-known through the 2000 Hollywood Blockbuster Erin Brockovich (starred Julia Roberts).  This now-classic film depicted a real-life case of drinking water contaminated with hexavalent chromate that resulted in the largest legal settlement in U.S. History. Hexavalent Chromate has also been named the No. 1 toxic enemy of the U.S. Military. But because of its superior anti-corrosion abilities, primers containing chromate are still being produced by most major paint companies, since its performance has not yet met by other material. Currently environmentally compliant market standard zinc/zinc oxides cannot protect light-metals such as aluminum and galvanized steel, and they are less effective in severe corrosive environments. Furthermore, zinc price has skyrocked in the past couple years, and at current usage levels, zinc reserves are facing depletion, predicted around the year 2027. Our conducting polymer (polyaniline) based anti-corrosion coating has reached 13,000 hrs of salt fog testing.  It is not only the 1st success of polyaniline based anti-corrosion coating after 35-years of worldwide intense research efforts in this field, it is also better than any anti-corrosion coating technology on the market today. Corrosion costs trillions of dollars worldwide, or 3-4% of a country's GDP. Based on a Federal Highway Administration two-year study on U.S. corrosion cost published in 2002, the 2001 U.S. direct corrosion cost was estimated at $276 billion, and the indirect cost was estimated at about the same amount. Organic coating, the most widely used corrosion protection method, accounts for 88.3% of total direct corrosion protection method costs, and was a $106 market in the U.S. alone in 2001.


Read more on U.S. corrosion impact, cost, and development

Click here for detail laboratory testing data and photo


Currently we are open for investors, licensing, project inquiry, or joint development for new products. If you are interested in our new coating technologies or have any questions/comments, please Contact Us

Go to Licensing Center


                  

We make the mighty, environmentally friendly, transparent, flexible, conductive, color-changing, but difficult to processe conductive polymers soluble, extrudable, in a consistent nano-composite form should enable other anticipated brilliant conductive polymer applications beyond anti-corrosion. Click here for more details

    

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AnCatt, 1st place, ACS Green Chemistry Business Plan Competition

            
Read a full article about our technology on the October 2013 PCI Magazine


Corrosion Test Results & Photo

Down Load TDS in PDF



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