Anti-Corrosion Coatings

anti-corrosion

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 has been use in hundreds of independent field tests and has 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.

The coating consists of a unique conducting polymer nano dispersion (CPND) based primer, a top layer and an optional inter layer. The polymer envelops the surface of metal and transforms the top layer 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. AnCatt coating technology significantly out performs current anti-corrosion coating products on the market by a whopping 3-6 times in longevity, while also been the first ever heavy metal free (green) high performance anti-corrosion technology, making it the next-generation of anti-corrosion coating technology.


Coating Features

  • Heavy-Duty Anti-Corrosion Protection: Withstands over 13,000 hours of Salt Fog (ASTM B 117) with no rusting or blistering. The test panels had no visible changes in appearance: no cracking, flaking, or chalking
  • Environmentally Friendly: The primer contains no heavy-metal pigments such as Zinc, Chromate, or Lead
  • Strong 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 a perfect score of 5A for each replicates following 8,300 hours of salt fog exposure
  • 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

Test-results

Our accelerated corrosion tests were conducted by the well known U.S.-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, AnCatt’s 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 itself from further rust expansion at the scribe lines. We waited until 13,000 hrs and amazingly, the rusting and blistering remained at a perfect score of 10. Please visit the corrosion test page or the full lab report for more details.

Comparision

Usage

Our coating system withstands 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. Currently our target market includes the Energy, Oil/Gas, Power, Mining, Machineries, Automobile and Aerospace industries.

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.


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. Government regulations are tightening on its usage world wide. The toxic effect became very well-known through the 2000 Hollywood blockbuster Erin Brockovich (starring 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.

Due to their superior anti-corrosion abilities, primers containing chromate are still being produced by most major paint companies, since their performance has not yet met by other material. Currently, the environmentally compliant market standard of zinc/zinc oxides cannot protect light-metals such as aluminum and galvanized steel, and they are less effective in severe corrosive environments. Furthermore, the price of zinc has skyrocketed in the past couple years, and at current usage levels, zinc reserves are facing complete depletion around the year 2027.

Enter AnCatt’s conducting polymer (polyaniline-based) anti-corrosion coating. Our unique formula has outlived 13,000 hrs of salt fog testing. Not only is this coating the 1st successful 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 — roughly 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.

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