Out of stock

Size: 5 Gallon
Coverage: 1,200 FT2 [112 M2]


USA Nanocoat’s RustCoat™ is a direct-to-metal (DTM)/ direct-to-rust permanent primer that protects a wide variety of ferrous materials, including hard rust metal surfaces from continued deterioration. RustCoat™ dries smooth, creating a strong bond between rusted metal surfaces and application-specific topcoats. RustCoat™ is environmentally friendly and is approved as a base coat for all Sherwin Williams and Carboline paints.

The primary use of RustCoat™ is to protect and restore ferrous materials from deterioration or further loss of structure through exposure to many naturally occurring elements. RustCoat™ also provides a unique method to bond metal substrates to concrete. RustCoat™ can be used in some cases as a stand-alone solution, although more often as a part of a more complex solution utilizing other RustCoat™ products. In addition, RustCoat™ can be used as a functional primer for other coating systems.




The destructive forces of corrosion and the damage it causes to vehicles, commercial trucks, machinery, and more costs billions of dollars each year. Consistent exposure to sun, rain, snow, and deicers can lead to the rapid deterioration of your vehicle’s metal, resulting in loss of value, poor appearance, and safety concerns. Our RustCoat™ can help by protecting and restoring metal from deterioration and further loss of integrity.

RustCoat™ is a dual component product, meaning that it consists of both a binding agent (RustCoat™ Emulsion) and a fine powder (RustCoat™ Powder) that dry smooth and create a strong bond with rusted surfaces. Consider using it on agricultural equipment that is constantly exposed to highly corrosive substances such as pesticides, fertilizers, and moisture to extend maintenance schedules and enhance equipment integrity. Also, use it on aviation, boating, heavy marine, industrial, and winter equipment to preserve, protect, and minimize costly repairs and replacement parts.

Our award-winning RustCoat™ is non-toxic and safe for use around the home as well. Prevent rust on seasonal lawn and garden equipment, bicycle/motorcycle chains, hinges, locks, play equipment, recreational vehicles, and more. Eliminate continued maintenance and ensure that your equipment is ready to use when needed without worrying about frozen moving parts. RustCoat™ is easy to apply, and features proved temperature resistance, flexibility, and longevity.


  • USA Nanocoat Applications



  • Concrete encased metal

  • Metal stairs and ramps

  • Corrosion Under Insulation (CUI)

  • Exhaust systems

  • Corrugated metal roofs

  • Rebar

  • Steel structures

  • Boilers & Furnaces

  • Metal doors

  • Pipe exteriors

  • Maritime vessels – top deck


  • 25% cementitious yet forms strong bonds to nearly all metal surfaces

  • Adhesion is maintained on surfaces with rust

  • Maintains flexibility, bending as much as 90 degrees without cracking or lifting when properly applied

  • Can be applied to “live” surfaces that expand and contract due to internal pressure hanges or external influences

  • No abrasive blasting or grinding is required prior to application- power washing and degreasing is adequate

  • Low VOC (< 17g / Liter)

  • Approved for continued warranty coverage for use with Sherman Williams and Carboline top coats

  • Saves maintenance costs and the need to replace materials

  • Extreme temperature resistance (-80ºF to +500ºF)

  • Easy application and clean-up

  • Odorless

  • Cost-effective

  • Uses recycled industrial material

Product Performance

Rust Protect is a dual component product, consisting of Rust Protect Emulsion, a uniquely blended binding agent, and Rust Protect Powder, a super fine powder. Rust Protect has the ability to bond with metal and provide a surface coating that encases and protects old deteriorating, ferrous products. Rust Protect is a universal coating which can be used as a primer base coat as well as a top coat. When used correctly, Rust Protect provides both the applicator and asset owner with a cost effective infrastructure maintenance program. Rust Protect is environmentally friendly due to its use of recycled industrial material, extremely low VOC level, and ease of application and use. Rust Protect has an advantage over other coatings by providing asset protection against many freeze/thaw, chemical and abrasion threats.

This unique performance characteristic results in:

  • Less prep time
  • Fewer containment issues
  • Lower disposal costs
  • Increased profitability
  • Greater bid conversion

The ability to apply Rust Protect directly to hard metal surfaces results in significantly less preparation time and lower labor costs without sacrificing performance. This reduction in labor costs allows contractors to submit bids that are up to 50% lower than bids using blasting or grinding. Despite the additional materials expense of purchasing Rust Protect, the much greater offset in labor charges allows the contractor to generate greater profit per job, even when the total bid calculation is lower than a bid using blasting or grinding.

Rust Protect has been tested to the following standards:

  • ISO 12944
  • ASTM B1117-1
  • ASTM D1654
  • ASTM D3359
  • ASTM D4060
  • ASTM D4541

Application & Storage

Rust Protect’s advanced formula is designed for application directly over hard rust surfaces while maintaining superior adhesion characteristics that are two to three times industry standards. The surface only needs to be power washed and degreased prior to application.