Question 1

I have a large storage building roof to coat. Can I use a garden sprayer?

Accepted Answer

As a Ablebody Seaman (Unlimited, Any Waters) and US NAVY VET. I've probably busted more rust than 99.9% of anyone hear. 
While working on the TW Nelson (Mobile oil's Survey Vessel) we helped develop this stuff. Also aboard Supertankers for several oil
Company's we got to try several different Brands of rust converter/reformer.. We brushed it. rolled it. sprayed it ( w/ air gun pick-up) and they all worked better than all previous methods.. and there were a bunch!!! In my opinion Corroseal was the Best of all!!  I still buy it in quart  & gallon sizes (when required as it goes a long way) DO NOT LET ANY OF THESE FREEZE!!! WATER BASED & WILL TURN INTO A ROCK. Talk about wasted $$$? 
Don't waste time & money on Rattle Cans as caps k-rap-out way before product does! U want to spray a large area? use air-sprayer w/ large orifice, more thin coats better than 1 thick. let dry. Just Bust off any Scale &  Leave the rust. wash down, let dry then get after it!
Just give up on acid & paste & all that k-rap. (I took more accidental showers in Ospho than I care to remember, before the new stuff) 
Wan-kers Away. 
Old Salty

Question 2

how long before rust comes back if not painted right away?

Accepted Answer

You don't necessarily need to paint over it. The rust doesn't comeback if you use Corroseal as directed. It seals the metal.

Question 3

how long before rust comes back if not painted right away?

Accepted Answer

Well, I bought it to touch up my deck chairs. The weather got cold and I have not had a chance to repaint them. I will do so in the spring. So that application is uncertain at present. However, since I had so much... My dishwasher racks had exposed metal where the rubber coating had broken down. I applied this stuff to those exposed areas, probably 2-3 months ago. I have not repainted or otherwise coated those areas. In the meantime, I have used the dishwasher multiple times (with that strong detergent!), and none of the areas I applied this stuff to has 1) lost its black color which was the result of the application, nor 2) begun to rust again. So, the coating seems very durable, even in the face of the adverse conditions in the dishwasher (water, heat, chemicals). YMMV

Question 4

If i brush down to bare metal with no rust remaining, would i be better off with a different primer? (other than cost that is. i already bought it.)

Accepted Answer

Corroseal needs the rust to bond to. If you're  at bare metal an epoxy primer would be best. Make sure you use a solvent to clean the surface to remove any dirt or oils that may have come from your hands. I've had great success with Corroseal on light to heavy rust.

Corroseal 80022 Water-Based Rust Converter Application Cleaner - 1 Qt

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