EPOXY TECHNICAL DATA RO-139

HIGH PERFORMANCE
9100 SYSTEM DTM EPOXY MASTIC

DESCRIPTION AND USES PRODUCTS (cont.)

The 9100 System DTM Epoxy Mastic is a two-component, high BASE COMPONENT (cont.)
solids epoxy coating for use in moderate to severe environments.
1 Gallon 5 Gallons DESCRIPTION
It is specifically designed for application directly on sound rusted
steel with minimum surface preparation. It can also be used on 204005 297081 Safety Orange
clean steel, galvanized metal, concrete (including concrete 204006 297079 Safety Red
floors), previously coated and slightly damp surfaces. It may also
be used for water immersion service, using the DTM Epoxy 323759 ----- Cafe
Mastic standard premix bases only with the Immersion Activator.
(Note: Not use for immersion service in potable water tanks). NOTE: Agriculture Canada accepted: 9115, 9145, 9165, 9171,
9179, 9186, 9192 and 9101.
The 9100 System is available in 340 and 250 g/l VOC versions.
Use the SC9100 System if a VOC of less than TINT BASES
100 g/l is needed.
1 Gallon 5 Gallons DESCRIPTION
If a satin finish is desired, use the Satin Finish Standard Activator. 9105405 ----- Red
This coating complies with USDA FSIS regulatory sanitation 9106405 ----- Yellow
performance standards for food establishment facilities. This 3
coating is impervious to moisture and easily cleaned and 9107405 9107375 Masstone
sanitized. 9108421 9108381 Deep
Note: The Immersion Activator and the Fast-Cure Activator 9109408 9109388 Light
produce a semi-gloss finish. Also, using the Fast-Cure Activator
may result with a slight color shift when compared with products TINTING
using the Standard Activator.
The 9100 System tint bases can be tinted with Rust-Oleum 2020
This DTM Epoxy Mastic can be used indoors or out. Epoxy Colorants or Evonik colorants. Tint should not be added to
coatings will yellow with age. This is most noticeable with interior Activators.
applications of white or light colors which are not subjected to
bleaching from sunlight. Exterior exposure over time will cause TINT BASE MAXIMUM COLORANT PER 2 GALLON KIT
fading and chalking with all epoxy type coatings. These changes
are cosmetic in nature only and film integrity and performance will QUANTITY TINT BASE DESCRIPTION
not be adversely affected. 32 Oz. Red
MPI #98 Certified1 32 Oz Yellow
1
Refer to the MPI website for the most current listing of MPI certified products. 32 Oz. Masstone
24 Oz. Deep
PRODUCTS
16 Oz. Light
BASE COMPONENT
1 Gallon 5 Gallons DESCRIPTION ACTIVATOR
91154022 ----- Aluminum (Semi-Gloss) 1 Gallon 5 Gallons DESCRIPTION (340 VOC g/l)
9122402 ----- Marlin Blue 9101402 9101300 Standard Gloss

9145402 ----- Equipment Yellow 91024024 91023004 Immersion Semi-Gloss

4
9165402 ----- Regal Red 9104402 A9100083004 Fast Cure Semi-Gloss
9168402 ----- Tile Red 1 Gallon 5 Gallons DESCRIPTION (250 VOC g/l)
9171402 9171300 Dunes Tan 205015 206232 Standard Gloss
9179402 ----- Black 2144304 ----- Immersion Semi-Gloss
9182402 9182300 Silver Gray 9103402 9103300 Low Temp Gloss
9186402 9186300 Navy Gray 2144324 ----- Fast Cure Semi-Gloss
9192402 ----- White 331254 ----- Standard Satin
2
266693 266697 Buff The 9115 Aluminum is not recommended to be used in water
immersion, as a floor finish, or as a prime coat for any finish other
9125402 ----- Safety Blue than itself.
3
9133402 ----- Safety Green Made-to-Order only. Contact Rust-Oleum Customer Service for
details
3 4
9144402 9144300 Safety Yellow Not for use with tint bases.

1 Form: ARJ-1503
Rev.: 020420
 EPOXY TECHNICAL DATA RO-139

HIGH PERFORMANCE
9100 SYSTEM DTM EPOXY MASTIC
COMPANION PRODUCTS PRODUCT APPLICATION (cont.)
NOTE: 9100 System may be used as a primer for High SURFACE PREPARATION (cont.)
Performance topcoats. For best results, use the 331254
CONCRETE FLOORS: Remove laitance and create a surface
Satin Activator.
profile by either acid etching with Rust-Oleum 108402
Cleaning and Etch Solution, or by grinding. If etching, consult
COMPATIBLE TOPCOATS5
with 108 Clean & Etch Solution Technical Data Sheet for
complete application instructions. Rinse thoroughly and allow
3100 System Speedy-Dry DTM Acrylic Enamel
to dry. The concrete must be fully dry prior to coating
3300 System Acrylic Aliphatic Urethane
application. After etching, the concrete should have a texture,
3700 System DTM Acrylic Enamel
which resembles fine grit sandpaper. Repeat the process if
3800 System DTM Acrylic Enamel
necessary. Surface sealers and curing agents must be
9400 System High Gloss Polyester Urethane
removed by grinding. Vacuum to remove fine dust and debris.
9700 System 250 VOC Acrylic Polyester Urethane
The floor should be dry and dust free prior to application.
9800 System DTM Urethane Mastic
Previously coated floors need to be in good condition with
5
Do not use any topcoat over 9115402 Aluminum. The 9115 Aluminum should proper adhesion to the concrete substrate.
only be topcoated with itself.
APPLICATION
PRODUCT APPLICATION Airless spray is the preferred method of application. However,
brush, roller, or air-atomized spray may also be used. Refer to
SURFACE PREPARATION (cont.)
table for thinning recommendations. For proper performance,
ALL SURFACES: Remove all dirt, grease, oil, salt and a dry film thickness of 5-8 mils per coat is required. Excessive
chemical contaminants by washing the surface with Krud brushing or rolling may reduce film thickness. Apply a second
Kutter® Original Cleaner Degreaser or other suitable cleaner. coat if necessary to achieve the recommended film thickness.
Rinse with fresh water and allow to dry.
Use the Standard Activator or Fast Cure Activator at air
STEEL: Hand tool (SSPC-SP-2) or power tool (SSPC-SP-3) temperatures between 50-120°F (10-49°C) and when the
clean to remove loose rust, scale, and deteriorated previous surface temperature is at least 5°F (3°C) above the dew point
coatings to obtain a sound rusted surface. For optimum and less than 120ºF (49ºC). Low curing temperatures and/or
corrosion resistance, abrasive blast to commercial grade condensation on the film while curing can affect appearance
SSPCSP-6, with a blast profile of 1-2 mils (25-50 µ). in the form of an amine blush. This can generally be removed
with soap and water; however, in a case of extreme blushing,
STEEL (IMMERSION): Abrasive blast clean to a minimum
the performance of the coating may be slightly affected.
SSPC-SP-10 Near-White Grade (NACE 2) and achieve a
surface profile of 1.5-3 mils. All weld spatter must be removed NOTE: The Fast Cure Activator may also be used in water
along weld seams, rough welds should be ground smooth, immersion. Allow 7 days for full cure prior to beginning
and all sharp edges should be ground to a smooth radius. immersion service.
PREVIOUSLY COATED: Previously coated surfaces must be Use the Low Temperature Activator. when application
sound and in good condition. Smooth, hard, or glossy finishes temperatures are between 40-60°F (5-15°C) and when the
should be scarified by sanding or sweep blasting to create a surface temperature is at least 5°F (3°C) above the dew point,
surface profile. The DTM Epoxy Mastic is compatible with Do not apply the material if the temperature is expected to fall
most coatings, but a test patch is suggested. below 40°F in the first 24 hours of cure. At 40°F, full cure will
be achieved in 7 days.
GALVANIZED METAL: Remove oil, dirt, grease and other
chemical deposits with Krud Kutter Original Cleaner Use the Immersion Activator for water immersion service at
Degreaser or other suitable cleaner. Remove loose rust, white air and surface temperatures between 60-100°F (15- 38°C).
rust or deteriorated old coatings by hand or power tool Apply when the surface temperature is at least 5°F (3°C)
cleaning or brush off blasting. Rinse thoroughly with fresh above the dew point, and when relative humidity is below
water and allow to fully dry. 85%. Do not use the Immersion Activator with tint bases. This
system may be used for both salt and fresh water; do not use
CONCRETE OR MASONRY: New concrete or masonry must
for the inside of potable water tanks. Apply two coats
cure 30 days before coating. Any concrete surface must be
alternating color between coats to ensure complete hide.
protected from moisture transmission from uncoated areas.
Allow 7 days cure after application of the second coat before
Remove all loose, unsound concrete.
immersion.
NOTE: Do not use tinted colors in water immersion.

2 Form: ARJ-1503
Rev.: 020420
 EPOXY TECHNICAL DATA RO-139

HIGH PERFORMANCE
9100 SYSTEM DTM EPOXY MASTIC
PRODUCT APPLICATION (cont.) PRODUCT APPLICATION (cont)
APPLICATION (cont.) MIXING
POOLS: When used with Immersion Activator, the DTM Epoxy Both the base and activator components are highly
Mastic premix bases can be used as a pool coating over existing pigmented. Mix each component thoroughly to ensure any
epoxy pool coatings, new bare concrete, plaster, Gunite, and settled pigment is re-dispersed before combining the
fiberglass. The pool must be completely empty and dry before components together. Combine at a 1:1 ratio by volume in a
coating. After pool is emptied, this typically requires 7- 10 days container large enough to hold the total volume. Mix
depending on temperature and humidity. To test the dryness of thoroughly for 2-3 minutes. Power mixing is preferred. Do not
concrete, Gunite or plaster pool surfaces, securely tape a 2 ft. by
mix more material than you plan to use within the listed pot
2 ft. piece of clear plastic onto a horizontal and vertical surface at
life.
the deep end of the pool. Check after 24 hours. If water
condensation is visible under the plastic, this is an indication that CLEAN-UP
the surface is not completely dry, and NOT suitable for coating.
Use 160402 or 165402 Thinner.
Allow additional dry time and retest. Follow surface preparation,
mixing and application instructions. Avoid painting in midday sun. SHELF LIFE
Application is recommended early in the day or late in the
Base components 3 years6 Activators 2 years6
afternoon when at least 2 hours of sunlight remain after
completion of the job. 6
Unopened containers. Some settling may occur requiring mechanical mixing
to redisperse pigment.
Allow minimum of 5-7 sunny days cure before filling pool. Early
contact with water can cause premature fading, chalking and PERFORMANCE CHARACTERISTICS
blistering. Super chlorinated water can cause a bleached-out
SYSTEM TESTED
appearance. Sunlight and UV will cause chalking and fading.
DTM EPOXY MASTIC WITH 9101 Activator
Do not use over: 1) chlorinated rubber, 2) synthetic rubber, 3)
vinyl, 4) acrylic. PENCIL HARDNESS

NOTE: In swimming pool service, early chalking may occur if the METHOD: ASTM D3363
water pH is outside the range of 7.2-7.6 and/or if the water RESULT: B (7 days), 4H (30 days)
temperature exceeds 100°F (38°C).
CONICAL FLEXIBILITY
EQUIPMENT RECOMMENDATIONS
METHOD: ASTM D522
(Comparable equipment also suitable.) RESULT: >32%
BRUSH: Use a good quality natural or synthetic bristle brush. CYCLIC PROHESION
ROLLER: Use a good quality lamb’s wool or synthetic fiber (3/8-
1/2"nap). Rating 1-10, 10=best

AIR–ATOMIZED SPRAY METHOD: ASTM D5894, 2300 hours

Atomized RESULT: 10 ASTM D714 for blistering
Method Fluid Tip Fluid Delivery Pressure RESULT: 10 ASTM D1654 for corrosion
Pressure 0.055-0.070 10-16 oz./min. 25-60 psi IMPACT RESISTANCE (direct)
Siphon 0.055-0.070 -- 25-60 psi
HVLP 0.043-0.070 8-10 oz./min. 10 psi (at tip) METHOD: ASTM D2794
RESULT:160 in. lbs.
AIRLESS SPRAY
ALKALI RESISTANCE
Fluid Pressure Fluid Tip Filter Mesh
1,800-3,000 psi 0.013-0.017 100 METHOD: ASTM D1308
RESULT: No effect
THINNING
TABER ABRASION
Thinning is normally not required, except for air-atomized spray.
For air-atomized spray application, thin only up to 10% by volume METHOD: ASTM D4060, CS-17 wheels, 500 gram load, 1000 cycles
with 160402 Thinner after the components have been mixed. If RESULT: 125 mg loss
the coating is going to be used in immersion service, 9102 or
9104 activator, then, use up to 10% 165402 Thinner for air- GLOSS
atomized spray and up to 5% of 165402 Thinner for airless spray.
METHOD: ASTM D4587
NOTE: Addition of more than 10% of 160402 or 165402 Thinner RESULT: 80%
will cause VOC to exceed 340 g/l. In this case, 333402 VOC
CAUTION: Exposure of the 9100 System during the curing stage of
exempt thinner can be used if needed.
the coating to the by-products of propane combustion may cause
NOTE: When using the Satin Activator, thin only with 333402 discoloration to occur. During application and curing, propane fueled
Thinner to maintain the VOC <250 g/l. fork-lifts and other vehicles or propane fueled heaters should not be
used in the area until the coating is fully cured. At least 72 hours.

3 Form: ARJ-1503
Rev.: 020420
 EPOXY TECHNICAL DATA RO-139

HIGH PERFORMANCE
9100 SYSTEM DTM EPOXY MASTIC
PHYSICAL PROPERTIES
9101 9102 9103 9104
Activator Immersion Act. Low Temp. Act. Fast-Cure Act.
Aliphatic Amine Polyamide Aliphatic Amine Polyamide/modified Amine
Resin Type
Converted Epoxy Converted Epoxy Converted Epoxy Converted Epoxy
Inhibitive Pigment Calcium Borosilicate Calcium Borosilicate Calcium Borosilicate Calcium Borosilicate
Xylene, Methyl Xylene, Methyl Xylene, Methyl Xylene, Methyl
Solvents Isobutyl Ketone, Isobutyl Ketone, Isobutyl Ketone, Isobutyl Ketone,
1-Methoxy-2-propranol 1-Methoxy-2-propranol 1-Methoxy-2-propranol 1-Methoxy-2-propranol
Per Gallon 11.4-12.6 lbs. 11.4-12.6 lbs. 9.3-10.4 lbs. 12.0-13.0 lbs.
Weight7
Per Liter 1.4-1.5 kg 1.4-1.5 kg 1.1-1.2 kg 1.4-1.6 kg
By Weight 86-89% 79-82% 78-81% 81-83%
Solids7
By Volume 78-81% 65-68% 72-75% 67-69%
Volatile Organic
<340 g/l (2.84 lbs./gal.) <340 g/l (2.84 lbs./gal.) <250 g/l (2.08 lbs./gal.) <340 g/l (2.84 lbs./gal.)
Compounds7
Mixing Ratio 1:1 Base:Act.(by vol.) 1:1 Base:Act.(by vol.) 1:1 Base:Act.(by vol.) 1:1 Base:Act.(by vol.)
Recommended Dry Film
5-8 mils (125-200µ) 5-8 mils (125-200µ) 5-8 mils (125-200µ) 5-8 mils (125-200µ)
Thickness (DFT) Per Coat
Wet Film to Achieve DFT 6.5-10.5 mils 7.5-12.0 mils 7.0-11.0 mils 7.5-12.0 mils
(unthinned material) (162.5-262.5µ) (187.5-300µ) (175-275µ) (187.5-300.0µ)
Theoretical Coverage at 1,250-1,300 sq.ft./gal. 1,045-1,090 sq.ft./gal. 1,155-1,200 sq.ft./gal. 1,075-1,100 sq.ft./gal.
1 mil DFT (25µ) (30.8-32.0 m2/l) (25.7-26.8 m2/l) (28.4-29.5 m2/l) (26.4-27.3 m2/l)
Practical Coverage at
125-225 sq.ft./gal. 100-175 sq.ft./gal. 125-200 sq.ft./gal. 115-190 sq.ft./gal.
Recommended DFT
(3.1-5.5 m2/l) (2.5-4.3 m2/l) (3.1-5.0 m2/l) (2.8-4.7 m2/l)
(assumes 15% material loss)
30 minutes
Induction Period None required None required 15 minutes
(60 min. < 65°F)
2-4 hours at 1-2 hours at 2-4 hours at 3-5 hours at 2-4 hours at 1-2 hours at
2 gallons 2-4 hours at 60°F (15°C)
70°F (21°C), 90°F (32°C) 70°F (21°C) 60°F (15°C) 70°F (21°C) 90°F (32°C)
Pot Life8 2 hours at <1 hour at 2 hours at 3 hours at 2 hours at <1 hour at
10 gallons 2 hours at 60°F (15°C)
70°F (21°C) 90°F (32°C) 70°F (21°C) 60°F (15°C) 70°F (21°C) 90°F (32°C)
12-24 hours
6-8 hours at 4 hours at 8 hours at
Tack-free at 6-8 hours at 70°F (21°C) 16-20 hours at 40°F (5°C)
70°F (21°C) 70°F (21°C) 50°F (10°C)
50°F (10°C)
Dry Times at 48-72 hours
6-12 hours at 5 hours at 10 hours at
50% Relative Handle 70°F (21°C)
at 8-14 hours at 70°F (21°C) 22-26 hours at 40°F (5°C)
70°F (21°C) 50°F (10°C)
Humidity 50°F (10°C)
16 hours to 72 hours to 16 hours to 8 hours to 1
4 hours to 1 year9
Recoat 1 year9 1 year9 1 year9 24 hours to 1 year9 year9
70°F (21°C)
70°F (21°C) 50°F (10°C) 70°F (21°C) 50°F (10°C)
300°F (149°C), 300°F (149°C), 300°F (149°C),
300°F (149°C),
Dry Heat Resistance Color may shift above 150°F Color may shift above 150°F Color may shift above 150°F
Color may shift above 150°F (66°C)
(66°C) (66°C) (66°C)

Maximum Immersion
NA 125°F (52°C) NA NA
Temperature
Shelf Life Unopened containers; 3 years Base components, 2 years Activator components
Safety Information See SDS
7
Activated material.
8
Pot life is affected by air temperature, amount of material activated and quantity of thinner used. Avoid activating large quantities at temperatures above 80°F (27°C). At
temperatures above 90°F (32°C), the pot life of unthinned material in 5 gallon pails may be very short (less than one hour). Final gloss maybe slightly higher for coating
applied near the end of the pot life.
9
If recoat time is extended, be sure the surface is clean and free of all contamination prior to coating. Actual environmental conditions may affect results, so a trial
is suggested to ensure acceptable results

4 Form: ARJ-1503
Rev.: 020420
 EPOXY TECHNICAL DATA RO-139

HIGH PERFORMANCE
9100 SYSTEM DTM EPOXY MASTIC
PHYSICAL PROPERTIES
205015 214430 214432 331254
Standard Activator Immersion Activator Fast-Cure Activator Satin Finish Activator
Aliphatic Amine Polyamide Polyamide/modified Polyamide/modified
Resin Type converted Epoxy converted Epoxy Amine converted Epoxy Amine converted Epoxy

Inhibitive Pigment Calcium Borosilicate Calcium Borosilicate Calcium Borosilicate Calcium Borosilicate
Aromatic Hydrocarbons, Aromatic Hydrocarbons, Aromatic Hydrocarbons, Aromatic Hydrocarbons,
Solvents Ketones and Alcohols Ketones and Alcohols Ketones and Alcohols Ketones and Alcohols
Per Gallon 11.4-12.4 lbs. 11.4-12.6 lbs. 12.1-13.2 lbs. 10.54-11.66 lbs
Weight7
Per Liter 1.4-1.5 kg 1.4-1.5 kg 1.4-1.5 kg 1.27-.1.40 kg

By Weight 86.4-88.4% 79.3-81.8% 81.3-83.5% 80.64-83.70%

Solids7
By Volume 77.8-80.4% 67.0-68.5% 68.3-69.8% 71.32-74.49%

Volatile Organic Compounds7 <250 g/l (2.08 lbs./gal.) <250 g/l (2.08 lbs./gal.) <250 g/l (2.08 lbs./gal.) <250 g/l (2.08 lbs./gal.)

Mixing Ratio 1:1 Base:Act. (by vol.) 1:1 Base:Act. (by vol.) 1:1 Base:Act. (by vol.) 1:1 Base:Act. (by vol.)
Recommended Dry Film
5-8 mils (125-200µ) 5-8 mils (125-200µ) 5-8 mils (125-200µ) 5-8 mils (125-200µ)
Thickness (DFT) Per Coat
Wet Film to Achieve DFT 6.5-10.0 mils 7.5-12.0mils 7.5-12.0 mils 7-11 mils
(unthinned material) (162.5-250µ) (187.5-300µ) (187.5-300µ) (175-275µ)
Theoretical Coverage at 1,250-1,290 sq.ft./gal. 1,075-1,100 sq.ft./gal. 1,095-1,120 sq.ft./gal. 1,145-1,195 sq.ft./gal.
1 mil DFT (25µ) (30.7-31.7 m2/l) (26.4-27.0 m2/l) (26.9-27.6 m2/l) (28.2-29.4 m2/l)
Practical Coverage at
130-220 sq.ft./gal. 115-190 sq.ft./gal. 115-190 sq.ft./gal. 120-200 sq.ft./gal.
Recommended DFT
(3.2-5.4 m2/l) (2.8-4.6 m2/l) (2.8-4.6 m2/l) (3.0-4.9 m2/l)
(assumes 15% material loss)
30 minutes
Induction Period None required 15 minutes None required
(60 min. < 65°F)
2-4 hours at 3-5 hours at 2-4 hours at 1-2 hours at
2 gallons 2.5-3 hours at 75°F (24°C) 2-4 hours at 70°F (21°C)
70°F (21°C) 60°F (15°C) 70°F (15°C) 90°F (32°C)
Pot Life8 2 hours at 3 hours at 2 hours at <1 hour at
10 gallons 2-3 hours at 75°F (24°C) 2-3 hours at 75°F (24°C)
75°F (24°C) 60°F (15°C) 70°F (21°C) 90°F (32°C)
6-8 hours at 8 hours at
Tack-free 6-8 hours at 70°F (21°C) 4 hours at 70°F (21°C) 6-8 hours at 70°F (21°C)
70°F (21°C) 50°F (10°C)
Dry Times at 8-14 hours at 10 hours at
50% Relative Handle 6-12 hours at 70°F (21°C) 5 hours at 70°F (21°C) 6-12 hours at 70°F (21°C)
70°F (21°C) 50°F (10°C)
Humidity
16 hours to 30 days9 at 70°F 16-72 hours at 24-72 hours at 4 hours to 30 days9 at 70°F
Recoat 16-72 hours at 70°F (21°C)
(21°C) 70°F (21°C) 50°F (10°C) (21°C)

300°F (149°C), 300°F (149°C), 300°F (149°C), 300°F (149°C),

Dry Heat Resistance Color may shift above 150°F Color may shift above 150°F Color may shift above 150°F Color may shift above 150°F
(66°C) (66°C) (66°C) (66°C)

Maximum Immersion NA 125°F (52°C) NA NA

Temperature

Safety Information See SDS

7
Activated material.
8
Pot life is affected by air temperature, amount of material activated and quantity of thinner used. Avoid activating large quantities at temperatures above 80°F (27°C). At
temperatures above 90°F (32°C), the pot life of unthinned material in 5 gallon pails may be very short (less than one hour). Final gloss maybe slightly higher for coating
applied near the end of the pot life.
9
If recoat time is extended, be sure the surface is clean and free of all contamination prior to coating. Actual environmental conditions may affect results, so a trial is
suggested to ensure acceptable results.

The technical data and suggestions for use contained herein are correct to the best of our knowledge, and offered in good faith. The
statements of this literature do not constitute a warranty, express, or implied, as to the performance of these products. As conditions and use
of our materials are beyond our control, we can guarantee these products only to conform to our standards of quality, and our liability, if any,
will be limited to replacement of defective materials. All technical information is subject to change without notice.

Rust-Oleum Corporation
11 Hawthorn Parkway Phone: 877∙385∙8155 Form: ARJ-1503
Vernon Hills, Illinois 60061 www.rustoleum.com/industrial Rev.: 020420