Rustoleum - 9100 - DTM Epoxy Mastic - Gallon Kits (Case of 2)

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This versatile epoxy coating quickly creates a tough, durable, protective surface. Just one coat of Rust-Oleum High Performance 9100 System DTM Epoxy Mastic is equal to multiple coats of competitive epoxy. Multiple activator options for unique applications. Sold as a gallon kit with Activator and this product only ships ground. Note: Sold as a full case of 2 gallon kits (2 Gallons of base, 2 gallons of activator).

  • Safety Orange
    Safety Red
    Safety Blue
    Marlin Blue
    Safety Green
    Safety Yellow
    Equipment Yellow
    This combination is not available
    Regal Red
    This combination is not available
    Tile Red
    This combination is not available
    Dunes Tan
    This combination is not available
    Navy Gray
    Silver Gray
    Color: not selected
  • Standard Activator
    Immersion Activator
    Low-Temperature Activator
    Fast-Cure Activator
    Activator: not selected
  • $485.00
Model #:  
  • Shipping

    This product ships factory direct, ground only. Please allow 2-4 weeks for delivery.

This product ships factory direct, ground only. Please allow 2-4 weeks for delivery.

  • Direct-to-metal (DTM) self priming formula—adheres to a variety of substrates
  • Superior long-term resistance to solvents, chemicals, abrasion and impact
  • Convenient 1:1 mixing ratio – no measuring required
  • Two-year rust-proof guarantee—maximum corrosion protection
  • Meets USDA requirements for incidental food contact; accepted for use in federally registered Canadian food facilities; <340 VOCs

For Best Results 

  • This is a two-component system—order base color and activator separately.

The 9100 System DTM Epoxy Mastic is a two-component, high solids epoxy coating for use in moderate to severe environments. It is specifically designed for application directly on sound rusted steel with minimum surface preparation. It can also be used on clean steel, galvanized metal, concrete (including concrete floors), previously coated and slightly damp surfaces. It may also be used for water immersion service, using the DTM Epoxy Mastic standard premix bases only with the Immersion Activator. (Note: Not use for immersion service in potable water tanks). 

This coating complies with USDA FSIS regulatory sanitation performance standards for food establishment facilities. This coating is impervious to moisture and easily cleaned and sanitized. 

Note: The Immersion Activator and the Fast-Cure Activator produce a semi-gloss finish. Also, using the Fast-Cure Activator may result with a slight color shift when compared with products using the Standard Activator. 

This DTM Epoxy Mastic can be used indoors or out. Epoxy coatings will yellow with age. This is most noticeable with interior applications of white or light colors which are not subjected to bleaching from sunlight. Exterior exposure over time will cause fading and chalking with all epoxy type coatings. These changes are cosmetic in nature only and film integrity and performance will not be adversely affected.

ALL SURFACES: Remove all dirt, grease, oil, salt and chemical contaminants by washing the surface with Krud Kutter® Original Cleaner Degreaser or other suitable cleaner. Rinse with fresh water and allow to dry. 

STEEL: Hand tool (SSPC-SP-2) or power tool (SSPC-SP-3) clean to remove loose rust, scale, and deteriorated previous coatings to obtain a sound rusted surface. For optimum corrosion resistance, abrasive blast to commercial grade SSPCSP-6, with a blast profile of 1-2 mils (25-50 µ). 

STEEL (IMMERSION): Abrasive blast clean to a minimum SSPC-SP-10 Near-White Grade (NACE 2) and achieve a surface profile of 1.5-3 mils. All weld spatter must be removed along weld seams, rough welds should be ground smooth, and all sharp edges should be ground to a smooth radius. 

PREVIOUSLY COATED: Previously coated surfaces must be sound and in good condition. Smooth, hard, or glossy finishes should be scarified by sanding or sweep blasting to create a surface profile. The DTM Epoxy Mastic is compatible with most coatings, but a test patch is suggested. 

GALVANIZED METAL: Remove oil, dirt, grease and other chemical deposits with Krud Kutter Original Cleaner Degreaser or other suitable cleaner. Remove loose rust, white rust or deteriorated old coatings by hand or power tool cleaning or brush off blasting. Rinse thoroughly with fresh water and allow to fully dry. 

CONCRETE OR MASONRY: New concrete or masonry must cure 30 days before coating. Any concrete surface must be protected from moisture transmission from uncoated areas. Remove all loose, unsound concrete.

CONCRETE FLOORS: Remove laitance and create a surface profile by either acid etching with Rust-Oleum 108402 Cleaning and Etch Solution, or by grinding. If etching, consult with 108 Clean & Etch Solution Technical Data Sheet for complete application instructions. Rinse thoroughly and allow to dry. The concrete must be fully dry prior to coating application. After etching, the concrete should have a texture, which resembles fine grit sandpaper. Repeat the process if necessary. Surface sealers and curing agents must be removed by grinding. Vacuum to remove fine dust and debris. The floor should be dry and dust free prior to application. Previously coated floors need to be in good condition with proper adhesion to the concrete substrate.

Airless spray is the preferred method of application. However, brush, roller, or air-atomized spray may also be used. Refer to table for thinning recommendations. For proper performance, a dry film thickness of 5-8 mils per coat is required. Excessive brushing or rolling may reduce film thickness. Apply a second coat if necessary to achieve the recommended film thickness. 

Use the Standard Activator or Fast Cure Activator at air temperatures between 50-120°F (10-49°C) and when the surface temperature is at least 5°F (3°C) above the dew point and less than 120ºF (49ºC). Low curing temperatures and/or condensation on the film while curing can affect appearance in the form of an amine blush. This can generally be removed with soap and water; however, in a case of extreme blushing, the performance of the coating may be slightly affected. 

NOTE: The Fast Cure Activator may also be used in water immersion. Allow 7 days for full cure prior to beginning immersion service. 

Use the Low Temperature Activator. when application temperatures are between 40-60°F (5-15°C) and when the surface temperature is at least 5°F (3°C) above the dew point, Do not apply the material if the temperature is expected to fall below 40°F in the first 24 hours of cure. At 40°F, full cure will be achieved in 7 days. 

Use the Immersion Activator for water immersion service at air and surface temperatures between 60-100°F (15- 38°C). Apply when the surface temperature is at least 5°F (3°C) above the dew point, and when relative humidity is below 85%. Do not use the Immersion Activator with tint bases. This system may be used for both salt and fresh water; do not use for the inside of potable water tanks. Apply two coats alternating color between coats to ensure complete hide. Allow 7 days cure after application of the second coat before immersion. NOTE: Do not use tinted colors in water immersion. 

POOLS: When used with Immersion Activator, the DTM Epoxy Mastic premix bases can be used as a pool coating over existing epoxy pool coatings, new bare concrete, plaster, Gunite, and fiberglass. The pool must be completely empty and dry before coating. After pool is emptied, this typically requires 7- 10 days depending on temperature and humidity. To test the dryness of concrete, Gunite or plaster pool surfaces, securely tape a 2 ft. by 2 ft. piece of clear plastic onto a horizontal and vertical surface at the deep end of the pool. Check after 24 hours. If water condensation is visible under the plastic, this is an indication that the surface is not completely dry, and NOT suitable for coating. 

Allow additional dry time and retest. Follow surface preparation, mixing and application instructions. Avoid painting in midday sun. Application is recommended early in the day or late in the afternoon when at least 2 hours of sunlight remain after completion of the job. 

Allow minimum of 5-7 sunny days cure before filling pool. Early contact with water can cause premature fading, chalking and blistering. Super chlorinated water can cause a bleached-out appearance. Sunlight and UV will cause chalking and fading. Do not use over: 1) chlorinated rubber, 2) synthetic rubber, 3) vinyl, 4) acrylic. 

NOTE: In swimming pool service, early chalking may occur if the water pH is outside the range of 7.2-7.6 and/or if the water temperature exceeds 100°F (38°C). 


(Comparable equipment also suitable.) 

BRUSH: Use a good quality natural or synthetic bristle brush. 

ROLLER: Use a good quality lamb’s wool or synthetic fiber (3/8- 1/2"nap). 


Fluid Tip
Fluid Delivery
Atomized Pressure
10-16 oz./min.
25-60 psi
25-60 psi
8-10 oz./min
10 psi (at tip)


Fluid Pressure
Fluid Tip
Filter Mesh
1,800-3,000 psi

THINNING: Thinning is normally not required, except for air-atomized spray. For air-atomized spray application, thin only up to 10% by volume with 160402 Thinner after the components have been mixed. If the coating is going to be used in immersion service, 9102 or 9104 activator, then, use up to 10% 165402 Thinner for airatomized spray and up to 5% of 165402 Thinner for airless spray. 

NOTE: Addition of more than 10% of 160402 or 165402 Thinner will cause VOC to exceed 340 g/l. In this case, 333402 VOC exempt thinner can be used if needed. 

NOTE: When using the Satin Activator, thin only with 333402 Thinner to maintain the VOC <250 g/l. 

MIXING: Both the base and activator components are highly pigmented. Mix each component thoroughly to ensure any settled pigment is re-dispersed before combining the components together. Combine at a 1:1 ratio by volume in a container large enough to hold the total volume. Mix thoroughly for 2-3 minutes. Power mixing is preferred. Do not mix more material than you plan to use within the listed pot life. 

CLEAN-UP: Use 160402 or 165402 Thinner

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