Abstract: A method of protecting a surface has the steps of providing a coating material containing sufficient aluminum flakes to provide a physical barrier to corrosion; and applying the coating material to a surface, thereby protecting the surface with an armor of aluminum. The method provides a coating material comprising about 3% to about 25% by weight of aluminum flakes, about 5% to about 20% by weight of aluminum flakes and about 7% to about 15% by weight of aluminum flakes. The aluminum flakes in the coating material can be non-leafing. A method of treating old concrete and rusting rebar, calls for providing a coating material containing sufficient aluminum flakes to provide a physical barrier to corrosion and polyisocyanates with sufficient unreacted NCO groups to scavenge water and provide a water-tight coating; and applying the coating material to the surfaces of damaged concrete and exposed rebar, thereby protecting the surfaces with an armor of aluminum.

Abstract: A method of protecting surfaces from corrosion calls for providing a coating material containing polyisocyanates with unreacted, active NCO groups; and applying the coating material to a rust covered surface, whereby the free NCO groups in the coating material react with the moisture in the rust to dehydrate the rust and produce a strong coating which keeps out water and oxygen which corrode surfaces. The active NCO content is about 3% to about 20% NCO groups. Also disclosed is a composition for coating an iron surface, the composition comprising polyisocyanates whose NCO content is between 5% and 30%; and aluminum flakes at about 5% to about 50% by weight.