Prevent Summertime Corrosion With These Industrial Rust Proofing Tips

Summer is the season for lots of things—going to the beach, growing plants and veggies, mowing the lawn, and cranking up the A/C. But summer is also rust season—especially when it comes to infrastructure and metalworking. 

Why? Rust and corrosion are active all year, but summer’s additional moisture and humidity create the perfect breeding ground, priming the proverbial pump to wreak havoc on infrastructure and metalworking shops.

When it comes to infrastructure, rust and corrosion are some of the biggest concerns—both with public infrastructure (think bridges) and on a much smaller scale like the metal in your buildings and equipment—machine bases, supports, and beams, among other surfaces. 

It’s not just that rust happens. Fixing the damage caused by rust and corrosion can be costly in time and money—expensive repairs and replacement parts and even missing customer deadlines or quotas due to reduced capacity. 

Fortunately, we aren’t at the mercy of rust. And that has a lot to do with understanding what causes it and how to choose the right rust proofing and corrosion prevention products and strategies. 

Rust vs. Corrosion—What’s the Difference?

But first, let’s get one thing straight. Oxidation causes materials to deteriorate. This process—corrosion—is typically due to exposure to air or chemicals and can be many colors. 

Rust is an orange-brown type of corrosion. It specifically refers to the oxidation of iron when it’s exposed to air and moisture. 

How Summer Environmental Factors Accelerate Corrosion
The specific particularities of summer are what make it the rust season. While a lot of it comes from increased heat and humidity, there are more environmental factors that can increase the risk of rust and corrosion.

High temperatures, Humidity, and Condensation
Summer means higher temps, and since warmer air holds more moisture, humidity ramps up. What’s more, when that warm, moisture-laden air touches cool metal surfaces—like those in your shop—water droplets form due to condensation. And that water can lead to rust. 

Air Pollution
Air pollutants and moisture can combine to create acids, which speed up corrosion. While pollution is always present, the added humidity of summer can make it more problematic for your shop. 

Saltwater Exposure
Salt is highly corrosive, so any equipment near saltwater needs special care. Keep in mind, it’s not just about being near the ocean. If you use chlorine, have water softener systems, or operate in or near swimming pools, you might also be at a higher risk.

UV Radiation
Our skin and rust inhibitors have one thing in common. They’re both prone to sun damage. In the case of rust inhibitors, UV rays break down protective coatings over time.

Summer Storms
Big influxes of moist air, like during a summer storm, can infiltrate your shop, get onto tools, and into nooks and crannies. 

How is Rust Prevented?
Staying ahead of rust, especially in a metalworking shop, means understanding and using the three ingredients that are critical for prevention. 

Maintain Your Metalworking Fluids
Test your fluids regularly to prevent contaminants. Also monitor concentration, pH, bacteria levels, hardness, chloride and sulfate levels, and tramp oils.

●     Target bacteria levels < 104 CFU/ml

●     Keep chlorides < 100 ppm

●     Chlorides + sulfates should not exceed 125 ppm 

Monitor Water Quality.
Monitoring water quality will help avoid hard water salts, chlorides, and sulfates. 

●     Water purification systems such as reverse osmosis (RO) and de-ionization (DI) can improve water quality. 

●     Blow-offs are a good way to remove excess fluid.

Control the Environment. 
To prevent moisture/humidity:

●     Maintain a controlled, air-conditioned storage area.

●     Keep parts stored away from open doors, battery storage, and high-traffic areas.

●     Use a desiccant (those little “do not eat” packets) to absorb moisture during storage and transportation.

Categories of Rust Proofing Products
Rust proofing products help extend the life of your equipment and prevent industrial rust. What works for your shop and equipment will vary based on what.

●        Corrosion inhibitors add a protective film or barrier that blocks corrosion. They can be added to coolants, paints, lubricants, and similar products. 

●        Protective coatings create a physical barrier that protects metal from moisture, salt, and anything that can corrode. 

●        Anti-corrosive lubricants and grease create a protective film that prevents rust and corrosion. The lubricant reduces friction and wear.

How to Choose the Right Corrosion Prevention Products
Which products will work best for you? Consider these as you evaluate your options. 

Your Environment
This is particularly important if your equipment is near salt water or in an area with very high summer temperatures.

Type of Metal
Different types of metals require different products.

Application Method and Maintenance
You’ll need to consider factors like drying time, the type of ventilation required, and whether the products are compatible with those you already use. In fact, this is one reason we recommend choosing a “family” of products that are designed to work with one another.

Application Tips for Maximum Protection
While the best practices for rust proofing your shop depend on a variety of factors, surface preparation, application techniques, and regular maintenance are the three keys to getting the most from your corrosion prevention products. 

Surface Preparation
●     Clean: Remove dirt, grease, and anything else that may undermine the rust inhibitor's adherence. Degreasers, rust removers, wire brushing, and sanding work well for this.

●     Dry: Before applying any corrosion-prevention products, ensure the surface is completely dry. Moisture can affect adherence and effectiveness. 

●     Profile: Sanding or roughening up the surface helps coatings adhere.

Application Techniques
●     Corrosion Inhibitors: To ensure thorough coverage, refer to the manufacturer’s directions for dilution and mixing instructions, as well as application methods (brushing, dipping, for example). 

●     Protective Coatings: Prepping the surface is vital. Follow the manufacturer’s instructions for preparation, application, drying times, and curing conditions. 

●     Lubricants and Greases: Clean surfaces thoroughly. Apply a thin, even layer to ensure complete coverage. 

Regular Maintenance Activities and Frequency

●     Corrosion Inhibitors: Typically, every 6-12 months, depending on the environment. Refer to manufacturer recommendations. 

●     Protective Coatings: Regularly inspect for signs of wear and tear. Reapply as needed, particularly in high-wear or exposure areas.

●     Lubricants and Greases: Inspect for dryness or contamination and reapply as necessary. Summer’s high temperatures can accelerate, dry out, and breakdown, so reapply more frequently.

Step-by-Step Guide to Implementing a Rust Proofing Strategy
If you want to avoid rust season this year and, in the future, create and implement a rust proofing strategy. While it won’t necessarily move your rust risk to zero, it will help you increase the life of your equipment, save time and money, and avoid headaches.

Here’s how to compile an easy-to-implement strategy and schedule.

Step 1: Identify and Document High-Exposure Areas
Any areas exposed to high humidity, with poor ventilation, or where water can pool. Moving parts and lubrication points are also prone to trapping moisture. 

Step 2: Document Your Surface Prep Protocol and Products.
Here are some examples to consider as you begin documenting—you’ll of course want to provide as much detail as possible.

Brush On
This technique works best for small areas, detail work, and touch-ups. Multiple coats are recommended.

Electrostatic
This method is ideal for complex shapes and hard-to-reach areas. A spray gun electrically charges the rust proofing product, attracting it to the metal and creating a strong bond and even coat. 

Flooding
Typically used for large, hollow cavities. A thin, rust proofing product (often oils or waxes) floods the cavity by pouring or spraying with a flood nozzle. The excess product can drain, leaving a protective film on the inner surfaces. 

Flow On
This method suits flat or gently sloping surfaces where the product can spread evenly. It flows and self-levels to coat the surface. 

Immersion
This method is ideal for small objects or parts. The object is completely dipped into a tank containing the rust proofing product, ensuring it reaches even the smallest crevices. 

Step 3: Follow Manufacturer Recommendations
Set an inspection and reapplication schedule based on the product manufacturer’s recommendations. 

Step 4: Ongoing Monitoring
Track inspections and reapplications. This makes it easier to recognize possible issues and adjust your plan. 

Summer Doesn’t Have to Wreak Havoc on Your Shop
Summer doesn’t need to be rust season. Taking a proactive, preventative approach and developing a rust proofing strategy will help safeguard your equipment and keep your shop running smoothly all summer without falling victim to industrial rust. 

Quaker Houghton offers an extensive line of rust preventive fluids (RPs) that can protect your metal parts during storage, transportation, and processing, regardless of your process or materials. 

Are you looking for product recommendations? Don’t hesitate to call us at 1-888-872-1375 or email us at insidesales.support@quakerhoughton.com