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. Protecting yourself against rust starts with understanding what causes it and how to choose the right rust-proofing and corrosion-prevention products. 

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. 

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.

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

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.

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.

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

Staying ahead of rust, especially in a metalworking shop, means understanding and using the three ingredients that are critical for industrial rust prevention. 

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 

Monitoring water quality will help you understand when hard water salts, chlorides, and sulfates reach critical thresholds. 

• 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.

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.

Industrial rust inhibitors help extend the life of your equipment and prevent industrial rust. What works for your shop and equipment will vary based on a variety of factors. Here’s a quick overview of our rust prevention products

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

Not sure which type(s) of industrial corrosion prevention products you need? Reach out to our team – we'll review your process and make some recommendations.

The specific process for rust prevention varies based on a number of factors— including your environment, your shop setup, and type of metal, among others. These steps provide a high-level overview of what to expect as you build industrial corrosion protection best practices into your processes

Taking time to evaluate your shop space as well as your general environmental conditions is important for understanding weak points in your process, as well as your risk for rust.

While important for every metalworking shop, don’t skimp on this step if your equipment is near salt water, in an area with very high summer temperatures, or located in areas that regularly see snow and winter temperatures.

Pay close attention to areas exposed to high humidity, with poor ventilation, or where water can pool. Moving parts and lubrication points are also prone to trapping moisture

Before diving in to rust proofing your equipment and products, here are some specific processes you’ll want to pay close attention to as you begin documenting—you’ll of course want to provide as much detail as possible.

• Your cleaning process: 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.
• Your drying process: Before applying any corrosion-prevention products, ensure the surface is completely dry. Moisture can affect adherence and effectiveness.
• Your surface profiles: Sanding or roughening up the surface helps coatings adhere. However, that’s not all – you'll also want to review your processes for each specific type of fluid and application.
• Corrosion Inhibitors: To ensure thorough coverage and prevent corrosion, 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.

   

Here are some of the different types of application types you’ll want to include in your documentation:

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.

Set an inspection and reapplication schedule based on manufacturer recommendations.

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.

While the best practices for rustproofing 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.

Track inspections and reapplications. This makes it easier to recognize possible issues and adjust your plan.

As always, refer to manufacturer recommendations, but generally, here’s what to expect for ongoing fluid maintenance to prevent rust:

• 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.

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 1-844-917-3751 or email us at

insidesales.support@quakerhoughton.com