When it comes to controlling corrosion in your building or facility, it pays to have a plan. The gradual deterioration of machinery and equipment from corrosion can represent a significant financial challenge for your company. Fortunately, there are several methods to help you avoid corrosion and preserve your company’s valuable assets. This process is known as: corrosion control.
What is Corrosion Control?
Corrosion control is the process of preventing and minimizing the effects of corrosion in an industrial setting. Industrial machinery can create excessive moisture, high temperatures, or use harsh chemicals which results in the decay and deterioration of nearby metals. Corrosion control uses protective coatings and anti-corrosive techniques to protect metal equipment and surfaces to prevent corrosion. Corrosion control is critical to prevent damage to equipment, company assets, and the building itself.
Why is Corrosion Prevention Important?
Preventing corrosion in an industrial setting is vital. When your company’s equipment and structures become corroded it can result in an employee injury, loss of productivity, and broken machinery. Consider your company’s expensive equipment. Corrosion can cause it to fail, resulting in an employee being injured, along with costly downtime while the machine gets repaired. Even worse, the machinery could fail to the point that it needs to be replaced entirely. It’s clear that ignoring corrosion can become an expensive problem. Luckily, there are plenty of ways to prevent corrosion from developing. Corrosion prevention protects employees, avoids lost productivity, and extends the life of your company’s valuable assets.
Methods for Controlling Corrosion in Industrial Buildings
Heat and humidity make corrosion a persistent issue in industrial environments. Fortunately, you can take steps to control the development of corrosion at your business. Regular maintenance, protective coatings, and metal alloys can all help slow or avoid corrosion. Let’s discuss all of your corrosion prevention options in detail.
Protective Coatings
Protective coatings are specialized materials that are applied to protect industrial machinery and equipment and to prevent corrosion. There are various types of protective coatings available including: paints and primers, powder coatings, plastic coatings, and wax coatings. Each of these types of protective coatings create a protective barrier that extends the life of industrial equipment and machinery. Here’s how they work.
Paints and Primers
Paints and primers provide an essential barrier to prevent corrosion. They’re especially important in an industrial setting where high temperatures, moisture, and corrosive chemicals are present. Paints can be formulated or include additives to increase their protection against corrosion. These specialized coatings provide a physical and chemical barrier for the surfaces they’re applied to. Keep in mind that these specialized paints will require regular touch-ups to ensure their effectiveness. The types of paints and primers used will depend on the specific environment and business needs.
Powder Coatings
Powder coatings are applied to metal surfaces to protect against corrosion. The powder coating is electrostatically applied to the surface and then cured in an oven. The powder then melts and becomes a smooth protective finish. Powder coating protects against scratches and abrasion, fading, weathering, and corrosion. Powder coating has low VOC emissions making them environmentally-friendly. Powder coatings are used in the automotive industry, consumer goods, and construction.

Plastic Coatings
Plastic coatings are applied to surfaces and objects to prevent corrosion in an industrial setting. They can provide protection against moisture, heat and chemicals, the environment, and scratching or abrasion. Plastic coatings can be sprayed on or the object can be dipped into the liquid plastic and then dried. Common types of plastic coatings include polyurethane, epoxy, acrylic, silicone, and other options. A plastic coating increases durability, helping to extend the lifespan of industrial equipment.
Wax Coatings
Wax coatings are similar to powder and plastic coatings, with the key differences being that wax coating is not permanent and not as durable as other options. The advantage of wax coatings is that they are inexpensive and easy to apply. Wax coatings are often used in situations where only temporary protection is needed like storage or transportation. They’re used to repel water, salt, and acids. Wax coatings can be applied by dipping, spraying, or brushing the wax onto the metal surface.
Corrosion Inhibitors
A corrosion inhibitor is any substance that’s used internally or externally on equipment to reduce or prevent corrosion. A common example of a corrosion inhibitor is antifreeze for your car. A corrosion inhibitor will neutralize corrosive agents, add a protective film, or prevent the occurrence of electrochemical reactions like rust. Corrosion inhibitors can be applied to surfaces or as an additive into equipment like cooling systems, boilers, and pipelines.
Hot-Dip Galvanization
Hot-dip galvanizing is a process that’s used to protect steel or iron from corrosion. The metal is coated with zinc which makes it more durable and corrosion-resistant. It’s called hot-dip galvanizing because the iron or steel is dipped into a molten bath of liquid zinc that’s been heated to over 800 degrees Fahrenheit. After the zinc cools, it hardens and results in a thick protective coating. The zinc coating protects the underlying metal even in harsh conditions. Hot-dip galvanizing is used in the automotive industry, ships and offshore structures, and construction.
Stainless Steel
Stainless steel can be used to prevent corrosion in an industrial setting. Stainless steel contains chromium, which reacts to moisture and oxygen by creating a layer of chromium oxide on the surface that prevents corrosion. Additional materials like nickel, molybdenum, or titanium can be added to stainless steel for protection against specific types of corrosion. Because of stainless steel’s passive corrosion protection it’s used in industries like food processing, chemical processing, construction, and marine environments.
Cathodic Protection
Cathodic protection is an anti-corrosion method that forces a protective layer of metal to “sacrifice” itself to protect the metal underneath. The two components (cathode and anode) act like a battery, passing electrons from the positively charged anode to protect the negatively charged cathode. As the protective anode decays and corrodes, the cathode avoids corrosion. Metals that can be used as the sacrificial anode include: zinc, magnesium, and aluminum. Cathodic protection is used to protect underground oil pipelines and marine structures and ships.
Metal Plating
Metal plating is a simple method of corrosion prevention that involves applying a protective metal coating to an object. This outer plate of metal acts as a barrier to protect the underlying surface from corrosion. Common metals used in plating include chromium, nickel, zinc, or copper. Plating is often used in the automotive industry, aerospace, oil and gas, and construction.
Metal Selection and Surface Conditions
Metal selection is a critical first step to control corrosion. Picking the right types of metals — that already have anti-corrosive properties — will give you a headstart on avoiding corrosion. Metal alloys like stainless steel or aluminum are already corrosion-resistant, and when combined with protective coatings they’ll be long-lasting even in tough industrial settings. Surface conditions for these metals are also important. Ensure that metal objects and surfaces have a smooth, clean surface that’s free from damage, otherwise they’ll be susceptible to corrosion. Careful metal selection and surface preparation will extend the life of your assets by helping avoid corrosion.
Environmental Modifications
Controlling corrosive elements in the environment can go a long way towards corrosion prevention. By modifying the temperature and humidity in a building you can reduce the rate of corrosion for your assets. Environmental modification can be achieved with the following:
Temperature control – The hotter it is, the faster metals can decay. Lowering the temperature in your buildings will slow the rate of corrosion.
Reducing humidity – Lots of moisture in the air leads to corrosion. By using dehumidifiers or air conditioning you can reduce the overall humidity and corrosion.
Ventilation – Improving your building’s ventilation can allow heat and corrosive vapors to escape instead of staying indoors with your equipment.
Isolation – You can completely remove equipment from a hot and humid area, or simply put it in storage when it isn’t being used. Either option will slow corrosion.
Environmental modifications can make a significant impact in the fight against corrosion.
Regular Maintenance
Regular inspections and maintenance are crucial to prevent corrosion. Schedule regular inspections to check equipment and metal surfaces for signs of corrosion like rust, pitting, or blistering. Keep work areas clean because an accumulation of dirt, grease, and other contaminants will invite corrosion. Re-apply protective coatings periodically as they’ll wear off over time. Inspections, cleaning, and application of protective coatings will help you avoid the development of corrosion.
Contact Alpine in Philadelphia
You can’t let corrosion get out of control at your business. It will reduce the life of your equipment, increase maintenance costs, and reduce employee safety. Taking the proper precautions to avoid corrosion is essential for the longevity of your company.
At Alpine Painting and Restoration, we can help you create and implement a corrosion control strategy. Through the use of protective coatings, corrosion inhibitors, and environmental modifications we can assist your business in the fight against corrosion. We’ve been proudly providing commercial painting services to Philadelphia-area businesses for more than three decades. Contact us today by phone or email to discuss how we can help you avoid corrosion.