Rust Prevention for Industrial Facilities

Rust and corrosion cost Australian businesses millions of dollars each year in repairs and replacements. Proper rust prevention through protective coatings can extend the life of your structural steel, equipment, and infrastructure significantly.

The Cost of Corrosion

• Structural integrity compromise
• Equipment failure and downtime
• Safety hazards
• Expensive repairs or replacements
• Reduced asset value

Types of Anti-Corrosion Coatings

Zinc-Rich Primers

Provides galvanic protection to steel:

• How it works: Zinc sacrifices itself to protect steel
• Best for: Structural steel, bridges, tanks
• Protection level: Excellent for severe environments

Epoxy Primers

Creates a barrier against moisture and chemicals:

• How it works: Forms impermeable barrier
• Best for: Industrial equipment, pipework
• Protection level: Good chemical resistance

Polyurethane Topcoats

UV-resistant finish coat:

• How it works: Protects primer from UV and weathering
• Best for: Exterior structures
• Protection level: Excellent durability

Rust Converter Primers

Converts existing rust to a stable compound:

• How it works: Chemically reacts with rust
• Best for: Maintenance painting over light rust
• Protection level: Good for touch-ups

Surface Preparation

Surface prep is critical for rust prevention:

For New Steel

• Remove mill scale
• Abrasive blast to SA 2.5 standard
• Apply primer within 4 hours

For Rusted Steel

• Remove loose rust and scale
• Abrasive blast or power tool clean
• Treat with rust converter if needed
• Apply primer immediately

Common Problem Areas

Pay special attention to:

• Joints and welds: Moisture traps
• Base of columns: Ground moisture exposure
• Roof purlins: Condensation damage
• Drainage areas: Water pooling
• Contact points: Different metals cause galvanic corrosion

Coating Systems

A complete system typically includes:

• Primer: Rust-inhibiting base coat
• Intermediate coat: Builds thickness and protection
• Topcoat: UV protection and aesthetics

Maintenance Schedule

• Annual: Visual inspection for damage
• 3-5 years: Touch-up damaged areas
• 10-15 years: Consider full recoating
• Immediately: Address any rust breakthrough

Signs You Need Rust Treatment

• Visible rust spots or staining
• Paint bubbling or flaking
• Chalking or fading of existing coatings
• Structural members losing thickness