6 Sources of Corrosion in the Workplace (And What to Do About It)

Corrosion is one of those issues that often lurks in the background, unnoticed, until it becomes costly.

From manufacturing facilities and warehouses to offices and hospitals, corrosion gradually undermines metals, equipment, and infrastructure within a business.

Understanding the source of corrosion is the first step toward preventing it. Although corrosion is a natural phenomenon, most of its most prevalent sources within a business can be managed or reduced through proper strategies.

It’s worth investing the time and effort into learning how to keep corrosion at bay. An ounce of prevention is, as the old saying goes, worth a pound of cure. So, it’ll be cheaper to prevent it.

Here are six sources of workplace corrosion and what businesses can do about each.

Temperature Extremes and Thermal Cycling

Recurring exposure to extreme temperatures, or constant cycles of heating and subsequent cooling, can accelerate corrosion processes in the workplace. When metals are exposed to extreme temperatures, they expand and contract, which can cause paint, coatings, and surface treatments to flake off and detach from the surface. Once this occurs, moisture and contaminants can reach the exposed surface and cause corrosion.

Using materials and coatings that are resistant to temperature extremes is a key step in preventing this kind of corrosion. Insulation can also be an effective solution, as it can prevent extreme temperature fluctuations on exposed surfaces.

Moisture and Humidity

Moisture is the leading cause of corrosion in most workplaces. When metals are exposed to moisture, such as water or high humidity, oxidation can occur.

Some workplaces are especially susceptible, including food processing facilities, warehouses, basements, and older facilities where condensation can form on pipes and equipment.

Businesses can manage moisture by installing ventilation, dehumidification, and insulation systems.

Airborne Contaminants and Industrial Pollution

Airborne pollutants are another form of corrosion that is often overlooked. Dust, salt, sulfur, and other pollutants can settle on exposed surfaces, especially. When moisture is introduced, it can cause a film to form on exposed surfaces and greatly accelerate corrosion.

Improving air quality can be an effective solution to prevent this type of corrosion, and installing air filtration systems and keeping surfaces clean can significantly reduce the risk.

Galvanic Corrosion from Mixed Metals

Galvanic corrosion occurs when two different metals are in contact with an electrolyte, like water or humidity. As a result, one metal will corrode more quickly than usual, while the other remains protected.

Preventing galvanic corrosion begins with raising awareness. Separating different metals from one another is the first line of defense. However, when that’s not possible, insulators like coatings, gaskets, and spacers made of plastic materials can be used.

Chemical Exposure

Many work environments contain chemicals that can accelerate corrosion. Cleaning solutions, acids, solvents, salts, and other industrial by-products can react with metal surfaces, causing rapid metal degradation. In some cases, airborne chemical fumes or vapors can deposit on metal surfaces and lead to corrosion over time.

Proper handling of chemicals is essential. The chemicals should be kept away from metal surfaces at all times. Additionally, proper ventilation in the work environment can help reduce chemical fumes.

Poor Material Selection

Using the wrong materials in the work environment is a hidden hazard that leads to significant workplace corrosion. Not all metals are the same since some react differently in different work environments. For example, carbon steel corrodes rapidly in humid environments, while aluminum corrodes rapidly when exposed to certain chemicals.

Selecting the right materials is essential. Business owners need to consider factors such as moisture, temperature, and the chemicals to be used when selecting appropriate materials.

Corrosion is a common issue in many work environments, but it doesn’t have to be. There are many sources of corrosion, including moisture, chemicals, materials, and maintenance practices. Each of these sources can be managed to prevent corrosion from occurring.