The Detroit Post
Thursday, 21 October, 2021

How To Rust Proof Galvanized Steel

David Lawrence
• Sunday, 18 October, 2020
• 9 min read

Scrubbing pad or wire brush Rust occurs when the steel is exposed to moisture; its formation is an electrochemical process between the molecules in the water and the molecules in the metal.

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Steel is a major building construction material. It is also used in the manufacturing of automobiles, machines and appliances.

To keep steel from rusting, a protective coating is placed on the surface of the metal. Many of the rusty looking assemblage elements that I add to my art actually start out as clean pieces of metal.

Galvanized steel Tray or some other type of container Adriatic Acid Baking Soda Salt Hydrogen Peroxide Vinegar Water Spray bottle Latex gloves Eye protection And the Sun Making sure you’re wearing gloves, eye protection, and are doing this outside in a well ventilated area, add the steel plates to the tray and pour enough Adriatic Acid to cover their surface.

Sometimes I’ll agitate the tray a little to ensure the acid is fully in contact with all the surfaces of the metal. When I feel that it’s been long enough I’ll add water and baking soda to the tray to neutralize the acid and make it easier to dispose of the solution.

I repeat this process a few more times, making sure to agitate the tray and flipping the pieces over to get both sides. For the last spraying I’ll just let the metal soak in the solution and forget about it for a few hours.

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The last step in all of this typically comes when I’ve completed one of my assemblages, and that is to give the steel a good clear coat. Galvanized steel has been used for almost 2,000 years because of its unrivaled ability to last a very long time and resist rust.

So how long does it take for a handy new galvanized steel bucket to rust and corrode into a useless heap of metal? A galvanized steel bucket (produced with any method) can last practically forever if it's gently used and kept dry and out of the rain.

Table 1 below predicts how long galvanized steel will last based on a 30-month corrosion study of environmental factors like wetness, humidity, and air pollutants in 2004. Prediction of When Zinc Layer will be Consumed on GalvanizedSteelGalvanizedSteel kept in the wet or soaked environments10 Years with a relative humidity of 100%34 Years with a relative humidity below 60%.211 Resource: Journal of Materials in Civil Engineering 2004 (11) The corrosion resistance of zinc coatings is determined primarily by the type and thickness of the coating but, varies with the severity of environmental conditions exposed to (as in the table above).

Hot dipped galvanized zinc coating resistance to corrosion depends primarily on a protective film (patina) formed on its surface. Zinc corrosion products of hot-dip galvanizing build-up (creating a patina layer) and insolubly cling to the metal in many environments.

The type of zinc galvanization and how that process controls the way in which the galvanized steel corrodes must be understood first. The environments, elements, and conditions that any given type of galvanized steel is exposed to, nevertheless, indeed determines how long it will last before corrosion.

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A 1926 study of galvanized steel corrosion in industrial, rural and sea regions found: The handy chart below (from American Galvanizers Association) illustrates how long galvanized steel will last before corroded areas should be maintained to prevent further deterioration.

Put another way, this chart shows how long it takes for galvanized steel to rust in different environments. The thicker the zinc coating the longer galvanized steel will last without corrosion.

As in the chart below and noted in the 1926 study, for each location the corrosion rate is essentially constant with time (9). Sulfide and phosphate air pollution, from point sources like automobile exhaust, cause galvanized zinc coating consumption.

Lower temperatures and humidity make temperate marine environments less corrosive to their tropical counterparts. It is rational, therefore, to attribute the greater corrosively of industrial atmospheres to the acid-forming SO2 pollution contained within them (9).

Concentrations of these pollutants were the highest values in winter; when fossil fuel combustion increases. Galvanized zinc coatings respond well in freezing and hot temperatures.

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For long-term continuous exposure the maximum recommended temperature is 392 F, according to a publication by American Galvanizers (8). Because the applications of steel are many, hot-dip galvanizing will continue to be called upon to ensure long-lasting and maintenance-free corrosion protection.

Although these buckets can take a fair about of abuse, for optimum performance choose a storage area that has adequate ventilation and has a low amount of moisture. The rusting process begins when iron reacts with oxygen in the presence of water, saltwater, acids, or other harsh chemicals.

Eventually, large areas of rust form that may cause the entire metal structure to disintegrate. If the object is located in a humid indoors environment, such as a garage or basement, install a dehumidifier.

Any type of mud or dirt adhered to the surface can hold water, so it’s important to keep metals clean. Dipping metal objects, such as clocks, into a bluing solution of water, sodium hydroxide, and potassium nitrate, provides strong corrosion resistance.

Commercially available rust prevention products in the form of aerosol sprays or cloth wipes also can protect metal objects, including tools, outdoor gear, vehicles, and large metal parts. Browse Metal Products at IMS Galvanization is a process used to preserve steel rust -free for many years.

First, the zinc coating acts as a barrier preventing oxygen and water from reaching the steel. Then, scrub with warm water and soap and apply a metal conditioner or other protective coating to prevent further oxidation.

Plus, hydrogen peroxide and vinegar can give off a moderate level of fumes, so you’ll want to work in a well-ventilated space anyway. Lightly sand the entire surface of the metal with a fine-grit sandpaper to shed any protective coating present that might prevent the object from rusting.

Place the sanded object in the center of a plastic bin that’s rested on either hard ground or a flat work surface in the garage. As it dries, the acid of the vinegar will begin to corrode the surface of the metal and you will start to see rust appear.

Pour two cups of hydrogen peroxide, four tablespoons of white vinegar, and one-and-a-half teaspoons of table salt into a plastic spray bottle. Once the salt has dissolved, spray the solution over the object to coat it partially or completely, depending on the desired effect.

Finally, spray a thin coating of clear acrylic sealer to the dry rusted object. It will set the rust and preserve the aged appearance for years to come while providing an acrylic barrier that keeps it from inadvertently staining any other metal or wood with which it comes into contact in the future.

But bolt a zinc anode (available from any boating store) to the wet, buried section if you like. It won't do any good when the soil is dry, but whenever it's wet it will protect the pipe.

All information presented is for general reference and does not represent a professional opinion nor the policy of an author's employer. The internet is largely anonymous & unsetted; some names may be fictitious and some recommendations might be harmful.

Disclaimer: This post may contain affiliate links, meaning, if you click through and make a purchase we may earn a commission. I don’t know about you but my heart skips a beat when I come across reclaimed wood, rusty metal, and forged iron.

There’s something to be said about pieces that speak their history through their old age and rusty patina, and it’s one of the reasons I’m so drawn to mountain homes and log cabins. Even something as small as a horseshoe all of a sudden seems to weigh a whole heck of a lot more than I ever realized.

Check out our recent video showing how easy it is to make metal rust : I have to tell ya, making metal rust in fast-forward was even more fun than I anticipated.

Update: If you watch the video at the top of the post you can see how using a small spray bottle or one with a misting option makes this method even easier! The first thing you will want to do is grab your steel /iron/metal and place it into a container or bucket.

After I placed my horseshoe in the container I poured some white distilled vinegar on top. I didn’t measure but I poured just enough so that it covered the horseshoe and then I sorta swished it around on top.

At this point, you’ll want to add peroxide on top of your metal objects. I then sprinkled …err dumped… a bunch of salt on my horseshoe and the rusty color started to come out even more.

Then I called Eric over because I was all excited to show him, but I wanted more bubbles and fizz, so I poured a bit more hydrogen peroxide on top. After a few minutes, I swished the horseshoe around in the solution to sort of rinse off the salt and then patted it dry with a paper towel.

You’ll want to add a clear sealer to prevent the rusty patina from flaking off and staining anything they touch. When I did seal them I just used some leftover Spar Urethane and a foam brush, but you can use any clear sealer and may prefer a spray-on kind.

And if you have a specific technique that you prefer when it comes to making new metal look old, we would love to hear about that too! After receiving a lot of comments and emails about this not working on certain objects I wanted to add that not all metals will rust.

I believe it has to have iron in it in order to rust, and if it’s galvanized, stainless steel or some other type of metal that doesn’t corrode then this process won’t work. I learned this the hard way by trying to rust some galvanized buckets I had on hand and read up about it here.

If you watch the video at the top of this post you’ll see the difference in the spray vs. dunk method. Basically, the spray method will allow more of the contrast of the original metal to show through and it is easier to work in layers and add more rust if you want.

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