Corrosion is one of the biggest threats to the longevity of wrought iron and metal products. Understanding how to prevent corrosion is essential for maintaining the quality and durability of projects. Here’s a detailed guide on effective methods for protecting wrought iron and metal from corrosion and extending their lifespan.

The Steps to Avoid Corrosion

Surface Preparation

Before applying any protective coatings or treatments, proper surface preparation is crucial. Here’s how to get it right:

Clean Thoroughly: Remove all dirt, grease, and old paint from the surface. Use a wire brush, sandblaster, or chemical cleaner as needed.

Remove Rust: If there’s existing rust, it must be removed completely. Use a wire brush, sanding, or a rust remover to get rid of all rust and scale.

Ensure Dryness: Make sure the surface is completely dry before applying any protective coating. Moisture trapped between the metal and the coating can cause corrosion.

Protective Coatings

Applying a protective coating is one of the most effective ways to prevent corrosion. Signs of coating failure include peeling, bubbling, or discoloration of the paint, as well as visible rust spots or corrosion. If you notice any of these issues, it’s important to address them promptly by cleaning, removing damaged coatings, and reapplying protective layers to prevent further deterioration.

Primers: Use a high-quality primer designed for metal surfaces. Zinc-rich primers are particularly effective as they provide a sacrificial layer that corrodes before the underlying metal. For best results, it’s recommended to strip old paint before applying new protective coatings. This ensures proper adhesion and effectiveness of the new primer and paint. If the existing paint is in good condition and properly adhered, you might be able to apply a new coat directly, but thorough surface preparation and cleaning are still crucial.

Paint: Apply a good-quality, rust-resistant paint over the primer. Consider using epoxy-based or polyurethane paints for added protection and durability. Applying a topcoat can provide additional protection, especially in harsh environments. Topcoats add an extra layer of defense against moisture, chemicals, and UV rays, which can degrade the underlying primer and paint. For optimal results, choose a topcoat that is compatible with your primer and paint.

Galvanisation: For extreme conditions, hot-dip galvanising is an excellent option. This process coats the metal in a layer of zinc, which acts as a protective barrier against corrosion. The appropriate thickness of protective coatings depends on the specific application and environmental conditions. Manufacturers often provide guidelines on recommended coating thicknesses. For more demanding environments, such as those with high moisture or chemical exposure, thicker coatings or additional layers may be necessary. Consult product specifications and industry standards for guidance.

Regular Maintenance

Routine maintenance is essential for preserving the integrity of wrought iron and metal products. Regular inspections should be conducted at least every 6–12 months, depending on the environment and use of the metal products.

Inspection: Regularly inspect your metal products for signs of wear, rust, or damage. Early detection can prevent more extensive corrosion issues.

Cleaning: Periodically clean the surfaces to remove contaminants that can contribute to corrosion. Use mild soap and water, and avoid harsh chemicals that can damage protective coatings. While some household cleaners may be effective, it’s best to use cleaners specifically designed for metal surfaces. For heavy-duty cleaning, consider metal-specific cleaners or degreasers.

Touch-Up: Address any scratches, chips, or areas where the coating has worn away. Reapply paint or primer as necessary to maintain protection.

Environmental Considerations

The environment in which your metal products are used can significantly impact their susceptibility to corrosion. High humidity and exposure to water accelerate corrosion. For outdoor applications, ensure that water runoff is properly directed away from metal surfaces.

In coastal areas, salt from the sea can accelerate corrosion. Consider using corrosion-resistant coatings specifically designed for salty environments. Industrial environments with pollutants can also increase the risk of corrosion. Regular cleaning and protective coatings can help mitigate these effects.

For harsh environments, consider using corrosion-resistant materials or alloys such as stainless steel (e.g., 304 or 316 grades), aluminium alloys, or coated metals like galvanised steel. These materials offer enhanced resistance to corrosion and can withstand challenging conditions such as high humidity, saltwater, or chemical exposure.

Additional Measures

In some cases, additional measures may be necessary: Corrosion Inhibitors: Use corrosion inhibitors in environments where metal components are exposed to harsh conditions. These chemicals can help protect the metal from oxidative damage.

Anodising: For aluminium and certain other metals, anodising can create a protective oxide layer that prevents corrosion.

Corrosion can often be repaired on-site if caught early. The process involves cleaning the affected area, removing rust and reapplying protective coatings. However, if corrosion has caused significant structural damage or weakened the metal, replacement of the affected components may be necessary to ensure safety and functionality.

Shop Wrought Iron Products Today

Preventing corrosion in wrought iron and metal products is a crucial step in ensuring their longevity and maintaining their appearance. By following these effective methods—proper surface preparation, applying protective coatings, performing regular maintenance, considering environmental factors, and taking additional measures—you can significantly extend the lifespan of your metal products.

For further assistance or specific product recommendations, feel free to reach out to us at DC Iron.