What Is Corrosion? Plus How to Prevent It
Corrosion might start small, but it’s a relentless enemy for industrial and commercial facilities. Whether you manage steel tanks, pipelines, or containment systems, unchecked corrosion can cause leaks, failures, safety incidents, and unexpected downtime. For plants running 24/7 or handling hazardous materials, there’s no room for surprise failures—proactive corrosion prevention is essential.
What Is Corrosion?
Corrosion is a natural process where metals deteriorate due to chemical reactions—often involving water, oxygen, or aggressive chemicals found in industrial environments. Over time, what starts as minor surface rust can penetrate deep into steel, undermining strength and leading to leaks, contamination, or even structural collapse.
Key factors in industrial corrosion:
- Moisture and humidity: Water accelerates the breakdown of metal surfaces.
- Exposure to chemicals: Acids, alkalis, and salts attack unprotected metals.
- Electrical phenomena: Stray currents or galvanic reactions can speed up corrosion in connected metal systems.
- Temperature extremes: Cycling between hot and cold can cause microcracks, letting in moisture and chemicals.
Why Corrosion Matters in Industrial Facilities
Corrosion isn’t just a cosmetic problem. It can:
- Weaken beams, tanks, and pipes, increasing the risk of failure
- Cause leaks of water, steam, gas, or hazardous chemicals
- Lead to costly emergency repairs, downtime, and regulatory penalties
- Threaten employee safety and environmental compliance
The global cost of corrosion is estimated at $2.5 trillion annually, but with the right strategies, most of these losses—and the associated risks—can be prevented.
Top Corrosion Prevention Techniques
1. Apply Advanced Protective Coatings & Linings
High-performance coatings and linings act as a barrier between metal surfaces and corrosive agents. RAK Industrial Services specializes in:
- Chemical-resistant coatings for tanks and pipes exposed to aggressive media
- NSF 61-certified linings for potable water systems
- Plural component coatings for rapid cure and maximum durability
- Containment coatings for secondary containment and hazardous chemical environments
2. Invest in Composite and Carbon Fiber Repairs
When corrosion is already present, advanced composite wraps—like carbon fiber—can restore and reinforce critical assets without shutdowns. These solutions bond directly to steel or concrete, sealing out moisture and chemicals, and adding long-lasting strength.
3. Schedule Regular Inspections & Maintenance
Proactive inspections using ultrasonic testing, visual checks, and corrosion-monitoring technologies catch early issues before they escalate. RAK Industrial Services can help develop a custom inspection program for your facility, prioritizing high-risk areas.
4. Manage Environmental Exposure
Control humidity, temperature, and chemical exposure in vulnerable areas. Use dehumidifiers, keep areas well-drained, and quickly clean up chemical spills to prevent localized corrosion.
5. Use Cathodic Protection for Buried or Submerged Assets
Cathodic protection systems apply a small electrical current to counteract natural corrosion processes in buried or submerged pipelines and tanks, greatly extending asset life.
Why Choose RAK for Corrosion Control?
- Emergency On-Line Leak Repair: We fix leaks and corrosion damage while your system stays operational—no shutdowns required.
- 24/7 Rapid Response: Issues don’t wait for business hours, and neither do we.
- Advanced Solutions: Carbon fiber, composite repairs, and state-of-the-art coatings deliver long-term protection.
- Compliance & Safety: All solutions are engineered to exceed industry standards for safety and environmental protection.
- Tailored for High-Stakes Environments: We specialize in serving facilities handling hazardous chemicals, managing multiple tanks, and operating around the clock.
Corrosion doesn’t have to dictate your maintenance schedule—or your bottom line. With the right prevention strategies, modern repair technologies, and a proactive approach, you can protect your facility, minimize downtime, and ensure business continuity.
