How to stop rust before it costs you dearly - 6 measures that work

Corrosion costs Norwegian industry an estimated 3–4% of GDP each year. That is no small sum, and most of it is unnecessary. If you open a container and find rust on components you have just paid for, the problem is already a fact. Then only two choices remain: scrap the parts, or spend time and money repairing them.

Both are expensive. The cheapest option is to prevent the problem.

Here are 6 measures you can implement immediately, without requiring large investments.

What does corrosion actually cost?

Before we go into the measures: let's put a figure on the problem.

A single instance of rust damage on a precision part can mean:

• Rework and cleaning: typically 1–3 hours of labor per part, depending on size and severity
• Scrapping: for critical tolerances, it is often the only alternative
• Delay: delayed delivery to the customer can trigger daily fines and loss of trust
• Claim costs: returned goods, shipping costs, and new production

For a manufacturing company that ships hundreds of parts per week, uncontrolled corrosion can quickly cost tens of thousands of kroner per month. VCI packaging usually costs a few kroner per unit. The math is simple.

1.  Use clean gloves and eliminate fingerprint corrosion

The problem: Sweat and oils from hands settle on the metal surface and start an electrochemical reaction. The result is visible fingerprint corrosion, which looks unprofessional and can be rejected by the customer.

The measure: Provide everyone who handles metal with clean nitrile gloves. Change them regularly - dirty gloves are just as bad as no gloves.

The cost you save: One rejected shipment can cost more than a year's supply of gloves for an entire department.

2. Pack only clean and dry metals

   The problem: Water and residues from metal processing; coolant, cutting oil, and grinding residue are the most common triggers of corrosion during storage and transport. If you pack metal with these residues inside the packaging, you are effectively creating a corrosion experiment.

   The measure: A clean and dry surface is a non-negotiable requirement before packing. Use compressed air, a drying cloth, or light degreasing where needed. Zerust Axxawash is a water-based cleaner with built-in VCI that cleans and protects in one step, preventing flash rust on machined parts.

   The cost you save: Degreasing one part takes minutes. Cleaning up corrosion or scrapping the part takes hours.

3. Pack at room temperature

   The problem: If you pack warm parts immediately after processing, humidity in the air condenses on the metal surface as it cools inside the packaging. Water + metal + enclosed space = rust. This is one of the most common and least obvious causes of corrosion we see.

   The measure: Let the parts cool to room temperature before packing. That might take an extra 20–30 minutes. It is worth it.

   The cost you save: A single damp shipment that develops rust during sea transport can mean a full claim. The waiting time is free.

The next tips are specifically for users of VCI packaging. VCI stands for Volatile Corrosion Inhibitor. VCI packaging products work by releasing molecules that inhibit corrosion. The molecules form a thin, protective layer on a metal surface. This invisible layer prevents moisture and environmental elements from reacting with the metal surface and causing corrosion. VCI packaging is available in many delivery systems, such as VCI film, VCI kraft paper sheets, and even drop-in VCI capsules.

Here are three tips to keep in mind to maximize the effectiveness of your VCI packaging products.

4. Ensure the VCI packaging is tightly sealed

   The next three measures apply specifically to you if you use VCI packaging (Volatile Corrosion Inhibitor). VCI technology works by molecules evaporating from the packaging and settling as an invisible protective layer on the metal surface. They stop corrosion without oil, grease, or chemicals that need to be washed off. Unsure whether to choose VCI plastic or VCI paper? Read our guide here.

   The problem: VCI molecules build up concentration inside a sealed bag. Leaks mean the concentration never becomes high enough, and protection fails.

   The measure: Fold or roll the bag tight and secure it with tape or zip ties. VCI bags can be heat-sealed. Check that no corners or seams are open.

   The cost you save: A VCI bag that isn't sealed provides zero protection, but you paid for it anyway. Sealing it properly is free.

6. Use enough VCI packaging

   The problem: Tightly packed parts, large packages with multiple layers, or complex geometries can prevent VCI molecules from reaching all surfaces. The result is partial protection where you find rust in the inner layers or cavities.

   The measure: For large packages or dense stacks: insert VCI paper sheets or VCI capsules between layers. A rule of thumb is one capsule per 0.1–1 m³ of enclosed volume, depending on the capsule, metal, and environment.

   We are happy to help you size the right packaging solution for your product; it is a service we offer free of charge.

   The cost you save: A correctly sized VCI solution typically costs 2–5% of the part's value. Scrapping or reworking the parts costs 20–100% of the value or more, if delivery deadlines are involved.

7. Isolate metals from cardboard and wood

   The problem: Pallets and cardboard boxes are hygroscopic; they absorb moisture from the air. In addition, cardboard and wood contain organic acids and chlorides that can be transferred directly to the metal surface and initiate corrosion. This is especially critical during sea transport and storage in humid environments. We have written thoroughly about how wood and pallets cause corrosion and what you can do about it.

   The measure: Use pallet covers with VCI or place VCI poly-film between metal and wooden surfaces. For boxes: line the inside with VCI film or use VCI kraft paper between the metal and cardboard.

   The cost you save: Pallet hoods and VCI film cost a few dozen kroner. A scrapped shipment can cost tens of thousands.

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   FAQ — quick answers

   What is VCI packaging?
   → Packaging infused with inhibitor particles (Volatile Corrosion Inhibitors) that evaporate and form a protective molecular layer on metal surfaces.

   Which metals does VCI protect against?
   → Steel, stainless steel, copper, brass, aluminum, and most alloys. Zerust VCI products are tested and specified for the most common industrial metals.

   How long does the VCI protection last?
   → From 6 months to over 2 years, depending on the product and how airtight the packaging is.

   Does the metal need to be washed after VCI storage?
   → No. The VCI layer is invisible, thin, and evaporates on its own upon normal exposure. No cleaning required.

   Is VCI approved for offshore and oil & gas?
   → Yes. Zerust VCI products are compatible with the requirements in NORSOK Z-006 and are used by companies in the Norwegian petroleum industry.

   Summary: Prevention is cheaper than repair

   Six simple measures. None of them require large investments, and most cost almost nothing. Nevertheless, they eliminate the most common sources of corrosion loss during handling, packing, and transport.

   Reál Marine has been an authorized dealer of Zerust VCI technology for over 20 years. We help companies in oil & gas, the maritime industry, general manufacturing, and production to find the right solution and size it correctly.

   Get in touch — we will help you choose the right solution:
   📞 51 94 47 00
   ✉️ post@realmarine.no

   → See the full assortment of VCI packaging and VCI capsules in the webshop.
   → Read also: How to protect pipelines against corrosion with Denso tape