Rust Control: Needless Expense or Smart Investment?

With the introduction of pre-emergent salts, rust has become an added cost of doing business for fleet owners.  Automotive manufacturers have been successful in increasing the life span of their vehicles, but no one anticipated the impacts of these next generation salts.  Although these salts have been embraced by local governments, environmental groups and the snow contracting community, fleet owners are extremely distraught.  Not taken into account were the effects these salts would have on vehicles and infrastructure. Many fleet owners are experiencing severe body rot, parts failures and something new – wiring harness issues – all due to rust corrosion.  These new salts are able to stick to the vehicles longer and are more active at lower temperatures.

Many Canadian fleet owners have been using some sort of rust control for many years.  Studies have shown that effective rust control products can return six times their cost in reduced rust-related expenses and increased vehicle resale value.  Fleet owners have found that they can extend the number of years they keep their vehicles while maintaining a clean rust-free image in the market place. Ten years ago we began working with a school bus fleet of 200 buses that required rust control.  Within a few years of our annual rust control program, they completely eliminated their Rust Restoration expense of $300,000 per year and today they have over 700 buses on our program.

It’s important to recognize, however, that not all rust control products are created equal.  There are generally four types of products in the market place: cathodic protection, wax and tar products, powder coating and oil products.  Cathodic protection is only effective when used on items which can be grounded such as ships, pipelines, and monuments.  While wax and tar products dry out and crack over time allowing moisture to get trapped, further perpetuating the problem.  And while powder coating is effective in the short term, over time tends to bubble and peel leaving a rusty surface exposed. 

Oil products are most commonly used in the Canadian market place.  Oiling is effective as it penetrates hard to reach areas and neutralizes the harmful effects of rust.  Oiling a rusty vehicle will help stop the corrosion process in its tracks.  In fact, many body shops that repair rusty vehicles will only warranty their work if the customer oil sprays the vehicle.  When using an oil product, look for one that has been designed specifically for corrosion control.  Used oils may contain acids which are more harmful than good. 

The application process may also differ.  Some applicators may only spray the underside of the vehicle.  It is also important that holes are drilled in order to reach inaccessible areas where rust can be prevalent.  Furthermore, cleaning, greasing and spraying winter equipment in the spring eliminates the opportunity for corrosion over the summer.  A local university spent over four thousand dollars in repairs on two salt spreaders less than two years old.  As a result, the equipment dealer suggested our program having witnessed customers using our services for years without experiencing similar rust-related repairs.

The Automotive Protection Agency (APA) suggests most modern vehicles will experience mechanical and body deterioration due to corrosion after five or six years and that rust deterioration will usually result in increased maintenance and repair costs, or a reduced market value for the vehicle on resale.  With the varying rust control options available, it essentially comes down to the product and process that will determine if rust control is a needless expense or smart investment.  However, an effective annual rust control program can be worth its weight in gold.