Wet Storage Stain vs.

White Rust
I have heard the terms wet storage stain and white rust used interchangeably. Are they the same and
how do they occur?
Many perceive wet storage stain to be the same as white rust
and use the two terms interchangeably. The truth is these two
phenomenons are not synonymous and although similar, they
do have distinct differences. Both wet storage stain and white
rust occur due to oxidation on a newly galvanized surface with
the presence of moisture and absence of free flowing air. The
protective zinc patina is not allowed to form by converting
zinc oxides and hydroxides to zinc carbonates.

Heavy Wet Storage Stain

Wet storage stain is the commonly known problem of white

surface oxide formed due to packing items too tightly and/or storing in a humid environment. If moisture can
bridge the gap between galvanized pieces, the local shortage of oxygen created by this moisture can set up a
galvanic cell that will give rise to rapid attack at those places where oxygen is deficient. The common solution
for wet storage stain is to store items with room to breathe and out of a wet and humid environment. Another
preemptive solution is to passive the zinc surface after galvanizing.
White rust, on the other hand, is associated with cooling towers. Cooling towers were first galvanized in 1965.
The white rust problem wasn't noticed until 1986. White rust appears on the surface of newly galvanized cooling
towers as a patch of white sticky material The white material has been identified as basic zinc carbonate (3Zn(OH)
2ZnC03H20). White rust can penetrate the zinc coating and quickly reach the iron-zinc intermetallic layers,
forming a visible red iron oxide.

Brown Staining on Galvanized Coatings

I recently received a hot-dip galvanized product with brown stains on the surface. How are these stains
created and what can be done to minimize their formation? Is this type of surface defect acceptable
according to the ASTMA123 specication?
A hot-dip galvanized product may develop a surface defect
known as brown staining, which is created when the iron in the
zinc-iron alloy layers oxidizes. The oxidizing of the free iron in
the intermetallic layers results in the discoloration of the
surrounding zinc coating, changing the surface appearance from
the well-known grey appearance of galvanized steel to a brown
color.
The formation of brown staining doesnt occur until the pure zinc
eta-layer or most of the eta-layer matrix surrounding the zeta
layer, has been consumed by corrosion or removed in the local
areas where the staining appears. A similar type of reaction can
occur on laundry, porcelain, dishes, utensils, and even glassware
when iron is oxidized, allowing brown staining to occur.

Brown Staining

The results of laboratory tests and eld

surveys have shown zinc coatings
applied to reactive, high-silicon steels
are more susceptible to brown staining
than zinc coatings applied to low
silicon steels. This is primarily due to
the differences observed in the
structural layout of the zinc coating on
the two types of steel after they have
been galvanized. When low-silicon
steels are galvanized, the eta-layer is
relatively thick and the intermetallic
structure is tightly compact, which make it difcult for any free iron particles to penetrate the zeta-layer and
become oxidized.
However, when high-silicon steels are galvanized, the eta-layer is relatively thin and the intermetallic structure is
not tightly compact. The zinc-iron alloy in the zeta-layer form stall, vertical columns that are spaced in a manner
which allow free iron particles to migrate to the top of the zinc coating. Once these free iron particles reach the
surface of the zinc coating, they may become oxidized and form brown stains on the surface. It is sometimes
difcult to visually distinguish red rust on the base steel from brown staining. However, a coating thickness gauge
can be used to distinguish between the two since red rust will only form if there is no zinc present at the specic
point on the product where the defect is located. If only brown stains are present, the base steel is not rusting and
the corrosion performance of the galvanized steel is not affected. Since there is the presence of zinc under the
brown stains, brown staining is acceptable according to the ASTM A123 specication.

Rust Bleeding on Overlapping Surfaces

A customer called and said his newly galvanized steel was rusting, and wanted to know why I didn't
galvanize the whole part. I did galvanize it all, what should I tell him?

Looking at the above pictures the customer sent, it is clear where the rust originated. This condition, called rust
bleeding, is the unsightly dripping of rust (iron oxide) from small gaps created by overlapping or contacting
surfaces on galvanized structures. Cleaning and flux solutions can penetrate gaps less than 3/32", but zinc cannot
due to its higher viscosity. Because zinc cannot enter the surfaces inside the gaps remain un-galvanized.

The cleaning and flux solutions that remain inside the gaps are vaporized as the steel approaches the galvanizing
temperature of approximately 850 F.
When these solutions are vaporized, anhydrous crystals are left inside the gaps. After the steel has been
galvanized, atmospheric moisture can penetrate the gaps and mix with the anhydrous crystals to form an acidic
and highly corrosive solution. When the solution corrodes the un-galvanized portions inside the gaps, corrosion
products accumulate and leak or bleed from the gaps, leaving a trail of rust down the side of the part.
Now that we can see what it looks like, what is the solution? Proper design of materials to be galvanized is the
best method to prevent rust bleeding, ASTM A385 recommends seal welding all overlapping or contacting
surfaces that have gaps less than 3/32".
Seal welding prevents cleaning and flux solutions from entering the gap. When these solutions are prevented
from entering the gap, rust bleeding will not occur. It is important to insure seal welds are complete and without
imperfectionsor pinholes. Imperfections or pinholes in the seal weld can allow moisture to penetrate the gap and
become trapped inside the sealed area. This creates a safety hazard to galvanizing personnel due to explosive
forces that can develop in the sealed area as the steel reaches the galvanizing temperature. When the enclosed
area is greater than 16 square inches, it is recommended to vent the structure per ASTM A385 .
The designer and fabricator are responsible for notifying the galvanizer when they plan to galvanize pieces with
overlapping or contacting surfaces. The galvanizer is not responsible for ensuring small gaps have been seal
welded or for repairing damage due to rust bleeding.
You can assure your customer the entire structure was galvanized, and explain rust bleeding from overlapping or
contacting surfaces is easily remedied. The stains can be removed from galvanized steel by rinsing with water
and scrubbing with a nylon brush.
Rust bleeding can be stopped at the source by sealing the overlapping or contacting surfaces. When the electrolyte
(in this case, the solution created by cleaning or flux solutions mixing with water) is prevented from entering the
area, the corrosion halts, Sealing can be accomplished with materials such as caulking or epoxy coatings. This
prevents water from penetrating the gaps and mixing with the anhydrous cleaning or flux crystals. These coatings
also prevent rust from exiting the gaps.