Protective Coating: What Does Corrosion Cost Industries and the Environment?

protective coating

All industries need to protect against rust and corrosion because it saves money and time as well as helping the environment to conserve natural resources. Whether as an engineer overseeing infrastructure, a manager at a manufacturing plant, or utility personnel with a whole room of tools, corrosion affects everyone. Corrosion can be prevented or controlled using a protective coating and other methods to reduce wasted resources and to extend the service life of assets.


The High Cost of Corrosion

Using the United States as a first example, a frequently cited study on corrosion is the commissioned study by the Federal Highway Administration. Their investigation calculated that both direct and indirect costs of corrosion come to around 3.1% of GDP in all industries. In 2016, the cost of corrosion for the US economy amounted to US$575 billion.


The World Corrosion Organization (WCO), an organisation dedicated to raising awareness on corrosion wastage, estimated that corrosion costs reached US$2.2 trillion globally. This wasted costs not only include corroded metals but also costs to rework equipment and machinery, loss of revenue, and price of reliability issues.


For Australia, according to research conducted by the Curtin University of Technology in Western Australia, corrosion is costing the Australian economy Aus$32 billion annually. That amounts to around Aus$1,500 per person in Australia each year.


Other Wastage from Corrosion

Though all industries can be hit by corrosion, the most affected are those in transportation and oil and gas. Corroded pipelines can cause leaks and spills, resulting in costly wasted resources and pollution. The manufacturing industry also suffers from wasted scrapping and rework that can go up to 30% of the production cost. In all industries, an additional 15% of the production cost may be due to the maintenance of extra inventory, lost inventory, warehousing wastage, repacking, production stoppages, and even personnel injuries.


The Good News on Protective Coatings

The good news is that corrosion and rust can be controlled or prevented. Prevention methods can include specialised packaging such as VCI (Volatile Corrosion Inhibitor) wraps and plastic, VCI silica gel desiccants, and protective coatings. With protective coatings (such as Unituff 452), corrosion prevention has advanced to a higher level of safety because of the ease of application and the ease of peeling off when the metal needs to be used after being taken out of storage. When used with other corrosion prevention packages (such as those mentioned available from Omni-tuff), engineers and managers can now design an anti-corrosion system that reduces or prevents the causes of rust and corrosion. Aside from using rust inhibitors, controlling humidity and reduction of corrosive contaminants can also be done.


Unituff 452

Unituff 452 is a protective coating for all types of metals that is easily peelable, flexible, and is a polyvinyl chloride copolymer solution. It is a heavy-duty membrane that can stop all kinds of moisture including moisture and rust creeps. It is easily applied using a paintbrush, paint roller, or spray gun. To get a fast quote or to get more information about Unituff 452, visit their website at