Corrosion Control for Control Rooms and Electronics: A Comprehensive Guide

Corrosion is a silent threat that can quickly damage sensitive electronics in industrial environments. Effective control room corrosion control is essential because corrosion can cause circuitry failures, reduce equipment reliability, and lead to costly production downtime.

Industrial control rooms often house critical automation systems, communication networks, and monitoring equipment. When corrosive contaminants enter these environments, they can rapidly degrade electronic components.

In this guide, we explore the causes of electronic corrosion in industrial facilities and practical strategies for improving control rooms corrosion control, including the use of ZERUST® corrosion protection technologies, such as ZERUST® ActivDri™ Packets, Vapor Capsules, and Axxanol™ 718-ESS electrical corrosion inhibitor spray.

The Corrosion Challenge in Industrial Control Rooms

Corrosion of electronics caused by airborne contaminants has been a persistent problem in heavy industrial environments such as:

• Paper mills
• Petrochemical refineries
• Wastewater treatment plants
• Power generation facilities

These facilities frequently produce sulfur-containing gases such as:

• Hydrogen sulfide
• Sulfur dioxide
• Mercaptans

These gases react with exposed metal surfaces on circuit boards and electronic contacts. Even at low concentrations, they can initiate corrosion that disrupts electrical performance.

Regulatory changes have also increased corrosion risks. The European Union’s Restriction of Hazardous Substances (RoHS) Directive introduced new materials for electronics manufacturing. While beneficial for environmental compliance, some of these materials are more susceptible to gaseous corrosion.

As a result, corrosion failures can now occur faster and in environments that were previously considered acceptable.

Types of Electronic Corrosion That Impact Control Rooms

Understanding corrosion mechanisms helps engineers implement better control rooms corrosion control strategies.

Two common forms of electronic corrosion include:

Whisker Growth

Metal whiskers are thin conductive filaments that grow from metal surfaces such as tin or silver. These whiskers can bridge electrical connections and create unintended current paths that cause system malfunctions.

Silver whisker growth on circuit boards often indicates sulfur contamination in the surrounding air.

Creep Corrosion

Creep corrosion occurs when corrosion products grow across circuit board surfaces and conductive traces. This corrosion spreads gradually across the board and can interfere with electrical signals.

Over time, creep corrosion can cause complete system failure if left unaddressed.

For example, silver whisker growth on circuit boards is a clear indicator of sulfur contamination. It forms unintended circuit paths and serves as a warning sign for manufacturers.

Environmental Conditions That Affect Control Rooms Corrosion Control

Modern control systems use smaller and denser electronic components that generate more heat. To prevent overheating, control rooms require increased airflow.

While airflow helps cool equipment, it also introduces airborne contaminants into electronic enclosures.

For this reason, industrial facilities often classify control room environments using the ISA G1 environmental classification system. Maintaining an ISA G1 Mild environment helps ensure reliable performance of sensitive electronics.

Most equipment manufacturers recommend maintaining:

• Copper corrosion rates below 300 Angstroms per month
• Silver corrosion rates below 200 Angstroms per month

Meeting these thresholds typically requires a combination of:

• Chemical filtration systems
• Particulate filtration
• Environmental monitoring

These measures form the foundation of a strong control rooms corrosion control program.

Particulate Contamination and Its Role in Electronic Corrosion

Dust and airborne particles also contribute to corrosion failures in control rooms. Contaminants typically affect electronics in three ways.

Mechanical Effects

Dust can block cooling airflow, interfere with moving components, and accumulate on sensitive surfaces.

Chemical Effects

Dust may contain sulfur compounds, chlorides, or other corrosive salts that react with electronic metals.

Electrical Effects

Fine conductive dust can alter electrical impedance or create unintended conductive paths between circuit traces.

When moisture is present, dust particles become even more corrosive. Moisture allows ions to migrate across circuit boards, accelerating corrosion damage.

Effective filtration helps reduce these risks. Recommended filtration levels include:

• MERV 8 filtration for recirculated air within computer rooms
• MERV 11 or MERV 13 filtration for outside air entering the control room

ZERUST® Solutions for Control Rooms Corrosion Control

In addition to environmental filtration, corrosion protection technologies can provide localized protection for sensitive electronics.

ZERUST® offers several products designed to improve control rooms corrosion control inside cabinets, panels, and other electronic enclosures.

ZERUST® ActivDri™ Packets

ActivDri™ Packets combine moisture control with Vapor Corrosion Inhibitor (VCI) technology in a single sachet.

These packets protect metal surfaces and electronic components from:

• Humidity
• Environmental contaminants
• Corrosive gases

The dual action technology both absorbs moisture and releases corrosion-inhibiting vapors that protect exposed metal surfaces.

ActivDri™ packets are simple to install and can protect components during:

• Equipment operation
• Storage
• Shipping

By reducing corrosion risk inside enclosures, these packets help improve system reliability and reduce unexpected downtime.

ZERUST® Axxanol™ 718-ESS Electrical Corrosion Inhibitor Spray

Axxanol™ 718-ESS is an electrical corrosion inhibitor designed for environments that contain acid gases and humidity.

The spray forms a thin, non-staining protective film on metal surfaces while maintaining electrical conductivity.

Typical applications include:

• Electrical cabinets
• Junction boxes
• Electronic connectors
• Machinery components
• Hinges and moving parts

Axxanol™ 718-ESS conforms to key aspects of MIL-PRF-81309H and contains no CFCs or 1,1,1-Trichloroethane. This makes it suitable for use in a wide range of industrial environments where corrosion protection is needed without interfering with electronic performance.

ZERUST® Vapor Capsules

Vapor Capsules release corrosion-inhibiting vapors into enclosed spaces.

These capsules protect metal surfaces inside:

• Electrical cabinets
• Control panels
• Junction boxes
• Instrument enclosures

Once installed inside a sealed enclosure, the vapor molecules disperse throughout the space and form a protective molecular layer on exposed metal surfaces.

Installation is quick and simple. Remove the protective backing and attach the capsule using the integrated adhesive strip.

Depending on the model and environmental conditions, Vapor Capsules can provide protection for one^‡ to two years^‡.

Benefits of ZERUST® Control Rooms Corrosion Control Solutions

ZERUST® technologies provide several advantages for protecting electronics and electrical equipment in industrial environments.

Reliable Protection
ZERUST® corrosion inhibitors protect sensitive electronics from moisture, airborne contaminants, and corrosive gases.

Easy Implementation
Products such as ActivDri™ packets and Vapor Capsules install quickly inside existing enclosures without major equipment modifications.

Safe and Proven Technology
ZERUST® corrosion inhibitors meet industry standards and are widely used across heavy industrial applications.

Customizable Solutions
ZERUST® corrosion specialists can help develop tailored corrosion protection programs for specific facilities and environments.

Improving Control Rooms Corrosion Control in Industrial Facilities

Maintaining reliable control systems requires proactive corrosion management. Airborne contaminants, humidity, and dust can quickly damage electronic components if left unmanaged.

A comprehensive control rooms corrosion control strategy may include:

• Environmental monitoring and filtration
• Moisture control technologies
• Vapor corrosion inhibitors for enclosed electronics
• Preventative maintenance and inspection

ZERUST® corrosion protection solutions help protect critical electronics, extend equipment life, and reduce costly downtime in industrial facilities.

If you are experiencing corrosion issues in control rooms or electronic cabinets, working with corrosion specialists can help identify the root cause and implement an effective protection strategy.

Tom White

Tom White is the Marketing Manager at ZERUST®, bringing almost a decade of expertise in Vapor Corrosion Inhibitor (VCI) technologies and corrosion prevention solutions. He leads strategic marketing initiatives that showcase ZERUST®’s global product portfolio, from sustainable VCI packaging films to advanced rust preventatives and cleaners. Tom is deeply involved in product launches, trade show planning, digital marketing, and customer engagement, ensuring that ZERUST®’s innovative solutions reach the right industries and decision-makers. With a strong focus on aligning technical expertise with customer needs, he helps drive the brand’s growth and strengthen its position as a leader in corrosion protection worldwide.

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