To prevent rust on spare parts in long-term storage, maintenance warehouses must use a system-based corrosion prevention strategy. Relying on a single product or step is rarely enough when parts remain idle for months or years.
Even indoors, temperature swings and humidity fluctuations can cause condensation on metal surfaces. Furthermore, over time, this moisture leads to oxidation, surface degradation, and unplanned rework. Effective long-term protection combines environmental control, surface preparation, protective coatings, and ZERUST® corrosion prevention technologies.
Control the environment to prevent rust on spare parts in long-term storage
The first step to prevent rust on spare parts in long-term storage is stabilizing the warehouse environment. Maintain relative humidity below 50 percent whenever possible. Use dehumidifiers or localized climate control in high-risk storage zones, such as near exterior walls or doors.
Stable temperatures reduce condensation cycles that form when warm air contacts cooler metal surfaces. Monitoring and recording humidity levels helps identify problem areas before corrosion develops.
Use ZERUST® VCI packaging to prevent rust on spare parts in long-term storage
ZERUST® VCI packaging provides clean, residue-free protection for spare parts stored indoors. ZERUST® ICT® VCI films, bags, and papers release corrosion-inhibiting molecules that diffuse throughout the enclosed space. These molecules form an invisible protective layer on metal surfaces without altering part dimensions or finish.
Add moisture-control products inside sealed packaging to further prevent rust on spare parts in long-term storage. ZERUST® ActivDri™ PWA moisture-control packets and ZERUST® ZDC® desiccants absorb residual humidity that may remain after packing.
For enclosed cabinets, bins, or complex assemblies, ZERUST® VCI emitters such as Vapor Capsules, ActivPak®, or Z-PAK® enhance protection by continuously releasing
corrosion inhibitors into hard-to-reach areas.
Apply protective coatings when packaging alone is not enough
When environmental conditions are severe or storage durations extend beyond one year, protective coatings add an important physical barrier. ZERUST® Axxanol™ rust preventative coatings are selected based on metal type, handling needs, and storage duration.
Light oil-based protectives like Axxanol™ 33 are commonly used for indoor storage up to one year‡. For extended protection, products such as Axxanol™ 750-NV, 758-NV, and A35-8030 provide barrier protection for up to two to five years‡.
In high-humidity or condensation-prone areas, grease-based options like Axxanol™ Spray-G or Axxanol™ Z-Maxx deliver robust, long-lasting protection. When clean handling is required, dry-to-touch inhibitors such as Axxanol™ 33CD, 34CD, A35CD-32, or A35CD-7 protect metal surfaces without leaving an oily residue.
Explore ZERUST® Rust Preventative Coatings
Match the right ZERUST® Axxanol™ coating to your storage duration, metal type, and handling needs for long-term corrosion protection.
Proper surface preparation is critical for long-term rust prevention
To successfully prevent rust on spare parts in long-term storage, parts must be properly cleaned and dried before protection is applied. Dirt, fingerprints, coolant residues, machining oils, and salts accelerate corrosion if left on the surface.
ZERUST® AxxaWash™ industrial cleaners and degreasers prepare metal surfaces for storage by removing contaminants. If an AxxaWash™ cleaner without rust inhibitors is used, protection should be applied immediately after cleaning to avoid flash rust.
When parts rest on pallets or shelving, place ZERUST® VCI Film between metal surfaces and wood to prevent moisture transfer and organic acid exposure from
the pallet material.
Inspect stored spare parts regularly to prevent rust over time
Routine inspections are a critical part of any long-term corrosion control program. Inspect spare parts every three to six months for condensation, surface corrosion, or damaged packaging.
Replace VCI materials, desiccants, or coatings as needed. Follow FIFO (First-In, First-Out) inventory practices to limit how long parts remain in storage and reduce overall corrosion risk.
A system-based approach to prevent rust on spare parts in long-term storage
By combining AxxaWash™ surface preparation, Axxanol™ protective coatings, ICT® VCI packaging, ActivDri™ moisture control, and routine inspections under the ZERUST® Z-CIS® Corrosion Inhibiting System methodology, maintenance warehouses can keep spare parts clean, dry, and ready for use.
For help selecting the right combination for your storage conditions, mailto:TechSupport@ntic.com to speak with a technical service representative.
Talk to a ZERUST® Corrosion Expert
Not sure which combination of coatings, VCI packaging, and moisture control is right for your spare parts?
ZERUST® technical service experts can help you design a system-based solution for long-term storage.
ICT®510-C VCI Film provides cost-effective and versatile protection against rust and corrosion damage for metal assets in shipping and storage. Additionally, it’s available in ferrous, non-ferrous, and multimetal formulations, as well as various-sized rolls, sheets, tubing, and bags.
ICT® VCI Poly Bags provide convenient and proven protection against corrosion damage for metals in shipping and storage. In addition, they are available in ferrous, non-ferrous, anti-tarnish, and multimetal protection types and various zipper, flat, and gusseted sizes.
ICT®420 is an acid-free, pH-neutral, and non-abrasive VCI kraft paper that merges the practicality and cost-efficiency of paper-based packaging with advanced corrosion protection. Consequently, it streamlines the preservation of metals during work-in-progress, shipping, and storage.
ActivDri™ PWA Packets are patent-pending, economical, effective, and easy-to-use dual-action, moisture control Vapor Corrosion Inhibitor (VCI) packets that protect against environmental contaminants and humidity that aggressively corrode metal parts, components, electronics, and electrical components/equipment
ZDC Desiccant Series features montmorillonite clay packaged in Tyvek material that offers an excellent barrier to water in liquid form while also allowing water vapors to pass through. This minimizes the risk of the desiccants causing corrosion that may come in direct contact with metals when compared to other desiccants made with different materials.
Vapor Capsules are portable VCI emitter diffusers containing proven ZERUST® Vapor Corrosion Inhibitors (VCI). They protect metals in hard-to-reach areas of control panels, electrical cabinets, or other enclosed spaces from corrosion, even when they are in operation. Additionally, use these VCI emitter diffusers as a supplement to other ZERUST® VCI packaging products for added protection.
ActivPak® is a versatile and powerful fast-acting VCI sachet designed to address flash rust and corrosion concerns in demanding scenarios, including overseas shipping and polluted factory environments.
Z-PAK® is an economical, effective, and easy-to-use vapor corrosion inhibitor (VCI) diffuser packet that can be used alone or, more typically, with other ZERUST® packaging products to provide robust temporary corrosion protection for ferrous metals during shipment, storage, or work-in-progress.
Axxanol™ 33 is a rust preventative oil that forms a light oily film, providing powerful corrosion protection against aggressive environments such as salt air and humidity.
Axxanol™ 750-NV is a rust preventative oil that forms a clear, thin, oily film on the metal surface, providing a moisture barrier and powerful corrosion protection against aggressive environments such as salt air and humidity.
Axxanol™ 758-NV is a non-staining rust preventive oil that forms a clear, thin, oily film on the metal surface, providing a moisture barrier and powerful corrosion protection against aggressive environments such as salt air and humidity.
Axxanol™ A35-8030 is a long-term rust preventative oil that forms a light, thin, oily film. As a result, it provides powerful corrosion protection against aggressive environments, such as salt air and humidity. In addition to corrosion protection, it provides lubricating properties that help reduce friction and support smooth assembly and disassembly of metal parts.
Axxanol™ Spray-G is a sprayable rust preventative grease that provides the protection of a grease in the convenience of a sprayable form. It’s designed to protect metal parts, equipment, and assemblies during long-term indoor and outdoor storage and challenging overseas shipping applications where a removable coating is essential.
Axxanol™ Z-Maxx Anti-Corrosion Grease Series consists of two products, Axxanol™ Z-Maxx and Z-Maxx LV. Z-Maxx is a thick NLGI 2 grease and is also offered as a lower viscosity (LV) NLGI 0 grease that is designed for spreadability and light lubrication properties.
Axxanol™ 33CD is a solvent-based rust preventative that forms a dry-to-touch film, eliminating oily surfaces that attract dust and other contaminants.
Axxanol™ 34CD is a solvent-based coating that forms a very light, oily, near dry-to-touch rust preventative film that provides powerful corrosion protection against aggressive environments.
Axxanol™ A35CD-32 is a solvent-based, non-staining rust preventative that forms a clear, thin, near dry-to-touch RP film. As a result, it provides powerful corrosion protection against aggressive environments, such as salt air and humidity.
Axxanol™ A35CD-7 is a high-flash solvent-based rust preventative that forms a clear, thin, dry-to-touch film. As a result, it eliminates oily surfaces that attract dust and other contaminants.
AxxaWash™ KF-121 is a low foam, alkaline, water-based metal cleaner that effectively removes light to medium-duty hydrocarbon soils from ferrous substrates. Additionally, it also serves as the ideal metal cleaner for applications requiring low temperatures.
AxxaWash™ KF-122 is a low-foaming, heavy-duty alkaline, water-based cleaner compatible with very hard water in a wide range of operating temperatures. Additionally, it also maintains low foaming under spray conditions.
ZERUST®/EXCOR® AxxaWash™ KF-123 is a low-foaming, mildly alkaline, high-performance water-based industrial parts washer that is designed for cleaning ferrous substrates. In addition, AxxaWash™ KF-123 provides flash-rust inhibition.
AxxaWash™ KF-124 is a low-foaming, mildly alkaline, water-based degreaser & cleaner with low operating temperatures. In addition to cleaning, AxxaWash™ KF-124 provides flash-rust inhibition.
AxxaWash™ KMS-220 is a low foam, low temperature, mildly alkaline water-based part cleaner with excellent oil-splitting capabilities. In addition, AxxaWash™ KMS-220 provides flash-rust inhibition.
AxxaWash™ KMS-305AL is a low foam, low temperature, alkaline water-based aluminum part cleaner designed for use with aluminum and ferrous metals in spray systems with its excellent oil-splitting capabilities.
AxxaWash™ KMS-310AL is a low-foaming, alkaline, water-based aluminum and ferrous cleaner that’s designed to be used in immersion, ultrasonic, spray, or drum washer processes.
