As AI data centers exceed 100 kW per rack, they are producing heat loads rivaling dozens of household ovens in a single cabinet. No wonder AI data center cooling systems are working harder than ever. While everyone focuses on computational power, energy efficiency, and keeping servers cool, corrosion quietly erodes the very systems that keep AI workloads running. Here’s what every AI data center operator needs to know:

The Rising Thermal Challenge in AI Data Centers

AI Workloads are pushing data center cooling systems to unprecedented limits. Modern AI Facilities regularly pack 50kW, 100kW, or even more per rack. These are thermal loads that traditional cooling simply can’t handle. To handle these unprecedented thermal loads, operators are deploying advanced cooling architectures, including direct-to-chip liquid cooling, rear-door heat exchangers, immersion tanks, and high-performance CRAC (Computer Room Air Conditioning) and CRAH (Air Handling) systems.

As cooling data centers becomes more complex and critical, one invisible threat accelerates across every component in the thermal management chain: corrosion. It may not seem as dramatic as a power outage or hardware failure, but corrosion silently erodes efficiency, shortens equipment lifespan, and leads to system failure. Despite this, surprisingly few discussions of AI infrastructure address it.

Protect Data Center Cooling Systems from Corrosion

AI workloads are pushing data center cooling systems to their limits. Discover how ZERUST® corrosion protection solutions help protect cooling infrastructure, extend equipment life, and maintain reliable AI operations.

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What Is Corrosion in Data Center Cooling Systems?

Corrosion is the gradual degradation of metal components through chemical reactions with their environment. In cooling data centers, this occurs when metals such as copper, aluminum, and steel are exposed to moisture, oxygen, coolant chemicals, and temperature fluctuations.
AI workloads make corrosion worse. This is because higher power densities mean:

Higher operating temperatures accelerate chemical reactions
Faster coolant flow erodes protective oxide layers
Frequent thermal cycling that stresses metal joints and seals
Mixed-metal systems increase galvanic corrosion risk

The result? Cooling infrastructure that degrades faster than ever before, often without visible warning signs until serious damage occurs.

How Corrosion Impacts Data Center Cooling Systems

AI-class cooling networks combine copper, aluminum, stainless steel, and brass components throughout their infrastructure. When these materials interact with humidity, oxygen, or degraded coolant fluids, several destructive processes begin:

Pitting and fouling: Creates small holes and deposits in chillers, manifolds, and heat exchangers, drastically reducing thermal transfer efficiency
Galvanic corrosion: Occurs when dissimilar metals (copper pipes connected to aluminum heat exchangers, for example) create electrochemical reactions that eat away at the more reactive metal
Coil oxidation: Damages the internal coils of CRAC units, restricting airflow and reducing cooling capacity
Coolant contamination: Corrosion byproducts circulate through the system, causing pressure drops, pump wear, and escalating energy consumption

Air-side economizer systems pull in outside air that may contain sulfur dioxide, chloride gases, and other atmospheric contaminants. These airborne pollutants accelerate corrosion in both IT hardware and HVAC components, particularly in coastal or industrial environments.¹ air side Sets of cooling towers in data center building.

The Real Cost of Corrosion in Cooling Data Centers

One major U.S. data center discovered the hard way what unchecked corrosion costs. Glycol-induced copper corrosion became so severe that operators had to replace the entire piping system with stainless steel, resulting in a seven-figure emergency repair that could have been prevented with proper corrosion management.²

The business impact of corrosion includes:

Reduced equipment lifespan: Heat exchangers, coils, and manifolds exposed to fouling, corrosion, or thermal stress can experience premature degradation, leading to service lives significantly shorter than their intended design life.
Leak and safety risks: In immersion-cooling environments, fluid leaks can damage nearby components and pose electrical or operational hazards if not promptly detected and contained.
High cost of downtime: For AI data centers or other critical workloads, unplanned outages can cost anywhere from $10,000 to over $40,000 per minute, depending on the scale and sensitivity of operations.
Energy inefficiency: Fouled or corroded heat exchangers can reduce thermal performance by 20–40%, increasing energy use and operating costs.
Reactive maintenance costs: Emergency repairs or replacements typically cost three to five times as much as planned preventive maintenance, according to industry reliability studies.

Recent research confirms that chilled-water and liquid cooling systems can show measurable corrosion damage in as little as one to two years without proper treatment.³ What starts as microscopic pitting quickly escalates into leaks, equipment failure, and expensive emergency repairs.

Understand the True Cost of Corrosion

Corrosion silently drains billions of dollars from global industries every year. Learn how corrosion impacts equipment, operations, and long-term infrastructure reliability.

Read About the Cost of Corrosion »

Why AI Data Center Operators Are Prioritizing Corrosion Prevention

Forward-thinking facility managers now treat corrosion prevention as a Tier-1 maintenance discipline rather than an afterthought.⁴ Here’s why:

Corrosion damage is insidious. Unlike a failed pump or clogged filter, corrosion progresses invisibly inside pipes, coils, and closed-loop systems. By the time conductivity changes or leaks appear, significant damage has already occurred.
AI cooling systems are particularly vulnerable. The combination of high heat loads, complex fluid dynamics, mixed-metal construction, and 24/7 operation creates ideal conditions for accelerated corrosion.
Prevention costs far less than reaction. Implementing corrosion control during installation or routine maintenance is a fraction of the cost of emergency pipe replacement, coolant system flushing, or unplanned downtime.

The question isn’t whether your cooling infrastructure will experience corrosion; it is how soon and whether you’ll address it proactively or reactively.

ZERUST® Corrosion Protection Solutions for Data Center Cooling Systems

air cooled water chillers with piping system.

ZERUST® provides engineered corrosion prevention solutions designed specifically for the demanding environment of cooling data centers. Whether you operate traditional CRAC units, chilled-water loops, or cutting-edge liquid immersion systems, our products integrate seamlessly into your existing maintenance protocols without disrupting operations.

Our comprehensive portfolio addresses corrosion at every point in your cooling infrastructure, during active operation and critical idle periods.

For Active Cooling Systems

Product	Application	Key Benefit
Axxatec™ HST-M100	Glycol and chilled-water loops	Stabilizes pH, prevents internal rust and pitting in closed-loop systems.
VCI Diffusers & Capsules	CRAC cabinets and control boxes	Emits protective vapor layer without impacting airflow or equipment operation. Non-Residue & Electronic safe.
Axxanol™ 718-ESS Spray	Coils, fittings, and electronics	Forms a thin, non-conductive film safe for use on live electrical systems.

For Idle & Backup Systems

Product	Application	Key Benefit
VCI Films & Packaging	Storage or shipment of metal components	Prevents oxidation during logistics and spare parts inventory.
VCI Diffusers for Manifolds & Pumps	Idle or standby equipment	Protects sealed systems during. maintenance periods or seasonal lay-up

How VCI Technology Works

How VCI works

All ZERUST® products leverage vapor corrosion inhibitor (VCI) technology, a proven approach that creates an invisible molecular barrier on metal surfaces. When applied to data center cooling systems, VCI molecules:

1. Vaporize and disperse throughout enclosed spaces or fluid systems
2. Settle on all exposed metal surfaces
3. Form a protective monomolecular layer that neutralizes corrosive agents
4. Self-replenish continuously, maintaining protection over time

The ZERUST® advantage: Unlike traditional preservation methods that require complete flushing before restart, ZERUST® VCI treatments remain compatible with normal cooling system operation. Simply power up your equipment; no draining, rinsing, or special procedures are required. This means faster returns to service and zero product waste.

Learn How Vapor Corrosion Inhibitor (VCI) Technology Works

Discover how ZERUST® Vapor Corrosion Inhibitor technology forms an invisible molecular barrier that protects metals from corrosion in enclosed spaces and complex cooling systems.

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Protecting Idle Cooling Systems: The Overlooked Vulnerability

Many data centers run backup chillers and supplemental cooling towers that sit idle for months during cooler weather. While operators focus on protecting active systems, these standby components face a serious corrosion risk that’s often underestimated.

Why Idle equipment corrodes faster:

Residual moisture trapped in “drained” systems that aren’t completely dry
Condensation from temperature and humidity fluctuations as seasons change
Stagnant fluid in partially-filled loops where inhibitors have degraded
Oxygen exposure in unsealed components accelerates oxidation
Concentration cells forming in low-flow areas with standing water

The harsh reality: Idle equipment can suffer more corrosion damage during three months of seasonal layup than during a full year of active, treated operation. When cooling demand returns and you fire up that backup chiller, hidden corrosion may have already compromised seals, weakened pipe walls, or contaminated the system.

ZERUST® Solutions for Seasonal Layup and Backup Systems

Wet Layup (Above Freezing Conditions):

Deploy Axxatec™ HST-M100 Corrosion-Inhibitor Additive in systems kept filled during idle periods. The formulation provides robust protection whether circulating or stagnant, and requires no removal before restart. Simply bring the system back online when needed.

Dry Layup (Freezing Risk or Drained Systems):

Install VCI Vapor Capsules inside drained chillers, cooling towers, manifolds, and pump housings. These diffusers release vapor-phase corrosion inhibitors that diffuse throughout void spaces, forming a protective molecular layer on all metal surfaces. As long as the system remains closed, protection continues for years.

Control Components:

Place VCI Capsules in electrical control boxes and pump housings to protect sensitive components from humidity and corrosion during extended idle periods.

The Operational Advantage:

When temperatures climb and cooling demand returns, your backup systems restart immediately, no special preparation, no hidden damage, no surprises. You maintain your full cooling capacity exactly when you need it most.

Warning Signs: When to Check for Corrosion

Don’t wait for a leak or system failure. Watch for these early indicators of corrosion in your data center cooling systems:

Increased energy consumption without corresponding load changes
Discolored coolant or visible particles in fluid samples
Rising differential pressure across heat exchangers
Unusual metallic taste or smell in coolant fluids
White, green, or blue deposits on pipe connections or fittings

If you notice any of these signs, immediate assessment and treatment can prevent minor issues from becoming expensive failures.

Implementing a Corrosion Prevention Program

Protecting your cooling infrastructure doesn’t require a complete system overhaul. A phased approach works for most facilities:

First Phase: Assessment – Week 1-2

Inspect existing cooling systems for visible corrosion
Test coolant chemistry and contamination levels
Identify mixed-metal connections and high-risk areas

Second Phase: Treatment – Week 3-4

Install VCI diffusers in CRAC units and control cabinets
Add Axxatec™ HST-M100 inhibitor to chilled-water loops
Apply protective coatings to exposed components

Third Phase Monitoring – Ongoing

Quarterly coolant testing and pH monitoring
Annual visual inspections of critical components
Preventive VCI replacement on manufacturer schedules

ZERUST® technical team can help you design a customized program based on your specific cooling architecture, climate conditions, and operational requirements.

The Future of Data Center Cooling Systems: Proactive Corrosion Control

Cooling system for AI data center As AI power density continues to climb, corrosion control is no longer maintenance; it’s design engineering. Facilities that integrate proactive corrosion management from day one gain measurable advantages: higher uptime, lower operating costs, and extended system life.

Don’t wait for corrosion to compromise your data center cooling systems. The damage is happening right now, invisibly, continuously, and expensively. So, whether you’re a facilities manager, MEP engineer, water treatment provider, or colocation operator, ZERUST® provides the tools and expertise you need to eliminate corrosion risks across your cooling infrastructure.

Ready to Protect Your Cooling Infrastructure?

Contact ZERUST® today for a customized corrosion-prevention assessment. Our team will evaluate your data center cooling systems, including backup and idle equipment, identify corrosion risks, and design a cost-effective protection program tailored to your facility.

Contact ZERUST® Corrosion Experts »

References

Shah, J. M., Gaynes, M. A., & Crawford, J. H. (2017). Qualitative Study of Cumulative Corrosion Damage of IT Equipment in a Data Center Utilizing Air-Side Economizer Operating in Recommended and Expanded ASHRAE Envelope. Journal of Electronic Packaging, 139(2), 020903.
Data Cooling Center Stainless Steel Case Study. (2023). CSI Designs. Retrieved from https://www.csidesigns.com
Corrosion Protection Reduces the Risk of Failure in Data Centre Cooling. (2021). Thermal Control Magazine. Retrieved from https://www.thermalcontrolmagazine.com
Corrosion: A Clear and Present Danger. (2021). Data Centre Magazine. Retrieved from https://datacentremagazine.com

Andrea Catarino

Andrea Catarino is a marketing professional at ZERUST® specializing in corrosion prevention solutions for industrial applications. She has been with ZERUST® since September 2024, focusing on translating complex technical concepts into clear, practical insights that help engineers, manufacturers, and maintenance professionals protect valuable metal assets.

In her role, Andrea works closely with technical teams to communicate the benefits of ZERUST® corrosion control technologies across a wide range of industries, including manufacturing, transportation, infrastructure, and energy. Her work highlights how corrosion prevention strategies improve operational reliability, extend equipment lifespan, and reduce costly downtime during production, storage, and shipment.

Andrea contributes to the development of content that supports the implementation of ZERUST® Vapor Corrosion Inhibitor (VCI) packaging, rust preventative coatings, and water-based corrosion control solutions. By aligning technical knowledge with real-world applications, she helps organizations better understand how to select and apply the right corrosion protection methods for their specific environments and challenges.

With a strong emphasis on sustainability, Andrea also explores how effective corrosion prevention supports environmental goals. Her work demonstrates how extending asset life reduces material waste, lowers resource consumption, and contributes to more efficient and sustainable operations across industrial supply chains.

Through her contributions to the ZERUST® blog, Andrea delivers product-focused insights, best practices, and practical guidance that help readers make informed decisions about corrosion protection strategies. Her content bridges the gap between technical expertise and everyday application, ensuring solutions are both effective and easy to implement.