How to Prevent Rust and Corrosion in Your Air System
Rust is one of the most destructive problems you can have in a compressed air system. Once corrosion starts, it doesn’t just stay in one place — it spreads through piping, tools, valves, actuators, filters, and even your compressor. And because Tennessee’s humidity is high most of the year, rust is a constant threat if moisture isn’t controlled.
At Industrial Air Services, we see the long-term damage that rust can cause to production lines across Nashville, Knoxville, and Chattanooga. The good news is that corrosion is almost always preventable when your air system is set up and maintained properly. Here’s how to keep rust from ever getting a foothold.
1. Start With Proper Moisture Removal
Moisture is the root cause of almost all corrosion problems.
If your air isn’t dry, your piping will eventually rust — even if it’s newer.
To keep moisture out:
Use a properly sized air dryer
Install a wet tank before the dryer
Ensure drains are working consistently
Replace clogged filters
Keep inlet temperatures under control
Most rust problems start with a dryer that’s undersized, overloaded, or not maintained.
2. Maintain Your Condensate Drains
A failed drain is basically an invitation for rust.
Issues include:
Float drains stuck open or closed
Timer drains not cycling
Zero-loss drains clogged with sludge
Oil buildup blocking discharge lines
If water can’t get out, it will absolutely find its way into your piping.
3. Use the Right Piping Material
Some materials simply resist rust better than others.
Best options:
Aluminum piping
Stainless steel
Copper (for smaller systems)
High risk for corrosion:
Black iron
Galvanized steel (flakes and sheds zinc into the air stream)
Many older facilities still use black iron, which rusts aggressively in humid environments.
4. Install Proper Slope in Your Piping
Your air lines should never be perfectly level.
They should slope ¼ inch every 10 feet toward drain points.
Correct slope:
Prevents water from pooling
Keeps moisture from reaching tools
Makes drains more effective
Reduces rust inside pipes
Flat or upward-sloping piping is one of the top causes of internal corrosion.
5. Add Drop Legs and Drain Points in the Right Locations
Every major branch should have a drop leg with a drain at the bottom.
Drop legs give moisture a place to collect before reaching tools.
Without them, water travels straight through the line and attacks everything downstream.
6. Keep Your Compressor Room Cool and Well-Ventilated
Heat accelerates moisture production.
Humidity makes it worse.
A hot, enclosed compressor room creates:
High inlet temperatures
More water in the air
Overworked dryers
Faster internal corrosion
Ventilation is one of the simplest ways to prevent rust across your entire system.
7. Inspect Filters Regularly
Wet filters eventually rust and send metal particles through the system.
Check filters for:
Saturation
Pressure drop
Rust flakes
Oil contamination
Crushed or misshapen housings
Changing filters on time prevents rust from forming inside the bowls.
8. Protect Tools and Production Equipment
Corrosion doesn’t stop at the piping — it attacks everything downstream.
Moisture causes:
Air motor failure
Valve sticking
Rust inside cylinders
Shortened tool life
Product contamination
Sensor failures
Dry air is essential if your tools and machines depend on air to function.
9. Monitor Dew Point During High Humidity
Tennessee summers create extremely high moisture loads.
Your dryer may work fine in winter but fail in July.
Monitor your dew point:
Refrigerated dryer: 35–50°F
Desiccant dryer: –40°F or lower
A rising dew point almost always means moisture is entering the system.
10. Have Your System Checked Annually
A yearly inspection catches:
Rust forming inside tanks
Pitting in piping
Failed drains
Dryer performance issues
Leaks from corrosion
Filter saturation
Weak spots before they burst
Corrosion is slow at first… then destructive. Annual inspections stop small issues before they become safety hazards.
Prevent Rust Before It Starts — Your Air System Will Last Years Longer
A compressed air system with moisture problems is a system headed for rust, restricted flow, pressure loss, tool failures, and expensive repairs. But with the right dryer, the right piping, and the right maintenance routine, rust can be eliminated before it ever begins.
If you’re seeing rust flakes, water in lines, or tools wearing out faster than normal, it’s time to address the moisture problem at the source.
Industrial Air Services proudly serves Nashville, Knoxville, and Chattanooga, providing moisture-control solutions, piping upgrades, dryer service, and complete air system maintenance.
📍 138 Bain Drive • LaVergne, TN 37086
📞 (615) 641-3100
🌐 www.industrialairservice.com
