Moving Beyond the Rust-Proof Myth Toward Smarter Metal Maintenance

Corrosion affects nearly every owner of metal equipment, from tools and bicycles to precision instruments, yet it is rarely discussed. The Association for Materials Protection and Performance (AMPP) estimates that corrosion costs the global economy more than $2.5 trillion each year. The organization also notes that proven corrosion control practices could save up to 35% of these costs. That gap suggests the issue lies less in available solutions and more in how owners understand rust.

Many buyers assume that rust-proof products exist. They tend to expect a single coating, spray, or treatment to protect metal for good. When rust comes back, they often feel misled and blame the product, the manufacturer, or the weather. Marketing that promises permanent protection could add to this confusion by setting expectations that are hard to meet. Knowing why rust returns is a useful first step toward managing it.

Rust forms through oxidation, a natural reaction between iron, oxygen, and moisture. Because the rust layer on iron is porous, the reaction can keep going beneath the surface, so the process can be slowed but never fully stopped. Protective measures like galvanizing help resist rust, though they tend to wear down over time without upkeep. The US consumed an estimated 57 million tons of iron and steel scrap in 2025, according to the US Geological Survey. Some of that metal may have reached the end of its useful life sooner than necessary.

Saltwater is often seen as the main cause of rust, but freshwater can also play a significant role. Metal that repeatedly gets wet and dries out tends to be more vulnerable to oxidation. Rinsing items with freshwater after salt exposure is unlikely to prevent rust if no further protection is applied. Human contact might also contribute, as natural oils and acids from skin can leave marks where corrosion can begin. Humid and coastal environments can speed up the process even further.

Dwight Settle, co-founder of SEAL 1, a United States-based company that develops bio-based metal care products, believes owners need a more realistic view of rust. Settle co-founded the business in 2011 after a 20-year career as a Navy SEAL. "Nothing we have found stops the rust and oxidation process," he says. "What we can do is help slow it down, but maintenance always has to be part of the picture." He adds that honesty about what protection can achieve matters as much as the protection itself.

According to Settle, many owners only start thinking about rust after it appears, when the damage has already begun. Many people assume new products arrive fully protected from the factory. "When you buy a new bike, a new grill, or a new tool, that is the time to treat it," he explains. "Think of it as an extended warranty for the things you already own." Early treatment could help extend the working life of metal equipment from the start.

Settle's company focuses on bio-based formulas, an approach he believes offers a safer alternative for everyday maintenance. He notes that some products labeled non-toxic still carry warnings against skin contact, eye exposure, or ingestion. "Buyers should be able to trust what a label says," he notes. "If a product claims to be non-toxic, it should mean exactly that." He explains that owners would benefit from reading safety warnings as closely as product claims.

In his view, the way owners think about rust needs to change. Products that last longer could mean fewer replacements, lower costs, and less usable metal sent to scrap. AMPP's estimate that existing practices could save up to 35% of corrosion costs suggests the answer lies in habit rather than new technology. "The tools to slow rust are already out there," Settle says. "What is often missing is the routine."

Settle recommends treating metal items before their first use rather than waiting for visible damage. He suggests drying and treating equipment after exposure to water, whether salt or fresh. Since protection wears off over time, regular reapplication could help maintain it. He also encourages buyers to look closely at any claim of permanent or rust-proof protection. "Rust never stops; you can only slow it down, and buyers deserve to know that," he explains.

Corrosion is a natural process that no product can fully eliminate. Owners who plan for it could extend the life of their equipment, reduce replacement costs, and keep it reliable for longer. According to Settle, a small amount of effort at the start might save time and money later. "Rust does not take a break," he says. "So maintenance probably should not either."