Agricultural harvesters face accelerated rust from moisture, soil, fertilizers and agrochemicals, with global corrosion losses reaching about $2.5 trillion (~3.4% of world GNP). Maintenance teams are turning to pH‑neutral cleaning and heavy‑duty, water‑displacing inhibitors to cut the damage and costs.
Industry: Agriculture | Process: Harvesting_Equipment
In fields from Indonesia to the US, rust is not a slow burn; it is a line item on the maintenance budget. A review of farm machinery corrosion ties exposure to plant moisture, slurry and fertilizers to higher energy use, production losses and sharply reduced service life of mower blades (IntechOpen).
Tropical humidity and coastal salt accelerate the problem. Field studies in West Java measured mild carbon steel corroding at ~2.8 mils per year (mpy, thousandths of an inch per year; ≈0.07 mm/yr) in just weeks (ResearchGate).
The scale is economic as well as technical. Corrosion losses are estimated at about $2.5 trillion (~3.4% of world GNP), with agricultural equipment costs alone in the billions (e.g., US agriculture ~$2 billion), and proactive prevention (coatings, inhibitors, maintenance) can slash these costs by 15–35% (IntechOpen) (IntechOpen). For maintenance managers, corrosion control is a high‑priority reliability program, not an afterthought.
Corrosive exposure on harvesting equipment
Contact with plant moisture, slurry or fertilizers raises metal oxidation and wear; research ties such exposure to increased energy use and production losses, and a sharply reduced service life of mower blades (IntechOpen). Near coasts, salt and humidity amplify the effect, with mild carbon steel in West Java corroding at ~2.8 mpy (≈0.07 mm/yr) within weeks (ResearchGate).
Globally, corrosion drains about $2.5 trillion (~3.4% of world GNP), and US agriculture alone is estimated at ~$2 billion in corrosion‑related costs; prevention can cut 15–35% from that burden (IntechOpen) (IntechOpen).
Water‑displacing inhibitor films (ASTM B117)
Water‑displacing (WD) inhibitors are low‑viscosity oils or solvent films that expel moisture and leave a protective barrier on metal; they adhere to carriages, fasteners and cavities, and resist wash‑off. A marine‑grade example is CRC 06026 Heavy‑Duty Corrosion Inhibitor, designed to protect fasteners and electrical parts even under salt‑spray. A widely cited product is WD‑40 Specialist Long‑Term Corrosion Inhibitor, tested under ASTM B117 (a standardized salt‑spray test—accelerated exposure to saline fog) and claimed to protect metal parts “40× longer than the competition,” with up to 1 year outdoor and 2 years indoor protection (wd40.com). WD‑40’s datasheet explicitly notes: “protects metal parts, blocking rust and corrosion for up to 1 year outdoors or 2 years indoors” (wd40.com).
Film durability, biodegradability and VOC (volatile organic compound) compliance, and ease of removal are key choice factors. Heavy‑duty films often contain waxes or polymers for longer life, while thin films favor easier cleanup. Application is effective only on dry, clean metal.
Performance is typically benchmarked by ASTM B117. WD‑40 Specialist was lab‑tested in 2020 (ASTM B117) and shown to far outperform a generic competitor (wd40.com). High‑quality oil‑film inhibitors can extend unprotected component life by months in storage; reapplication is advised at least once per rainy season or annually in high‑wear environments. Manufacturers publish coverage data (m² per liter) and corrosion‑test hours for comparison. For field programs on harvesters, maintenance teams increasingly specify an industrial corrosion inhibitor along with clear application windows and inspection intervals.
Neutral cleaning and post‑wash passivation
Heavy equipment accumulates oils, dust and agro‑residues that must be removed before coating. pH‑neutral detergents (pH≈7–8; pH is a measure of acidity/alkalinity) are recommended because they clean effectively without attacking metal or paint. Neutral, biodegradable formulas free of phosphates/chlorides are safer for operators and reduce flash‑rusting risk that acidic or strongly alkaline cleaners can cause (lazrtek.com). One industry source notes “traditional harsh chemicals can corrode surfaces, degrade paint, and damage sensitive components,” whereas neutral‑pH biodegradable cleaners “ensure thorough cleaning without causing harm” (lazrtek.com).
In practice, an industrial parts‑washer detergent handles light soils on painted metal, while drivetrain areas may require a stronger alkaline or solvent degreaser, followed by thorough rinsing. Many fleets standardize on a biodegradable heavy‑duty water‑based degreaser for routine washdowns, reserving solvent options for stubborn contamination.
Passivation—in this context, leaving a thin protective film that reduces metal reactivity—can be built into the wash step. Specialized cleaners deposit an anti‑rust film as they clean. Master STAGES Clean fluids, used in parts washers, remove oils while depositing a protective coating: one “One Step” cleaner provides 2–4 weeks of indoor corrosion protection on steel after wash, and another spray‑wash compound leaves a “thin rust inhibiting film” on steel parts (masterfluids.com) (masterfluids.com). These in‑process inhibitors serve as short‑term passivation, buying time until a durable coating is applied. Where passivating rinses are used, accurate addition via a dosing pump helps maintain consistent concentration.
Chemical selection and compliance parameters
Selection balances effectiveness against safety and regulation. Heavy‑duty chassis and fasteners benefit from water‑displacing oils (e.g., WD‑40 HD, CRC 060, LPS‑3), applied by wiper or spray. Vapor‑phase inhibitors (VpCI—vapor‑phase corrosion inhibitors) in packaging or coating fluids protect inside cavities. Cleaning agents should be COSHH‑compliant (hazardous‑substance safety) and biodegradable where possible. In Indonesia, many maintenance chemicals are classified B3 (hazardous/toxic) and must be on approved lists (beta.co.id).
Safety Data Sheets (SDS) should confirm low VOCs and absence of banned ingredients (examples in guidance include hexavalent chromium, phenols, nitrites). WD‑40 Specialist is described as “50‑State VOC compliant” (wd40.com). Many modern metal cleaners likewise avoid heavy metals. If unavoidable, containment and B3 waste disposal are required (beta.co.id). Greener formulation choices—biodegradable surfactants and corrosion inhibitors such as triazoles instead of nitrites—reduce environmental load (beta.co.id) (lazrtek.com).
Application protocols for field maintenance
Inspect and pre‑clean: remove loose debris with brushing or air to improve cleaning; identify painted versus bare metal areas requiring different handling.
Wash with detergent: use a high‑pressure washer or spray rack with pH‑neutral, biodegradable detergent; align pressure and detergent to soil type (alkaline‑surfactant for grease; mildly acid/descaler for mineral scale, with acids followed by neutralization); agitate as needed.
Rinse thoroughly and dry: rinse all soap with clean water; use air blowers or heat drying to eliminate standing water in crevices; ensure no puddles remain—moisture left even briefly can start rust.
Apply corrosion inhibitor: on clean, dry surfaces, spray or wipe a uniform coat on exposed metal and connectors; focus on joints, undercarriage and pooling areas. Thick joints or electrical terminals can benefit from heavier “creeping” oils such as CRC REDi‑Shield that penetrate and seal. For large surfaces, WD‑40 Specialist or similar dries to a transparent film. For moving parts (pins, bushings), use an oil or grease with corrosion additives.
Reapply or top up: in heavy rain or high humidity, re‑coat every few weeks or at season start; in storage or transport, one application may suffice for months; always reapply after subsequent wash cycles because solvents or water can remove films.
Monitoring, cost outcomes and records
Programs should track results: note when and where rust appears, and record product batch, application dates and any deviations. Inspection targets guide action (e.g., 20% rust on a rear axle triggers recoat). Well‑implemented programs often extend equipment life 20–50%, cut repaint/repair costs and reduce downtime—consistent with data that good corrosion control can save up to 35% of related costs (IntechOpen). The principle is consistent execution: clean, then coat, and repeat as needed.
Regulatory and safety requirements
Indonesian rules classify most maintenance solvents and additives as B3 hazardous chemicals; operators must follow Directorate General of Pollution Prevention & Control rules, comply with PPNo.74/2001 (B3 management), and meet local K3 (OSHA) requirements. PPE (gloves, goggles) is necessary during application. Select greener formulations where possible; biodegradable surfactants and triazole inhibitors lower environmental load (beta.co.id) (lazrtek.com). Wash water should be collected for treatment or safe disposal; oily or acidic runoff should not enter drains.
