Corrosion is often perceived as a technical problem. But in reality, it's an economic problem.
Each corroded component not only implies material damage, but also a series of associated costs that directly impact the profitability of an operation.
In many industries, the cost of corrosion can represent between 2% and 4% of industrial GDP..
However, much of that impact remains hidden.
What do we mean by the cost of corrosion?
Corrosion doesn't begin when a part fails. It begins much earlier, when the protection system is inadequate for the working environment.
The actual cost is divided into two main categories:
Direct Costs
- Component Replacement
- Corrective Maintenance
- Plant Shutdowns
- Warranty and Claims Management
Indirect Costs
- Productivity Loss
- Field Failures
- Unplanned Technical Interventions
- Reputational Damage with the Client
- Contractual Penalties
These costs are usually the highest, but also the least visible within the organization.
A common example in industry
In sectors such as agricultural machinery, energy, or automotive, it is common to find fasteners (screws, nuts, washers) exposed to highly aggressive environments:
- Constant Humidity
- Fertilizers and Chemicals
- Thermal Changes
- Exposure to the Elements
In these cases, a corrosion failure involves more than just replacing a part.
It involves:
- Shutting down equipment
- Mobilizing technical resources
- Impacting Operations
- Compromising the End Customer Experience
A low-cost component can have a disproportionate economic impact.
The most common mistake: deciding based on initial cost
In many cases, the coating selection is based solely on price.
But this logic ignores a key variable: The total lifecycle cost of the component.
A more economical protection system may:
- Fail Prematurely
- Require Additional Maintenance
- Generating Higher Operating Costs Over Time
How to Reduce the Cost of Corrosion
Reducing the economic impact of corrosion depends not on a single solution, but on a sound protection strategy.
Some key factors include:
- Appropriate selection of the coating system
- Analysis of the actual operating environment (not ideal conditions)
- Compatibility with the component type and mechanical requirements
- Performance stability over time
- Minimization of process-related risks
Corrosion is not just a technical problem. It's a financial problem.
Companies that understand its true impact:
- Optimize their operating costs
- Reduce field failures
- Improve product reliability
While those that underestimate it continue to incur hidden costs year after year.
About Us
At Chousa SRL, we help industrial companies reduce failures and costs associated with corrosion through surface treatment solutions tailored to each application.
Our approach combines technical expertise, field experience, and a strong commitment to quality.
Are you experiencing corrosion problems? Contact us and find a solution.