Problems With Rust and Corrosion on Rollforming Machines

New Tech Machinery (NTM) portable rollforming machines are the best in the industry, as our machine owners can tell you. They can travel anywhere and work under nearly any conditions. However, if not properly maintained and cared for, they can develop rust and corrosion.

In this article, we examine where rust can develop, how to deal with it, and, most importantly, how to prevent it. 

New Tech Machinery is a leader and pioneer in the portable rollforming industry, producing our first portable rollformer over 30 years ago. Our first Mach II portable gutter machine, manufactured in 1994, still produces a perfect gutter. Our original panel machine, the SSR, still operates in metal shops nationwide. With proper care and maintenance, there’s no reason your NTM portable rollformer can’t provide decades of service for your operation.

Allowing rust and corrosion to develop in your rollforming machine can cause damage to the machine and panels or gutters. In this article, you’ll learn:

• What causes rust to occur
• How to address rust on machine frames
• Managing rust on rollers
• Bearings and other components

Understanding Rust: Where Rust Occurs and Why

Rust primarily appears on rollforming machines in two areas: the machine frame and the rollers. The frame, made from welded and painted steel, is susceptible, especially in humid or coastal environments where salt air promotes corrosion. Even with advancements like painted aluminum, regular inspection is essential.

Rollers, on the other hand, face direct contact with the metal being formed and must maintain a clean surface to ensure panel or gutter quality. If stored in a damp environment without proper ventilation, rust can form on the rollers. Rust can leave marks on the metal you’re running and interfere with the overall quality of the product.

Rust can also appear on bearings, which may need replacing if damaged.

Addressing Rust on Machine Frames

Machine frames often show surface rust over time, especially in environments with high humidity or near coastlines. While surface rust typically doesn’t compromise structural integrity, regular cleaning and proper storage are essential:

• Regular Cleaning: Wipe down the machine frame regularly to remove dust and moisture, which can accelerate corrosion.
• Storage: Store your machine in a dry, well-ventilated area away from direct exposure to rain or coastal elements.
• Follow a regular maintenance schedule.

Managing Rust on Rollers: Materials and Maintenance

Rollers require specific attention to prevent surface rust from affecting product quality, including leaving marks on the material or causing bending or warping. Here’s how to manage roller corrosion effectively:

• Maintenance Practices: Regularly clean rollers with a fine Scotch-Brite pad to remove surface rust. Apply a protective layer of carnauba wax or lubricants like Super Lube to inhibit further corrosion between uses.

If you encounter roller corrosion, clean the roller with a dry wax or mild solvent.

Bearings and Additional Components

Bearings are also susceptible to rust and corrosion, which can lead to panel or gutter fabrication issues and increased maintenance costs:

• Regular Inspection: Check bearings periodically for signs of rust or wear, particularly in humid or coastal areas.
• Replacement:  Replace rusted bearings promptly to prevent further damage.

Future Directions: Enhanced Corrosion Resistance

NTM has advanced efforts to make our machines more rust-resistant. We replaced our steel covers with brushed aluminum on our SSQ II MultiPro, and we continue to explore new ways to protect rollers and parts from corrosion.

While rust and corrosion pose ongoing challenges for rollforming machines, regular maintenance and proper storage can extend your machine’s lifespan and keep it running smoothly.

For information about our metal panel or gutter machines, contact us to speak to one of our knowledgeable account managers.