TR3

Guidelines for
Minimizing Water
Staining of Aluminum

Water Staining of Aluminum

Guidelines for Minimizing
 The 2009, fifth edition has been revised through the support
of the Technology Committee of the Sheet and Plate Division.

ALUMINUM ASSOCIATION SHEET AND PLATE

DIVISION COMPANIES
Alcoa Inc. JW Aluminum Company
Aleris Rolled Products Kaiser Aluminum
AMAG Rolling GmbH Corporation
ARCO Aluminum Inc. Nichols Aluminum
Golden Aluminum, Inc. Novelis Inc.
IMPOL Aluminum Corp. Rio Tinto Alcan
Jupiter Aluminum United Aluminum
Corporation Corporation
Wise Metals Group

About
The Aluminum Association
The Aluminum Association, Inc. is the trade association for
producers of primary aluminum, recyclers and semi-fabricated
aluminum products, as well as suppliers to the industry.
Based in Arlington, Virginia, with offices in Detroit, Michigan,
the Association provides leadership to the industry through its
programs and services which aim to enhance aluminum’s
position in a world of proliferating materials, increase its use as
the “material of choice,” remove impediments to its fullest use,
and assist in achieving the industry’s environmental, societal,
and economic objectives. Member companies operate about
200 plants in the U.S and many conduct business worldwide.

NOTICE
Disclaimer
The use of any information contained herein by any member or
non-member of The Aluminum Association is entirely voluntary.
The Aluminum Association has used its best efforts in compiling
the information contained in this book. While the Association
believes that its compilation procedures are reliable, it does not
warrant, either expressly or implied, the accuracy or completeness
of this information. The Aluminum Association assumes no
responsibility or liability for the use of the information herein.

All Aluminum Association published standards, data,

specifications and other technical materials are reviewed and
revised, reaffirmed or withdrawn. Users are advised to contact The
Aluminum Association to ascertain whether the information in this
publication has been superseded in the interim between
publication and proposed use.

FIFTH EDITION, MAY 2009 1525 Wilson Blvd., Suite 600

Arlington, VA 22209 www.aluminum.org
Guidelines for
Minimizing Water Staining
of Aluminum

Contents

1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2. Causes of Water Stain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
A. External Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
B. Moisture Condensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3. Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4. Inspection Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
5. Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6. Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Appendices

1. Aluminum Water Stain Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

2.A. Instrument Suppliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.B. Suppliers of Water Indicator Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
2.C. Suppliers of Water Stain Preventatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3
 1. Introduction but may cause processing problems where
additional surface finishing or fabrication is to be
performed. Virtually all staining problems occur
Aluminum is naturally attractive and resistant to
during shipping, handling, or storage. Some of the
corrosion. Unlike most other metals, it takes care of
incorrect practices that result in water staining and
itself. When exposed to dry or moist air it combines
ways to minimize or avoid the staining are
with oxygen to form a tough, transparent,
discussed in this pamphlet. A summary of the
protective oxide coating. In the presence of
measures to minimize water staining is provided
moisture, aluminum will not rust as will steel, but
in Appendix 1 and is reproduced as a handy wall
under certain conditions aluminum will stain. Such
chart, which is included with this pamphlet.
stains are usually found objectionable for esthetic
Copies of the chart may be obtained from
reasons; they have no significant effect on strength
The Aluminum Association.

2. Causes of Water Stain water vapor. Relative humidity, expressed as a

percentage, provides a measure of the amount of
Aluminum and other metals can stain when water is water vapor actually in the air compared to the total
trapped between wraps, sheets or other mating amount of water vapor that the air can hold. As the
surfaces. If there is no air flow to remove the water, temperature of air increases, its capacity to hold water
prolonged contact between the water and the metal vapor increases.
causes a reaction between the two which results in Dew point is the temperature at which water
water stain. Figures 1 and 2 show examples of water vapor from the air begins to condense and is affected
staining on aluminum coiled and flat sheet, by the relative humidity and temperature of the air.
respectively. There are two main sources of this water: The dew point can be determined from a chart (see
Table 1), based on simple measurements of air
A. External Sources temperature and relative humidity. The type of
Obvious sources are rain, snow and water leaks. instrument used to measure (and log) temperature and
Water coming in contact with the surface of the relative humidity is shown in Figure 3. The older style
aluminum from sources such as a leaking tarp on a of thermometers containing mercury should not be
truck or a leaking roof in a storage area has the used because mercury from broken thermometers can
potential for causing water stain. corrode aluminum and other metals. Some suppliers
of these instruments are listed in Appendix 2.A.
B. Moisture Condensation
This is the more complex of the two sources and
therefore harder to understand and control. Air
normally contains moisture in the form of invisible

Figure 1 – Water Stain on Coil Figure 2 – Water Stain on Sheet

4
Figure 3 – Digital Instrument for Measuring
Temperature & Humidity
Figure 4 – Condensation on Cold Aluminum Cans

Water vapor condenses on the surface of a metal if 2. During Loading:

the temperature of the metal drops below the dew Loading metal removed from a cool or cold
point of the surrounding air. A familiar example of storage area into a warm trailer or railroad car,
condensation is the fogging of one’s eyeglasses on a humid day, can result in condensation on
upon entering a warm room after being in the cold the aluminum. This can occur during any season
outdoors. Another common example is condensation of the year; however, for some areas it may be
on a cold beverage can as shown in Figure 4. more pronounced in summer.
As mentioned before, when the temperature of
aluminum drops below the dew point of air, water 3. During Unloading-Moving Cold Metal Into
comes out of the air and deposits on the surface of Warm Storage:
the aluminum. The temperature of the aluminum Condensation at the unloading point is more
can drop below the dew point of the air under the likely to occur during the cooler months. The
following circumstances: following example may help to clarify this point:
Metal at 16°C (60°F) in a warehouse is
1. During Storage: loaded into a trailer and shipped. The metal is in
When storing metal, it is not recommended to transit for about two days. The outside
leave warehouse doors open especially during temperature is - 1°C (30°F). Within a two-day
the spring and fall months, when there may be transit period, the temperature of the metal
extreme differences in temperature between day gradually decreases to -1°C (30°F). When the
and night. During the night, cold air enters and aluminum reaches its destination, it is unloaded
starts cooling the metal. During the day, if the and moved directly into a warehouse where the
temperature and humidity of the air increase temperature is 16°C (60°F) and the relative
rapidly, the dew point rises quickly. But, the humidity is 50%. From Table 1, the dew point of
temperature of the aluminum increases at a much the air is 5°C (41°F). Since the temperature of
slower rate; this sets up the condition where
the aluminum is now lower than the dew point
water begins to condense on the surface of the
of the air, conditions are ideal for water to
aluminum.
condense on the surfaces such as the edges of
Obviously this process is not limited to fall
stacked sheet or coils. The condensed moisture
and spring months but may occur whenever
there are large enough fluctuations in can enter between the sheets and wraps by
temperature and humidity. capillary action and may produce water stain.

5
 Table 1: Dew Point Calculator

Air Temperature in Degrees Celsius

Air
Temp % Relative Humidity
°C 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10
43 43 42 41 40 39 38 37 35 34 32 31 29 27 24 22 18 16 11 5
41 41 39 38 37 36 35 34 33 32 29 28 27 24 22 19 17 13 8 3
38 38 37 36 35 34 33 32 30 29 27 26 24 22 19 17 14 11 7 0
35 35 34 33 32 31 30 29 27 26 24 23 21 19 17 15 12 9 4 0
32 32 31 31 29 28 27 26 24 23 22 20 18 17 15 12 9 6 2 0
29 29 28 27 27 26 24 23 22 21 19 18 16 14 12 10 7 3 0
27 27 26 25 24 23 22 21 19 18 17 15 13 12 10 7 4 2 0
24 24 23 22 21 20 19 18 17 16 14 13 11 9 7 5 2 0
21 21 20 19 18 17 16 15 14 13 12 10 8 7 4 3 0
18 18 17 17 16 15 14 13 12 10 9 7 6 4 2 0
16 16 14 14 13 12 11 10 9 7 6 5 3 2 0
13 13 12 11 10 9 8 7 6 4 3 2 1 0
10 10 9 8 7 7 6 4 3 2 1 0
7 7 6 6 4 4 3 2 1 0
4 4 4 3 2 1 0
2 2 1 0
0 0

Air Temperature in Degrees Fahrenheit

Air
Temp % Relative Humidity
°F 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10
110 110 108 106 104 102 100 98 95 93 90 87 84 80 76 72 65 60 51 41
105 105 103 101 99 97 95 93 91 88 85 83 80 76 72 67 62 55 47 37
100 100 99 97 95 93 91 89 86 84 81 78 75 71 67 63 58 52 44 32
95 95 93 92 90 88 86 84 81 79 76 73 70 67 63 59 54 48 40 32
90 90 88 87 85 83 81 79 76 74 71 68 65 62 59 54 49 43 36 32
85 85 83 81 80 78 76 74 72 69 67 64 61 58 54 50 45 38 32
80 80 78 77 75 73 71 69 67 65 62 59 56 53 50 45 40 35 32
75 75 73 72 70 68 66 64 62 60 58 55 52 49 45 41 36 32
70 70 68 67 65 63 61 59 57 55 53 50 47 44 40 37 32
65 65 63 62 60 59 57 55 53 50 48 45 42 40 36 32
60 60 58 57 55 53 52 50 48 45 43 41 38 35 32
55 55 53 52 50 49 47 45 43 40 38 36 33 32
50 50 48 46 45 44 42 40 38 36 34 32
45 45 43 42 40 39 37 35 33 32
40 40 39 37 35 34 32
35 35 34 32
32 32

Example: Read the air temperature in the left hand column and the humidity at the top of the above
chart. If the temperature of the storage area is 13°C (55°F) and the relative humidity is 60%,
the intersection of the two shows the dew point of the area to be 4°C (40°F). If the metal
coming in is below 4°C (40°F), water will condense on the metal.
6
3. Packaging with special paper, foam sheets or other materials to
protect the surfaces against abrasion. Even though
Packaged aluminum coils, flat sheet, and plate should some interleaving papers contain an additive to inhibit
be wrapped with various papers, plastic films, or water staining, the normal precautions during transit,
laminates that provide reasonable protection against handling, and storage should be followed. It is very
moisture penetration during shipment and storage. important that the coil or sheet metal package is
Coils should have caps on the ends for either vertical securely attached to the skid to eliminate any
or horizontal stacking and shipment. When using a possibility of movement which can tear or otherwise
shrink wrap, it should envelop the entire package to compromise integrity of the packaging during
ensure any condensation has an opportunity to run off shipping. Use of desiccants is not recommended due
and not penetrate the package. However, it should be to rapid overload conditions that can occur during
recognized that any such packaging may not be air- long routes and the very large quantity of moisture
tight, and changes in temperature or humidity may that can accumulate on cold surfaces.
still result in condensation on the aluminum surfaces.
Packaged aluminum, even if protected with
“waterproof” materials, should not be stored outdoors.
Wrapping materials should be left intact (and
repaired if torn) until the aluminum is used. If
moisture is condensing on the packaging as shown in
Figure 5, the moisture should be removed but not the
packaging. If the packaging is soaked or if the
aluminum is wet, then the procedures mentioned on
page 9 should be followed.
When surface quality is critical, aluminum flat
sheets and plate should be additionally interleaved Figure 5 – Moisture condensation on packaged metal

4. Inspection Procedures A. If any physical or water damage is found on the

skids, packaging or the metal, this should be noted
Because there is normally a time limit on carrier on the receiving papers. Any package that is torn
claims, incoming inspection becomes a vital part of and exhibits a significant water accumulation should
the receiving process. Without incoming inspection be considered suspect and scheduled for additional
the receiver cannot know what the condition of the review and potentially targeted for immediate usage
metal is and how susceptible it may be to water subject to production schedules and constraints. If
staining. Without this knowledge the necessary steps possible the coil or flat sheet should be inspected
to prevent the staining cannot be taken: and reoiled via recoiling or restacking operation. If
it has been recorded, the temperature/
humidity data should be transmitted
to the shipping point to assess
particular conditions, track trends and
develop improved routing, packaging
or mode of transportation.
B. Water vapor will condense on the
surface of the metal if its temperature
is lower than the dew point of the air
in the storage area. (See Figure 6) It is
important, therefore, to check the
temperature of a few coils in every
shipment and compare that
temperature to the dew point of the
storage area. (Refer to section 5. A.3)

Figure 6 – Heavy Water Condensation on a Coil

7
 The temperature of the aluminum can be easily absorbent material, can identify exposure to
measured by using a probe thermometer, as shown in moisture by changes to the shape and/or color of
Figure 7, or by cutting a 6 inch by 6 inch flap in the the tag depending upon the specific indicator used.
wrapping paper and placing a contact, dial-type Figure 9 shows a new tag while Figure 10 shows
thermometer on the surface of the aluminum, as the effect of exposure to a water mist. If the tag
shown in Figure 8. After recording the temperature, shows exposure to moisture, follow the directions
it is important to reseal the package by replacing and in Appendix 1.
taping the flap. If not repaired, condensate could run
down the inside of the wrap and result in water stain.

C. An alternative method of identifying coils exposed

to moisture is through the use of moisture tags
(a.k.a. “Weeping Eyes”). See Appendix 2.B. for a
list of suppliers. These tags, made of moisture

Figure 7 – Probe Thermometer Figure 9 – Unexposed Moisture Label

Figure 8 – Contact thermometer Figure 10 – Moisture Label after Water Mist Exposure

5. Prevention 1. STORAGE:
Intact packages should be stored in a dry area
There are three methods of preventing water stain: with good ventilation to ensure stabilization of
A. Prevent water in any form from coming into contact the package. Temperature and humidity
with the metal variations within the warehouse should be kept
to a minimum by keeping outside doors closed.
B. If water is already in contact with the metal, remove it
For surface critical products, air conditioned
C. Consider precautionary measures to minimize water warehouses with limited access are preferred. If
staining use of an air conditioned warehouse is not
feasible, packages should be periodically
A. Prevent water in any form from coming inspected to verify that storage conditions have
into contact with the metal not deteriorated. Stock should be rotated as
To prevent the water from getting between wraps, quickly as possible.
sheets or other mating surfaces, it is critical to prevent It is also advisable to have forced circulation
the temperature of the metal from getting below the heaters in the storage area to maintain the
dew point of the surrounding air. temperature of the metal above the dew point of
the ambient storage environment. Without fans to

8
 distribute heat, storing aluminum near walls, a. Do not move cold metal into a warm storage
doors, windows, and other cooler areas may area (remember the fogging of eye-glasses).
provide the conditions for condensation. Allow the metal to warm up slowly. This can
Neither packaged nor bare aluminum be done by placing the unopened package in
should be stored outdoors unless water stain a cooler area, free from drafts.
is not detrimental for the end use. b. Check the condition of the metal every few
hours to make sure that no water has
2. SHIPMENTS: condensed on the surface.
For surface critical products it is important to c. Communication is essential. Any evidence
minimize day/night temperature cycling during of improper shipping mode, damaged
typical storage and/or transit, and the preferred packaging, and any obvious water staining
method is to use insulated trucks or rail cars. It should be reviewed with the metal producer.
is essential that long layovers at truck and rail
depots are minimized. If this mode is not B. If water is already in contact with the
feasible due to metal shape or economic metal, remove it
considerations, and flat bed trucks are used, it Steps should be taken to remove this water before it
is very important that the load is completely stains the aluminum.
covered using high integrity tarpaulin. The Unfortunately, there is no easy way to remove
truck bed and tarpaulin should be dry prior to the water. Contacting the supplier may be helpful.
loading and securing the load. Ensure that coils The supplier is generally familiar with prevention
and sheet metal are securely attached to their techniques and can provide assistance. Some
skids, and that the skids are properly secured to possible procedures that might be recommended
prevent movement and damage to the are:
packaging. To help assess the history of the 1. If at all possible, process the aluminum
shipment it is recommended that portable, immediately and dry it as it is being used.
temperature/humidity recorders be incorporated This is the only sure way of getting rid of
in the load. Quick review of the the water.
temperature/humidity data will allow an 2. If in coil form, unskid and unpackage the
assessment of the potential risk of water stain aluminum, lay it on its side and use fans to
and will facilitate a decision on any need for blow air around it-hot air if possible.
potential salvage of the metal received.
It is important to: C. Consider precautionary measures
a. Minimize in-transit times and temperature to minimize water staining
cycling. If water stained metal is a major recurring problem,
b. Use insulated or heated trailers in the a way of minimizing the problem would be to coat
winter whenever possible. the aluminum with a water stain preventative. Most
c. Check tarps on open-top trucks to make sure aluminum suppliers have such preventatives but
there are no holes. The carrier should re-tarp hesitate to use them without prior knowledge of a
the truck after each intermediate delivery. customer’s operations to ensure that there are no
d. Use portable, temperature/humidity recorders compatibility problems with the end use application
for critical products. and/or local environmental regulations. If requested
by the purchaser, synthetic (water free) oils, which
3. RECEIVING: provide a high level of protection, may be applied
If during the incoming inspection process the by the aluminum producer during their
temperature of the metal is found to be below fabrication/processing sequence. However, some
the dew point of the air in the storage area, the aluminum suppliers may not be able to coat all
following steps should be taken: items. A list of suppliers of water stain preventatives
is shown as Appendix 2.C.

6. Conclusion

The Aluminum Association hopes this pamphlet has Some of the recommended procedures may
provided a better understanding of water stain, its require added efforts, but the value of the aluminum
causes, and some of the steps that can be taken to and assured production schedules may justify the
prevent it. suggested precautions.

9
 Appendix 1: Aluminum Water Stain Prevention
A. When you receive metal: heated warehouse immediately, it may sweat
1. Check for wetness. and get water stained.)
a. Is the metal wet? Is the wrapping paper c. After the metal is reasonably warm (about a
puckered up or wet? day later), move it to the warehouse.
b. If it is wet, note it on all copies of the
receiving papers. B. When you move metal between areas:
c. Inform the Purchasing Department or Check to see if the temperature in the area the metal
Quality Control immediately. will be taken to is higher than the temperature in the
d. Remove the water or, if possible, area the metal is coming from.
immediately use the metal. If the difference is more than 11°C (20°F):
a. Only move as much metal as will be used
2. Check to see if the metal feels cold. If it does:
immediately.
a. Tell your supervisor immediately. b. Tell your supervisor.
b. Leave the metal in a cool indoor area away c. Leave the remainder of the metal where it is
from drafts to allow it to warm up slowly. (If until ready for use.
this is not done, and the metal is put in a

Appendix 2: Suppliers
A. Measurement Instruments
The Thermometers and hygrometers for measurement of air temperature and relative humidity and
thermometers for measurement of metal temperature may be obtained from:
Cole-Parmer Instrument Company McMaster-Carr Company Thomas Scientific
625 East Bunker Court P.O. Box 54960 P.O. Box 99
Vernon Hills, Illinois 60061-1844 Los Angeles, CA 90054-0960 Swedesboro, NJ 08085
1-(800) 323-4340 1-(562) 692-5911 1-(856) 467-2000 - General
1-(847) 247-2929 - Fax 1-(562) 695-2323 - Fax 1-(800) 345-2100 - Customer Service
info@coleparmer.com - E-mail 1-(856) 467-3087 - Fax (Worldwide)
www.coleparmer.com
la.sales@mcmaster.com 1-(800) 345-5232 - Fax (US Only)
www.mcmaster.com value@thomassci.com - E-mail
Fisher Scientific
2000 Park Lane Drive Tech Instrumentation, Inc. www.thomassci.com
Pittsburgh, PA 15275 160 W Kiowa Ave VWR International LLC
1-(800) 766-7000 PO Box 2029 1310 Goshen Parkway
1-(800) 926-1166 - Fax Elizabeth, CO 80107 West Chester, PA 19380
www.fisherscientific.com 1-(800) 390-0004 1-(800) 932-5000
1-(303) 841-7567 1-(610) 431-1700
1-(303) 840-8568 - Fax 1-(610) 431-9174 - Fax
sales@techinstrument.com - E-mail www.vwr.com
www.techinstrument.com

B. Moisture Indicating Labels C. Water Stain Preventatives

BGR Inc. CRC Industries, Inc. Quaker Chemical Corp.
6392 Gano Road 885 Louis Drive World Headquarters
West Chester, OH 45069 Warminster, PA 18974-2869 One Quaker Park
1-(800) 628-9195 1-(800) 556 - 5074 910 Hector St.
1-(513) 755-7100 1-(215) 674-4300 Conshohocken, PA 19428-0809
1-(513) 755-7855 - Fax 1-(215) 674-2196 - Fax 1-(610) 832-4000
www.bgrinc.com crcwebmaster@crcindustries.com - E-mail www.quakerchem.com
ITW Metals Group www.crcindustries.com
1-(800) 862-7997 Henkel Surface Technologies
1-(630) 268-9919 - Fax 32100 Stephenson Highway
sfisher@fleetsig.com - E-mail Madison Heights, MI 48071
www.fleetsig.com 1-(800) 521-6895
1-(248) 583-9300
1-(248) 583-2976 - Fax
www.finishing.com/Products/henkel

The lists in these appendices are included only as a convenience. No attempt has been made by the Association to evaluate the effectiveness of the
products, nor does listing here constitute an endorsement. The lists are not to be considered all-inclusive, but do represent all such suppliers known to
the Association at the time of publication of this document. Some of the companies listed have additional United States sales offices or outlets where the
products can be purchased. Other suppliers will be added as they become known to us and their names will be made available in response to inquiries
and at republication of this document. The responsibility for the selection, determination of suitability, and proper use of the products is left to the user.
10
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