New rigging wires are rusty

[Popeye88]

Hello Everyone,

This is my first thread here, and I’m looking forward to hearing your thoughts on this issue. I recently replaced the standing rigging on my 33-foot sailboat, and after just six months, six out of the eight wires are showing rust in a candy-stripe pattern. The rigging company that performed the replacement mentioned using 'KOS' brand wires and Bluewave terminals. Interestingly, the terminals show no rust, but some of the wires are visibly affected.

The rusting started around the second month after the replacement. When I reported it, the company cleaned the wires using Ferronet, but the rust has since reappeared. Today, I conducted a test with a magnet and noticed that the rusted wires are magnetized, whereas the two wires without rust are not.

I’m seeking your feedback on this matter because I believe wires should last longer than six months in good condition. I’ve attached a few close-up photos for reference and would greatly appreciate your input.

Thank you!

[bgallinger]

Your standing rigging should be made from 316 Stainless Steel wire or a minimum 304 Stainless Steel wire. I suspect your rigging may be a lessor grade of stainless steel.

[barnakiel]

I never believed things until I got hit.


In our boat, a rigging wire broke, mid-length, corroded thru. I checked the other side and that one was going too. Wires 5 years old, well cared for (washed with fresh water periodically).


I also have here a 25 ? years old inner forestay - made in Sweden about 2000. This one is spotless and looks still usable.


Stains like yours are now standard on new rigging. But they were uncommon in the past.



Long story short - we are sold crap quality wires. Perhaps by innocent riggers.


I was told when the big mills melt inox steel in China and India, they use scrap metal of all sorts, and so the end product is not SS at all, but rather a bastardized version of it. I do not claim this is the case, but this explanation makes plenty of sense.


I do not know who makes quality ss wires today. Someone probably does - perhaps for architectural or aeronautics use.



barnakiel

[Greatest Lakes]

That sucks. You definitely got some bad material. My guess is the manufacturer had a spool of the wrong stuff and it got past quality control, if they have that. I'd hope the rigger can get it straightened out with his vendor and be able to redo it. Standing rigging is worth having 100% correct, as if it fails, it's a huge problem.

[deltaten]

Anecdotally....I used to work for a Co. that did laser steel cutting. When they started having issues with the cutter heads, they called in factory guy. He told them it was suspect steel and had samples tested. Yep...no, it wasn't spec or quality. He showed them samples and x-rays of Chinese plate, complete with half meted machine nuts, bits of debris and chunks of what appeared to be brake rotors, all embedded in the sheet.

About the same time, I had a buddy that was a QC inspector working in a huge cast steel plant in China 3 to 6 months of each year. He told horror stories about safety issues and oddments used to make up crucible mass.

So.....it's no surprise to me that there is suspect product on the market.
Just sayin'

[thinwater]

KOS is a well-respected South Korean manufacturer with world-wide plants. Some of the production is in the US. Not Chinese. It's not good to hurl insults without any investigation.

https://www.koswire.com/en/company/history.asp

[grantmc]

Originally Posted by Popeye88

recently replaced the standing rigging and after just six months, six out of the eight wires are showing rust. The rigging company that performed the replacement mentioned using 'KOS' brand wires and Bluewave terminals. Interestingly, the terminals show no rust, but some of the wires are visibly affected.

I would go back again and discuss with the rigger. It's their responsibility and they are:

1. equipped and qualified to make a considered judgement, and
2. know where the components used in the job that were used were sourced.

Also if there is an issue it's likely more than just your own boat that may be effected and they'll probably already have experience with the issue and have plans going forward.

Stainless steel, including SS 316, can exhibit some magnetic properties and rust staining under specific conditions. Here’s why this might happen:

1. Material Characteristics
Magnetism:
SS 316 is an austenitic stainless steel, which is generally non-magnetic in its annealed state. However, during the cold-working process (such as stretching or forming the wire), it can develop localized magnetic properties. This could explain why your rigging wire shows magnetism.

Corrosion Resistance:
Although SS 316 is highly corrosion-resistant, it’s not entirely immune, especially in marine environments where exposure to saltwater, chloride ions, and oxygen can lead to surface staining or pitting.

2. Possible Causes of Rust Stains
Contamination from Tools or Surfaces:
If non-stainless steel tools or surfaces were used during installation, small particles of iron or carbon steel could have been transferred to the wire. These particles rust, giving the appearance that the wire itself is rusting.

Incomplete Cleaning Post-Installation:
Rigging often involves handling lubricants, dirt, or contaminants during installation. If the wire wasn’t properly cleaned after installation, surface contaminants might oxidize, causing staining.

Galvanic Corrosion:
If the rigging wire is in electrical contact with dissimilar metals (e.g., aluminum or carbon steel fittings), galvanic corrosion can occur. This might lead to localized rusting, especially in the presence of saltwater.

Environmental Factors:
Marine environments are harsh, and even stainless steel can develop surface staining due to constant exposure to salt spray, humidity, and lack of adequate airflow to dry the metal.

3. Preventative and Corrective Actions
Clean Thoroughly:
Use a marine-grade stainless steel cleaner or a mild acid like oxalic acid to remove rust stains. Afterward, rinse thoroughly with freshwater.

Passivation:
Passivating the stainless steel (treating it with a nitric or citric acid solution) can restore its protective chromium oxide layer, improving corrosion resistance.

Electrolytic Polishing:
For severe magnetism or surface issues, electro-polishing can be done to remove impurities and enhance the surface finish.

Use Proper Insulation:
Ensure there is no direct contact between the stainless steel wire and dissimilar metals to avoid galvanic corrosion. Plastic or rubber insulators can help.

Regular Maintenance:
Frequent rinsing with freshwater and applying a corrosion inhibitor can minimize staining in a marine environment.

Given these issues appeared so quickly, it may indicate improper installation practices. Or it may not.

Apart from generalities we here on the internet are not in any sense enabled with enough facts about your boat and its rerig job to offer any useful advice. We don't have any clue where the job was done, nor the scope of the job. For example what level of quality your budget allow? some opt for best quality other owners want cheap, cheap and cheaper.

As you will have read for yourself the thread has already made a number of assumptions and proffered a variety of racial prejudices.

[boatpoker]

Grantmc wrote a pretty good explanation but 304 will corrode much faster than than 316 ... My first guess would be 304.

Check the magnetism difference between a good wire and a bad wire. 304 will have stronger magnetic attraction than even fouled 316.

I'd definitely go back to the installer, there is something wrong.

[Sailing August]

304 stainless will rust. Always go for 316L.
You can use Naval Jelly to passivate the rust on your 304

[thinwater]

Originally Posted by Sailing August

304 stainless will rust. Always go for 316L.
You can use Naval Jelly to passivate the rust on your 304

ASTM, MIL, and ISO passivization methods use either nitric acid or citric acid. Naval Jelly is for rust removal and is based on phosphoric acid.

[Popeye88]

First of all, thank you all for the responses — I really appreciate it!

In response to some of the questions:

The wires with rust have stronger magnetic attraction, while two of the wires without rust show no magnetic attraction at all.

Today, the rigger came for an inspection and claimed everything was in perfect condition. I feel he might be reluctant to acknowledge the issue. I requested the certificates for the cables and terminals used, but instead, he sent me a note with his company's stamp, simply stating that the wire used is of the KOS brand — not an actual certification.

As for the cleaning material, many recommend Spotless Stainless, but I am located in Spain and haven't been able to find it on the local market. Are there any alternatives, or a place where I can purchase it?

Thanks!

[gonesail]

right. perfect condition

[svtickles]

Originally Posted by Popeye88

Today, the rigger came for an inspection and claimed everything was in perfect condition. I feel he might be reluctant to acknowledge the issue. I requested the certificates for the cables and terminals used, but instead, he sent me a note with his company's stamp, simply stating that the wire used is of the KOS brand — not an actual certification.

Very disappointing. Where is the rigger based? I appreciate you don't want to name them. Good to know for others to avoid.

We have 5-yr old rigging. It was installed in the UK. There's zero rust. Had a rigger in Greece inspect it this spring and he mentioned it looks brand new.

There is however, a little bit of rust on the base under the turnbuckles. I believe this is surface contamination due to iron flying in from the Sahara across the Med. It's a pain to keep clean.

[boatpoker]

Originally Posted by Popeye88

First of all, thank you all for the responses — I really appreciate it!

In response to some of the questions:

The wires with rust have stronger magnetic attraction, while two of the wires without rust show no magnetic attraction at all.

Today, the rigger came for an inspection and claimed everything was in perfect condition. I feel he might be reluctant to acknowledge the issue. I requested the certificates for the cables and terminals used, but instead, he sent me a note with his company's stamp, simply stating that the wire used is of the KOS brand — not an actual certification.
!

How did your rigger explain the differences of magnetic attraction ?

[donradcliffe]

It appears to be only one strand of the cable that is rusting. Poor QC from the Korea, if you believe the rigger.