Are rusted or damaged shells safe to shoot? Whether you are loading up your pump-action, semi-automatic, or maybe your great-great-grandfather’s antique muzzle loader shotgun, you need to know if that rusty old shell is safe to shoot.  Unfortunately, we can’t turn back time and undo years of damage that our Zerust plastabs or VCI capsules could have prevented, but this doesn’t mean that you can’t still enjoy shooting that old ammo. We’ll help you to know what’s safe to shoot and which ammo to discard. To keep existing ammo in good condition, use smart storage strategies including VCI protection.

Paper Vs. Plastic

Nowadays, shotgun cases are made of plastic, but paper cases were popular up until the 1960’s.  While still in production, they are less common. A benefit of paper cases is that they are biodegradable, but this is a bit of a moot point as the metal head doesn’t degrade, so even paper shells aren’t perfectly environmentally friendly. Moisture is a problem for paper shells, which can cause the shell to swell and damage. Plastic cases are the standard today, and modern shotguns are designed for them. They are cheaper and more water resistant. They won’t swell in damp conditions, ensuring they will fit in the chamber reliably. Their strength over paper means they will be easier to reload, and good quality shells can be reloaded multiple times. Unfortunately, the plastic cases are not biodegradable, but in our opinion, the ability to reload them multiple times offsets the issues caused from the plastic. Damaged paper or plastic cases should be discarded as they can be stuck or cause misfires when attempting to shoot.

Brass Head and Primer

The paper and plastic components of shells don’t rust but the head and primer can corrode.  Significant corrosion around the primer can cause misfires, such as hangfires, where there is a delay when firing before the round goes off, or a squib load, where the bullet is not ejected from the barrel. Hangfires and squib loads are both dangerous as they can cause the gun to rupture or the shell to explode unexpectedly! Due to the risks of misfires, we suggest discarding shells that show corrosion around the primer. Minor corrosion around the brass head can be handled with a wire brush or steel wool. Heavier corrosion around the sides might cause the shell to be stuck in the chamber which could be dangerous! We recommend discarding shells that are too corroded to seat easily.

Smart Storage Includes Zerust VCI Protection

To prevent future issues, we recommend storing shells in their original boxes to ensure the exact details of the shells are preserved, inside sealed ammo boxes that keep moisture out. Aim for consistent temperatures and controlled humidity, so the living space of a home is ideal. In areas that have high humidity, a dehumidifier is recommended near the storage area. Keep weapons and ammunition in a safe to minimize the chance of theft or falling into children’s hands.  Zerust Plastabs or Vapor Capsules can be used inside of ammo cases or any smaller enclosure, providing up to 5 years of rust protection. Our VCI poly bags can be used for shell storage if desired—add dessicant packs to ensure the absorption of any minor residual moisture.

Not Just For Ammo Protection

Zerust protects more than just ammo. Our innovative Magic VCI Bullet protects the inside of the gun barrel for your 12 or 20 gauge shotgun, by emitting VCI vapors inside of the barrel that inhibits rust. This is a simple and convenient way to protect your shotgun. Our tube and barrel strips can be cut to length and inserted into any tube or barrel, providing superior VCI protection inside the barrel that doesn’t leave messy residue. For shipping or travel, we offer VCI Firearm Protection Bags and VCI Fleece Lined Firearm Bags, ideal for carrying your weapon to the range or on a hunting trip.

If you have more questions, contact us for information on VCI products to help with rust prevention of a range of consumer products by emailing or calling (330) 405-1965.