I've installed quite a bit of sheetrock, and it seems that the nail heads always eventually rust, when located near a shower or tub. The screws do a much better job, but it sure seems like it wouldn't be too difficult to manufacture an aluminum alloy nail that would not rust. I've looked for something like this, but no luck. Any ideas? Thanks.

Maybe use galvanized roofing nails, stainless steel screws, exterior screws. Make sure the nails you are using are not rusted or starting rust to begin with.
There must be heavy moisture if the nails are rusting w/ spackle, primer & 1 or 2 coats of paint covering them.
Bath fans being used to help control moisture in the room?

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Originally Posted by skiberger

maybe use galvanized roofing nails, stainless steel screws, exterior screws. Make sure the nails you are using are not rusted or starting rust to begin with.
There must be heavy moisture if the nails are rusting w/ spackle, primer & 1 or 2 coats of paint covering them.
Bath fans being used to help control moisture in the room?

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We are located in the southeast, so there is a lot of humidity. And we do use bath fans. Most of the rust occurs above tubs & showers.
The nails we use are galvanized, just like roofing nails. The rust will sometimes begin right after painting with a water-based primer!
Just seems like a simple solution to manufacture aluminum alloy nails. Surely, somebody makes these things.

You can buy aluminum roofing and trim nails. They are mainly meant for aluminum siding and trim. However, they don't have the rings to keep them from popping. If rust is that big of a problem, I would try to find short galvanized deck screws.

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Originally Posted by labman

You can buy aluminum roofing and trim nails. They are mainly meant for aluminum siding and trim. However, they don't have the rings to keep them from popping. If rust is that big of a problem, I would try to find short galvanized deck screws.

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I've seen the aluminum roofing nails. That's what got me thinking about aluminum sheetrock nails. I would be afraid to use roofing nails, without the ridges.

I might consider the galvanized deck screws, for the bath areas. That's not a bad idea! Actually, I've had much better luck with the standard, black coated sheetrock screws, as far as rust. I don't know the coating process, but they do pretty well in water.

Have you considered using brass or bronze nails/screws ?

I'm not sure what your availability is like for you but in the UK they are readily available in most DIY chains.

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Originally Posted by Curlyben

Have you considered using brass or bronze nails/screws ?

I'm not sure what your availability is like for you but in the UK they are readily available in most DIY chains.

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Brass screws are readily available, but somewhat expensive. Not sure how the price compares to stainless, but I know they are a little pricy.

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Originally Posted by ytek

Brass screws are readily available, but somewhat expensive. Not sure how the price compares to stainless, but I know they are a little pricy.

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It may just be worth the added expense for added piece of mind.
I have a feeling that even stainless with rot given time as all it takes is a slight imperfection to cause this.