GE refrigerator CFE28TSHBSS rear wall rusted and ice forming

[LadyTech]

This unit has never been connected to water. It maintains perfect temperature. When it was moved to do some kitchen remodeling, they noticed the exterior wall, behind the ice room had rusted through and a large chunk of ice had formed. I have since cut off all that rusted sheet metal and removed the ice. It runs great. I noticed ice forming on the exposed insulation after a week of removing it. I have no idea why this is happening. Could it be a design flaw? Would adding more insulation solve the problem? Do I need to add sheet metal or something to seal out the ambient air? Any suggestions are welcomed. Has anyone seen this before? If so, what was the fix? I appreciate any thoughts or suggestions. 

 

[ECtoFix]

When the opportunity arises, such formation of ice is perpetual - meaning that once the insulating/sealing panels are compromised, ice will form if there is still ANY moisture present within the .  As such, when THAT freezes, multiple layers of condensation (from the air) will grow more ice. 

Wet insulation is virtually the same as NO insulation.

You would need to do THREE things:

• Completely remove all moisture from the existing insulation and from within the cavity between the inner and outer shells of the unit.  THAT, in and of itself, would be a nearly impossible feat.
• Re-insulate using whatever grade of insulation they install during factory production. 
• Yes, add sheet metal (and sealed with silicone) to seal out ambient air.

BTW:  Such an issue isn't something you'll find many (if ANY) technicians getting involve with.  Normally they'd just suggest replacing the unit.

Have I ever done this?  - NO.  But I have encounter some similar circumstances on commercial (MUCH pricier) freezer systems.  Freezers are a unique challenge when insulating/sealing systems are compromised or done incorrectly.

Could this be a design flaw?  - No way of knowing. 

Have you consulted with GE about the matter?  I don't know how old your unit is, but for a household unit at THAT price range, it sure seems there should be some warranty considerations here.

[Vance R]

Not on a GE refrig. Frigadaire has similar issue where the line for the ice maker evap are too close to the back wall. Ice and rust issues on metal. Their final fix was to send out a 2" thick huge sheet of dense closed cell insulation to cover the whole back.

1 hour ago, ECtoFix said:

Have you consulted with GE about the matter? 

+1

[LadyTech]

Vance, this is a Frigidaire Gallery and not a GE. Your right. This ice is forming at those areas. I also noticed an area inside the freezer near the evaporator, the liner was discolored and cracked as if someone put a heat gun to it. The evap had iced up on that side but normal frost pattern everywhere else, probably from pulling in ambient air.  The ice was on the opposite side of where the refrigerant lines enter. I already condemned the unit at time of service. I did haul it off for them. I like knowing what the exact cause of failure is, and since I have no life other than work, it gives me something to do. Maybe I should just get a life. LoL