> we mist at least once a day
What's the substrate type? Humidity? Usually in racks you don't need to mist but once a week or so, if ever. I never need to mist my tubs. If you're misting several times a day it could be scale rot from substrate that's too damp.
I use PVC to clutter up my tanks and haven't noticed a problem, but check for sharp edges on them. Sometimes there's poky bits.
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