How To Remove And Prevent Rust on Metal

How To Remove And Prevent Rust on Metal

Rusting may easily impact the durability of a metal structure and results in the deterioration of metal core parts. It can make the metal bodies look unsightly and may cost your business thousands of dollars. 

When exposed to moisture and oxygen, metal tends to develop iron oxide popularly known as rust. Rusting is a common problem in ferrous metals containing high levels of iron elements. Rust is an orange-brown discoloration that builds up on the metal and eventually makes metal brittle and flaky. If not taken appropriate measures and care, rust can corrode the deepest layer of the metal and damage the structure beyond repair. 

The entire oxidation process can comprise the strength, appearance, structure, and lifespan of your metal objectives. 

Rust protectants, using non-ferrous alloys, regular maintenance, and more can help overcome rust-related problems and bring more productivity to your businesses. In this guide, we will walk you through ideas to remove rust from metal and some simple rust prevention methods that can add more life to your metal structures. 

How To Remove Rust From Metal?

Now, let us look at some of the most effective and beneficial rust removal methods that you can use to remove rust from your household and other metal equipment. 

  • White vinegar - Apply white vinegar to the infected areas and leave for a few hours. In case of large rust spots, leave the solution for at least 24 hours and wipe it with a soft cloth. 
  • Lime and salt - Apply a sufficient layer of salt on the infected area and rub with half-cut lemon or lime juice to restore the appearance of the metal structure. 
  • Baking soda paste - Mix warm water and baking soda to make a thick paste and apply the same on the infected area and leave for a few hours. Remove the paste using a soft cloth. 

Even after trying all the home remedies, if you are unable to get rid of rust-related problems, seek help from experienced and knowledgeable professionals to add more life to your metal structures. 

How To Prevent Rust?

Most people believe that the only way to prevent rusting is replacing the damaged metal structure with the new one, which is misleading. Rust can be easily prevented using the right rust prevention methods and regular maintenance. Some of the best and most effective rust prevention methods include: 

1. Galvanizing 

Galvanizing is one of the most popular and widely used rust prevention methods. Here, the metal is coated in a protective zinc coating to prevent rusting. The metal is dipped in hot solution or galvanized liquid to evenly spread the solution across the structure. Galvanization refrains oxygen and water from entering the core areas of the structures and damaging them beyond repair. 

2. Apply oil

Oil and water don’t mix up together and hence, applying oil can prevent moisture spots. Regularly oiling the metal structure can help you prevent rusting and stabilize the appearance of your metal structure. Oiling can be a cost-effective rust prevention solution for small businesses that can’t afford expensive alloy metals. Avoid using thick or cooking oils as they might create heavy layers on the metals and consume a lot of time to clean. 

3. Regular maintenance 

Lack of regular maintenance is one of the major reasons why metal structures catch rust and corrode easily. Regular cleaning of your metal structures from moisture spots, dirt, dust, and more can help boost the efficiency of your business equipment and avoid premature wear and tear. Avoid leaving water spots on your metal structure, regularly apply rust-prevention paint, and use a razor blade to get rid of small infected areas. 

4. Powder coating 

Powder coating is the modern rust prevention method used by several industries. In this method, a thin layer of dry powder is applied all over the metal structure and then heated to create a protective liquid layer to prevent rusting. Polyester, nylon, acrylic, vinyl, urethane, and epoxy are popular and widely used powder coating options. The powder coating is applied using a rust-prevention spray process called electrostatic spray. 

5. Organic coating 

Organic coatings are one of the most cost-effective ways of securing your metal from rust-related problems. Oil and other organic solutions are common organic coatings used to prevent rusting. However, if you are looking for a chemically advanced solution, POR-15 rust preventive coating can be one of the best alternatives. 

6. Appropriate pre-design 

Pre-design process plays an important role in boosting the efficiency and lifespan of your metal structures. Proper design planning can allow air to circulate freely around the metal structures and minimize or eliminate the water penetration to reduce the risk of rusting. If this is your first time designing metal structures for your business, consider seeking help from experts. 

7. Bluing 

The bluing rust prevention method is most useful in offering limited protection for small metal items against rust. In this process, the metal sheet or structure is dipped into a solution of potassium nitrate, water, and sodium hydroxide. The process leaves a blue-black appearance on the metal surface, hence the name bluing. The bluing rust prevention method is used to protect firearms, fine clocks, and other small metals to avoid corrosion and rust. 

8. Painting 

Paints can help you protect the metal and restore the appearance of your structure effectively. Regular painting can slow down the rusting process and make your metal look new all year round. For better results, consider using rust-prevention spray solutions after painting your equipment to create a double protective layer. 

9. FOZZ 

FOZZ is another modern rust prevention technique that can be applied after painting your metal to create an extra protective layer. FOZZ is the process of applying a balanced blend of phosphoric acid, wetting agents, extenders, and other chemicals to create a rust-prevention layer on your metal structure. FOZZ is not a paint but a primer applied on the metal after painting a certain portion. 

We hope the above pointers helped you find solutions to all your ‘how to prevent rusting?’ concerns. 

Top Metals That Don’t Rust 

Here are some of the top metals that don’t rust easily and have a longer lifespan than other metals

  1. Aluminum
  2. Brass
  3. Galvanized steel
  4. Stainless steel
  5. Copper
  6. Bronze 


What are the 4 ways to prevent rusting?

You can easily prevent rusting by regularly applying oil to your metal structures, using rust-prevention paint, and rust-prevention spray, and opting for galvanized metals. Additionally, you can also use some home remedies when treating small rust spots or household equipment.

How can rust be prevented permanently?

For permanent solutions, opt for non-ferrous metals such as aluminum, copper, lead, nickel, titanium, and other alloy metals. Cutting the outermost layer or infected area of your metal can also help prevent rust from spreading to other parts of the metal body. 

At Metals Cut4U, we offer customized metal services at affordable prices. Get your metal sheets professionally cut in any shape, size, and pattern of your choice.To learn more about the melting points of metals or our services, call us at 440-822-6381 and speak with one of our representatives.

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