How to Remove Rust from Metal in Factories & Industrial Sites

Rust can present a significant risk for your industrial site – in more ways than you think

Rust may seem like a minor inconvenience at first glance, or may be docked as a low priority issue if it’s in an out of the way place, but it can be a major hazard. Rust can weaken metal structures if left to spread, or at the very least be unsightly for your visitors and customers.

In extreme cases, it can impact the performance of your machinery or lead to compliance issues with contamination or risks of structural collapse. 

That’s why it’s extremely important to protect your industrial assets from rust before it has a chance to form. Or, in cases where rust has developed, to treat it quickly with a method that’s best suited to the case at hand, with consideration to both the type of surface and the condition of the rust. 

How does rust form?

Rust forms naturally through a process called oxidation. It occurs when iron or its alloys (like steel) are exposed to moisture and oxygen over time. Corrosion, on the other hand, can include rust but includes any type of metal or non-metal oxidation, whereas rust refers only to iron oxidation. 

Iron oxide (rust) slowly eats away at the metal causing pits and cracks, which weakens the structural integrity over time and even leads to holes and gaps in the metal. 

High humidity, chemical exposure and higher temperatures can increase the rate at which rust develops; all of which are obviously present in industrial environments where conditions can be harsh.

Understanding how rust is formed and how the process is accelerated in industrial environments is important for putting together a prevention plan and, if necessary, repairs and mitigations for the future.

Rust can easily develop across your industrial site if precautions aren’t taken

Whether it’s on pipelines, storage tanks, machinery or steel infrastructure, rust can spread quickly once it starts. We find that industrial rust is most common on machinery and infrastructure built a decade ago and beyond, where rust prevention may not have been thought of when it was installed, or where prevention coatings like galvanising or painting have degraded over the years. 

Regular inspections of your industrial assets are important to keep on top of, so that you know what areas of your site are at most risk, and which areas are of high priority. It’s easy to become complacent or lose track of areas that might be at risk, especially with larger sites. 

Of course, it’s easier to prevent rust from forming if precautions are taken at the time of installation, as we’ll talk about below. Or, if the damage has already been done, it’s best to treat the area with rust-resistant methods to protect it from coming back in the future.

7 different ways to remove rust from metal

5 different ways to prevent rust

1. Galvanising

• Dip or coat the metal in a thin layer of additional metal, usually zinc or another metal that’s more reactive than iron .
• The galvanising layer will therefore oxidise instead of the iron underneath, protecting it.
• Surfaces can be dipped in galvanising solution or sprayed in situ with professional specialist kit.

2. Painting

• Painting adds another layer of protection to the metal that moisture needs to get through before it can affect the iron or steel.
• Rust inhibiting industrial paint adds an extra layer of protection that addresses the rust directly.

3. Regular maintenance

• Keep close eye on areas where rust is forming or shows signs of forming, as it can be easier to treat in small areas.
• Keep an eye on where paint, galvanised areas or other anti-rust coatings might be failing or degrading.
• Keep areas clean and free of grime build up.

4. Lubricant

• Lubricating the metal creates a barrier between the surface and any moisture or oxygen in the air.
• However, this is obviously not a permanent solution and needs to be applied regularly.
• Surfaces will become dirty very quickly.
• Lubricants are perhaps only a feasible option for moving machinery.

5. Rust inhibitors and converters

• Rust inhibitors and converter are chemicals that create a barrier between the metal and the air, preventing oxygen and water from reaching the surface.
• They are available in various forms:
  • Rust inhibiting paint
  • Rust converter chemicals
  • Rust inhibiting oil

The rust removal and treatment method we think is best

We use needle guns (also known as needle scalers) for our projects as they effectively remove paint and loose rust from metal surfaces prior to painting. While they may not take the surface back to bear metal, if you use the correct primers and rust-inhibiting paints, then you don’t need to. 

We believe that rust is best removed and treated with a combination solution. We use needle gun scaling on account of its health and safety benefits when compared to shotblasting, acids or other methods of removing rust. We then treat and prepare the surface for painting with a rust inhibiting converter that creates a barrier between the metal and the paint; essentially, a paint primer that effectively destroys and converts rust. We then paint the surface with rust-inhibiting paint for a further layer of protection.

We believe that this method provides the best balance of a high standard of rust removal and protection, alongside maintaining health and safety. While there are many methods of effective rust removal like shotblasting and acids, the health and safety risks make these too dangerous when weighed against the results. 

Industrial rust removal and prevention needs to take into account the stage of rust corrosion, where the rust is (for instance, in hazardous areas like industrial basements or at high level), and how the subsequent waste will be disposed of. 

Partnering with an industrial cleaning and painting company can offer you the best combination of removal, treatment and painting to both repair and protect your rusted surfaces at the same time. Having the right company on your roster also frees up your team to do the jobs they’re meant to do.