How to remove rust: step-by-step DIY guide

Rust starts with an orange spot and can spread quickly. If you tackle it in time, metal stays usable and good-looking. In this blog you will read how to remove rust from fencing, hinges, tools and other metal parts and how to protect the metal afterwards.

⚠️ Sanding and brushing off rust produces dust and small particles. Always wear safety glasses, gloves and a dust mask. Is the rust on a load-bearing structure, or is the metal already badly weakened? Have a professional assess it. A professional is never superfluous with structural parts.

What do you need?

Materials

• A Fila No Rust rust stain remover for rust stains on hard surfaces. Follow the manufacturer's instructions.
• A flat brush for lacquer and a suitable anti-rust paint or coating to protect the metal.
• blue painter's tape and masking film to cover the surroundings.

Tools

• A four-row wire brush, a paint scraper or multifunctional scraper to remove loose rust and paint.
• sanding block grit 120 and sanding block grit 220 for sanding.
• A ABS sponge float and an 12-litre bucket for cleaning.

Personal protective equipment

• work gloves with nitrile coating, safety goggles and a FFP2 dust mask.

Preparation

Decide how deep the rust goes. Surface rust can be brushed and sanded, deep rust can weaken the metal. Cover the surroundings and work in dry weather. Read the instructions of the rust remover manufacturer and test it on an inconspicuous spot first.

Step by step: how to remove rust

1. Remove loose rust and flaking paint with the wire brush or scraper.
2. Sand the surface until you see bare metal, first coarse and then fine.
3. Dust off the metal and clean it with a sponge and water. Let it dry completely.
4. If needed, use the rust remover on stains and rinse afterwards according to the instructions.
5. Apply the anti-rust paint or coating with a brush in thin layers.
6. Let everything dry before you use the metal again.

💡 Treat the metal as soon as possible after sanding. Bare steel starts to rust again within a short time.

Common mistakes

• Removing only the visible rust and not protecting the substrate.
• Working without safety glasses and a dust mask.
• Painting on a wet surface.
• Sanding too hard and damaging the metal.

Working safely

Wear gloves against sharp edges and chemicals, safety glasses against particles and a dust mask. Work in a well-ventilated space and always read the label of the product. You will find more safety tips in our blog on safe working on the construction site. Read more about painting and brushes in our blog on paint rollers and brushes, and about masking in our blog on masking tape and protective film.

Read also: How to paint a radiator and How to paint a door

Frequently asked questions

Can I remove rust from a fence myself?

Yes, brushing, sanding and protecting is something a DIYer can do well.

When do I call a professional?

With badly rusted structures or load-bearing parts, or if you doubt the strength of the metal.

How do I stop rust coming back?

By applying a suitable anti-rust paint or coating after sanding and checking regularly.

Where can you find everything for this job?

At Saniso, the online store for DIYers and professionals, you will find tools, materials and personal protective equipment for your job.

• Browse our construction tools and our workwear and safety.
• Create a customer account and order easily.
• Working on a bigger project or want to hand over the job? Request a project quote.
• Book a showroom visit, at least 24 hours in advance.
• Not sure which material suits your job? Get in touch with us.

In doubt about the approach? Feel free to call in a professional.

Saniso – Build your home with Saniso.