8 Reasons Why You Should Hire a Metal Fabricator
Steel is one of the most used materials in the world. It's used in buildings, bridges, cars, appliances, and even kitchen tools. It's strong, versatile, and built to last. However, one question we often hear in metal fabrication is: Can steel rust?
The simple answer is yes, but not all steel rusts the same way or at the same speed. Steel is mostly made of iron, and when iron is exposed to oxygen and moisture, it forms rust (iron oxide). This reddish-brown layer weakens the metal over time, which can lead to structural damage if not properly managed. However, different types of steel react differently to rust.
For example, carbon steel is highly prone to rust. In contrast, stainless steel contains chromium, which creates a protective layer to resist rust. Galvanized steel is coated with zinc to prevent rusting, and weathering steel (Corten steel) is designed to form a stable rust layer that actually protects the metal underneath.
Understanding how and why steel rusts can help you choose the right type of steel for your needs and keep it in top shape. In this blog, we'll break down the factors that cause rust, ways to prevent it, and what to do if your steel starts to corrode.
Understanding Rust and Corrosion
If you've ever seen a reddish-brown layer forming on metal, that's rust. Rust is simply iron oxide, which develops when iron (or steel, which contains iron) reacts with oxygen and moisture in the air. Over time, this reaction eats away at the metal, weakening its structure.
Rust vs. Corrosion: What's the Difference?
Many people use the terms rust and corrosion interchangeably, but they're not the same. Rust is a type of corrosion that specifically affects iron and steel. Corrosion, on the other hand, is a broader term for the chemical breakdown of metals due to environmental exposure. For example, aluminium doesn't rust, but it does corrode by forming an oxidized layer. Similarly, copper turns green when it corrodes (like on old statues or roofs).
What Speeds Up Rusting?
Several factors can accelerate rust formation, including:
- Moisture (Water Exposure) – Steel rusts faster in humid environments, especially when exposed to rain, condensation, or standing water.
- Oxygen – The more oxygen available, the quicker rust forms. This is why steel exposed to open air rusts more than steel buried underground.
- Salt (Chlorides) – Saltwater environments, like coastal areas, speed up rusting dramatically because salt makes the water more conductive, helping the rusting process happen faster.
- Acids and Chemicals—Industrial pollutants, acid rain, and chemical spills can rapidly corrode steel by breaking down its protective layers.
By understanding these conditions, you can take steps to protect steel from rusting in construction, fabrication, or everyday use.
Factors That Affect Steel Rusting
Rust is more than just an eyesore—it weakens steel, compromises structural integrity, and shortens the lifespan of metal projects. Over the years, I've worked with all types of steel in different environments, and I've seen how quickly rust can take hold if the right precautions aren't in place. Here's what makes steel rust faster and how to stop it.
Environmental Exposure
Steel exposed to humidity, rain, and salty air rusts at an alarming rate. I've worked on outdoor steel structures near the coast, where rust started forming in just weeks because of the salt in the air. Even high humidity in warehouses can cause surface rust on raw steel if it's not stored properly.
Chemical Exposure
Certain chemicals eat away at steel, making it more vulnerable to rust. I've seen cases where industrial fumes, acid spills, and even harsh cleaning agents have stripped protective coatings, exposing the bare metal underneath. In fabrication shops, steel near welding fumes or cutting fluids can also develop rust spots if not cleaned properly.
Coating and Protection
A good protective layer makes all the difference. I've worked on steel parts that stayed rust-free for years thanks to paint, powder coatings, and epoxy finishes. On the other hand, I've also seen what happens when coatings get scratched—rust starts creeping in almost immediately, especially in damp conditions. Galvanization (zinc coating) is another great method. I've handled galvanized steel left outside for years, and even when scratched, it holds up far better than untreated steel.
Alloy Composition
Not all steel rusts the same way. Stainless steel, which contains chromium, holds up well even in damp environments. I've worked with 304 stainless steel for general fabrication, and it resists rust well unless exposed to saltwater. 316 stainless steel, with its added molybdenum, is my go-to choice for coastal or chemical-heavy environments—it simply doesn't rust like regular steel.
How to Prevent Steel from Rusting
Keeping steel rust-free takes a combination of the right materials, coatings, and maintenance. Here's what has worked best in my experience.
Apply Protective Coatings
Paint, powder coatings, and epoxy create a solid barrier against moisture. On past projects, I've seen painted steel last decades without rust, but only when the coating was properly applied and maintained. Scratches or chips need quick touch-ups, or rust will start spreading underneath.
Use Galvanized Steel
Galvanized steel is one of my top choices for outdoor applications. The zinc coating acts as a sacrificial layer, meaning it corrodes before the steel does. I've worked with galvanized steel fencing and roofing that has lasted over 20 years with minimal rust, even in harsh conditions.
Choose the Right Stainless Steel
I always recommend stainless steel for jobs where steel is constantly exposed to moisture. 304 stainless steel is good for most indoor applications. Still, for anything near the ocean or in industrial settings, 316 stainless steel is the way to go. I've seen lower-grade stainless steel rust in coastal areas because it lacked the right alloy composition.
Perform Regular Maintenance
Regular cleaning and applying rust inhibitors help extend steel's lifespan. I always advise clients to wipe down steel surfaces, keep them dry, and apply protective oils on exposed metal parts, especially in humid environments. Even a simple coat of WD-40 or machine oil on tools can prevent surface rust.
Reduce Environmental Exposure
Steel should be stored indoors, covered, or protected from constant water exposure whenever possible. I've seen steel beams last decades when properly stored, while similar beams left out in the rain rusted beyond repair within a few years. If steel has to be outdoors, good drainage and proper design to prevent water pooling make a huge difference.
From workshop tools to large-scale steel structures, rust prevention is all about choosing the right materials, applying the right protection, and keeping up with maintenance. When done right, steel can last for decades without major corrosion issues.
What to Do If Steel Rusts? (First-Hand Solutions from a Metal Fabricator)
No matter how well steel is protected, rust can sometimes form. I've dealt with rust on everything from small metal parts to large structural beams, and the key is to act fast before it spreads. Here's what works best for removing rust and restoring steel.
Mechanical Rust Removal
For surface rust, the quickest way to clean steel is with abrasive methods:
- Sanding – Fine-grit sandpaper works for light rust spots, especially on smooth surfaces.
- Grinding – For heavier rust, I use an angle grinder with a flap disc or grinding wheel.
- Wire Brushing—A stiff wire brush (manual or attached to a drill) removes loose rust and prepares the surface for treatment.
I've used these methods on rusted gates, machinery, and tools, and they work well. However, they also remove a layer of metal. A softer approach is better for delicate pieces.
Chemical Rust Treatments
If grinding or sanding isn't an option, chemical rust removers work well.
- Rust Converters – These turn rust into a stable, paintable surface. I've used them on metal fences and machinery when full rust removal wasn't practical.
- Acid-Based Removers—Phosphoric acid or vinegar effectively breaks down rust. I've soaked small parts in vinegar overnight, and they come out clean with minimal scrubbing. Commercial rust removers work faster for larger surfaces.
Always neutralize acids after use, or they can weaken the metal over time.
Electrolysis for Small Parts
For rusted bolts, tools, or small metal components, electrolysis is an excellent, hands-off solution.
- A water and baking soda solution, combined with a power source, removes rust without damaging the metal.
- I've used this method on rusted wrenches and old steel brackets—it pulls the rust right off, leaving clean, solid steel underneath.
Restoration and Recoating
Once rust is removed, the job isn't done. Steel must be protected to prevent rust from returning.
- Primer & Paint – A rust-inhibiting primer and high-quality paint seal the metal.
- Oil Coating – For tools and machine parts, a light coat of oil prevents moisture from settling in.
- Galvanization or Powder Coating – If possible, a more permanent protective finish ensures long-term rust resistance.
I've seen too many cases where rust was removed, but no protection was applied—within weeks, it was back. Treating steel properly after rust removal makes all the difference in keeping it rust-free for the long run.
FREQUENTLY ASKED QUESTIONS
Conclusion
Steel is one of the strongest and most versatile materials. However, it’s not invincible—rust can weaken it if left unchecked. While all steel has the potential to rust, the risk depends on its composition, environment, and level of protection. The good news is that rust can be managed and even prevented with the right coatings, maintenance, and material choices.
Working with steel, I’ve seen how proper care—like using rust-resistant alloys, protective coatings, and routine maintenance—can significantly extend its lifespan. If rust does appear, acting quickly with the right removal and restoration techniques will keep steel in good condition. Whether you’re working with construction materials, machinery, or household items, understanding how rust forms and how to stop it ensures your steel lasts for years to come.