No one loves rust. It’s just an annoyance, one that’s inconvenient at best, and equipment-ending at worst. Luckily, sandblasting is one of the most effective methods for stripping a surface back to bare metal for re-treatment. The purpose of sandblasting is to remove paint, scale, contaminants (including deep-seated surface rust), and provide a clean base for coating, welding, or repair.
But here’s something many people overlook: before blasting, you need to deal with rust. Skipping this step can make the whole process less effective and, in some cases, even damage the surface you’re trying to restore.
If you work in manufacturing, vehicle restoration, or heavy equipment maintenance, understanding the importance of rust removal before sandblasting can save you a whole lot of time, money, and frustration.
What Rust Actually Does to Metal
Rust is a type of corrosion that happens when iron or steel reacts with oxygen and moisture. Over time, it eats into the metal, creating pits and flakes that give rise to the classic rusty appearance you’ve likely seen before. However, it’s not just a visual issue; this also weakens the material structurally and leaves behind an uneven surface.
When you sandblast over rust, the abrasive particles may remove some of it, but they also tend to push rust deeper into the pits. Instead of eliminating the problem, you can end up sealing contamination into the surface. That contamination then undermines any paint or protective coating you apply afterwards.
This is how flash rust occurs, which is why we are so careful with our approach when doing rust removal before sandblasting and recoating a surface once we are done.
Put simply, if the rust is still present once the sandblasting is complete, then the job has failed.
Why Do Rust Removal Before Sandblasting?
The primary purpose of sandblasting is to prepare a surface for its next stage, whether that involves painting, powder coating, or structural repair. However, for sandblasting to do its job properly, the surface underneath must be sound.
Rust removal before sandblasting is beneficial for several reasons.
For one, you get better adhesion for paint, primers, and protective coatings to stick to clean metal. If rust is left in place, coatings will eventually bubble and peel. You’ll also notice a more even finish, as sandblasting over a large area of surface rust can leave the surface patchy.
But perhaps most importantly, you’ll notice less wear on your equipment. Rust particles are harder and more irregular than paint. Blasting them deep into the metal’s surface can invite flash rust, so taking the time to remove large pieces of surface rust beforehand can actually make blasting even more effective.
How We Remove Rust Before Sandblasting
There’s no single method for removing surface rust before sandblasting. Remember, sandblasting is designed to remove rust from a surface, but pre-treating with rust removal makes this process even more effective. The right approach will depend on the severity of the corrosion and the type of metal being worked with.
Some of the most common approaches include mechanical cleaning, chemical rust removers, or even hand tools like chisels for smaller jobs.
Once the worst of the corrosion is gone, our sandblasting can then smooth the surface and prepare it for a protective coating that will keep that rust away.
Why Sandblast After Removing the Rust?
It might seem like, once the flakiest parts of the rust are gone, that sandblasting is no longer necessary. But with the rust cleared away, sandblasting becomes a vital finishing tool. The blast media scours the surface, leaving behind a uniform texture that coatings love to stick to. This texture, known as “profile,” is our gold standard for ensuring coatings adhere for a long time.
We ensure that rust removal is done before sandblasting, where necessary, as we notice an immediate difference in the blasted surface, paint application, and the finished job.
In some situations, sandblasting alone is more than enough. However, in some cases, rust removal is a vital step first.
Why we take this so seriously:
In industries such as heavy equipment maintenance, marine work, or vehicle restoration, rushing the preparation stage is a false economy. A poor finish means recoating or reworking sooner, which doubles the cost and downtime for you (or creates a need to replace the equipment altogether).
This is why our assessment is so important. It allows us to know when to emphasise rust removal before sandblasting as part of the process, which means no callbacks, wasted materials, or issues.
For businesses, this means equipment and assets that stay in service for longer periods. For restorers, it means vehicles and machinery that look better and hold their value. And for anyone relying on sandblasting, it means getting the job done properly the first time.
Have your surfaces assessed and prepared by our expert team.
At Hamilton Blast & Paint, we are here to help our local industrial partners maintain their equipment with ease. Contact us about on-site sandblasting and rust removal for your equipment today.