Powder-coated parts often suffer exposure to harsh outdoor environments, where moisture and sunlight cause damage over time. You can do several things to keep powder-coated components in better condition for longer. First, you must understand the factors that can cause rusting with a powder coat, then take measures to lower the chances that it will occur.
Will a Powder Coat Rust?
While a powder coating doesn’t rust, the metal under it does, making the finish appear rusted as well. The metal underneath a powder coat rusts when water seeps under the protective layer or when excessive sunlight damages it. You might see rust streaks, which aren’t necessarily dangerous to the metal, or rust spots, which can damage a piece’s structural integrity.
Why Is My Powder Coat Rusting?
Your powder coat might rust for several reasons. If the part begins to deteriorate in less than five years, it could be a result of poor powder application. The metal may have had dust and oils that weren’t entirely removed during pretreatment, causing the powder coat to adhere less firmly. As the protective layer breaks down in those areas, it leaves room for water to enter and degrade the metal. Sometimes, a coating has invisible gaps that are impossible to detect until water enters them and causes rust.
A powder coat can also rust due to exposure to harsh environments like rain, snow and beating sun. These environmental factors can break down the weakest parts of a coating, like corners or bends that typically receive less coverage. As the coating flakes away, water and corrosive elements like salt directly touch the metal.
How to Prevent Powder Coat Rust
Protecting a powder coat begins with the application process. The more thorough the application, the fewer imperfections a piece will have. With fewer imperfections, the part will be less exposed to environmental factors. You can also protect against dings and use a gentle cleaning agent to avoid breaking down the coating after it has been applied.
Since surface preparation and coating thickness significantly impact durability, professional application is critical. The metal surface should undergo thorough cleaning and pretreatment to ensure optimal adhesion. Most professionals will use a primer for additional protection, especially for parts exposed to severe weather conditions.
Although regular maintenance is essential for extending the life of your powder-coated surfaces, too much cleaning can cause excessive wear and erosion. Establishing a routine at the beginning of each season to remove salt, dirt and other contaminants with a pH-neutral cleaner and soft cloths should be sufficient. You must avoid using abrasive materials or harsh chemicals that could scratch or weaken the protective layer.
Design modifications can help prevent rust formation in outdoor installations. To prevent moisture buildup, ensure proper drainage, avoid water collection points and install components with adequate ventilation. Routine inspections can also help identify minor issues before they develop into larger problems.
How to Fix Powder Coat Rust
When a powder coating begins to break and allows the metal underneath to rust, the best way to fix it is to remove the rust and recoat the metal. This process involves blasting the rust off, smoothing the edges around the rusted areas, then pretreating and coating the piece as normal.
It is crucial to repair a rusted area immediately since the rust can rapidly spread. When ignored, rust can cause significant damage to the underlying metal and lead to flaking, exposing the part to further corrosion. Restoration requires careful attention to detail and extensive expertise. A professional must thoroughly assess the damage to determine the most practical repair strategy if it is repairable.
The surrounding areas must have proper masking and protection to produce a clean, smooth finish. Since hidden rust can continue to spread under a new coating, all rust must be removed before recoating the area. Using several thin layers of coating to build up the damaged area to the part’s overall thickness helps ensure the coating’s structural integrity and prevent future failures.
Why Trust Keystone Koating for Your Powder Coating Requirements?
Experience and expertise matter when choosing a powder coating company. Keystone Koating brings decades of proven excellence to each project. Technology like our innovative eight-stage pretreatment system sets us apart from the competition by delivering superior adhesion and long-lasting results that protect your investment.
Superior quality is the core of our operation. Each project undergoes rigorous inspections at multiple stages, from surface preparation through final curing. Our certified technicians regularly undergo advanced training to stay current with industry advancements.
We invest in state-of-the-art equipment while maintaining multiple production lines to handle projects of all sizes. These capabilities enable us to extend cost-effective pricing without sacrificing product quality. Our commitment to superior customer service means we work closely with each customer to understand their unique needs and develop a personalized solution.
Keystone Koating Provides Powder Coating Services
At Keystone Koating, we use a comprehensive coating process to achieve an ideal finish for your piece. We even have optional upgrades to provide better protection against weather and ultraviolet light. Contact us for a quote on your powder coating needs.
Updated December 16, 2024. Originally published March 7, 2023.