How to Paint Rusty Railings

Co-authored by Patrick Coye

Last Updated: June 18, 2022 References Approved

Metal railings become rusty as their protective coats wear off. To restore metal railings to good condition that will last for many years, you must first remove the rust and paint the railings with primer. You can remove the rust well without spending too many hours if you use the right tools and the right method. ^{[1]
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Expert Source

Patrick Coye
Painting Specialist
Expert Interview. 22 July 2020.}

Steps

1
If the railing is large, work when you have two consecutive dry days to work.
- You could spend most of the first day scraping off the old paint.
- If on the first day you only scrape, you must paint the second day, or at least before the next rain.
2
Cover the area around the railings carefully. Use drop cloths for larger spaces and painter's tape for smaller spaces.^{[2]
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Expert Source

Patrick Coye
Painting Specialist
Expert Interview. 22 July 2020.}

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3
Wear protective clothing. Wear long pants and a long-sleeved shirt. Put on safety goggles and a dust mask before starting any work. Metal flakes will be scattered as you prepare the metal. If you use a wire brush grinder, pieces of wire from its wheel may fly off.^{[3]
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4
Mix a solution of half vinegar and half water in a bucket.
- You can also use diluted, mild detergent.
5
Scrub the railing thoroughly with your cleaning solution. This should remove dirt and remaining rust.
6
Rinse the railing and allow it to dry before continuing.
7
Scrape the straight sections with a sharp wood chisel or a wire brush to remove all rust and loose paint. Sharpen the chisel periodically with a belt sander or a metal file.^{[4]
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- Scrape off spiraled railings, ornate areas, and areas where one piece is welded to another using a wire brush attachment on a drill, or an "angle grinder" with a wire brush attachment. These are the only good ways to remove the rust. Eye goggles are necessary. Angle grinders are the best tool to remove heavy rust.
- Scrape out rust and loose paint from the bases of the railings, where they are mounted into the concrete. Water collects here and causes the railings to rust, often badly. ^{[5]
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8
Sand the surface of the railing with medium-grit sandpaper. Medium grit is between 80 and 120 grit. This is called scuff-sanding and it should take gloss off the surface and allow the primer and paint to bond more easily.^{[6]
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Expert Source

Patrick Coye
Painting Specialist
Expert Interview. 22 July 2020.}
- Sand rough spots with coarse sandpaper, from 40 to 60 grit.
9
Rub the surface of the railing with a tack cloth to remove dust from sanding.
10
Apply rust-inhibiting primer immediately after sanding and wiping the rail. This is sometimes called "direct-to-metal" primer. Some products are called "rust arrestors". First apply your coat of paint, then brush it into the crevices before it dries.^{[7]
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11
Check your primer's directions on how long it must dry before your second coat. Once again, use a brush to get into all the crevices of the metal railing.
- If you don't finish in one day, apply primer and paint the next day to prevent the bare metal from rusting. Don't paint before 10:00 AM because the railings could be damp from morning dew.
12
Allow the primer to dry according to the product's directions.
13
Apply the topcoat.^{[8]
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Research source} You can use a spray can, 4" roller or brush. Brush the coat with a paint brush to remove any drips and get into the crevices.
- Many people prefer to use semi-gloss or high-gloss paint for their topcoat. These finishes add a shine to the railings and can make them easier to clean.
14
Allow the topcoat to dry completely.
15
Apply a second coat if you choose to, for longer protection..
16
After the topcoat has dried, apply caulking around the bases of the railings where they enter the concrete. Water collects here and causes rust.
17
Clean the brushes according to the paint can's instructions.

Expert Q&A
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Question

How can I prevent more rust from forming when painting?

Patrick Coye
Painting Specialist
Patrick Coye is the owner and operator of Patrick’s Painting & Home Improvement in Alexandria, Virginia. With over 15 years of experience in residential construction, Patrick specializes in painting, wallpaper removal/installation, drywall, staining decks and fences, and kitchen cabinetry painting. To date, Patrick and his team have painted over 2,000 houses and stained over 800 decks. Patrick's Company won a "Top Job" award from the American Painting contractor magazine in 2020.

Patrick Coye

Painting Specialist

Expert Answer

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Any type of oxidizing primer is going to be best to inhibit the growth of rust.
Question

The railing is rusted and pieces of the metal flake off, leaving different uneven levels. How do I fill the low levels to make it smooth again?

Community Answer

You don't fill them in. You sand them even. You can also use a wire brush to get off as much of the flakes as possible.
Question

Is there a particular type of vinegar that I should use?

Donagan

Top Answerer

Any kind is fine. White vinegar's a little cheaper.

Warnings

Don't inhale rust or metal flakes. Wear a dust mask to avoid harm to your respiratory system.

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Paint only when the temperature is within the limits given on the can, and when the if the humidity is not unusually high.

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Don't paint before 10:00 AM. The railings will be damp with morning dew.

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