Maintaining a rust-free palisade fence is crucial for preserving its structural integrity and aesthetic appearance over the long term. These tall, spiked fences made of steel or wrought iron are a popular perimeter fence choice in the UK, but also prone to rusting in the cool, damp climate. The main causes of palisade fence rust include exposure to rainfall and moisture, as well as scratches or damage to paint coatings that allow oxygen and water to initiate corrosion on the metal surface. Periodic inspections followed by proper cleaning and rust removal techniques can add years of life to a fence vulnerable to the elements. Investing some labor at the first signs of rust spots pays dividends through minimized cost and time for repairs down the road.
Fencing contractors are often consulted for professional advice on how to prevent and mitigate rust issues, as they possess specialized knowledge and experience in dealing with various types of fencing materials and their maintenance requirements.
Tools and Materials
List of essential tools and materials followed by an explanation of each item’s purpose in the rust removal process.
Taking on a palisade fence rust removal project requires gathering a few key tools and supplies:
- Wire brush – This abrasive brush is ideal for scrubbing off surface rust from the fence panels using manual friction. Wire brushes come in a range of bristle thicknesses based on how severe the rust is.
- Sandpaper – Assorted grits of sandpaper help remove larger rust spots and smooth the metal surface after brushing. Coarse 80-100 grit works for heavy corrosion, while higher 220-400 grit puts a polish on light rust areas.
- Rust converter – Rust converters chemically treat and transform rust into an inert protective barrier. Brush or spray it on for superior corrosion protection.
- Protective gear – Gloves, safety glasses, and work clothes keep hands from getting scraped up and eyes from being exposed to rust particles and chemicals. A particle mask also helps when dealing with airborne contaminants.
- Paint and primer – Quality primer coats the sanded metal for the best paint adhesion results. The top enamel paint finishes the job in any preferred color while preventing future rust formation.
A well-equipped toolbox allows you to thoroughly remove rust from fence posts, rails, and fittings while protecting yourself along the way. The right pairing of manual abrasion tools with chemical converters and protective sealants helps accomplish the end goal of stopping rust in its tracks and preventing repeat occurrence.
Assessing the Rust Damage
Tips on inspecting the fence closely to gauge the rust severity, as deeper corrosion necessitates more intensive removal procedures before painting.
Before diving into cleaning and painting, take time to methodically inspect the fence line and identify all areas of rust buildup. Carefully look over posts, palings, rails, brackets and hardware. Pay special attention to junction points between metal parts which are prone to rust. Use the findings from this inspection to categorize each affected area as having either surface, moderate or severe (deep) levels of corrosion:
- Surface rust – This presents as light scaling or pitting confined to the outer metal layer. You may be able to pick these flaky rust spots off with your fingernail.
- Moderate rust – More prominent blisters that penetrate deeper and cannot be removed by picking. The original metal shape and structure remains mostly in tact.
- Severe rust – Flaking, bubbling, cracks and extreme metal deterioration often down to the core infrastructure. Severe cases call for replacement parts after intensive repairs.
Make notes on spots that require extra preparation such as peeling old paint near rusted areas or structural points needing repairs before painting. Addressing these facilitators allows rust treatments to penetrate and protect deeper while you still can before the corrosion compromises fence stability. Catching this progression early keeps future headaches at bay.
Preparing the Work Area
Environment, workspace and personal setup tips for safely and effectively removing rust from the fence.
Outdoors fence care projects require some forethought into the work conditions that promote safety and productivity:
- Choose mild weather without rain, overly sunny/hot days, or strong winds that frustrate progress. Work under shade as possible.
- Clear away shrubs and decorative items touching the fence for unobstructed access.
- Cover nearby vehicles, play equipment, furniture and structure walls from chemical dripping or spray residue.
- Lay drop cloths underneath the fence project zone to save the lawn and garden beds below.
- Wear old work clothes and closed toe shoes. Don safety glasses and chemical-resistant gloves once the project begins.
- Set up tables or carts for neatly organizing all your tools, brushes, sandpaper, paints, rust converter and other chemicals within easy access from the project workspace. Establish a systematic work flow pattern.
Taking protective steps for landscape items near the project site prevents making collateral damage from the intensive repair work. Establishing an efficient workspace allows you to fully focus on the fence rust removal at hand.
Rust Removal Techniques
Step-by-step processes for using manual abrasion and chemical rust conversion to thoroughly remove corrosion from the fence surface.
With the prep work fully complete, move systematically down the fence making steady progress addressing every area tagged during inspection. Focus on fully removing all rust down to shiny, smooth metal able to accept protective paint.
Eliminating Surface Rust with Wire Brushes
Here is the process for operating manual wire brushes:
- Put on gloves and safety glasses – brushed particles become airborne.
- Select a brush width able to span the surface for efficient scraping motion.
- Position body in stable stance or ladder for freely scrubbing with both arms.
- Adjust pressure based on rust severity; heavy layers need more force.
- Maintain a 45° brush angle to avoid excessive digging into good metal.
*Use short, tight circular motions to breakup and sweep away rust. - Pause periodically to bang brush against solid object to eject rust buildup caught in the wires.
- Focus on same spot repetitively until all rust lifts off and only gray metal remains.
- Collect all loosened rust debris with a vacuum or broom for proper hazardous waste disposal.
Take a final pass assessing spots possibly needing further attention like hairline rust traces in crevices. Switch to angled detail brushes for precision on nuts, bolts and brackets.
Removing Moderate Rust with Sandpaper
Sanding tackles more prominent corrosion levels:
- Wear a protective particle mask and eye wear.
- Begin sanding using lower 80-100 grit paper to rapidly strip off rust.
- Progress to higher 220+ grit papers for smoothing away etching and pits until original surface appears.
- Fold sandpaper into smaller profiles to increase pressure on difficult spots.
- Swap out clogged paper for fresh sheets to retain abrasion effectiveness.
- Angle sanding motion in direction of the grain to prevent deep scratch marks.
- Completely sand down to untarnished metal for paint adhesion.
- Carefully vacuum up metal filings which are hazardous when inhaled or left on the lawn.
Switching between coarse and fine papers removes all traces of rusts of varied depths across affected zones.
Applying Rust Converters
For the most robust results against aggressive rust, apply a converter coating after cleaning:
- Wipe away all dust or debris from sanding using clean, dry rags.
- Mask off adjacent surfaces not needing protection.
- Read product instructions carefully and test on inconspicuous area first.
- Apply converter by brushing evenly onto all former rust-infected zones.
- Allow to dry fully per manufacturer directions. Product turns dark purple when cured.
- Apply a second coat on extremely corroded areas, allowing dry time between each.
- Once fully cured, the converter seals and strengthens the surface against new corrosion forming.
Conscientious surface prep combined with converter chemistry bonds a reinforced shield across vulnerable metal.
Highlighting the importance of thorough and meticulous rust removal across every inch of fence surface needing attention. There are no shortcuts to lasting results.
Painting and Sealing
Process for properly priming and painting the fence after repairs, followed by application of protective sealant. Proper finishing steps lock out moisture and oxygen from creating new rust.
After eliminating all signs of rust and corrosion, the fence still needs protective finishing to shield exterior steel parts from rain exposure or abrasions that remove paint over time:
Applying Primer
The success of the paint job relies on careful prep application of quality primer:
- Select exterior grade, anti-corrosive metal primer compatible with chosen top-coat enamel.
- Stir primer thoroughly and pour into roller pan. Use angled brush for hard to reach spots.
- Apply a uniform primer coat across all metal parts cleaned of rust residues.
- Allow to dry fully per manufacturer directions prior to adding top paint layers.
- Primer seals surface pores and facilitates paint adhesion for long-lasting hold.
Painting the Fence
With primer cured, now paint the fence:
- Choose durable 100% acrylic latex or oil based enamel for best exterior performance.
- Pour paint into tray and fully load roller sleeve or pad applicator. Use angled brushes for precision work.
- Apply paint in smooth, even strokes from top to bottom of fence line. Maintain wet edge border where new paint meets existing to prevent lap marks.
- Work systematically across pickets, posts, cross beams and hardware for complete coverage. Go back for second coats on absorptive areas once dry.
- Allow painted fence to cure for several days adhering to manufacturer guidelines before exposing to rain or potential scratching from yardwork nearby.
The final step after painting secures a shield against moisture and oxygen which degrade paint and exposures metal to rusting dangers:
- Select durable exterior grade sealant designed for metal that allows the coating colors to show through.
- Thoroughly mix sealant if needing dilution. Carefully follow instructions.
- Use brush or spray applicator for full thin coat across all fence parts, corners and crevices.
- Allow sealant to dry per manufacturer directions. Second coat offers optimal corrosion and abrasion protection.
- Reseal fence surface with fresh application every 2-3 years.
Proper prep with comprehensive paint coverage and sealed protection maintains the fence barrier security and aesthetic for maximum longevity. Performing a full rust removal and repainting annually saves exponentially on potential costly repairs down the road resulting from delayed care.
Frequently Asked Questions
What causes rust on palisade fences?
Common causes of rust on palisade fences include damage to paint or galvanization from normal wear and tear exposing metal to moisture, particularly in damp climates like the UK. Scratches, dings and worn spots create points of entry for oxidation. Road salts and fertilizer spray hitting fences introduces contamination. Additional factors range from acidic atmospheric pollution to heavy rains and naturally occurring metal deterioration over the long term.
Can I use household items for rust removal?
Technicians caution against using home items not designed for working with rust and metals. Vinegar, citrus acids (lemon juice), commercial rust removers and naval jelly work with light surface rust. Salt solutions made of molasses or laundry detergent help lift deeper rust layers but still require sanding to smooth. Damaging acid etch marks may remain. Wire brushes and sandpaper alone often prove ineffective for moderate to severe palisade fence rust and corrosion. Seek products made specifically for metal restoration.
How often should I inspect and maintain my palisade fence?
A palisade fence should be inspected at minimum once yearly for signs of rust formation or spots where paint finish appears compromised. Addressing light surface rust when caught early prevents escalation into deep metal perforations over subsequent seasons. Clean and paint fences showing wear every 2-3 years or whenever scratches or stains appear. Harsh oceanfront or industrial sites warrant inspections every six months. Establish a routine seasonal inspection and care ritual for long-lasting palisade fence protection based on climate and exposure threats in your region of the UK.
Is it possible to prevent rust from forming on a palisade fence?
While outdoors palisade fences stand inherently vulnerable to rust over their lifetimes, owners can take proactive preventative care measures:
- Use top-grade rust-inhibiting primers and exterior latex or enamel paints to protect galvanized and bare metal parts. Reapply fresh coats every 2-3 years before major stripping occurs.
- Wash off fertilizers or lawn chemicals contacting the fence before they eat at protective finishes.
- Check for and repair scratches, dings or cracking paint allowing moisture access through the barrier.
- Spray metal parts with corrosion inhibiting wax- or oil-based sealants as an added moisture barrier. Reapply annually.
- Consider aluminum, vinyl or composite fence materials highly rust resistant compared to galvanized or bare steel.
Conscientiously addressing weaknesses when spotted controls damage from cascading into expensive restoration later.
Are there professional services available for rust removal on fences?
Savvy homeowners lacking tools or skills for intensive palisade fence rust removal and painting projects can hire reputable local trades companies offering these specialized services. Qualified metalwork technicians equip with commercial-grade pneumatic wire brushes, sandblasters, rust converters, primers, paints and sealant applications for superior corrosion protection compared to individual amateur results. Professionals also train on working safely while handling hazardous contaminants generated in the process. Search for bonded and insured companies known for quality fence care and repairs for best ROI on the service investment for resilient longevity.
How long does the paint and sealant protection last?
Duration expects from quality rust resistant primers, paints and sealants on a palisade fence averages 2-5 years pending wear factors. Fences under trees yielding sap or fruit stains may need reprotecting annually. Conversely, a remote back garden area away from kids or gardening tools might go 5 years before exposing vulnerabilities. The marine environment’s salt air and regular heavy rains also accelerates protective finish degradation quicker than inland regions. Commit to inspecting a minimum of annually for early attention to erosion spots. Budget full repaint or professional care service costs every third year.
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