Metal doors are great for building security. But a rusty metal door? Not so much. Rusted metal doors weaken security. And they’re a bit of an eyesore too — they damage your business curb appeal and can be off-putting for customers.
If you notice that your steel doors are showing signs of rust, it’s important to take action quickly. Left untreated, rust can spread and lead to costly door replacements. So here’s everything you need to know about why metal doors rust, how to fix the problem and signs it may be time to call in the experts.
What makes a metal door rusty?
Doors get rusty when metal is exposed to moisture and oxygen for long periods. Once rust starts, it spreads fast. The most common causes of rust on metal doors include:
- Leaks and water exposure. Exterior steel doors, doors near loading bays and doors near kitchens (where you have the kettle boiling most of the day) are all prone to water damage.
- High humidity. If your warehouse or factory has high levels of moisture in the air, this can accelerate the development of rust.
- Damaged coatings. Steel doors come with special coatings that protect the metal from moisture and oxygen. Scratches, dents and areas of worn-down paint expose the metal, making it more vulnerable to rust.
- Poor maintenance. Door maintenance is essential. If your doors haven’t been cleaned, inspected or repainted in years, rust is much more likely to take hold.
The problem with rusted doors?
Rust isn’t just a cosmetic issue. It poses a serious security risk. A weakened metal door can be easier to break through, which means your business becomes more vulnerable to theft and unauthorised access. Rusted door hinges and locks may fail too, making it harder to properly secure your business premises.
Rusty doors can also pose a safety risk to your staff. If your metal doors form part of a fire escape route, corrosion may prevent personnel from leaving your building quickly and easily.
And the final reason to do something about rusty doors? The cost of leaving it too late. Deal with rust in its early stages and you can salvage your metal doors. But leave rust to take hold and you will end up shelling out for door repairs or replacement.
Signs your metal door has a rust problem
Not all rust is obvious. So here are some signs of rust to look out for:
- Orange-red streaks — when it’s wet, rust can run, leaving streaks near hinges and door knobs
- Red, black or white blotches — discoloured blotches on your door (not necessarily the orange-red colour you associate with rust) are an early sign that you have a problem
- Bubbling or peeling paint — this indicates that rust is forming underneath your paint
- Visible rust patches — the most obvious signs of rust are orange, red and brown spots appearing on the surface of your metal door, its hardware or hinges
- Flaking or pitted metal — if your door has a serious rust problem, the rust will start eating away at the metal, making the door weaker
- Stiff or squeaky hinges — when door hinges are rusty, it’s harder to open and close your doors
- Loose or corroded hardware — rust doesn’t just affect the door — it can impact locks, handles and frames too
If you see any of these signs of rust, it’s time to take action.
How to remove rust from metal doors
The best way to deal with rust depends on the extent of the damage. Here are some ways to remove rust from metal doors.
Sand and repaint your metal door
If rust is only on the surface of your door and hasn’t damaged its structure, you can use sandpaper or a wire brush to remove the rust. Next, clean and dry your door before applying a coat or two of rust-proof primer. Then, repaint using a high-quality, rust-proof paint.
Oil or replace rusted door hinges and hardware
If rust has got into your hinges and locks, you can use a rust dissolver or rust converter to treat the affected areas. Then, apply a lubricating oil to prevent further rusting. But if door hardware is too corroded, you should replace it entirely. Rusty locks and handles compromise building security, so it’s best not to take any chances.
Get a metal door replacement
Not all rusty doors can or should be repaired. If rust has eaten through the metal and weakened the door — or if rust keeps returning despite your DIY repairs — it’s time to call in the experts. A door replacement is the safest and often the most time and cost-effective option in the long run.
Preventing rust on metal doors, hardware and hinges
Dealing with a rusty metal door is a pain. So taking steps to avoid rust developing in the first place is a really good idea. Here are some of the things you can do to prevent rust on metal doors, hardware and hinges:
- Clean your doors regularly. Wipe down steel doors on a regular basis to remove dirt and moisture.
- Reduce moisture. Check for and fix any leaks close to your metal doors. Improve building ventilation to reduce humidity.
- Repaint when necessary. Keep your doors protected with rust-resistant paint. It’s a good idea to check your doors every couple of months for dents and scratches.
- Choose rust-resistant materials. Steel is particularly resistant to rust. You can also get metal doors with a rust-resistant coating.
- Schedule maintenance. Book a regular door service and have your doors inspected by a professional to keep them as solid and secure as the day you bought them.
How Secure Door Systems can help
Our team of engineers keep doors safe, secure and operational with door maintenance and door repair services. We can get your rusty metal doors back in top working order.
Doors too rusty to be repaired? If you’ve decided that a door replacement is your best option, Secure Door Systems can help here too. We can provide and install rust-resistant steel doors for your industrial or commercial business.
Whether you want glazed steel doors, high-security steel doors or steel personnel doors, we’ll help you find the fit and finish best suited to your building.
Get in touch to get a steel door quote today.
Rusty metal door FAQs
Can you paint over rust?
No, you can’t paint over rust. You need to remove the rust before you repaint the metal surface. Otherwise, the rust will spread underneath the paint.
To remove the rust, use a wire brush, sandpaper or a scraper. Next, clean and dry the surface. Apply a primer that is designed for use on rust. Then paint, using a rust-resistant paint.
Do steel doors rust?
Steel is a strong material and more resistant to rust than many other metals. But it isn’t immune to rust.
That being said, when properly cared for, steel doors can last for decades. To protect your steel doors from rust:
- keep them clean and dry
- ensure that coatings and paintwork aren’t chipped or scratched
- schedule regular door maintenance
