Corroseal Rust Converter

Restore and Protect Metals with the Best Rust Converter

Rust is the natural enemy of metal. As soon as iron or steel is exposed to moisture and oxygen, oxidation begins. The dreaded reddish-brown rust appears, spreading slowly but steadily across the surface of the metal, weakening it and eventually causing it to fail.

While sanding, grinding, and painting can temporarily fix rust issues, the problem will inevitably return unless the rust is properly treated. That’s where a rust converter like Corroseal comes in. Rust converters transform existing rust into an inert protective layer, stopping the spread of corrosion and preserving the integrity of the metal.

Corroseal is one of the most popular and effective rust converter products on the market. In this comprehensive buying guide, we’ll explore everything you need to know about this innovative rust treatment solution.

What is Corroseal Rust Converter?

Corroseal is a water-based rust converter made by Rust-Oleum. It stops rust in its tracks and prevents future corrosion. The active ingredient is tannic acid, derived from natural plant extracts.

When applied to rusted iron or steel, Corroseal undergoes a chemical reaction with the rust. It converts the reddish-brown iron oxide into magnetite, a tough black protective coating. The converted rust acts as a primer and seals out moisture to halt further corrosion.

In addition to tannic acid, Corroseal contains propylene glycol and methanol to aid penetration into rust layers. A corrosion inhibitor is also added to enhance its protective properties.

How Does Corroseal Rust Converter Work?

Corroseal works through a process called chelation. The tannic acid in the formula seeps into pores and cracks in rust buildup. It then chemically binds to the iron oxide molecules.

This process transforms the rust into an inert, stable substance. The iron oxide loses its oxidative properties so it can no longer spread corrosion.

The tannic acid leaves behind the magnetite coating, which adheres tightly to the metal surface. This coating acts as a protective barrier against moisture and oxygen, preventing further rust formation.

Corroseal dries to a black finish. This allows you to easily see treated areas. It also provides a sound foundation for topcoat painting if desired.

What Surfaces Can Corroseal Be Used On?

Corroseal can be applied to most iron and steel surfaces:

• Automotive bodies and frames
• Truck and tractor parts
• Shipping containers and tanks
• Bridges and structural steel
• Iron railings and furniture
• Farm equipment and machinery
• Wrought iron gates and fences
• Steel pipes and fittings
• Cast iron

It’s ideal for outdoor metal surfaces that are exposed to the elements as it provides long-lasting rust protection. Corroseal is not recommended for galvanized steel or other zinc surfaces. Make sure to test it on a small inconspicuous area first.

How to Apply Corroseal Rust Converter

Applying Corroseal is a straightforward process:

1. Clean the surface. Remove any loose rust, flaking paint, oil and grease with sandpaper, steel wool or abrasive blasting. Wash with soap and water.
2. Dry and degrease the area. Wipe down with denatured alcohol to eliminate moisture and oily residues.
3. Use masking tape and plastic sheeting to protect nearby surfaces. Apply Corroseal in a well-ventilated outdoor area.
4. Shake the bottle thoroughly. Corroseal separates during storage so you need to mix it before using.
5. Apply a uniform coat using a brush, roller or sprayer. Work it into the rust and pores. One coat is sufficient for most applications.
6. Allow at least 24 hours drying time before applying a finish coat. Temperatures under 50°F may require longer drying.

Make sure to follow all directions. Applying too little Corroseal won’t effectively convert all the rust. Too much can result in drips, sagging or poor adhesion.

Where Can I Buy Corroseal Rust Converter?

Corroseal is sold at most hardware stores, home improvement centers, automotive parts suppliers and industrial distributors including:

• Home Depot
• Lowe’s
• Ace Hardware
• True Value
• NAPA Auto Parts
• Grainger
• Fastenal

It’s available in small 8 oz containers up to one-gallon cans for larger jobs. Make sure to check the expiration date as Corroseal has a shelf life of about 2 years when properly stored.

Buying online from Amazon or the Rust-Oleum website can provide the best price for bulk orders. Corroseal also offers an aerosol spray can for convenience.

What is the Price Range for Corroseal?

Corroseal costs between $10 and $50 depending on the size. The 8 oz container is around $10. The most popular quart size averages $15-20. Gallons range from $30-50.

This affordable rust converter provides excellent value. A little Corroseal goes a long way towards stopping rust and corrosion damage. The cost is minor compared to repairing or replacing rusted metal.

Sales and promotions at retailers like Home Depot can help you save even more. Stock up during the winter months when Corroseal goes on sale.

How Long Does Corroseal Take to Dry?

Drying time is approximately 24 hours at 70°F and 50% humidity. It dries through water evaporation so allow more time in cooler and drier conditions. Humid environments may also prolong drying.

Corroseal typically dries to the touch within 1 hour. You’ll notice the color change from brown to black as the rust converts. Don’t touch the treated surface until completely dry.

Drying produces a harmless phenolic odor. Ensure proper ventilation during application and curing. The fumes dissipate as Corroseal dries.

Is Corroseal Rust Converter Safe to Use?

When used as directed, Corroseal is safe for DIYers and professionals. Safety precautions include:

• Use in well-ventilated area – Avoid inhaling fumes
• Wear gloves and eye protection – Avoid skin and eye contact
• Wash hands after use – Contains methanol and oxalic acid
• Keep away from open flames – Flammable until dry

The converted rust finish is non-toxic when dry. Corroseal contains no chromates, lead, or other hazardous heavy metals. It’s water-based and VOC-compliant for safer clean up and disposal.

Never pour Corroseal down drains. Dispose of any waste according to local regulations. Rinse containers before recycling.

What are the Active Ingredients in Corroseal?

Corroseal contains:

• Tannic acid – Derived from natural plant sources, converts rust into magnetite
• Methanol – Penetrates and cleans rust buildup
• Propylene glycol – Inhibits flash rusting
• Corrosion inhibitor – Forms protective barrier, enhances weatherproofing

No chromates, lead, or acids. Uses safer organic acids and alcohol solvents.

The exact percentages are proprietary. But Corroseal leverages its combo of rust-converting tannic acid and protective inhibitors to penetrate, convert and seal rust.

How to Prepare a Surface for Corroseal

Thorough surface prep is key to getting the best results from Corroseal. Follow these steps:

1. Remove loose rust and flaking paint with a wire brush, scraper or sandpaper. Wear eye protection and gloves.
2. Clean with a degreaser or soap and water. Rinse thoroughly.
3. Dry surface completely to prevent flash rusting. Wipe down with denatured alcohol.
4. Use 40-60 grit sandpaper to rough up smooth, glossy regions. This helps Corroseal penetrate.
5. Spot prime any bare metal with Rust-Oleum Rust Reformer.
6. Mask off nearby surfaces with painter’s tape and plastic sheeting.

Proper prep ensures Corroseal can deeply penetrate rust and react with the iron oxide. This allows full conversion to an inert coating.

Can Corroseal be Painted Over?

The converted rust finish left by Corroseal provides good protection on its own. But for enhanced weather resistance and aesthetics, Corroseal can be painted over.

Allow Corroseal to dry for 24 hours before topcoating. Then apply:

• Rust-Oleum paints
• Oil or latex-based paints
• Enamels
• Urethanes
• Epoxies
• Powder coating

The converted rust finish helps paint adhere better compared to painting over raw rust. Corroseal also seals and neutralizes rust to prevent bleed-through or lifting of the paint.

Remove any excess dust or dirt before painting for best results. Scuff sanding isn’t required but provides added adhesion.

What Are the Reviews for Corroseal?

With decades of proven performance, Corroseal earns outstanding reviews:

• “Stopped spreading rust completely” – Users report Corroseal halts existing rust and prevents new corrosion better than other products.
• “Easy to apply” – The water-based formula brushes on easily without drips or runs.
• “Good value for money” – Corroseal’s affordable price and long-lasting effectiveness make it a budget-friendly option compared to replacing rusted parts.
• “Doesn’t require sanding or primer” – The ability to convert rust and prime in one-step simplifies projects.

The few negative reviews cite inadequate surface prep prior to applying Corroseal. When used as directed on properly cleaned steel or iron, it delivers excellent rust protection.

How to Store Corroseal Properly

Store Corroseal in a dry area between 50-90°F. Avoid direct sunlight and moisture. Keep the bottle/can tightly sealed to prevent evaporation.

Shake the container periodically if stored for longer than 6 months. The liquids can separate over time. Shaking reconstitutes it.

With proper storage, Corroseal has a shelf life of 2 years from the manufacturing date. The expiration date is printed on the bottom or near the barcode.

Discard if the liquid becomes thick, gelled, or shows separation that cannot be mixed by shaking vigorously. Rust converters lose effectiveness as the active ingredients degrade.

Does Corroseal Require a Primer?

Corroseal does not require a separate primer – it acts as its own primer while converting rust.

On bare metal, spot treat any areas of flash rust with Rust Reformer first. Then apply Corroseal over the entire surface.

On rusted surfaces, Corroseal will deeply penetrate, convert the rust, and leave a protective coating. No other primer needed.

For added corrosion resistance, topcoat with a rust-inhibitive enamel paint. But Corroseal bonds well to converted rust without a primer.

How Effective is Corroseal?

With proper application, Corroseal stops existing rust and prevents new corrosion for 1-3 years or longer:

• Converts rust into a protective barrier that seals out moisture
• Bonds tightly to treated metal – won’t chip, peel or wash away
• Adds no volume – won’t flake off like paint over rust
• UV-resistant for outdoor use
• Doesn’t require sanding between coats
• Compatible with paint finishes

Independent lab testing shows Corroseal resists 500+ hours of salt spray exposure – longer than other leading rust converters.

Regular touch-ups on damaged areas will maintain its protective effects. Use Corroseal to nip rust in the bud before it spreads.

Can Corroseal be Used on Vehicles?

Yes, Corroseal is safe and effective for use on automotive surfaces like:

• Body panels
• Frames and undercarriage
• Chrome bumpers and trim
• Wheel wells
• Brake and fuel lines
• Engine parts

It stops further rust damage and maintains the integrity of the steel. Customers report excellent results using Corroseal on vintage cars and motorcycles to combat rust issues.

For best results, degrease and abrade surfaces prior to application. Then control humidity and drying time to avoid flash rusting. Apply topcoat paint for a durable finish.

What are Common Issues Using Corroseal?

Most problems arise from improper surface prep or application:

• Not cleaning and drying the surface – Allowing oil, grease or moisture to prevent adhesion
• Applying too thin – Failing to penetrate and convert all the rust
• Applying too thick – Causing drips, sagging, or curing issues
• Rushing topcoat – Painting before Corroseal has fully dried

Carefully following all Corroseal’s label directions helps avoid these issues. Pay special attention to completely cleaning and drying the metal before application.

How to Clean Up After Using Corroseal

• Wipe up spills or drips immediately with rags. Avoid skin contact.
• Once dry, the cured coating can be scraped or peeled off surfaces.
• Clean application tools like brushes and rollers with soapy water.
• Use paint thinner if needed for dried residue on equipment.
• Dispose of any waste according to local regulations. Don’t pour down drains.

Corroseal uses safer water-based chemistry than harsh solvents. But be sure to wear gloves and wash up properly after use as it contains methanol and oxalic acid.

What is the Shelf Life of Corroseal?

Corroseal has a shelf life of 2 years when stored properly in an unopened container.

Tightly reseal the lid after each use. Store in a dry area between 50-90°F and out of sunlight.

Shake periodically to reconstitute ingredients that may separate over time. Corroseal remains effective for touch-ups long after initial application provided it’s stored correctly.

Check the bottom or near the barcode for an expiration date. Discard if expired. The rust converter will lose effectiveness as ingredients degrade beyond the shelf life.

Are There Any Alternatives to Corroseal?

Corroseal is a top-rated rust converter, but other good options include:

• Rust-Oleum Rust Reformer – also contains tannic acid
• Loctite Naval Jelly – uses phosphoric acid
• Evapo-Rust – non-toxic and biodegradable rust remover
• FDC Rust Converter – low odor water-based formula
• Gempler’s Rust Converter – commercial-grade phosphoric acid

Test samples first to ensure compatibility with your surface. While converters share similarities, performance can vary.

Corroseal remains a favorite for its well-proven tannic acid formula, trusted Rust-Oleum brand quality, and decades of positive results.

Restore Metal Surfaces with Corroseal

Rust takes a toll on metal over time. Surfaces become pitted and weak. Parts fail. Structures require expensive replacement.

But Corroseal offers an easy, affordable way to extend the life of iron and steel. Simply apply this innovative rust converter to transform rust and protect against future corrosion.

Use this guide to choose the best Corroseal product for your project. Follow the application instructions carefully for optimal results. Then stand back and admire the restored look and enhanced durability of your metal surfaces.