What is RustSeal?
RustSeal is a single-component, moisture-cured rust encapsulating coating that bonds to bare or lightly rusted metal and cures to a non-porous, ceramic-like film that permanently stops rust and prevents its return. It resists road salts, fuel, and most chemicals up to 600°F without cracking, peeling, or chipping.
200 sq ft
Per Gallon (2 Coats)
1K Formula
No Hardener Needed
RustSeal is an industrial-grade, high-solids rust preventive coating with advanced color formulations that create an airtight, waterproof seal stopping oxidation and corrosion at the source. Whether for automotive, industrial, or home use, RustSeal is a permanent and cost-effective solution for protecting metal surfaces in any environment.
Unlike temporary treatments, RustSeal locks out water and air so oxidation cannot take hold underneath the film. Gloss levels vary by color: Galvanized cures to roughly 30% sheen, Satin Black to 70-75%, Gloss Black to 85-95%, and other colors to 75-85%.
RustSeal is backed by KBS Coatings' satisfaction guarantee. Satisfaction guaranteed!
Video: RustSeal Extreme Durability and Flexibility Demonstration
RustSeal bonds directly to bare metal, treated rust, galvanized steel, fiberglass, and properly prepped concrete. RustSeal is formulated for rusted metal specifically, so tight surface rust does not need to be removed before coating, only loose scale and oil. RustSeal is used on automotive frames, chassis, and fuel tanks; marine hulls and bilges; industrial steam pipes and storage tanks; and household items like steam radiators and garage floors.
- Automotive — frames, chassis, floor pans, wheel wells, fenders, trunks, firewalls, engines, suspension parts, axles, roof drains, leaf springs, coil springs, and doors. Nearly every part on a vehicle except the exhaust.
- Marine — engine rooms, hulls, masts, bilges, heat exchangers, decks, chain lockers, pumps, fuel tanks, and boat trailers.
- Industrial — heavy transport equipment, steam pipes, sealing concrete, air conditioning repair, fiberglass repair, re-bar coating, steel roofing, and fuel or waste-water treatment tanks.
- Household — steam radiators, hand rails, support beams, lawn equipment, garage floors, pipes, appliances, and lead-based paint encapsulation.
RustSeal is surface tolerant, meaning it applies directly over treated rust or bare metal without a separate primer step, and it cures to a non-porous, chemical-resistant barrier rated to 600°F. RustSeal is a moisture-cured, single-component formula that strengthens with humidity exposure rather than requiring a mixed hardener.
- Surface Tolerant: Applies directly over treated rust and bare metal, no separate primer coat required.
- 1K Formula: Ready-to-use, single component with no hardener to mix.
- Moisture Cured: Strengthens with exposure to humidity in the air.
- Deep Penetration: Superior adhesion to bare metal, galvanized steel, and other substrates.
- Non-Porous: Creates a permanent barrier against moisture and oxygen once cured.
- Chemical Resistant: Repels fuels, oils, acids, and alkalis without breaking down.
- High Heat: Withstands continuous temperatures up to 600°F (315°C).
- Flexible: Will not crack, flake, or peel under expansion and contraction.
- Long Shelf Life: 2+ years unopened; 6 months after opening when stored cool and dry.
Does RustSeal Change Color or Sheen in Sunlight?
RustSeal is not intended as a final finish in areas with repeated or prolonged direct UV exposure, since UV light will cosmetically alter its color and sheen over time. The rust protection itself does not degrade under UV. On surfaces not exposed to direct sunlight, like the underside of a vehicle, RustSeal holds its color and works well as a final finish on its own.
One quart of RustSeal covers about 50 square feet across two coats, and one gallon covers about 200 square feet across two coats, based on a recommended 4-5 mil dry film thickness. Theoretical coverage at 2 mils dry film thickness is 400 square feet per gallon, but KBS recommends a minimum of two full coats for lasting protection.
| Size | Coverage (2 Coats) |
|---|
| 8oz | 12.5 sq. ft. |
| Pint | 25 sq. ft. |
| Quart | 50 sq. ft. |
| Gallon | 200 sq. ft. |
Marine or wet-exposure note: for marine applications or surfaces consistently exposed to water, apply a minimum of three coats rather than two.
Pro Tip: Expect 30-40% less coverage on bare wood, rough, or sandblasted surfaces due to material loss during application.
RustSeal differs from standard rust-inhibitive primer in that RustSeal is a finished coating rather than a base layer: RustSeal cures to a hard, non-porous film rated to 600°F and needs no topcoat for rust protection, while standard primer must be topcoated to resist moisture and UV.
| | RustSeal | Standard Rust Primer |
|---|
| Applied over rust | Yes, simply remove loose flaky rust | No, generally requires bare metal |
| Topcoat required | No, for rust protection on surfaces not exposed to sunlight (UV) | Yes |
| Heat resistance | 600°F continuous | Varies, commonly under 250°F |
| Recoat window | 2 to 6 hours | Varies by product |
| Coats needed | 2 minimum | 1 primer plus topcoat |
Standard primer is the better choice when the surface will be finished in a wide automotive color palette that RustSeal's fixed color range does not cover, since RustSeal is formulated as a protective coating first and a finish color second.
RustSeal works as the third step of the KBS 3-Step System, applied after cleaning and etching the surface.
- Step 1 — KBS Klean
- Water-based cleaner and degreaser that removes grease, oil, and contamination before etching.
- Step 2 — RustBlast
- Acid etching treatment (think chemical sandpaper) to prepare bare or lightly rusted metal for RustSeal.
- Step 3 — RustSeal
- Permanent rust-encapsulating coating that seals the prepped surface.
See the Full 3-Step System
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Have questions before you buy? Find answers to the most common RustSeal questions below — or
order RustSeal now and get it shipped same day.
RustSeal is a single-component, moisture-cured rust encapsulating coating that bonds to bare or lightly rusted metal and cures to a non-porous, chemical-resistant film rated to 600°F. Unlike primer-based systems, RustSeal is surface tolerant and needs no separate hardener, so it goes on directly over treated rust in one product.
RustSeal bonds to bare metal, treated rust, galvanized steel, fiberglass, and properly prepped concrete. It is used on automotive frames and fuel tanks, marine hulls and bilges, industrial steam pipes and tanks, and household items such as radiators, hand rails, and garage floors.
Yes, simply remove loose flaky rust. RustSeal is formulated for rusted metal specifically, so tight surface rust does not need to be removed before coating, only loose scale, flaking rust, and oil. For best results, KBS recommends the 3-Step System: KBS Klean to clean, RustBlast to etch, then RustSeal to permanently seal.
Apply a minimum of 2 thin coats at roughly 2 mils dry film thickness each for general use. For marine applications or surfaces consistently exposed to water, apply a minimum of 3 coats. Recoat once the previous coat is dry to the touch, typically 2 to 6 hours depending on temperature and humidity.
One gallon of RustSeal covers approximately 200 square feet across two coats. A quart covers about 50 square feet, a pint about 25 square feet, and an 8oz can about 12.5 square feet, all at the recommended 4-5 mil dry film thickness. Expect 30-40% less coverage on bare wood, rough, or sandblasted surfaces.
RustSeal withstands continuous temperatures up to 600°F (315°C) once fully cured, making it suitable for exhaust-adjacent parts, engine bays, and industrial equipment. Ideal application temperature is 55°F to 82°F; RustSeal should not be applied in rainy or high-humidity conditions.
No, for rust protection on surfaces not exposed to sunlight (UV). RustSeal is a finished coating, not a primer. A topcoat is only needed if the part will be in direct, prolonged UV exposure, since sunlight will cosmetically fade RustSeal's color and sheen over time without affecting its rust protection. Opaque topcoats like BlackTop, KBS Top Coater, or KBS MAXX all bond well over cured RustSeal; a clear topcoat does not block UV.
Yes, RustSeal can be applied with a bristle brush, foam brush, roller, or spray equipment, and it self-levels well enough that brush marks flow out. For spraying, thin 5-10% with KBS #1 Thinner if needed, never lacquer thinner, and strain through a 100 micron filter before use.
Clean tools and spray equipment with KBS #1 Thinner or lacquer thinner immediately after use. RustSeal must be cleaned up before it dries, since it cannot be removed by any solvent once fully cured. Wear gloves to avoid skin contact and staining; if contact occurs, remove immediately with thinner followed by soap and water.
The KBS 3-Step System is KBS Klean to clean and degrease the surface, RustBlast (an acid etching treatment, think chemical sandpaper) to etch bare metal and remove light corrosion, and RustSeal to permanently seal the prepped surface against rust. Using all three products together gives the strongest, longest-lasting result on rusted metal.
Applying RustSeal to a Vehicle Door: Product Overview
