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RustSeal Flow Chart: Rust Prevention Steps for Steel

KBS RustSeal rust preventive coating logo The KBS 3 Step System Guide Complete RustSeal Directions KBS Klean Directions RustBlast Directions Can I Top Coat RustSeal? RustBlast After Sandblasting? RustSeal Tech Data Sheet RustSeal Questions and Answers RustSeal Instructional Videos All Application Flow Charts Order RustSeal

The RustSeal flow chart maps the KBS 3-Step System for steel. Unless the metal is freshly sandblasted with fresh sand, remove loose rust, clean with KBS Klean, etch with RustBlast, then brush or spray two coats of RustSeal. In direct sunlight, finish with an opaque, UV-stable topcoat such as BlackTop, KBS Top Coater, or KBS MAXX.

RustSeal Flow Chart at a Glance

3 Steps
Klean, RustBlast, RustSeal
30 Min
Minimum RustBlast Wet Time
2 Coats
Minimum RustSeal, 2 Mils Each
3 to 6 Hrs
Topcoat Window, Dry to Touch
ALWAYS WEAR PROTECTIVE GLOVES AND SAFETY GLASSES. ALWAYS WORK IN A WELL-VENTILATED AREA. When spraying, wear an air-supplied, NIOSH/MSHA approved organic vapor particulate respirator. Please heed all labeled warning and caution notices on all products.
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On This Page

The RustSeal Flow Chart

Start at the top and follow the arrows. The yellow boxes are decisions: your answer tells you which way to go.

START WITH YOUR STEEL
New SteelRusted SteelRusted Steel with Flaking Old Coating
Was the steel freshly sandblasted with fresh sand, handled only with gloves, and blown free of dust?
NO
Start the full 3-step system below. This includes steel blasted with plastic media, bead, or soda: those media do not leave enough profile, so RustBlast is still required.
YES
Skip the prep and go straight to Step 3, RustSeal.
Remove Loose Material
Wire brush, wire wheel, or sand off loose, scaly rust and any flaking old paint or coating.
Clean with KBS Klean
Scrub with diluted KBS Klean, rinse thoroughly with water before it dries, and let the surface dry.
Etch with RustBlast
Keep RustBlast wet for a minimum of 30 minutes, longer on heavier rust. While it is still wet, rinse it off with water.
Let It Dry
Allow the surface to dry thoroughly before RustSeal.
Seal with RustSeal
Brush or spray on 2 thin covering coats of RustSeal. Recoat when the first coat is dry to the touch, typically 2 to 6 hours.
Will the RustSeal see prolonged direct sunlight, or do you want a different topcoat color?
NO
Project complete. Out of the sun, RustSeal is the final finish.
YES
Topcoat with an opaque, UV-stable topcoat. A clear coat will not protect RustSeal from UV. Timing depends on how long the final coat has cured:
Dry to the Touch: 3 to 6 Hours
Apply BlackTop, KBS Top Coater, or KBS MAXX directly.
Past That Window: 24 Hour Cure
Let the final coat fully cure for at least 24 hours. Then scuff with 320 grit, or dust with Fusion Self-Etching Primer and let it cure 30 minutes. Then topcoat.
PROJECT COMPLETE

This flow chart is a general application guideline. It does not cover every application or environmental situation. If you still have questions, contact us for technical assistance.

Download the Printable Flow Chart (PDF)

Where Does Your Steel Start?

The only thing that changes between jobs is the starting point. Find your surface, then follow the chart from there.

Your Surface
Start At
Freshly sandblasted with fresh sand, handled with gloves, dust blown off
Step 3, RustSeal
Blasted with plastic media, bead, or soda
RustBlast is still required before RustSeal
Sandblasted, then touched bare-handed or left sitting
Step 1, the full 3-step system
New steel that was not blasted
Step 1, after scuffing or sanding
Rusted steel
Remove loose rust, then Step 1
Rusted steel with a flaking old coating
Remove loose rust and the flaking coating, then Step 1

It is not necessary to remove every trace of rust. RustSeal bonds to and permanently seals the tight rust that remains once the loose scale is gone.

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Timing at Each Step

Step
How Long
Before Moving On
1. KBS Klean
Scrub 5 to 10 minutes for general cleaning
Rinse thoroughly before it dries, then let dry
2. RustBlast
Keep wet at least 30 minutes; 40 to 60 minutes on moderate rust; 1 to 2 hours on heavy rust
Rinse before it dries, then dry completely
3. RustSeal recoat
Dry to the touch, typically 2 to 6 hours
Past 8 hours: wait 24 hours and scuff with 320 grit
Topcoat
Dry to the touch, usually 3 to 6 hours
Or after a 24 hour cure: scuff with 320 grit, or dust with Fusion SEP and wait 30 minutes

The RustBlast rinse does two jobs: it neutralizes the acid and it keeps a heavy zinc phosphate layer from building up. A slight white powder left afterward is a thin zinc phosphate coating that helps RustSeal adhere. Full details are in the KBS Klean Directions, RustBlast Directions, and RustSeal Directions.

Topcoat or Leave It?

RustSeal is not UV stable. Its rust protection does not degrade in sunlight, but its color and sheen will chalk and fade under prolonged direct UV. On frames, undercarriages, and anything else out of the sun, RustSeal is a durable, good-looking final finish on its own.

For sun-exposed work, topcoat with an opaque, UV-stable coating: BlackTop, KBS Top Coater, or KBS MAXX. Clear coats such as DiamondFinish Clear and KBS MAXX Clear let UV through to the RustSeal underneath, so they do not solve the fading. More in Can I Top Coat RustSeal?

Products in This Flow Chart

KBS Klean
RustBlast
RustSeal
Fusion Self-Etch Primer
BlackTop
KBS Top Coater

Frequently Asked Questions About the RustSeal Flow Chart

It shows the order of the KBS 3-Step System on steel and the two decisions along the way. First, whether the metal is freshly sandblasted, which decides where you start. Second, whether the RustSeal will sit in direct sunlight or needs a different color, which decides whether it gets a topcoat. For the full procedure, see the KBS 3 Step System guide and the RustSeal Directions.
Not if it was blasted with fresh sand, handled only with clean gloved hands, and the loose dust was blown off. That surface can go straight to RustSeal. Plastic media, bead, and soda blasting do not leave enough profile, so those surfaces still need RustBlast. More in Do I Need RustBlast After Sandblasting?
No. Remove loose, flaky rust and any flaking old coating with a wire brush, wire wheel, or sandpaper so the surface is solid. RustSeal bonds to and permanently seals the tight rust that remains.
Keep RustBlast wet on the surface for a minimum of 30 minutes on smooth or lightly rusted steel, 40 to 60 minutes on moderate rust, and 1 to 2 hours on heavy rust. Reapply so it never dries, then rinse with water before it dries. The rinse neutralizes the acid and avoids a heavy zinc phosphate layer. Let the surface dry completely before RustSeal.
Apply a minimum of 2 thin covering coats, about 2 mils each, for general applications, and a minimum of 3 for marine or industrial use. Recoat once the previous coat is dry to the touch and leaves no fingerprint, typically 2 to 6 hours. If more than 8 hours pass, wait a full 24 hours and lightly scuff with 320 grit before recoating.
Only where it sees prolonged direct sunlight, or when you want a different color. RustSeal is not UV stable: its rust protection holds, but its color and sheen chalk and fade in the sun. Out of the sun, such as a frame or the underside of a vehicle, RustSeal is the final finish.
There are three ways. Apply the topcoat once the final coat of RustSeal is dry to the touch, usually 3 to 6 hours. Or let it fully cure for at least 24 hours, scuff with 320 grit, then topcoat. Or let it fully cure for at least 24 hours, dust with Fusion Self-Etching Primer, let the primer cure 30 minutes, then topcoat. See Can I Top Coat RustSeal?
Not for UV protection. A clear topcoat such as DiamondFinish Clear or KBS MAXX Clear lets sunlight pass through to the RustSeal underneath, which still chalks and fades. Use an opaque, UV-stable topcoat instead: BlackTop, KBS Top Coater, or KBS MAXX.

Still have questions about the RustSeal flow chart? Our technical team is ready to help.

More RustSeal questions and answers: RustSeal Questions

Get Instant Answers from the KBS Support Desk Contact Us for Technical Assistance

Instructional & How-To Videos

Tips and Tricks on the KBS 3-Step Rust Prevention System
How To Apply Another Coat of RustSeal Over Fully Cured RustSeal

Watch more RustSeal videos on the KBS Instructional Videos page.

The Stop Rust Quart Kit includes KBS Klean, RustBlast, and RustSeal for about 50 square feet. For a full frame or up to 200 square feet, choose the Stop Rust Gallon Kit.

Shop the Stop Rust Quart Kit Shop the Stop Rust Gallon Kit
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