How to prevent rust on metal doors

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Let's admit it: doors take a lot of abuse. They get kicked, leaned against, banged up by walkers. And it's OK, because they're metal doors, and the metal can take it. However, metal has a weak point - it rusts, especially in areas where humidity levels are high. Think about an indoor pool, for example. And the moisture affects areas beyond the pool, such as locker rooms, showers, and foyer.

When left unprotected, the doors and other metal components begin to rust, and will eventually look like this:

Rusty door before paintingRusty door before painting service

The Rust Proof Solution

We were requested to find a rust-proof solution for one of our customers' indoor pool and locker room metal doors.

Now, there is a good system for protecting a metal door from rust. Every painter knows it: you sand it, wipe it, prime it with a rust-inhibiting primer, and paint it.

Only how do you do that when the area you're working in is constantly HOT and HUMID? The paint dries before the brush touches the door, you have to work at top speed, and even with that, the beautiful finish doesn't harden properly. In the end, all you have is an unsightly door and high levels of frustration.

We thought about building a booth around every door in the pool to control the humidity level. We thought about taking the doors off and finishing them in a spray shop.

Pitt-Glaze waterborne epoxy

And then we found a product that solved our problems: Pitt-Glaze water-borne acrylic epoxy.

Yes, epoxy. Isn't it that awfully smelling stuff that kills anything that breathes within a hundred feet from it?

Not this one!

It's a water-borne epoxy. It's truly low odor - no one in the building knew we were painting right under their nose (excuse the pun).

Epoxy-painted door

And, because it's an epoxy finish, it prevents moisture from getting to the door and other components, and so prevents rust!

We had to work rather swiftly, and definitely couldn't put the roller down without the paint starting to form a film. However, the paint was rolling out nicely, and the result was a good looking door with a hard finish and no brush/roll marks. Best of all, the concern with rust is taken care of.

Did I mention that this finish is also mildew-resistant and holds up well to frequent cleaning, corrosion, and the overall physical abuse that high traffic can create? I think this Pitt-Glaze epoxy is my new favorite.

I just got a call from a customer: "Can you paint our parkade doors with something bulletproof?"

And I'm happy to answer: "Yes, we can!"