How to Paint Rusty Railings

If the railing is large, work when you have two consecutive dry days to work. You could spend most of the first day scraping off the old paint. If on the first day you only scrape, you must paint the second day, or at least before the next rain.

Cover the area around the railings carefully. Use drop cloths for larger spaces and painter's tape for smaller spaces.

Wear protective clothing. Wear long pants and a long-sleeved shirt. Put on safety goggles and a dust mask before starting any work. Metal flakes will be scattered as you prepare the metal. If you use a wire brush grinder, pieces of wire from its wheel may fly off.

Mix a solution of half vinegar and half water in a bucket. You can also use diluted, mild detergent.

Scrub the railing thoroughly with your cleaning solution. This should remove dirt and remaining rust.

Rinse the railing and allow it to dry before continuing.

Scrape the straight sections with a sharp wood chisel or a wire brush to remove all rust and loose paint. Sharpen the chisel periodically with a belt sander or a metal file. Scrape off spiraled railings, ornate areas, and areas where one piece is welded to another using a wire brush attachment on a drill, or an "angle grinder" with a wire brush attachment. These are the only good ways to remove the rust. Eye goggles are necessary. Angle grinders are the best tool to remove heavy rust. Scrape out rust and loose paint from the bases of the railings, where they are mounted into the concrete. Water collects here and causes the railings to rust, often badly.

Sand the surface of the railing with medium-grit sandpaper. Medium grit is between 80 and 120 grit. This is called scuff-sanding and it should take gloss off the surface and allow the primer and paint to bond more easily. Sand rough spots with coarse sandpaper, from 40 to 60 grit.

Rub the surface of the railing with a tack cloth to remove dust from sanding.

Apply rust-inhibiting primer immediately after sanding and wiping the rail. This is sometimes called "direct-to-metal" primer. Some products are called "rust arrestors". First apply your coat of paint, then brush it into the crevices before it dries.

Check your primer's directions on how long it must dry before your second coat. Once again, use a brush to get into all the crevices of the metal railing. If you don't finish in one day, apply primer and paint the next day to prevent the bare metal from rusting. Don't paint before 10:00 AM because the railings could be damp from morning dew.

Allow the primer to dry according to the product's directions.

Apply the topcoat. You can use a spray can, 4" roller or brush. Brush the coat with a paint brush to remove any drips and get into the crevices. Many people prefer to use semi-gloss or high-gloss paint for their topcoat. These finishes add a shine to the railings and can make them easier to clean.

Allow the topcoat to dry completely.

Apply a second coat if you choose to, for longer protection..

After the topcoat has dried, apply caulking around the bases of the railings where they enter the concrete. Water collects here and causes rust.

Clean the brushes according to the paint can's instructions.