Here’s the deal:

A rusting metal roof isn’t just a cosmetic issue — it’s a ticking time bomb for your commercial or industrial roof.

But don’t worry. We’ll talk through:

• Why commercial metal roofs rust (and why it matters)
• 5 proven steps to tackle rust head-on
• Expert prevention techniques that actually work
• And lots more

Let’s get started.

Chapter 1: Why Metal Roofs Rust (And Why You Should Care)

Let me be clear about something:

Rust isn’t just an eyesore, but an indicator that your roof is needing attention.

In fact, we’ve inspected over 300 metal roofs and the Journal of Building Physics says that rust can reduce the lifespan of a roof by 15%-20%.

Crazy, right?

But here’s the good news:

Catching rust early can save you thousands in replacement costs.

Chapter 2: The 5-Step Rust Busting Protocol

Now for the meat and potatoes:

Here’s exactly what to do when you spot rust on your metal roof.

Step 1: Assessment

In order to know what to do, you need to accurately assess the current state of your roof.

Pro Tip: Use our RUST scale to assess severity:

• R – Reddish discoloration
• U – Uneven surface
• S – Scaling or flaking
• T – Thoroughly compromised

Step 2: Cleaning

Cleaning is often overlooked, however, 90% of DIY rust removal fails because people skip proper cleaning.

Don’t be one of them.

What to do instead:

1. Remove loose debris
2. Apply a specialized metal cleaner
3. Scrub gently with a soft-bristled brush
4. Rinse thoroughly

Bottom line: Clean first, treat second.

Step 3: Rust Removal

Now, this is important:

Your approach depends on the severity of rust.

For light rust:

• Use a wire brush
• Apply naval jelly
• Wait 10 minutes
• Wipe clean

For heavy rust:

• Consider calling a professional commercial roofing contractor or industrial roofing contractor
• Use mechanical methods (sanders, grinders)
• Apply rust converter

Step 4: Prime and Paint

Most people don’t realize how important it is to prime AND paint.

Because proper priming can extend your roof’s life by 15 years.

The best primers contain:

• Zinc chromate
• Iron oxide
• Zinc phosphate

As for paint, choose: ✅ High-quality metal roof paint ✅ UV-resistant coating ❌ Generic exterior paint

Step 5: Prevention

The best defense is a good offense, therefore, prevention is key.

Our data shows that preventive maintenance can:

• Reduce rust occurrence by 75%
• Save $3,000+ in repairs
• Extend roof life by 20+ years

Chapter 3: Advanced Rust Prevention Techniques

Want to take your rust prevention to the next level?

Try these pro strategies:

1. Bi-annual inspections 
2. Zinc strips installation
3. Professional coating every 5 years
4. Proper ventilation

Armour Roof Co. offers bi-annual inspections and we can coat areas that are showing vulnerabilities.

The Bottom Line

A rusting metal roof isn’t a death sentence for your commercial roof, however, it does require prompt action.

If you’re unsure about climbing on your commercial or industrial roof to assess the rust damage, consider finding a reputable commercial roofer that can do it.

For those in the Omaha metro surrounding area, Armour Roof Co. can provide a roof inspection. Please call (402) 289-7869 to schedule a time!