Tackling a Massive Rust Removal Job: Lessons from the Field

In this post, we’re breaking down a large-scale rust removal job at a steel fabrication facility. With a rust-covered wall over 20 feet tall, this project required precision, the right chemicals, and innovative techniques. Follow along to learn how we tackled this specialty cleaning task and discover tips for making high-ticket jobs easier and more profitable.

The Job: Rust-Covered Industrial Wall

We were called to a steel fabrication facility where rust had built up on a massive wall behind their machinery. The rust wasn’t just surface-level—it was thick and bonded to the structure. A previous contractor attempted to clean it with SH (bleach), but this was ineffective since rust is a non-organic issue.

Our solution? Rust Rescue, a specialty chemical designed specifically for rust removal.

Step-by-Step Process

1. Assessment and Planning

   • Inspected the wall to understand the severity of the rust.
   • Set client expectations: the wall wouldn’t be perfect but would look dramatically better.

2. Initial Application

   • Sprayed Rust Rescue using PPE to protect ourselves.
   • Let the chemical dwell for a few minutes to break down the rust.

3. Rinsing the Wall

   • Used a ball valve to rinse away the loosened rust.
   • Observed the need for a second coat in some areas.

4. Scaling Up with 24V Pump

   • Transitioned from a 12V to a 24V pump for better reach and coverage.
   • Used a man lift provided by the company to access the upper sections.

5. Final Coat and Touch-Ups

   • Applied a final coat in stubborn areas.
   • Ensured even coverage for a consistent, clean look.

Challenges and Solutions

• Water Access: The back of the building lacked a water supply. We worked around this by refilling our water tank from the front of the building.
• Proper Chemical Usage: Previous contractors failed by using the wrong chemicals. Training in chemical applications is crucial for success in specialty cleaning jobs.

Key Lessons

1. The Right Tools and Chemicals Matter: Rust removal requires specialized products like Rust Rescue—not SH or general cleaning agents.
2. Set Realistic Expectations: Communicate with clients about what’s achievable. They’ll appreciate transparency and be more satisfied with the results.
3. Pricing Reflects Value: Don’t undercharge! A contractor who quoted $350 for this job didn’t understand its scope and left money on the table.

High-Ticket Jobs Made Easy

This job demonstrated that specialty cleaning doesn’t have to be hard. With the right knowledge and tools, you can take on projects like this and command premium prices.

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