FAQ

Rust is the result of a reaction, typically occurring in particularly humid environments, between iron molecules and oxygen molecules from the air and other natural components. If not removed, rust can lead to progressive deterioration of the iron, eventually resulting in the complete breakdown of the item in extreme cases of neglect. Rust appears with a reddish color.

The likelihood of rust formation increases in environments where certain phenomena occur, such as acid rain caused by pollutants that lower the natural pH of rainwater, saline fog produced near coastal areas, or corrosive gases from industrial zones. Additionally, possible current leaks caused by automatic door motors should also be considered.

To prevent rust from appearing on hardware, follow these simple rules:

• Avoid contact with water.
• If the surface comes into contact with water, dry it as soon as possible.
• Do not create scratches on the surface, as these cracks can become reservoirs for contaminants.
• For movable parts (e.g., hinges, bolts, iron handles, etc.), lubricate them periodically, preferably with a water-repellent grease. Lack of lubrication can create friction, making the iron vulnerable to corrosive agents.

First, assess the extent of the rust damage, paying special attention to critical areas: edges, joints, weld points, and areas where ornamental
elements meet, as these are where water may accumulate most easily.

Sometimes, if the rust is only superficial on smooth surfaces, a thorough wipe with a dry cloth may be sufficient.
In other cases, more specific intervention is required, using protective gear for hands (gloves) and eyes (goggles), and depending on the
severity of the damage:

• Sandpaper
• Wire brush
• Rotary brush (specific accessory for drills)

For more severe cases, sandblasting is used. This industrial operation involves a jet of sand propelled by compressed air that removes the metal’s surface layer and is performed in sealed rooms.

The most practical method to prevent rust on hardware is to isolate the metal from agents that can cause oxidation. The simplest and easiest
way is to cover clean iron with a layer of anti-rust paint. This can be applied using a spray can, brush, air compressor with a spray gun, or roller.

A very effective way to remove residual rust stains left after cleaning and prevent their formation is by using a rust converter. These are now available in different colors and are usually based on synthetic resins dispersed in water, making them low in toxicity and suitable for use in poorly ventilated areas. These resins chemically react with rust, neutralizing it. The choice of technique depends on the surface being treated.

The most effective and durable solution is applying a very thin layer of stainless metal, such as zinc. However, this operation is recommended for larger objects, as it must be performed on an industrial scale by specialized companies equipped with large tanks where the object is dipped in molten zinc.

If you want to avoid using synthetic products to clean the iron we can provide some advice:

• it may be sufficient, for a delicate cleaning of the Wrought Iron, to dilute neutral soap or dish soap in a bucket full of water (proportion 15 ml per liter of water) avoiding the use of products containing chlorine.
  or you can use white wine vinegar, instead of soaps (proportion: one glass per 2 liters of water).
• Using a sponge or a cloth, pass over the entire surface to be cleaned, until the dirt is completely removed. With another cloth rinse with clean water. Finally dry very carefully eliminating any trace of humidity.

The frequency of maintaining an iron item should depend on the type of finish and its location: indoor or outdoor.

For indoor use, if the iron is raw and not painted (which is not recommended for outdoor use), maintenance should be regular, at least
weekly.

If the iron is painted, it is sufficient to remove dust and anything that could cause rust on a monthly basis

To determine the “ideal” type of finish for iron, it is essential to consider the final use of the product, its location, and its function.

For indoor use, particularly for frequently used items like handrails, raw iron can be maintained with regular cleaning. If you want to provide some protection while preserving the raw iron’s charm, it is advisable (and recommended) to apply a beeswax finish. This provides a natural effect while preventing rust formation. Maintenance in this case may be needed once or twice a year, with touch-ups of the wax layer.
Another durable solution is applying a clear matte varnish.

For outdoor use, it is recommended that, before choosing the type of finish, the item undergoes a corrosion protection treatment. This involves applying an anti-corrosion layer, either a rust-inhibiting paint or rust converter. After this, the item can be painted (at least two coats) in the colors and shades that suit individual preferences. Various painting techniques exist: brush or roller application, spray painting with a compressor-connected gun, or powder coating. In industrial settings, powder coating is an option where the paint, reduced to very fine sand, adheres to the iron using electrostatic forces. The piece is then heated to a temperature above 120°C to cure the resins contained in the paint particles.

You can use common types of brushes available on the market, carefully selecting the appropriate one based on the type of item to be painted. The following brushes are typically used:

• Round Brush: Ideal for painting irregular parts (friezes, flowers, leaves, etc.)
• Flat Brush: Suitable for painting fairly large surfaces
• Angle Brush: Useful for painting hard-to-reach areas
• Small Brush: Best for touch-ups or special effects

The only method for assembling iron to create any item, from a simple piece of furniture to a fence, is through welding. However, before starting any welding operation, which must be carried out in a well-ventilated area to disperse the toxic gases and fumes resulting from the process, it is essential to ensure that all safety precautions are taken:

• Wear a fire-resistant and chip-proof apron
• Use insulating gloves
• Wear a welding mask (Caution! Do not weld without protecting your eyes with a mask; the ultraviolet radiation from welding can damage your vision)
• Use insulating footwear
• Wear clear safety glasses for finishing stages

There are two types of welding: continuous wire welding and electrode welding. Before starting, ensure that the pieces to be joined are clean from rust, grease, sand, or other impurities.
Welding reaches temperatures of up to 3000° / 3500° C. These high temperatures melt the base metal of the two pieces, creating a small cavity where the molten metal from the wire or electrode is placed, thus forming a single body.

The progress of the welding should be smooth and even along the entire length of the weld. On flat surfaces, the progress is more or less zig-zag, depending on the needs. Once the welding phase is completed, it is necessary to move on to the grinding phase to remove any excess material deposited by the operation.

To renew a handrail, fence, or gate that is already installed, you can find elements such as scrolls, spears, etc., on the market that can be integrated into the existing hardware. These elements can be applied with a simple weld or using the appropriate amount of two-component metal adhesive. See the following example.