Barbecues are a popular form of cooking and provide endless culinary enjoyment. However, a common and headache problem for BBQ grill owners is the rusting of the grill grates. Rust not only affects the aesthetics of the charcoal and grill, but may also have a serious impact on its performance and longevity. So, what exactly can you do to prevent your grill grates from rusting? Let's take a closer look.
I. Grill Rust - Why it Happens
Rust is the result of a chemical reaction between metal and oxygen and moisture in the air. Outdoor barbecue grill grates are usually made of metal, and when they are exposed to humid air or come into direct contact with moisture, the process of rusting begins silently. Oxygen combines with atoms on the surface of the metal to form metal oxides, which we call rust. Over time, the rust layer thickens and the corrosive effect deepens, which not only destroys the surface structure of the charcoal grill, but in serious cases even weakens the stability of the whole grill and affects its normal use.
Different usage scenarios can significantly accelerate the rusting process. For example, in areas with frequent rainy seasons or high air humidity, if corten bbq grill is left in the open air for a long time without any protective measures, moisture will continue to adhere to the surface of the grill, greatly increasing the chances of rusting. In addition, after each use of charcoal and grill, if the residual food and grease are not cleaned up in time, these organic materials will absorb the moisture in the air, creating a humid and nutrient-rich environment that further promotes the generation of rust.
Preventing rust is far easier than removing it. Regular cleaning and maintenance of your charcoal and grill is the key to keeping it in good condition and preventing rust. Corten BBQ grills, for example, have a powder-coated grill surface to prevent rust, but this requires proper care to maintain the integrity of the coating. Simply seasoning the outdoor barbecue grill on first use as instructed in the owner's manual (this is usually a simple heating process) and keeping the grill clean at all times will reduce the risk of rusting.
Clean and Dry the Grill
Initial cleaning should be done immediately after each use of the grill. While the charcoal bbq grill is still hot, a wooden grill scraper makes it easy to scrape debris and food residue from the grill grates, as the residue has not fully cooled and hardened, making it less likely to stick to the grill. For stubborn food stains, here's another trick: rub half an onion or lemon along the small outdoor grill. The acid in the onion and lemon will soften the grime that's stuck to the grill, making it easier to remove. You can also dip the onion or lemon in a little coarse salt for added friction to better remove food particles. After the grill is finished and the Corten BBQ grill has cooled completely, it's time for a deep clean. First, spray the grill with a cleaner (we recommend a powerful natural cleaner) and then brush it with a nylon bristle brush. Note that you should never use a wire brush, as the bristles of a wire brush can come off and mix with food, posing a safety hazard. If you don't have a brush, a thick paper towel or disposable cleaning cloth will also work well for cleaning. Once you're done cleaning, be sure to dry the grill grates with a paper towel or cloth before covering the grill's lid to prevent moisture residue from causing rust. In addition to the grill, the exterior of the grill should not be neglected. Keep the entire bbq grill clean by wiping away all debris, food residue and grease from the exterior surfaces.
Remove Excess Grease and Food Particles
It is vital to promptly remove food and grease from the barbecue grill after each use. It is also important to clean the metal grease tray or drip tray that collects food crumbs, grease and oil droplets. It is important to note that for some older models of grills, some rust on the grease tray is normal, and since it does not come into direct contact with food, it is generally not a health hazard. However, if the grease tray is perforated due to rust, you will need to replace it with a new one, which you can purchase through the appropriate channels. Disposable aluminium foil liners are available for the grease drip trays of most barbecues, which protect the tray and reduce the likelihood of rusting.
Grease trays should be cleaned at least twice a year, regardless of their susceptibility to rust. If the outdoor barbecue grill is used more frequently, it will need to be cleaned more frequently. The amount of grease that accumulates is also related to the type of food being grilled. For example, grilling a fatty steak directly on the grill grates will produce more grease than grilling vegetables or using a grill pan.
While grease buckets and jugs are less likely to rust, it's still a good habit to clean them regularly. If you use a liner in your grease bucket or kettle, simply remove the liner and throw it away when grease builds up. Otherwise, after the grill has cooled completely, the grease needs to be scraped out of the bucket and thoroughly cleaned. Be sure to wipe away all grease and food residue from the inside and outside of the bbq grill. When cleaning, avoid abrasive cloths or cleaners, as well as products that are not certified as food-safe or are not suitable for the brand and type of grill you are using.
Deep Clean Occasionally
After every few uses of the grill, a deep clean is required. For wood pellet grills, the grease tray needs to be cleaned before it is filled. If you line the grease tray with aluminium foil, cleaning becomes much easier. It is also necessary to use a wet/dry hoover or an industrial hoover to suck up the ash from burning wood pellets. During the deep cleaning process, thoroughly clean the heat baffle, grease drip tray, drum liner and grill grates. Avoid cleaning thermocouples or resistance temperature detectors (RTDs) unless you see a visible accumulation of dirt on them that needs to be removed.
Using Rust-Preventive Products
For Corten barbecue grills, the powder coating on the grill surface is inherently rust-resistant. Always read the warranty terms and care instructions for your grill before using a rust-resistant product. Any coated product used on the grill should be safe for use around food and able to withstand high temperatures. At the very least, after cleaning and drying the grill grates, you can apply a coat of oil to them. The oil will season the grill grates and will not only prevent food from sticking, but it will also form a protective film on the metal surface, stopping the oxygen that causes rust from coming into contact with the metal. Applying oil is especially important when you notice areas where the powder coating on your grill grates is worn, flaking, or showing scratches.
III. How Long Can a Steel BBQ Grill Last After Rusting?
Corten steel grills show more rapid surface rusting, but it corrodes much slower than ordinary mild steel. Even if a rusted steel bbq grill looks rusty, the structure remains in good condition. This is because Corten steel only rusts on the surface, and the surface layer of rust serves to protect the steel inside. In the early stages of rusting, the rust may drip onto the surface below and form stains. To avoid this, place some tarps underneath the edge of the grill and allow the rust to drip off. After a few months, the rate of rust will gradually slow down and no more drips will occur. It is normal for Corten steel to vary in the rate of rusting. This may be due to a film of oil still remaining on the surface of some of the sheets, resulting in slower rusting. For plates that are slow to rust, they can be cleaned once with salt water, which will help speed up the rusting process. The rusting process is significantly accelerated when the sheets come into contact with rainwater. Over time, the colour of Corten steel changes. From an initial orange colour, it gradually changes to a reddish brown, brown and eventually close to black.
Stainless steel barbecue grill rust is mainly due to the following reasons: firstly, the use of hard cleaning tools such as steel wire balls, or barbecue grill is subject to collision and scraping, which may destroy the passivation film on the surface of the stainless steel, which will trigger rust. Secondly, long-term contact with substances such as salt water and chlorine-containing detergents can lead to pitting of stainless steel. In addition, in the welding process, if the protection measures are not appropriate, the chromium element at the weld will be lost, reducing the corrosion resistance of stainless steel. To prevent stainless steel grills from rusting, you can take the following measures: use a soft cloth or sponge for cleaning, avoid using hard cleaning tools. Try to avoid contact between the grill and corrosive substances such as salt water and chlorine-containing cleaners. When choosing stainless steel grill, give priority to 304 or 316 and other high-quality stainless steel materials.
Cast Iron
Cast iron itself is prone to rust, especially in a humid environment. Moreover, if it is not cleaned and maintained in time after use, food residues and grease will accelerate the rusting process. Ways to prevent cast iron grills from rusting include ‘pot-opening’ the grill before initial use, i.e., forming a protective film of grease on the surface of the grill. After each use, clean the grill while it is still hot and apply a coat of cooking oil. Store the barbecue grill in a dry, well ventilated place.
Galvanised steel
Galvanised steel barbecue grills rust mainly due to wear and tear or flaking of the galvanised coating, which can expose the underlying steel and trigger rusting. In addition, acidic foods or cleaning agents can corrode the galvanised layer. To prevent galvanised steel barbecues from rusting, avoid using hard cleaning tools to prevent scratching the galvanised layer. Avoid exposing the grill to acidic foods or cleaning agents. Regularly check the condition of the galvanised layer and repair the damaged parts in time.
Carbon Steel
Ordinary carbon steel is very easy to rust, especially in humid environments. Moreover, if it is not cleaned and maintained in time after use, it will rust faster. Measures to prevent carbon steel grills from rusting are similar to those for cast iron: ‘open’ the grill before use to form a protective film of oil. After each use, clean it while it is still hot and apply a coat of cooking oil. Store the grill in a dry, well ventilated place. The causes of rusting vary from one material to another, but they are all closely related to environmental humidity, usage habits, and cleaning and maintenance methods. Choosing the right material and adopting the correct use and maintenance methods can effectively extend the life of your barbecue grill so that you can enjoy a delicious barbecue experience for a longer period of time.
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