Will my clear coat powder coat squat rack develop rust over time?

PK here from Fringe Sport, and today I want to break down clear coat powder coat finishes—what they are, how they work, and how they handle rust. Let’s dive in!

What is a Powder Coat Finish?

Powder coating is a common protective finish for metal, including gym equipment like squat racks. Here’s how it works:

1. Bare Steel Preparation: The raw steel is first sandblasted to remove impurities.
2. Powder Application: A special powder paint is sprayed onto the steel.
3. Baking Process: The coated steel is baked in a large oven, creating a durable, protective layer.

The main purpose? To prevent rust on the steel. A matte black powder coat is a popular choice, and we use it on many of our products.

What is a Clear Coat Powder Coat Finish?

Clear coat powder coating follows a similar process to black or colored powder coating, with one major difference:

• After sandblasting, skilled workers grind the steel, leaving visible grind marks on the surface.
• A clear powder is applied and baked onto the metal, creating a transparent, protective layer.

This finish retains the natural look of the metal while adding durability.

A beautiful clear coat powder coat finish on the Fringe Sport Dane rack

Does Clear Coat Prevent Rust?

Yes, but with some nuances:

• Structural Rust Protection: Clear coat effectively protects against structural rust that could weaken the steel.
• Cosmetic Rust Possibility: Over time, a clear coat may allow small patches of cosmetic rust, often appearing as faint "spidering." This doesn’t affect the functionality, safety, or stability of the equipment—it’s purely aesthetic.

This spidering is common across all clear coat finishes, whether it’s on gym equipment, bicycles, or even cars.

An example of clear powder coat rust spidering on a bicycle

An example of rust spidering on a non Fringe Sport rack

An example of rust spidering on a clear coat powder coat Fringe Sport Dane rack

Is Clear Coat Right for You?

If you’re particular about finishes and don’t like the idea of any visible rust, even minor spidering, a clear coat finish might not be your best option. Instead, consider a solid-colored powder coat for a pristine, long-lasting look.

However, if you appreciate the handmade, industrial character of a clear coat and don’t mind a little spidering over time, this finish is a great choice! It looks amazing and provides excellent protection.

A word from another creator

Chris Mosley from Mutant Metals had this to say about clear powder coatings and rust:

"TLDR: clear coat can be a gamble and rust doesn’t necessarily reflect product quality. You must assess your individual situation to decide if clear coats are right for your space.

I've seen the posts and gotten a message asking how we prevent rust on our clear coats because their import rack is rusting and they feel it’s related to poor manufacturing practices. As you can see from this picture, this isn’t the only industry it’s an issue.

Clear coat 95% of the time in fitness equipment is clear powder coating. When powder coat gets scratched the base metal becomes exposed to the air and moisture accelerates oxidation. This happens on nearly all equipment; the difference is you can see the oxidation under the clear coat vs a solid color. On solid colors you’re not going to see it happening until the powder bubbles off. Whether visible rust actually develops will depend on a lot of factors like sweat, humidity, cleaners, the absence of an oil barrier, proximity to salt water etc.

The other issue with clear coat is in manufacturing. When steel is bought, it usually has a layer of mill scale and oil from the manufacturer that helps prevent oxidation. As soon as that is ground off the clock is ticking. If the raw metal is exposed to the open air too long, microscopic nucleation sites of rust can develop. Even after being coated these sites can grow. You see this in coatings that aren’t scratched but still develop rust especially if they have been sitting in a box for a long time. These sites can spread like a disease. Powder coat needs to applied typically within 24 hour or less after the grinding operation to reduce this risk, this in itself isn’t an exact science.

Regardless if everything is done right. Visible rust is always a risk with clear coat and typically don’t recommend sinking a ton of money into it unless you live in a dry climate, have a room that is well ventilated with good air movement, and regular maintenance is performed. Wiping your clear rack down with a thin layer of oil like 3 in 1 once a month to cover scratches is likely a good practice. If you find rust tends to develop on any of your other equipment, clear coats, no matter who makes them, may not be a great investment. Hope this is helpful to those considering these finishes"

Final Thoughts

All clear coat powder finishes are prone to cosmetic oxidation over time. If that’s not your thing, go with a solid color powder coat. But if you’re cool with the unique, rugged aesthetic, then clear coat is the way to go.

Thanks for tuning in! Now go crush something heavy today—rock that clear coat and lift away!