Reviving Rusty Cast Iron: A Guide To Restoring Your Pan's Glory

If your cast iron pan is rusty, don't panic! It can be saved. Cast iron pans are prone to rust when the iron comes into contact with moisture and oxygen, which causes a chemical reaction called oxidation. This oxidation produces iron oxide, or rust. To remove rust, you can scrub it with steel wool or a scouring pad, or soak it in a vinegar and water solution, and then scrub. Once the rust is removed, wash, dry, and reseason your pan.

How to remove rust from a cast iron pan

Cast iron cookware is made of a mix of pig iron, steel, and alloys. Without a protective layer of carbonized oil (called seasoning), cast iron is susceptible to rust. Even a well-seasoned pan can rust if it's left in the sink to soak, put in the dishwasher, allowed to air-dry, or stored in a moisture-prone environment.

But don't worry, there's no need to throw away a cast iron skillet that's a little (or a lot) rusty. Here are the steps to remove rust from a cast iron pan:

Step 1: Remove the Rust

Use fine steel wool, a scouring pad, or a kitchen towel to scrub away the rust from affected areas. For minor surface rust, rub about 1/3 cup of kosher salt into the surface of the pan until the spots of rust are removed. For more serious cases, you can soak the pan in a mixture of equal parts water and distilled white vinegar. Keep checking the pan every 15 minutes or so, and remove it from the solution once the rust easily flakes away.

Step 2: Wash the Pan

Wash the pan with warm, soapy water and scrub with a bristle brush, gentle scouring pad, or mesh sponge to remove any lingering rust. This step may remove portions of the seasoning, but that's okay because you're preparing to re-season the pan.

Step 3: Dry the Pan

Completely dry your cast iron skillet with a paper towel or lint-free cloth. You can place it on the stovetop on low heat for a few minutes to make sure it's completely dry.

Step 4: Re-season the Pan

Add a very thin layer of cooking oil (such as vegetable oil) to the entire surface of the pan, including the bottom and handle. Preheat your oven to 450-500 degrees F. Place aluminum foil on the bottom rack of the oven to catch any excess oil. Put your cookware upside down on the center rack and bake for 1 hour. Then turn off the heat and allow the pan to cool in the oven.

Step 5: Maintenance

To maintain your cast iron pan, always ensure it is completely dry before putting it away, and store it in a low-humidity spot. If you're stacking multiple pans, line each one with a few layers of paper towel or invest in breathable pan separators. Repeat the complete seasoning process once or twice a year for regular upkeep.

How to restore a rusty cast iron pan

Cast iron pans are versatile and hard-wearing, and can last a lifetime if properly cared for. However, they are susceptible to rust if not maintained. If your cast iron pan has started to rust, don't panic! Here is a step-by-step guide on how to restore it to its former glory:

Step 1: Remove Rust

Use fine steel wool or a scouring pad to scour the rusty sections of the pan until the original black iron emerges. If the rust is particularly stubborn, you may need to use a stronger abrasive tool. Get the pan wet, add a little soap, and scrub in small circles, focusing on the rustiest parts first. Rinse away any residue or remaining rusty bits.

Step 2: Wash the Pan

Wash the pan with warm water and mild dish soap. Use a bristle brush or a gentle scouring pad if needed. Make sure to remove any remaining soap and rinse thoroughly.

Step 3: Dry the Pan

Use a clean dish towel or paper towels to dry the pan immediately after washing. You can also place the pan on the stovetop on low heat for a few minutes to ensure it is completely dry.

Step 4: Apply Oil

Add a thin layer of cooking oil, such as vegetable oil, to the entire surface of the pan, including the bottom and handle. Be sure to use just enough oil to create a thin layer, as too much oil can result in a sticky surface.

Step 5: Place the Pan in the Oven

Place a sheet of aluminum foil or a foil-lined baking sheet on the bottom rack of the oven to catch any oil drips. Place the cast iron pan upside down on the top rack of the oven. Heat the oven to between 350°F and 500°F for one hour.

Step 6: Let the Pan Cool

Turn off the heat and allow the pan to cool completely in the oven before using it again.

Tips for Preventing Rust:

• Never soak the pan in water.
• Don't let the pan air-dry. Wipe off excess water with a towel and dry on the burner.
• Lightly oil the pan after use with a thin layer of vegetable oil before storing.
• Avoid cooking acidic ingredients like tomatoes or vinegar, as these can eat into the seasoning and lead to rust.
• Use the pan often. Cast iron pans can start to rust if they are stored for long periods without much air circulation or use.

How to prevent rust on a cast iron pan

Cast iron pans are susceptible to rust when exposed to moisture and oxygen for extended periods of time. Rust can interfere with the protective seasoning of the pan, making it difficult to cook on. However, there are several steps you can take to prevent rust from forming on your cast iron pan:

• Ensure that your cast iron pan is thoroughly dried after washing. You can place it on the stovetop on low heat for a few minutes to ensure it is completely dry.
• Always store your cast iron pan in a low-humidity environment. If stacking multiple pans, use breathable pan separators or layers of paper towels to prevent moisture from becoming trapped.
• Avoid leaving your cast iron pan in the sink to soak or putting it in the dishwasher, as this can lead to rust.
• Season your cast iron pan regularly. This creates a protective layer of fat molecules that bind to the pan, creating a non-stick surface and guarding against rust.
• When seasoning your pan, use a thin layer of cooking oil with a high smoke point, such as vegetable oil. Avoid using too much oil, as this can lead to a sticky surface.
• After applying the oil, buff any excess and place the pan upside down in an oven preheated to 450-500 degrees Fahrenheit for about an hour. Then, turn off the heat and allow the pan to cool in the oven.
• Be cautious when cooking acidic foods in your cast iron pan, as these can strip away the seasoning and make the iron more prone to rusting.
• Use dish soap sparingly when cleaning your cast iron pan, as it can strip away the seasoning, making the pan less rust-resistant.
• Regularly use your cast iron pan to help maintain its seasoning. The natural oils from the food contribute to the protective layer on the surface.

By following these steps, you can help prevent rust from forming on your cast iron pan and keep it in top condition for years to come.

Is it safe to cook with a rusty cast iron pan?

It is not recommended to cook with a rusty cast-iron pan. While it is unlikely to harm you, according to the United States Department of Agriculture, rust is not food safe and shouldn't be ingested. There is a chance that some of the rust could end up in your food, even if it is a negligible amount.

Rust can also add an unpleasant, metallic flavour to your food and make using the skillet more difficult. Food is more likely to stick to the pan without the protective layer of carbonized oil, or "seasoning", that cast iron requires.

If your cast-iron pan has rusted, it can be restored. First, scrub the rusty sections with steel wool, then wash the pan with warm, soapy water. Dry the pan with a paper towel or a lint-free cloth, and place it on the stovetop on low heat for a few minutes to ensure it is completely dry. Then, add a thin layer of cooking oil to the entire surface of the pan. Place the pan upside down in an oven preheated to between 350–500°F, with foil on the bottom rack to catch any oil drips. Bake for 1 hour, then turn off the heat and let the pan cool in the oven.

To prevent rust from developing, ensure your cast-iron pan is completely dry before putting it away, and store it in a low-humidity spot.

What causes a cast iron pan to rust?

Cast iron is made of a mix of pig iron, steel, and alloys. Without a protective layer of carbonized oil, known as seasoning, cast iron is susceptible to rust. Even a well-seasoned pan can rust if it's left in the sink to soak, put in the dishwasher, allowed to air dry, or stored in a moisture-prone environment.

Rust forms when iron reacts with oxygen and water. In other words, cast iron can rust if you leave water on it for too long. You can still use water (and soap) to cook in or clean cast iron, but you shouldn't let water sit on the pan for an extended period. When cleaning a cast-iron skillet, it's best not to let it soak for more than a couple of minutes. Cast iron is porous, so there may be some moisture remaining even if you dry the pan with a towel.

To prevent rust, it's recommended that you always dry your cast-iron pan over medium-low heat on the stove to evaporate any lingering water. Once your skillet has been washed and thoroughly dried, you should coat it all over with a thin layer of seasoning oil, both inside and out. This will create a nice, non-stick layer of seasoning the next time you heat up your skillet and protect it from rusting while it's not in use.

Always ensure your skillet is completely dry before putting it away, and store it in a low-humidity spot. If you're stacking multiple cast-iron pans, line each one with a few layers of paper or a kitchen towel, or invest in breathable pan separators that won't trap moisture.

Frequently asked questions