How to Keep Your Grill From Rusting With the Right Cover
Carly Vicnair - Brand Marketing Coordinator, Coverstore
Carly is a Brand Marketing Coordinator focused on driving brand growth and campaign execution.
What Actually Causes Grill Rust
Learning how to keep your grill from rusting starts with oxidation, the reaction that happens when iron or steel is exposed to oxygen and moisture over time. On a grill, this can happen faster than most people expect. Grills cycle through extreme heat and then cool down, often while still holding residual moisture from rain or humidity. That repeated expansion and contraction weakens protective coatings, leaving raw metal exposed.
It's not just rain that causes problems. Morning dew, coastal humidity, and even steam from cooking can all contribute. Rust on grill grates usually shows up first, followed by burner tubes and any seams or joints where water can collect and sit. Cast iron grates are especially prone to rust if they aren't properly seasoned and protected. Knowing how to properly season and clean your grill is just as important as covering it. See our guide: How to Clean and Protect Your Grill.
How a Good Cover Stops Rust
A quality grill cover works as a barrier between your grill and the elements. It blocks direct rain and moisture, reduces exposure to humidity, and shields the grill from UV rays that degrade protective coatings over time.
The key word is "quality." A thin, poorly fitted cover can actually create problems of its own, trapping moisture underneath rather than deflecting it. Look for covers made from water-resistant materials with ventilation built in, designed to let air circulate while keeping precipitation out. The fit matters too. A cover that's too loose billows in the wind and gaps at the edges; one that's too snug can be difficult to remove and may hold moisture against the grill surface.
Coverstore offers grill covers in both standard sizing and custom options, across four collections, so you can match the right level of protection to your climate, grill size, and style preferences. See our roundup: Best Grill Covers.
Cover Features That Make or Break Rust Protection
Not all grill covers are built the same. Here are the features that matter most when rust prevention is the goal:
- Water-resistant fabric: Look for covers rated to resist water penetration, not just repel light mist. Heavy-duty polyester or solution-dyed acrylic fabrics hold up best over time.
- Breathability and ventilation: A breathable grill cover with built-in vents or mesh panels allows moisture to escape rather than pool underneath.
- Secure fit with closures: Buckle straps, drawstrings, or cinch closures keep the cover in place during wind and prevent it from lifting and exposing the grill. In windy climates, this is especially critical. A cover that blows off provides zero protection. If you live in an area prone to high winds, look for a higher-tier collection with reinforced closure systems and weighted hems that anchor the cover more securely to the grill.
- UV resistance: Sun exposure breaks down both the cover material and your grill's finish. UV-resistant fabric extends the life of both.
- Reinforced seams and hemlines: These prevent tearing at stress points and keep the cover's protective shape over years of use.
Coverstore's four collections range from dependable everyday protection to premium covers built for harsh coastal climates, intense sun exposure, and high-wind environments, so there's an option for every backyard setup.
Rust-Preventive Products and Oils That Actually Help
A cover handles the weather, but the metal itself benefits from a little help. Here is how to prevent rust on grill grates between cooks, without buying anything exotic:
- Oil the grates after cleaning: Once the grates are clean and fully dry, wipe on a thin coat of a neutral high-heat cooking oil. The oil seals the surface and keeps oxygen away from bare metal, which is the same principle behind seasoning a cast iron pan.
- Understand that grease and oil are not the same thing: A deliberate thin coat of oil protects. Leftover cooking grease does the opposite, because it holds moisture and food acids against the metal and speeds up corrosion. That is why rusty grill grates are so often the ones that were put away dirty.
- Skip the wire brush: Wire bristles can break off, lodge in the grates, and end up in food. A nylon brush, a wooden scraper, or a balled-up piece of foil does the job without that risk.
- Check the manual before using any rust-prevention product: Coatings and sprays vary widely in whether they are food-safe and heat-safe. Your grill's owner manual and warranty terms are the deciding vote, not the label.
- Dry the grill before it goes under the cover: No product compensates for trapped water. Drying is the single highest-value habit in the whole routine.
Rust Prevention by Grill Material
| Material | How Rust Shows Up | What Prevention Looks Like |
|---|---|---|
| Stainless steel | Surface staining and discoloration before true pitting | Treat spots early with a stainless cleaner, then polish. Rinse exterior surfaces regularly near coastlines and pools |
| Cast iron grates | Orange bloom across the cooking surface, fast if stored damp | Season regularly and re-oil after every clean. Never soak or air dry |
| Porcelain-enameled cast iron | Rust starting at chips and scratches in the enamel | Use soft tools to avoid chipping, and touch up or replace grates once the coating breaks |
| Powder-coated steel | Bubbling and rust creeping out from nicks in the coating | Keep the exterior dry and covered, and address chips before moisture gets underneath |
| Burner tubes and flame tamers | Corrosion from drippings combined with condensation | Clean drippings out on a schedule and inspect these parts seasonally |
Gas grills from major brands often combine several of these materials in one unit, which is why gas grill grates rusty at the edges can sit under a hood that still looks new. If you own a popular model, a brand-matched cover takes the guesswork out of fit. Shop Weber grill covers or browse all BBQ grill covers by size.
Common Mistakes That Cause Rust Despite a Cover
Even with a cover in place, rust can still develop if a few common mistakes are made:
- Covering a wet grill: Putting a cover over a grill that's still wet from rain or a recent cook traps moisture underneath and accelerates rust. Always allow the grill to dry fully before covering.
- Never cleaning the grates: Food residue holds moisture and speeds up oxidation on cast iron and steel grates. Regular cleaning and seasoning is essential.
- Letting the drip tray and grease pan fill up: Pooled grease is a moisture reservoir sitting in the lowest, least ventilated part of the grill. Emptying the tray is part of rust prevention, not just cleanliness.
- Using a cover that doesn't fit: An ill-fitting cover leaves gaps where wind-driven rain can get in. Custom sizing eliminates this problem entirely.
- Skipping the cover during nice weather: Rust doesn't only form in rain. Humidity and morning dew can do damage even on sunny days. Consistent use of your cover is the most effective prevention strategy.
- Ignoring the flame tamers: Flame tamers for gas grills sit directly above the burners and take the brunt of heat and drippings. They're a common rust point that's easy to overlook.
- Not securing the cover in windy conditions: A cover that lifts and flaps in the wind isn't doing its job. In areas with frequent strong winds, upgrade to a cover with more robust closures to ensure it stays put.
Best Practices for Using the Cover
Getting the most rust protection out of your grill cover comes down to consistency and a few smart habits:
- Allow the grill to cool completely before covering. Heat trapped under the cover can cause condensation.
- Wipe down the exterior of the grill before re-covering, especially after rain.
- Season cast iron grates regularly to maintain their rust-resistant coating.
- Check the cover periodically for tears, worn seams, or areas where water may be pooling.
- During extended storage, consider removing the grates and storing them indoors if you won't be grilling for several weeks.
- Remember that indoor storage is not automatically dry storage. Sheds and garages swing through their own condensation cycles, so keep the grill covered inside too, and run a dehumidifier in the space during long humid stretches.
- If you live near the coast or next to a pool, rinse and dry the exterior on a regular schedule. Salt and chlorine in the air accelerate corrosion even on stainless surfaces.
- Match your cover to your climate. If you live in a high-humidity, coastal, or high-wind area, invest in a higher-protection collection with reinforced weather resistance and more secure fastening features.
- In windy regions, check that all straps and buckles are properly fastened every time you cover the grill. A partial closure is nearly as bad as no cover at all.
Industry Expertise and Company Credentials
Coverstore has been helping customers protect their outdoor investments for over 20 years. With four distinct grill cover collections, custom sizing options, and a range of colors and styles, Coverstore makes it easy to find the right level of protection for any grill, any climate, and any backyard.
Grill Cover Feature Comparison
| Feature | Why It Matters for Rust Prevention | Especially Important For |
|---|---|---|
| Water-resistant fabric | Blocks moisture from reaching the grill surface | All climates |
| Ventilation panels | Prevents trapped moisture from condensing underneath | Humid regions |
| Secure fit with straps | Keeps cover in place, sealing out rain and wind | Windy and coastal areas |
| UV-resistant coating | Protects cover material and grill finish from sun damage | Sun-intense regions |
| Custom sizing | Eliminates gaps that allow water infiltration | Unusually shaped or oversized grills |
| Reinforced seams | Maintains cover integrity over time, preventing tears | High-wind environments |
Grill Rust and Cover Protection: Key Stats
- 70M+ barbecue grills and smokers owned by Americans, with the majority stored outdoors year-round.
- 60%+ humidity is the threshold above which uncovered grills can show visible surface rust within a single off-season.
Sources: Hearth, Patio and Barbecue Association (HPBA) Industry Data, and general materials science literature on iron oxidation and humidity thresholds
Expert Perspectives on Rust Prevention
Ryan Donovan - Digital Growth & Optimization Analyst, Coverstore
Ryan is a Digital Growth & Optimization Analyst focused on SEO, experimentation, and performance optimization.
Key Takeaway
"Between researching the topic, hearing from grill owners, and knowing our products inside and out, one theme comes up constantly. The grills that hold up best over time are the ones that are covered consistently, with a cover that actually fits."
Addressing Common Objections
Some grill owners assume that covering their grill is unnecessary in mild climates or during the summer months. In reality, rust doesn't require a rainstorm. Humidity and overnight dew are enough to begin the oxidation process. Others worry that a cover will hold heat after cooking and cause damage. This is easily avoided by allowing the grill to cool fully before covering, a step that takes no more than 20 to 30 minutes.
Frequently Asked Questions
How do I keep my grill from rusting?
The most effective combination is consistent use of a well-fitted, water-resistant grill cover, regular cleaning of the grates, and allowing the grill to dry before covering. Seasoning cast iron grates, emptying the drip tray, and checking flame tamers for buildup also make a significant difference over time.
How do I keep my gas grill from rusting?
Gas grills need the same cover-and-dry routine, plus attention to the parts unique to them. Drippings collect on flame tamers and burner tubes, and grease pools in the drip tray, so clearing both on a schedule removes the moisture that corrosion needs. A cover sized to your specific model keeps wind-driven rain out of the cabinet where the gas line and igniter sit.
Will a grill cover actually prevent rust, or can it trap moisture and make it worse?
A quality cover with proper ventilation prevents rust rather than causing it. The risk of trapped moisture comes from covering a wet grill or using a non-breathable cover with no airflow. Coverstore's covers are designed with ventilation features that allow moisture to escape while keeping rain and dew out.
Can I put a grill cover on a hot grill?
No. Wait until the grill is completely cool, which usually takes 20 to 30 minutes after the burners are off. Covering a warm grill traps rising water vapor against the metal, and that condensation is exactly the condition rust needs. There is also a fabric risk, since residual heat can scorch or melt a cover resting against a hot lid or firebox.
How do I keep my grill grates from rusting?
Clean the grates after every use to remove food residue, and season cast iron grates regularly with a light coat of cooking oil. Dry them fully rather than letting them air dry, since standing water is what turns clean grates into rusty grill grates. Storing the grill covered and dry between uses is equally important. For a full walkthrough, see our guide on how to clean and protect your grill.
Can you cook on a rusty grill, and is it safe?
Light surface rust on grates can be scrubbed off and the grates re-seasoned before cooking. However, heavy rust that flakes or pits the metal is a sign the grates need to be replaced. Rust itself is not considered acutely toxic, but cooking on heavily corroded grates introduces unnecessary risk and affects food quality.
Should I use a water-resistant or a breathable grill cover to stop rust?
Ideally, both. The best grill covers are water-resistant on the outer surface to repel rain while also incorporating breathable panels or vents to allow moisture vapor to escape. Choosing a cover that only does one or the other leaves a gap in protection, either from precipitation or from trapped condensation.
Limitations to Consider
- Existing rust: A cover alone won't reverse rust that has already formed. Affected areas need to be treated or replaced first.
- Extreme coastal environments: In areas with salt air exposure, even high-quality covers require more frequent inspection and may benefit from supplemental protective coatings on the grill itself.
- Oversized or unusual shapes: Custom sizing is recommended for grills where standard covers may not provide a secure fit.
- High-wind areas: No cover is fully effective without proper securing. Always use all available closures and consider a higher-collection cover with more robust fastening systems.
- Warranty terms vary: Some grill manufacturers cover rust-through on specific components and exclude cosmetic surface rust entirely. Check your grill's warranty before assuming corrosion is a covered defect.
What Customers Are Saying
"Great product that is well built and fits as ordered. The process from ordering to receiving was fantastic. I chose the Prestige for our new grill for a few reasons. First is the warranty on the cover. 10 years is great. Second, the product size options were endless and easy to get what we needed for our grill. Lastly, if you sign up for emails etc, I received a nice discount which made the decision to purchase a bit easier. Thanks for making such a sturdy well built product for us. Go online and get you one, you won't be let down."
"I only get my patio furniture and grill covers from the Coverstore, and it's been years, maybe over 20 years. I started out with the lower level and as time went on and my furniture and grills were pricier, and I needed to protect my investments, so did my choice in protection. I live in an area in California where we have full on beat you down sun and high winds at times. I need the strongest and most durable protection covers as I don't want to be replacing them more often than I need to. I ordered the Ultima outdoor furniture covers about 2 years ago and they have lasted and protected well so I don't doubt that this grill cover will do just as well. The fit for my grill was perfect with buckle down cinch and clips. No complaints here."
"Fits my grill great. Love the buckle straps on sides and buckle that goes under the grill to keep it from raising up."
Explore Coverstore Grill Covers
Shop our various collections of BBQ and grill covers to find your perfect match.
Final Thoughts
Knowing how to keep your grill from rusting is mostly a matter of removing variables, and the fix is simpler than most people think. A well-chosen, properly used grill cover takes care of the big three: moisture, UV exposure, and inconsistent protection. Pair that with regular cleaning, dry storage, and a little seasonal maintenance, and your grill can stay in grilling shape for years to come.