A grill with loose rust is not safe, as rust may stick to the food; a grate with minor surface rust can be cleaned and treated to continue using it. While ingesting rust may not likely cause harm from one meal, continuous ingestion may be problematic for the intestinal tract.

Should I replace rusty grill grates?

Rust on the Grill

A small amount of rust on a grill grate shouldn't be cause for too much concern. ... But if there are large splotches of rust throughout the grate that go deep into the metal and can't be completely removed with a wire brush, it's time to retire that grate.

Is it normal for a grill to rust?

Rusting is a common occurrence on metallic objects, particularly those left outside. Some high quality grills are immune to rust to some extent, however without proper care they might get rusty as well. The biggest effect of grill rust is its corrosive effect on metal.