Emery Cloth Vs. Sandpaper: When To Use Each

When you want to remove material or smooth surfaces, you need a quality abrasive. Both emery cloth and sandpaper can do the job and do it well, but they’re intended for different types of projects, and knowing which one to apply can make a difference in the finished workpiece.

The main difference between emery cloth and sandpaper is that the abrasive grains on the former are coarser and harder, allowing it to remove rust, oxidation, or old paint without disintegrating under pressure. In contrast, sandpaper has a wider grit range, so you can use it for anything from basic shaping to fine finishing. 

Knowing when to use each one is key to product longevity as well as the success of your project. In this guide, we’ll explain what you need to know about emery cloth vs. sandpaper usage, including application techniques and when you’ll want to reach for one instead of the other.

What is Emery Cloth?

Emery cloth is a rugged abrasive consisting of a woven cloth backing and emery particles, a granular rock containing aluminum oxide and iron oxide (magnetite or hematite). The cloth material, which is usually made from cotton or polyester, is flexible and tear-resistent while the grayish-black emery grit (typically available in sizes from 36 to 220) is secured to its surface by industrial-grade resin or glue.

Emery cloth is ideal for metalworking tasks like rust removal, deburring, polishing, and cleaning corrosion from steel, aluminum, or brass. It resists shredding, conforms to curves, and suits both wet and dry applications, so it’s ideal for plumbing and auto repair. However, when used on a softer material like wood, tiny metallic particles can embed in the grain and react with the natural extractives (tannins) in the wood (especially in the presence of moisture), causing black or gray iron stains.

As an abrasive, emery cloth lasts longer than most sandpaper and can be reused after washing. The cloth backing doesn’t tear even when you're working with sharp edges or applying heavy pressure. It handles wet sanding applications without disintegrating, and the heat resistance prevents the backing from scorching during high-friction work.

What is Sandpaper?

Sandpaper consists of heavy-duty paper with abrasive particles adhered to the surface. It’s used to manufacture sanding sheets as well as belts, discs, and rolls. Because sandpaper comes in different sizes and grit types, you can use it in a wide range of tasks, from heavy paint removal to fine finishing. Since a high-quality sandpaper can do an excellent job at smoothing as well as surface preparation, it’s a key tool in workshops where woodworking and metalworking are carried out.

At Red Label Abrasives, we manufacture sandpaper sheets with the following abrasive types:

• Aluminum Oxide: This is the industry standard for common applications. Open coat aluminum oxide excels at planing, stripping, roughing, and finishing on all wood types, while closed coat aluminum oxide handles snagging, weld removal, and grinding of metals. Its affordability makes it the go-to choice for workshops that need reliable performance without premium costs.
• Silicon Carbide: This abrasive is harder and sharper than aluminum oxide, so the cut rate remains the same through the entire life of the belt. The ability to remove material without excessive heat buildup makes it perfect for finishing stabilized wood, resins, epoxy, and other heat-sensitive applications. Silicon carbide also works well for automotive paint preparation and solid surfaces like marble and glass.

Emery Cloth vs. Sandpaper: an Overview

When to Use Emery Cloth

Emery cloth is a fixture in metalworking shops, so if you work in metal fabrication or a related field, you’ll want to stock up. Since the abrasive grain is made from the natural mineral emery (a composite of aluminum oxide and magnetite), it’s hard enough to cut metal yet tough enough to resist fracturing under pressure. The cloth backing resists shredding and tearing during aggressive sanding, making it ideal for:

• Rust Removal and Surface Prep: Emery cloth strips rust, oxidation, and corrosion from metal surfaces faster than sandpaper without falling apart. It's ideal for surface preparation, rust removal, and weld clean-up. It's typically used on steel, brass, copper, aluminum, and zinc to remove rust or corrosion, as well as clean them up prior to painting or welding. 
• Deburring: In fabrication work, emery cloth is frequently used for deburring sharp edges left after cutting or machining metal stock. Running a strip of emery cloth around a rotating shaft also cleans away surface imperfections and minor scoring without causing significant material loss. 
• Knife Making and Blade Finishing: Emery cloth is also used in knife making. You can clean the blade first with coarse and then finer grit emery cloth, before polishing it on an emery wheel. Grease-based chemical compounds such as Emery and Tripoli do a great job of eliminating fine scratches from the knife's surface after the grinding stage.
• Curved and Irregular Surfaces: The flexible backing lets emery cloth conform easily to pipes, dowels, shafts, and contoured parts. Plumbers cleaning copper pipes before soldering wrap emery cloth around the pipe and rotate it to remove oxidation evenly. You can even tear strips and use them as polishing cords for hard-to-reach areas.

How to Use Emery Cloth

If you’re using emery cloth for your project, start by selecting the right grit for your task:

• 60 to 80 grit for heavy rust removal or stock removal
• 100 to 120 grit for smoothing and final surface prep. 

Cut or tear a workable piece from your roll (emery cloth tears cleanly along the weave). For flat surfaces, wrap the cloth around a sanding block to maintain even pressure and prevent rounding edges. For curved work, hold the cloth in your hands and conform it to the shape. Apply moderate pressure and work in consistent strokes: too much pressure generates excess heat and clogs the abrasive. After use, you can rinse the emery cloth with water or solvent and reuse it multiple times before the grit wears out.

Pro Tip: For wet sanding, add a few drops of lubricating oil to the surface, which reduces heat buildup and extends the life of the cloth. 

As we stated earlier, emery cloth isn't the right choice for wood finishing, as the tiny bits of iron can permanently damage natural wood. The coarser grit range also means you can't achieve ultra-fine finishes that call for 220 grit or higher. It costs more per foot than paper-backed sandpaper, which matters if you're doing light-duty work that doesn't demand the extra durability. For woodworking, drywall, or other non-metal applications, save your emery cloth and reach for sandpaper instead.

When to Use Sandpaper

Sandpaper is ideal for woodworking, drywall finishing, paint preparation, and any task where you need a wide grit range available. Examples include:

• Woodworking and Furniture Finishing: The sandpaper grades used most for furniture finishing fall in the finer categories: that is, from 120 grit through 220 grit, with 320, 400, and 600 grit used for special purposes. A good general rule for grit progression is to use 100 or 120 grit for initial sanding, 150 or 180 grit for the next pass, and 220 grit for the final pass. 
• Drywall and Paint Prep: Medium to fine (100 to 220) grit sandpaper works well on drywall. To avoid damaging the drywall surface, don't use anything below 100 grit sandpaper. You’ll want to use 80-100 grit for leveling out thick drywall joints and uneven seams, and 120-150 grit for eliminating imperfections and preparing the surface for painting. Finish with 180-220 grit. 
• Automotive and Wet Sanding: Use coarse sandpaper of 24- to 40-grit to remove old paint, 150-grit to smooth out the scratches, 240- to 400-grit for wet sanding primer, and 1,500- to 4,000-grit for smooth finishing. It's common to use 1500- and 2000-grit sandpaper when wet sanding both headlights and automotive paint.
• Plastics: Silicon carbide sandpaper is the best choice for plastic, as it cuts efficiently without excessive friction or clogging. Grit progression is key: starting with coarse grits (60–180) for heavy imperfections, moving to medium (220–400) for smoothing, and finishing with fine (600–1000) or ultra-fine (1200–3000) grits for polishing. 
• Knife Making and Blade Finishing: Like emery cloth, you can use sandpaper in knife making. At Red Label Abrasives, we sell knife making kits with all the grit sizes and belt types you’ll need to remove metal stock, shape the knife, and achieve a mirror finish. Available abrasives include ceramic, zirconia, and closed-coat aluminum oxide.

While the grit tells you how fast a product will cut, the backing weight indicates how resilient the product is. Abrasives are generally categorized by a letter system, ranging from "A" (the lightest) to "F" (the heaviest). Choosing the wrong weight can lead to premature tearing or a finish that is too stiff for the job.

Paper Backings (A to F Weights)

• A-Weight (Lightweight): This is the thinnest, most flexible paper. It is typically used for light hand-sanding or finishing between coats of paint or lacquer.
• C and D-Weights (Medium weight): These are the "all-purpose" choices for workshops. They balance strength and flexibility, making them ideal for hand-sanding blocks and some orbital sanders.
• E and F-Weights (Heavyweight): These thick papers are intended for heavy-duty machine sanding. You’ll see them used in floor sanding or for large-scale industrial wood leveling where tear resistance is vital.

Cloth Backings (J, X, and Y Weights)

You’ll want to use sandpaper with a cloth backing if you’re doing more aggressive sanding or working in a wet environment. Options include:

• J-Weight (Jeans): Like a pair of denim jeans, this backing is thin and very flexible. It is the go-to choice for sanding contoured surfaces, such as furniture legs or turned bowls, because it conforms to shapes without breaking.
• X-Weight (Extra): This is the industry standard for most sanding belts, as it can handle the high heat and tension of a belt sander without stretching.
• Y-Weight (Heavy Duty): The "tank" of backings, y-weight is a heavy polyester cloth used for the most aggressive applications, such as grinding down weld beads or heavy stock removal on hardwoods.

Pro Tip: If you are sanding a flat surface, a stiffer X-weight or E-weight backing will help keep the surface level. If you are sanding a curved banister or a pipe, a J-weight cloth or A-weight paper will "wrap" around the workpiece much more effectively.

How to Use Sandpaper

The golden rule of sanding is that you should not skip more than one grit as you progress through the sanding stages. Every scratch you make must be removed by the next finer grit: skip a step and you risk locking in scratches that show up only after staining or coating. 

For example, if you start with P80 and need to finish at P240, rather than using every grit from P80 to P220, you can do P80 to P120 to P180, and then P240. Hardwoods generally allow for starting with coarser grits (like 80) compared to softwoods (often starting at 120 or 150). Metals vary too; heavy rust might need 40-60 grit, while smoother metal could start much finer. 

You’ll want to wear safety gear that protects you from the dust generated by sanding. 

• Mask or Respirator: Wearing a mask or respirator is especially vital when sanding drywall, as these tools protect your lungs from inhaling the dust that can lead to respiratory issues. Masks should be rated for fine dust; an N95 respirator filters at least 95% of airborne particles. 
• Hand Protection: If you're simply hand-sanding a piece of wood, some basic hand protection should be enough. Grinding metal is much riskier, as you can cut yourself on razor-sharp pieces of metal or burn yourself with sparks or hot metal fragments. Reach for heavy-duty leather gloves or welding gloves when you're grinding metal. 
• Eye Protection: Wearing safety goggles is essential. Choose goggles that fit snugly and provide a strong seal around the eyes, ensuring that no dust can sneak through small gaps. 

Emery Cloth vs. Sandpaper: Project Selection Table

Red Label Abrasives: A Cut Above The Rest

Choosing between emery cloth and sandpaper comes down to what material and application you’re working with. Emery cloth excels at metal grinding, rust removal, and deburring, but isn’t ideal for wood. Sandpaper has the grit range and versatility needed for woodworking, drywall finishing, and automotive paint prep. Any workshop or manufacturing facility that carries both will have everything they need for most applications. 

At Red Label Abrasives, we manufacture sanding belts, sanding discs, and sanding sheets in grits suitable for all stages of material shaping, removal, and polishing. Whether you work in a factory-scale facility or need to restock your private workshop, we can help. If you have questions or would like to place an order, please fill out a contact form or call 844-824-1956 today.