For brackets, frames, and panels, the aluminum vs.. steel call is usually about what matters most on your build: weight, stiffness, corrosion, and temperature.
Steel is often the pick when you need a part that stays rigid and takes a hit. Aluminum is often the pick when you want to cut weight and you are building for outdoor exposure where corrosion is a concern. If the job will see winter road spray or washdown, that environment should be part of the material and finishing decision from the start.
Aluminum vs. Steel Quick Table*
Steel vs. Aluminum Fabrication for Metal Brackets
If you keep the bracket shape the same, steel will usually feel more rigid, and aluminum will usually feel lighter. That comes from two basic properties:
- Weight: Aluminum is about 2.7 g/cm³ vs. steel about 7.85 g/cm³, so aluminum starts much lighter for the same size.
- Bend resistance: Steel’s stiffness number is commonly listed around 200 GPa vs. aluminum around 69 GPa. That means steel tends to bend less than aluminum at the same thickness and shape.
Choose aluminum when the bracket is big enough that weight affects handling, shipping, or install. Choose steel when the bracket must hold position with less flex at the same geometry.
Corrosion on Aluminum vs. Steel in Edmonton
Corrosion risk mostly comes down to moisture and road salt or washdown. Deicing salt is a documented corrosion threat for architectural metals and other construction materials in winter road environments.
- Aluminum: resists corrosion in many conditions because it forms a thin oxide film in air, but chloride-heavy wet exposure can still cause issues.
- Carbon steel: more likely to rust in wet exposure without protection.
- Stainless steel: typically the best corrosion choice of the three because chromium forms a protective film. (Performance still depends on grade and environment.)
To keep rust risk down on outdoor parts, talk to GC early about powder coating in Edmonton so we can match the material and finish to your real exposure conditions.
Sheet Metal Fabrication and Temperature Swings
Temperature swing shows up as panel gaps that change season to season, and holes that do not line up as easily on long parts (like sheet metal). Aluminum typically has a higher thermal expansion value than steel, meaning aluminum typically expands/contracts more as temperatures change.
Aluminum panels are more likely to need a little more “room” in the design for temperature movement on long spans. Steel panels typically move less with temperature than aluminum, which can make tight fits easier to manage on long parts.
Welding and Fabrication at GC Custom Metal
At GC Custom Metal in Edmonton, we support both aluminum and steel projects with integrated fabrication at our shop This includes:
- MIG and TIG welding
- Fabrication using both steel and aluminum
- In-house powder coating using a three-stage flow: washing, painting, and baking (curing)
We operate out of a 32,000-square-foot facility in Edmonton, where we offer a full range of metal fabrication services from design to assembly. This includes welding, powder coating, bending, cutting, CNC and machining.
Contact GC Custom Metal to discuss your project and the best metal suited for the job.
FAQ
Is aluminum or steel better for outdoor brackets in Edmonton?
It depends on exposure and how the bracket is assembled. Deicing salt is a known corrosion threat in winter road environments, and galvanic corrosion can occur when aluminum and steel are connected and exposed to the threat.
Is aluminum or steel better for outdoor use in Edmonton?
In many everyday outdoor conditions, aluminum often performs well because it forms a protective oxide film in air. Carbon steel can rust when it is exposed to moisture and oxygen, so it often needs a protective finish for outdoor exposure. Deicing salt can raise corrosion risk for metal parts in winter road environments.
What should I include in an RFQ so you can recommend aluminum vs steel faster?
Add three notes: the environment (especially salt or washdown), whether aluminum will touch steel, and any tight-fit areas where hole alignment or gaps matter.
Why Choose Contract Manufacturing Under One Roof?
With GC, it’s simple:
- Fewer vendors to manage
- Fewer touch points on your floor
- Less risk of damage
- Quicker turnaround
- Fewer transportation headaches
- Assemblies that scan into inventory and move straight to the line
You keep your focus where it belongs: on your project.
Contact GC Custom Metal to work with a team that’s been honing our craft since 1982, and knows the value of consolidated metal fabrication. Contact us today to start your quote.
GC Custom Metal Fabrication Ltd. is a full-service metal fabrication shop in Edmonton, Alberta. They provide a full range of services to the highest quality standards, which is all made possible by their 32,000 square foot shop and extensive technical capabilities. Request a quote from GC Custom Metal today or contact us with questions.