Aluminum Vs Steel Handrails

Should I choose aluminum or steel handrails?

It’s a question many have asked, and though there are many opinion articles written to peddle one product over the other, few of them truly address the benefits of each and why both products deserve to exist. Understanding each option may help you decide what best fits your needs and your budget. 

Material Properties:

Corrosion

If you have been searching for information on this subject, more than likely you’ve already heard that aluminum railings are better because they don’t rust. This is only partially true, or at the very least not comparing two completed products to one another. 

Rust, a specific type of corrosion, occurs when Iron undergoes a chemical reaction to create Iron Oxide in the presence of moisture. It is known for its red color and powdery coating. By definition, aluminum cannot rust because rust is a specific type of corrosion referring to Iron. 

This is not to say that aluminum cannot corrode. The conditions required are simply different. 

A steel railing requires a quality metal finish, such as galvanizing, powder-coating, or paint to mitigate corrosion, and when properly applied, a steel railing can be expected to offer a long service life without rusting. While aluminum offers natural advantages as a raw material, it is infrequently used without some form of metal finish as well. Aluminum railings are frequently anodized, powder-coated, and painted to prevent corrosion and for aesthetic benefits. The most common options we see are powder-coated steel railings or powder-coated aluminum railings, both of which will have excellent corrosion resistance. 

Weight and Strength

Weight savings are also often mentioned in this debate, and there is a place for this. Most often, this will be a factor that is irrelevant to a consumer however unless they intend to install or relocate any railings themselves. 

Aluminum generally offers a weight savings of approximately 30% for equal volume, however, in many cases, thicker aluminum is used for strength benefits and nullifies most of the weight-saving benefits. In cases where strength is less of a concern and weight savings can be achieved, these materials are still unique in their other properties such as stiffness, hardness, and fatigue resistance. 

Steel and aluminum each come in many forms. Each is versatile when alloyed or heat-treated to achieve specific properties for applications they are needed for. In nearly all cases, handrails will be built from basic mild steel or a basic 6000 series aluminum. Side by side, steel will have superior strength, hardness, and fatigue strength. What this means in plain terms is that the lighter-weight aluminum railings will have more flex, will be easier to scratch and dent, and will not hold up as long against cycled loading before welds or base material begins to crack or tear. 

Cost

Comparing pricing between these two options is dependent on a range of factors. At face value, aluminum is generally 30% more expensive when compared to dimensionally comparable steel materials. That being said, in cases where powder-coating is applied, aluminum may present a small amount of savings as a zinc primer may not need to be applied to achieve suitable corrosion resistance. Additionally, there may be savings found on installation as well. Lighter weight materials can be handled more easily with fewer people or less lifting equipment. 

A Place for Each:

Aluminum

Railings of this kind are generally made for items that are primarily aesthetic, such as decorative fencing, garden railing, decorative gates, and any other application that sees less physical stress and wear and tear. Forming this material is cost effective and for low stress applications, thin aluminum can be used to achieve an inexpensive product that looks nice. Under heavier use, aluminum will see wear noticeably faster. Good for DIY projects, and projects where aesthetics are more important than functionality. Premade kits are readily available.

Steel

Railings of this kind can be versatile. With many decorative cast and formed parts available, steel railings can be decorative and achieve a more traditional “wrought iron” look. They can also be well suited for simpler minimalist designs that are more modern. Due to the strength and stiffness of steel, railings of this material will feel sturdy and solid in the hand making them a good choice for railings that will see heavy use. This heavier material is not as readily available in DIY kits, and is more commonly a custom product.

Conclusions:

If you were hoping to find an answer to the debate at the bottom of this article, I’m sorry to disappoint. The truth is, both types of railings are good in their own ways and useful for different things. If you’re unsure of which would be better for your project after finishing this article, we’re happy to talk with you about your needs and help you make a selection. No matter the project, being armed with the information you need makes it easier to get the product you’re looking for and make working with a contractor a more positive experience.