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Sayfa is now Kattsafe

We’ve built a name for ourselves by continuously innovating safer, simpler height access and fall protection systems, and now it’s time for our business to evolve too.

Bringing everything we do under one new name makes it even simpler to work with us and use our products. And behind it all, we’re still the same team, quality products, and customer service that you’ve come to expect.

Aluminium versus steel – a comparison of the pros and cons

Aluminium Versus Steel – A Comparison Of The Pros And Cons

When it comes to choosing between aluminium and steel products for your next project, there are several factors to consider. Both materials have their own unique characteristics, advantages and disadvantages, and the decision ultimately depends on your specific needs and preferences. In this guide, we’ll explore the pros and cons of each material to help you make an informed decision.


Both aluminium and steel are used extensively in the construction of ladders, platforms, stairs, guardrail and walkway. Although steel was originally the traditional material of choice for these products, aluminium has grown more and more popular due to its unique qualities and versatility.

Aluminum is a lightweight metal that is known for its strength, corrosion resistance, and thermal conductivity. It is commonly used in the aerospace industry, automotive industry, and construction industry. One of the primary advantages of aluminum is its weight-to-strength ratio. It is significantly lighter than steel while still being strong, making it an ideal choice for applications where weight is a concern. Aluminum also has a high resistance to corrosion, which makes it an excellent material for harsh outdoor environments.

Steel, on the other hand, is a heavier and stronger material than aluminum. It too is commonly used in the construction industry, manufacturing industry, and transportation industry, however is much more susceptible to corrosion than aluminum, often requiring additional maintenance and protection measures.


When it comes to cost, steel is generally the more affordable option (kilo for kilo). However, the cost of aluminium has been decreasing in recent years, making it a much more competitive option. Also, you often require a lot less kg/m2 of aluminium to achieve the same result. Additionally, as aluminium is lightweight it is easier to transport which can significantly reduce freight costs. These advantages, along with reduced installation times and the lack of requirement for heavy lifting machinery can, more often than not, offset the initial cost differences.

Where aluminium does come to the fore is in the lifetime costs compared with steel. With no painting, treatments or coatings required to maintain its integrity and durability aluminium components can be a huge financial benefit long term in regards to maintenance and labor costs.

For both materials more labour and production downtime cost savings can be made if the components are modular and can be assembled in situ without the need for on-site welding or specialist tools or personnel.

Strength and Durability

When it comes to strength and durability, what aluminium might lack in structural strength it more than makes up for in its durability and versatility. It is highly resistant to rust and corrosion, making it a great choice for outdoor applications or in areas with high humidity. It is also of note that if higher strength aluminium components are needed these can be engineered to produce products that weigh significantly less than steel but still have the required strength to weight ratios.

Steel, whilst being a stronger material, as previously mentioned is prone to rust and corrosion, which can weaken its structural integrity over time

Corrosion Resistance

One of the biggest advantages of aluminium over steel is its corrosion resistance. Aluminium naturally forms a protective oxide layer on its surface, which helps to prevent rust and corrosion.

Steel, on the other hand, is susceptible to rust and corrosion, especially in environments with high levels of moisture or salt. While steel can be treated with coatings or galvanising to improve its corrosion resistance, these types of treatments will incur additional material and labour costs which over the course of the product’s lifetime can amount to a substantial amount of money.

Weight and Flexibility

When it comes to weight, aluminium is the clear winner. It is a much lighter material than steel, making it a popular choice for applications where weight is a concern, such as in the aerospace industry.

Lighter weight components also assists greatly with installation meaning that there is a significantly reduced risk of manual handling injuries and also in many cases no requirement for heavy lifting equipment.

Aluminium is also more flexible than steel, which can be an advantage in certain applications where flexibility is needed, such as in the construction of buildings that need to withstand earthquakes or other natural disasters.

Environmental & Sustainability Factors

When it comes to environmental impact, aluminium is generally considered to be the more eco-friendly option. This is because aluminium is infinitely recyclable, meaning it can be recycled over and over again without losing its quality.  Nearly 75% of all aluminum ever produced is still in use today.

Steel, on the other hand, can only be recycled a limited number of times before it begins to degrade. Additionally, the production of aluminium requires less energy and emits fewer greenhouse gases than the production of steel.

In summary

The choice between aluminum and steel ultimately depends on the specific application and requirements of the project. When considering the options remember to take all factors into consideration and be aware of the additional costs such as labour to install, downtime on-site and on-going maintenance which may result in the product costing much more than your original budget.

With all things considered aluminium takes a front seat as the most value for money, effective and versatile material.