Comparing Aluminium Sheet Metal to Steel and Other Metals

Here’s a detailed look across key performance criteria:

Density and Mechanical Strength: Weight-Saving Without Compromising Performance

Aluminium’s low density makes it ideal for reducing structural loads, enabling lighter, more energy-efficient buildings and vehicles. For instance, 5083 aluminium alloy offers excellent strength for marine, transport, and architectural panels—at just a third of the weight of steel.

Strength / Density Comparison: 

Corrosion Resistance: Long-Term Durability Without Coatings

Aluminium forms a naturally protective oxide layer, eliminating the need for galvanising or frequent repainting in most applications. For example, in coastal or high-humidity environments (such as, in parts of the UK’s southwest or industrial zones), marine-grade aluminium (e.g. 5083 or 5754) outperforms steel without the need for constant treatment or inspection.

In comparison:

- Mild steel corrodes quickly without coating, increasing lifecycle maintenance

- Stainless steel does offer excellent resistance - but at a much higher cost

- Copper resists corrosion but discolours over time (known as 'patina', a thin layer that variously forms on the surface of copper, brass, bronze, and similar metals and metal alloys), which can be undesirable in some modern architectural contexts

Fabrication & Formability: Aluminium’s Advantage in Sheet Forming

Aluminium sheet is exceptionally versatile and easy to use with UK-standard equipment and processes, such as:

- Cutting & Punching: aluminium sheeting is readily laser cut or CNC punched with minimal tool wear

- Folding & Bending: aluminium’s ductility allows tight radius bends without cracking, especially in softer alloys like 1050-H14

- Welding: TIG and MIG welding are both widely used, especially in marine and transport fabrication

- Surface Finishing: powder coating, anodising and pre-painted sheets offer corrosion protection and decorative appeal

In comparison, mild steel is more rigid and heavier to process, increasing tooling and labour demands. Stainless steel also requires specialist tooling and slower processing speeds due to work-hardening characteristics.

Cost Comparison: Beyond the Price Per Tonne

Result: for façades, roofing, rainscreens, and lightweight framing, aluminium often delivers a lower total cost of ownership than heavier alternatives.

Thermal and Acoustic Properties

- Thermal Conductivity: aluminium (205 W/m·K) conducts heat well, making it ideal for heat sinks, cladding systems with insulation layers, and solar shading

- Expansion Rate: aluminium’s thermal expansion (~24 x10⁻⁶/K) must be considered in large panels or extrusions, especially in curtain walling—manageable through proper detailing

- Sound Insulation: aluminium is less dense than steel, offering slightly less acoustic insulation. Laminated systems or composites are typically used where sound reduction is critical

Environmental Impact and Circular Economy

The UK’s commitment to net-zero construction by 2050 aligns perfectly with aluminium’s recyclability.

- Recycled Content: UK and European mills commonly offer aluminium sheet with >75% recycled content

- Embodied Carbon: recycled aluminium has an embodied carbon footprint of ~0.5–1.0 kg CO₂/kg compared to virgin steel at ~2.0 kg CO₂/kg

- Scrap Value: aluminium has a high retained value, incentivising recovery and recycling at end-of-life

Aluminium sheet meets criteria under BREEAM, LEED, and other sustainable construction frameworks, enhancing your building’s environmental credentials:

Conclusion

Aluminium sheet metal provides a technical and economic advantage in many construction, infrastructure, and manufacturing applications. When compared to steel, stainless steel, or copper, aluminium’s strength-to-weight ratio, corrosion resistance, workability, and sustainability credentials make it a standout choice—especially in the UK market where environmental compliance and cost-efficiency are driving forces.

As a UK-based aluminium extrusion and sheet fabrication specialist, BWC Profiles supply precision-cut, finished, and formed aluminium sheet products tailored to your project requirements. Whether you’re designing a rainscreen system, a transport enclosure, or a sustainable building envelope, we offer the technical support, material expertise, and in-house fabrication to deliver to spec, on time, and to budget.