The Difference Between Aluminium and Steel for DIYers and Home Projects

When planning a project, choosing materials is one of the most critical decisions you’ll make. Two of the most popular materials in Australian construction projects are steel and aluminium, and while they may appear similar at a glance, they serve very different purposes.

At Edcon Steel, we offer an extensive range of aluminium and steel products, and our team is available to help DIYers and home renovators understand which is best suited for their projects.

Here, we outline the key differences between aluminium and steel, examining their strength, weight, cost, corrosion resistance, and best-use applications so you can make the right decision with confidence.

"Choosing between aluminium and steel isn't just about price—it's about performance, location, and long-term value."

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Key differences

Weight and Handling

Aluminium is much lighter than steel. In fact, aluminium weighs about one-third as much as steel, making it an ideal material when weight savings are a priority. Aluminium is often used in window frames, trailers, and cladding, where reduced weight lowers the overall load and improves handling. Steel, while heavier, provides the muscle needed for major structural elements like beams, posts, and bearers.

Strength and Structural Integrity

Steel is stronger than aluminium when comparing similar-sized sections. It has higher tensile and yield strength, meaning it can withstand heavier loads and greater stress before deforming. This makes steel the preferred choice for framing, roofing structures, beams, and columns in both residential and commercial construction. Aluminium, while still strong for its weight, is more prone to bending and denting under heavy loads, so it’s often used for non-structural or light-load components.

"Aluminium is lightweight, corrosion-resistant, and ideal for exposed applications—especially in coastal environments."

Corrosion Resistance

Aluminium naturally forms a thin oxide layer that protects it from corrosion. This means it’s inherently more corrosion-resistant than steel, especially in coastal or high-humidity environments. Steel, on the other hand, requires protective treatments like galvanising (HDG), pre-galv, powder coating or painting to prevent rust.
At Edcon Steel, we offer a full range of galvanised and coated steel products to make sure your materials are suitable for the Australian climate.

Cost Considerations

Steel is generally more affordable than aluminium when compared by strength per dollar. This makes steel a popular choice for large-scale and budget-conscious projects. Aluminium tends to be more expensive upfront, but its low maintenance and corrosion resistance may offer savings over time, particularly in marine or high-exposure environments.

Workability and Fabrication

Aluminium is easier to cut, drill and shape than steel. It’s more pliable and can be machined using lighter tools, making it ideal for on-site adjustments and DIY use. So, if you have small projects and a limited tool kit, aluminium is worth considering. It is lighter, softer and easier to work with than steel. And a huge plus is – it is cleaner.

Steel requires more heavy-duty tools and typically more labour-intensive processes. However, Edcon Steel makes it easy by offering cut-to-size, drilling, and fabrication services, so you don’t have to worry about that on-site.

Aesthetics and Finish Options

Both steel and aluminium offer great finishing options, including painting, powder coating, and anodising (aluminium only). Steel can be hot-dip galvanised, pre-galvanised, or left raw for painting and welding. Aluminium is popular for clean, modern aesthetics, especially in exposed architectural applications.

"Steel delivers unmatched strength for structural applications, making it the go-to for builders across Australia."

Applications in Australian Construction

✅ Use Aluminium For:	✅ Use Steel For:
Window frames and door frames	Beams, bearers, structural posts
Decorative fencing and screens	Wall framing and bracing
Roof flashings and trims	Roof trusses and lintels
Lightweight cladding	Garage, shed, warehouse builds
Coastal or marine projects	Stair Stringers and Treads
Caravans and trailers	Load-bearing decks, especially in bushfire areas

At Edcon Steel, we supply a wide range of both aluminium and structural steel, all cut to your specification and available for pickup or delivery Australia-wide.

"At Edcon Steel, we offer the best of both worlds—premium aluminium and steel, all backed by expert advice."

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Whether you’re a DIYer or home renovator, our team is here to help you make the right choice. We’ll guide you through the pros and cons of each material and ensure your project is built to last.

With thousands of aluminium and steel products in stock, you can visit our stores to browse the range or pick up an online order. Our staff are on hand to answer any questions you have about our full range of products and services, so feel free to contact us for your steel or metal solution today.

"From DIY carports to major commercial builds, we help customers pick the right metal for the job."

Frequently Asked Questions (FAQs)

Is aluminium better than steel for outdoor use?

Aluminium naturally resists corrosion, making it ideal for coastal or outdoor environments. However, hot-dip galvanised (HDG) steel is also a great outdoor option with excellent durability.

Which is stronger: aluminium or steel?

Steel is stronger and more rigid than aluminium, making it better for load-bearing structures. Aluminium offers strength relative to its weight but isn’t suitable for heavy structural loads.

Can you weld aluminium like steel?

Yes, but aluminium requires different techniques and equipment. If you plan to weld onsite, consult with a professional—or order fabricated aluminium directly from Edcon.

Is aluminium more expensive than steel?

Typically, yes. Aluminium costs more upfront, but its long-term resistance to rust and maintenance needs can offset the higher price depending on your project.

Can Edcon Steel help me choose the right material?

Absolutely. Our experienced team will help you match the right product—aluminium or steel—to your job, budget, and environment. We also cut to size and deliver nationwide. Let me know if you'd like this formatted for blog upload, broken into social snippets, or tailored for print collateral.