Metal Canopies: Choosing Steel vs. Aluminum for Durable Design

Choosing the right metal canopy for a project requires balancing factors like durability, cost, weight and customization capabilities to ensure the building meets its function and aesthetic goals. 

Deciding between steel and aluminum for a canopy requires evaluating the performance, aesthetics and long-term value of each material as well as considerations of climate, budget and building codes. 

By selecting the right material, you can deliver a high-performing, long-lasting design for your customers.

The Importance of Material Selection for Metal Canopies

Selecting the right metal for a commercial building canopy is important to ensure you get the performance you need and the finished look you want. Making the wrong choice can lead to unnecessary maintenance, structural inefficiencies or inconsistent aesthetics.

Factors like span length, local climate, load requirements and desired finish all play into the decision, and learning more about each material and its unique advantages will help you make the best design decision. 

Comparing Steel and Aluminum Canopies

When it comes time to select the right metal canopy for your specific project, it’s best to compare the materials side-by-side while keeping your project needs in mind.

Durability in Harsh Weather Conditions

When it comes to durability in harsh weather conditions, both steel and aluminum canopies perform well, but their performance is different based on the strengths of each material.

Aluminum’s Strength Against The Elements

Aluminum’s natural corrosion resistance makes it a great choice for commercial canopies, especially in environments where moisture, salt or pollutants make other materials unusable.

Unlike steel, aluminum forms a protective oxide layer when exposed to air, shielding it from rust and degradation without needing heavy coatings or ongoing treatments. That’s why so many professionals choose aluminum canopies for coastal buildings, industrial sites or areas with high humidity where long-term durability is essential.

Aluminum is also quite resistant to UV damage and performs well through freeze-thaw cycles without cracking or degrading, making it a top choice for environments that experience extreme temperatures throughout the year. 

Steel’s Strength Against The Elements

Steel excels in high-load environments, so it’s a good choice for regions with heavy snow, strong winds or seismic activity. Steel’s strength and rigidity allow it to span large areas without deflection. 

Steel also has great fire resistance, and it’s compatible with a wide range of cladding materials, making it easy to meet local fire codes and advantageous for areas prone to wildfires. 

However, in coastal or highly corrosive environments, steel may require more frequent inspection and maintenance to prevent rust, especially at welds or fasteners. It also requires proper galvanization or powder coating to resist corrosion and weathering.

Design Flexibility and Aesthetics

Steel and aluminum both offer design flexibility that allows you to create canopies that fit the overall design aesthetic of a building. However, their innate qualities make each material better suited for certain types of design.

Aluminum’s Design Versatility

Aluminum, which is lighter than steel, gives architects greater freedom to create shapes and detailed profiles that would be too challenging or too expensive to create with steel.

The malleability of aluminum means that architects can create sleek curves, minimalist lines and custom extrusions that integrate smoothly with other building design elements. Factory-applied finishes like anodizing, baked enamels, high-performance powder coating, and 70% PVDF give aluminum canopies color, texture and corrosion resistance.

Aluminum is also beneficial for retrofit projects or constrained urban sites where access and staging are limited. Aluminum canopies are easy to install as they are much lighter than steel canopies and require less structural support. This allows for a quicker installation with smaller crews and lighter equipment, ensuring designs can be achieved even in challenging site conditions.

Steel’s Design Versatility

Steel’s strength allows for longer spans and cantilevers with fewer support columns, opening up space and preserving clean sightlines. It’s well-suited for bold, linear designs and modern industrial aesthetics.

Finishes like galvanizing and powder-coating give architects more visual options while also adding durability to the finished steel canopy.

While steel supports a wide range of cladding materials and can be fabricated into complex structural forms, its heavier sections may limit fine detailing and require added cost and labor. 

Additionally, steel canopies present challenges in smaller site locations. Because of their heavier weight, they require bigger machinery to move them, and not all project sites have space to accommodate the larger equipment.

Cost Considerations

Cost is another factor that can make choosing between steel and aluminum canopies tough. Steel is generally less expensive per pound than aluminum, which means it’s a budget-friendly choice for large structures that require high strength and support. 

However, it’s essential to look at long-term value compared to the initial investment. 

Examining Aluminum’s Cost

Aluminum usually costs more up front, but that higher initial investment can be offset by reduced structural demands, faster installation and lower maintenance. 

Because aluminum is so much lighter than steel, money can also be saved on transportation and the framing and foundation requirements. 

Additionally, prefabricated aluminum systems are created using precise, off-site fabrication and are shipped ready to install. This sets crews up for faster on-site assembly, making it easier to stay on schedule and within budget. It also minimized disruptions to occupied buildings during a retrofit, which prevents businesses from closing and losing money. 

When it comes to long-term value, aluminum canopies offer a long-lasting strength with minimal maintenance. Many commercial buildings require durability without expensive upkeep, such as schools, retail centers or transportation facilities. 

Aluminum canopies are perfect for these types of projects as they deliver a clean, modern solution that performs reliably with minimal maintenance for decades.

Examining Steel’s Cost

Because steel is widely available and has a cost-effective fabrication process, it is typically the cheaper option when it comes to upfront costs. However, steel’s heavier weight often means higher transportation and installation expenses compared to aluminum. 

Steel canopies also typically have multiple trades involved in order to get to a completed product, including steel fabrication, roofing, and painting. Adding multiple trades can increase the final cost associated with the finished product. 

Additionally, depending on the area’s climate, choosing a steel canopy may mean more upkeep and maintenance over time, contributing to long-term costs. 

Choose The Right Canopy For Your Next Project With Mapes

If you’ve decided that an aluminum canopy is the best option for your project, Mapes has the solutions you need. We can help elevate your designs with high-performing and stunning canopies that are built to endure.

Our experts are here to talk through our options with you to ensure you get the perfect canopy design for your project. Browse through our available products or reach out to our team to get started on bringing your canopy design visions to life.