While steel is often a popular choice for construction projects due to its strength, aluminium has some key advantages for plant platforms and safe access systems.
This article examines the difference between aluminium and steel for plant platforms and safe access systems in terms of strength, durability, handling, workability, design flexibility and sustainability.
Strength & weight
Steel is one of the strongest materials available to the construction industry today. However, it is also very heavy. The weight of steel can be a disadvantage for plant platforms and access systems — especially when used on roofs or other elevated applications — as it adds significant loads that must be factored into the design of supporting structures.
Aluminium weighs approximately one-third of the weight of steel, yet it boasts a much higher strength-to-weight ratio. With clever engineering, aluminium provides a similar strength to steel at a fraction of the weight. This makes it an ideal choice for rooftop applications where weight is a concern.
Durability
With the exception of certain steel alloys, carbon steel is more likely to degrade when exposed to the elements. To prevent aesthetic damage and maintain structural integrity, steel-based access systems require protective coatings and long-term regular maintenance.
By contrast, aluminium can typically be used in its natural or ‘mill’ finish without compromising the integrity of the product. This makes it the metal of choice in harsh marine and chemical environments while also presenting excellent longevity in normal external applications.
Installation & handling
As steel is heavier than aluminium, it often requires more equipment and manpower to transport and install. Using steel for plant platforms and access systems may require heavy lifting machinery to be brought onto site — an expense which is frequently overlooked or undervalued during budgeting. The weight of steel also increases the risk of manual handling injuries.
As aluminium is much lighter, it is easier to handle and transport. This means aluminium plant platforms and access systems can be installed faster, and with less labour and resources. Aluminium plant platforms and access systems can also be prefabricated, which speeds up on-site assembly.
Workability
Using steel for plant platforms and safe access projects can be challenging due to workability limitations. It is difficult to modify on-site and may require significant time and effort to cut or reconfigure. More concerningly, cutting or drilling steel on a finished roof deck or near other coated surfaces can cause rust marks from hot corrosive swarf. Steel also requires complex finishing processes whenever modifications are made, to ensure the integrity of the product is not compromised.
Aluminium offers peace of mind when it comes to post-install adjustments. It is quick to cut and drill, increasing the volume and speed of work that can be completed. Plus, its corrosion resistant properties mean that specialised coating processes are not required. All in all, aluminium makes it easier to achieve an exact fit with minimal disruption to the program.
Design flexibility
Steel comes in a limited variety of standard profiles which can restrict the design possibilities when it comes to plant platforms and safe access systems. In some cases, steel may require excessive engineering to achieve a certain result, leading to increased costs, longer project timelines and more complicated installation processes.
Contrastingly, aluminium is available in a wide variety of extrusion shapes. This means it can be customised to meet specific design requirements, improving both the aesthetic and functional aspects of plant platforms and safe access systems.
Sustainability
Evaluating the sustainability of steel versus aluminium is complex. While both materials are fully recyclable, the energy used — and emissions generated — through production, recycling, and transport differ.
Raw steel requires 10x less energy to produce compared to aluminium and can be recycled using only 25% of the energy needed for primary production. However, raw steel almost always requires secondary processing — such as galvanising — which increases its environmental impact. In regard to transport-related emissions, steel produces more than aluminium due to its heavier weight.
While aluminium requires more energy to produce at first, it’s incredibly long-lasting and can be recycled using only 5% of the energy needed for primary production. It is also much lighter than steel, meaning that it can be transported using fewer emissions. At Hart, we prioritise certified low carbon aluminium products which are sourced, processed and delivered in a manner than is traceable and verified. Opting for low carbon aluminium significantly reduces its environmental impact throughout its lifecycle.
Aluminium is an excellent choice for plant platforms and safe access systems due to its strength-to-weight ratio, durability, ease of handling, workability, design flexibility and sustainability. That said, the material use should always be determined by the demands of the application and environment.
At Hart, we only use proven products and materials for our projects, ensuring the longevity and durability of your plant platform and safe access system. Our project consultants will review the scope, timeframe and budget of your project and recommend products and materials to suit your needs.
