One of the most common questions we get at T & C Fabrication is whether a project should be built from steel or aluminum. The answer depends on the application, the environment, and the budget. Here on Vancouver Island, the coastal climate makes that choice even more important.
Steel: Strength and Value
Steel is the workhorse of metal fabrication. It is stronger than aluminum pound-for-pound, easier to weld, and significantly cheaper per ton. For structural applications — equipment frames, heavy gates, industrial brackets — steel is almost always the right call. Mild steel is easy to work with and readily available, while high-strength varieties like T1 and AR400/AR500 are ideal for heavy equipment and wear applications.
The downside of steel on Vancouver Island is corrosion. Our wet coastal climate means bare steel will rust quickly. The solution is proper finishing — hot-dip galvanizing, powder coating, or paint systems designed for marine environments. A well-finished steel gate or fence will last decades with minimal maintenance.
Aluminum: Lightweight and Corrosion-Resistant
Aluminum weighs about one-third as much as steel and naturally resists corrosion — a huge advantage for marine, aquaculture, and coastal residential projects. Marine-grade alloys like 5086 and 6061-T6 are our go-to choices for float systems, dock components, railings, and anything that will live in or near saltwater.
Aluminum costs more per pound than steel and requires specialized TIG welding techniques. It is also softer, so it is not ideal for high-wear or high-impact applications. But for projects where weight savings and corrosion resistance matter, the higher upfront cost pays off in reduced maintenance and longer service life.
Our Recommendation
For most residential gates and fencing, we recommend galvanized and powder-coated steel — it gives you the best combination of strength, aesthetics, and value. For marine and aquaculture projects, aluminum is the clear winner. For heavy equipment repair, steel is almost always the answer.
Not sure which metal is right for your project? Contact us or call Ted at 250-202-1643 for a free consultation. We will recommend the best material for your specific application and budget.
