Steel Vs. Aluminum: Which Is Better for Custom Warehouse Equipment?

When properly engineered, custom warehouse equipment promotes better ergonomics and enhances storage. Generally, that means more profitability and fewer bottlenecks for your operation.

However, your equipment needs to match the way you work — and for the best results, you’ll need to choose materials that adequately address your needs.

At BHS, our team can create custom warehouse equipment with steel or aluminum. For most heavy-duty material handling applications, we recommend steel, but lighter materials can be advantageous in certain environments.

Below, we’ll provide an overview of the differences between steel and aluminum and provide tips for making an appropriate decision. To start planning custom equipment for your warehouse, contact us at 1.800.BHS.9500.

Advantages of Steel Material Handling Equipment

When researching materials, remember that “steel" and “aluminum" refer to various alloys.

Aluminum alloys use aluminum as the main metal, but may also include silicon, copper, tin, magnesium, or other elements to reinforce certain properties. Steel is an alloy of carbon and iron, with other elements such as chromium (stainless steel) added.

Different types of equipment require different alloys with appropriate properties. Additionally, the tempering process (which treats the material with high heat) can affect the qualities of the product. With that in mind, we’ll discuss the general qualities — and advantages — of each material.

Steel Is Usually Stronger Than Aluminum

The strength of metals varies depending on heat treatment and composition, but steel is harder and heavier than aluminum. That usually means more tensile strength, more resistance to dents and dings, and better durability overall.

Of course, there are many ways to measure strength, and hardness — while important — isn’t always the most applicable. Yield strength (the maximum load that the material can withstand without permanent deformation) is a better measure for material handling equipment, and in most cases, steel has a higher yield strength than aluminum.

For most industrial and warehousing applications, steel is the better choice. With that said, different steel alloys have different properties. In some cases, aluminum alloys may have a higher strength-to-weight ratio than steel.

An experienced custom material equipment partner can help you determine the correct material for your application. Engineering experience matters, and choosing the right alloy for the job can ensure a better return on your investment.

Steel Is Heat Resistant

All metals sacrifice yield strength at high temperatures, but steel is much more heat resistant than aluminum. Special heat-resistant steels are also available for high-temperature applications (usually defined as between 500 and 1150 degrees Celsius, or 932 and 2,102 degrees Fahrenheit).

In contrast, aluminum loses about half of its strength by the time it reaches 315 degrees Celsius (600 degrees Fahrenheit). Because aluminum becomes stronger at lower temperatures — and steel becomes more brittle — aluminum might be a better choice in cold storage warehouses and other low-temperature applications.

Advantages of Aluminum Material Handling Equipment

While powder-coated steel is an exceptional choice for industrial material handling equipment, aluminum is lighter (and sometimes, much less expensive).

Once again, certain aluminum alloys are better at serving certain purposes, but aluminum has several established benefits.

Aluminum Has A Lower Weight/Density Ratio

The primary advantage of aluminum is its low weight. Stainless steels typically have a density of around 8 grams per cubic centimeter (g/cc), or about 0.289 pounds per cubic inch (lb/in³). Unalloyed aluminum has a much lower density of around 2.7 g/cc (0.0975 lb/in³).

In practical applications, that means aluminum is about 1/3rd of the weight of steel. If you’re designing custom material handling equipment that may need to move around your facility — for instance, storage shelves — aluminum might be a more practical choice. Of course, low-density materials have a lower storage capacity, so you’ll need to consider each application when making this determination.

Aluminum’s low density also makes it a less expensive choice than steel in most circumstances. While steel is usually less expensive per pound, aluminum is less expensive by volume.

Aluminum Is More Versatile

Aluminum is extremely malleable and ductile, and designers have considerable freedom when designing aluminum equipment. If the equipment requires an intricate design, aluminum can typically meet the necessary dimensions without difficult engineering considerations.

Again, experience matters. BHS’s engineers have decades of combined experience with steel metalworking, and they’re capable of designing custom equipment to exact customer specifications without sacrificing strength or durability.

What About Steel Corrosion?

Another well-known advantage of aluminum is its corrosion resistance. While aluminum can still corrode when exposed to salts, aluminum oxide essentially shields metal from oxidation, preventing rust. Aluminum equipment requires no paint or other shielding for basic corrosion resistance.

However, it’s important to remember that steel can be protected from corrosion with appropriate manufacturing processes. BHS equipment features a scratch-resistant powder coating for long-term durability and improved aesthetics.

With appropriate engineering considerations, a powder-coated finish can maintain a vibrant look for years with minimal maintenance. The bottom line: Steel is a stronger choice, and with proper treatment, corrosion is a minor concern.

Choosing Between Aluminum and Steel for Warehouse Equipment

Aluminum and steel are the most common metals for warehouse equipment applications — and with good reason. Both materials are affordable, durable, and recyclable.

But while some aluminum alloys are exceptionally strong, steel is typically stronger and more reliable for long-term use. If you’re building a custom packing desk or stock picking cart, that matters: Your equipment needs to hold large amounts of materials while sustaining bumps, scratches, and extreme temperatures.

Aluminum is a better material when yield strength is less important. For example, if you’re building custom shelving for long-term storage, you might prefer low-weight shelves that can be moved or replaced when necessary.

Start Planning Your Custom Warehouse with BHS

To ensure that your equipment will fit your workflow — and provide years of durable service — you’ll need help from an experienced fabricator. Collecting some basic information about the equipment’s application can streamline that process.

Questions to keep in mind:

• Will the equipment be stationary or mobile?
• For mobile equipment, what dimensions are necessary to ensure maneuverability? Measure entryways, exits, elevators, and other potential travel paths.
• Should the equipment include fork pockets or casters?
• For storage equipment, how many surfaces will be required?
• What are ideal ergonomic heights for storage surfaces and (where applicable) handles?

As a leader in custom warehouse equipment, BHS can help you find options for your facility — and adapt features as needed. From Order Picking Carts (OPCs) and Mobile Lift Tables to custom-built gantry cranes, all of our products can be custom-built to meet your operation’s specific requirements.

With every custom order, we prioritize ergonomics and durability. Whether you opt for equipment constructed with heavy-duty, powder-coated steel or high-strength aluminum, our engineers provide the guidance you need to make the most of your investment.

To learn more, contact a member of our sales team at 1.800.BHS.9500 or fill out our product info request form.