The Benefits of Galvanised Steel in Metalwork
Stainless steel is often seen as the gold standard when it comes to corrosion resistance. Its sleek appearance and strong reputation make it a popular choice across construction, architecture, and manufacturing. But there’s a question that often gets asked: ‘can stainless steel rust?’
The short answer is yes. Although it is far more resistant than standard steel or iron, stainless steel is not entirely rust-proof. Its performance depends on its environment, the way it is maintained, and the grade of stainless used.
At Smart Steels, we work with a range of materials depending on the requirements of the project, and in many cases, galvanised steel offers superior long-term protection, especially in outdoor or high-impact environments.
Why Can Stainless Steel Rust?
Stainless steel is an alloy that includes chromium, which reacts with oxygen to form a thin, invisible protective layer of chromium oxide. This layer prevents water and air from reacting with the underlying metal, allowing the steel to resist corrosion.
However, this protection can be compromised. In harsh environments, such as coastal areas with high salt levels or industrial zones with pollution and chemicals, that passive layer can become damaged or eroded. If this happens, the stainless steel reacts with the elements in much the same way as untreated steel, leading to surface corrosion or pitting.
Contaminants, scratches, and certain cleaning products can also affect this protective layer, making even high-grade stainless steel vulnerable if it’s not properly cared for.
What Is Galvanised Steel?
Galvanised steel is regular carbon steel that has been coated with molten zinc, usually through a process called hot dip galvanising. This creates a barrier that physically prevents moisture and oxygen from reaching the steel surface.
Unlike the chromium oxide layer in stainless steel, the zinc coating on galvanised steel offers what’s called ‘sacrificial protection’. This means that even if the surface is scratched, the zinc corrodes before the steel beneath it does, maintaining corrosion resistance over time.
During hot dip galvanising, the steel is dipped into a bath of molten zinc, forming a series of zinc iron alloys as it cools. These layers bond metallurgically to the steel, creating a tough, durable coating that’s ideal for exterior and heavy-use applications.
Galvanised Steel in Metal Fabrication
In architectural and structural metalwork, the properties of galvanised steel make it an obvious choice. Whether we’re fabricating staircases, fencing, steel frame buildings, or outdoor railings, using galvanised steel offers several clear advantages:
- Exceptional rust resistance and longevity
- Enhanced performance in harsh environments
- Compatibility with paint coatings for added protection or aesthetic finishes
- Lower cost than many stainless or specialist strength steels
- Versatility across both sheet metal and structural profiles
- Ease of fabrication, welding, and finishing in the manufacturing process
Galvanised finishes also offer a consistent, matte grey appearance that suits both industrial and modern design schemes. For clients who want both performance and style, it’s an excellent middle ground between raw steel and higher-priced stainless solutions.
When Should You Choose Galvanised Steel Over Stainless?
The decision between stainless and galvanised steel comes down to environment, exposure, and budget. In dry, indoor environments, stainless may be the preferred option for its aesthetic appeal and clean finish. But for external structures or installations that face moisture, pollution, or abrasion, galvanised steel often performs better over the long term.
For example:
- Outdoor handrails or balustrades that face rain or snow
- Walkways and staircases exposed to public use and cleaning chemicals
- Structural steel frames that need long-term reliability without frequent maintenance
- Coastal or roadside locations where steel products face salt and grit
Make the Right Choice With Your Metalwork
So, can stainless steel rust? Yes, and especially if exposed to harsh or corrosive environments without proper maintenance. While it offers impressive corrosion resistance, it isn’t invincible.
For many applications, particularly external or high-traffic areas, galvanised steel offers a smarter, more resilient option. Its zinc coating and durable surface make it ideal for installations where performance matters as much as appearance.
Smart Steels is here to help you make the right choice, supplying and installing steelwork built to endure.
How Can Smart Steels Help?
At Smart Steels, we fabricate and install high-quality steelwork that lasts. We advise clients on the best material for their application, whether that’s high-grade stainless, galvanised sheet metal, or painted steel solutions. Every project is different, and choosing the right material is essential to achieving durability, safety, and visual appeal.
Our team uses proven techniques, expert finishing, and professional installation to ensure every piece we deliver performs in the long term. From steel or iron structural frames to complex staircases and architectural features, we’re proud to offer metalwork that inspires our clients.
FAQ
Does stainless steel need maintenance to prevent rust?
Yes. Regular cleaning and avoiding contamination helps preserve its protective layer.
How long does galvanised steel last outdoors?
Hot dip galvanised steel can last between 40 and 70 years, depending on conditions.
Can galvanised steel be painted?
Yes. with the right surface preparation and primer, it holds paint coatings well.
Is galvanised steel stronger than stainless steel?
Not necessarily in terms of tensile strength, but its resistance to corrosion gives it a performance edge in many settings.
Where is galvanised steel most commonly used?
In steel frame buildings, fencing, staircases, and other structural or architectural metalwork.
Can damaged galvanised steel be repaired?
Yes. Zinc-rich primers or touch-up coatings can restore its corrosion resistance.