The GA blog

Aluminium design characteristics 

This post explores the architectural quality and design characteristics of aluminium – from its sustainability and ease of fabrication to its strength, durability and versatile surface finishing options.

For example, did you know that around 35% of the aluminium used globally now comes from recycled material, and almost 75% of the 1.5 billion tonnes of aluminium ever produced is still in use today?

Abundance and sustainability

Aluminium’s abundance adds to its green credentials. It is the third most common element on Earth and the most abundant metal. Only silicon and oxygen are more plentiful.

Aluminium is harmless to animals and plants. Over 7% of the Earth’s crust is made up of bauxite – the ore from which aluminium is extracted.

Corrosion resistance

Aluminium is highly resistant to weathering, even in polluted urban and industrial environments. It also resists attack from many acids.

This excellent corrosion resistance comes from the permanent presence of a self-repairing oxide film on its surface. If scratched or cut, the protective film naturally reforms, maintaining the material’s durability.

In moist environments where bi-metallic corrosion could occur, it is important to isolate aluminium from other metals using a suitable gasket, paint, or coating. In particularly harsh external settings, Gooding Aluminium recommends either anodising or powder coating to enhance protection against airborne contaminants.

Ease of fabrication

Aluminium’s forming and handling characteristics are among its greatest advantages. It is easy to cut, fold and work using a wide range of processes. This reduces processing times and helps to keep production costs down.

Fire and temperature resistance

Aluminium does not burn, even in its thinnest gauge.

Its thermal conductivity is about four times that of steel, and its specific heat is twice as high. This means heat is dispersed more efficiently, and more energy is required to raise the temperature of aluminium than steel.

Aluminium alloys are non-combustible, as defined by BS476: Part 4, and provide Class 1 surface spread of flame to BS476: Part 5. Temperatures found in typical building environments have no impact on aluminium’s performance.

Food safety

Thanks to its natural oxide surface coating, aluminium is safe to use in food preparation and service areas.

Machinability

Aluminium is suitable for high-speed machining, including milling and turning, making it a cost-effective material for manufacturing.

Non-magnetic properties

Aluminium is non-magnetic, making it ideal for use in electronic environments such as computer rooms and for applications involving electrostatic screening.

Production strides to reduce emissions

While bauxite (the source of aluminium) is easy to mine, extracting aluminium is power-intensive. The process includes:

1. Separating alumina from bauxite
2. Refining alumina into aluminium

Electricity accounts for around a third of the cost of producing a tonne of aluminium. Fortunately, over 55% of global aluminium production is now powered by renewable ‘white energy’.

Modern smelting technologies – including pre-baked anode systems – are improving energy efficiency by up to 25%. Research is ongoing into carbon-free anode materials that could eliminate PFC (perfluorocarbon) emissions entirely.

Reflective properties

Aluminium is an excellent reflector of light and heat. It reflects approximately 75% of visible light and 90% of radiant heat, making it a popular choice for lighting, trim and insulation applications.

Recycling and environmental performance of aluminium

Aluminium is considered one of the most sustainable building materials available. It is 100% recyclable without losing quality, and the process requires just 5% of the energy used in primary production.

Recycling one kilogram of aluminium saves:

• Over 7kg of bauxite
• 4kg of chemicals
• 13 kilowatt hours of electricity

Globally, about 35% of aluminium in circulation is recycled, and 75% of all aluminium ever produced remains in use. In the construction sector, around 85% of aluminium is collected and recycled at the end of its life.

Strength to weight ratio

Aluminium is the lightest of all common metals, with a specific gravity of 2.7 – about one third that of steel.

Its high strength-to-weight ratio delivers significant weight savings. Compared with steel, aluminium assemblies can be up to 50% lighter, reducing transport costs and making handling and installation quicker and easier.

Commercially pure aluminium (99.5%) offers excellent formability and a useful degree of hardness. Strength can be further increased by alloying with other elements such as copper, magnesium, manganese, silicon and zinc. Many aluminium alloys can also be heat treated to increase strength.

Surface finishing options for aluminium

Aluminium is available in a range of surface finishes to suit the project and environment:

• Mill finish (untreated aluminium): suitable for internal, low-contact areas. Requires protection during production and installation.
• Anodised finish: enhances the natural oxide layer through a non-toxic process. Durable and ideal for external applications.
• Powder coating: a solvent-free process that delivers a durable, colour-rich finish. Powder coatings are virtually VOC-free and well suited for architectural aluminium.

Conclusion

From its corrosion resistance and lightweight strength, to its recyclability and aesthetic potential, aluminium remains a versatile and future-proof material for architects and designers. Its sustainable performance, ease of fabrication and wide range of finishes make it a popular choice for both interior and exterior applications across UK architecture and design.

At Gooding Aluminium, we supply a wide range of perforated aluminium panels, sheet products and custom-fabricated items — including ceiling panels, radiator covers, and airflow grills. Our made-to-measure services and technical support ensure you can specify aluminium with confidence.

Explore our full range of aluminium design products, or use our Build-a-Spec tool to get started.