Most of what we build is carbon steel with a powder coat. It's strong, it's affordable, and it holds up well if the finish is done right. But it isn't always the right call, so here's how we think about it.
Steel, stainless or aluminum
| Carbon steel | Stainless | Aluminum | |
|---|---|---|---|
| Cost | Lowest | Highest, often 2 to 3 times steel | In between |
| Rust | Will rust if the finish is chipped | 304 is fine for most exterior spots. 316 near pools and salt. | Doesn't rust. Can oxidize dull. |
| Strength | Stiff and strong | Stiff and strong | Lighter and flexes more, so posts get bigger |
| Best for | Most interior and exterior rail, stairs, gates, structure | Cable rail hardware, modern exteriors, pool areas | Big gates you want lighter, some deck rail |
Steel we use most: A36 plate and flat bar, A500 square and rectangular tube, and schedule 40 pipe for grab-style handrail. Stainless is usually 304 unless you're around a pool or in a spot that sees de-icing salt, then 316.
Finishes
Powder coat
Our default for anything outside. It's baked on, so it's tougher than paint and comes in almost any color. Matte and textured black are the most popular by a mile. The one downside: parts have to fit in the coater's oven, so very long rail runs get built in sections and joined on site.
Paint
Good for interior pieces and anything that needs touch-ups down the road. Cheaper and quicker than powder coat. Outside, expect to touch it up every few years.
Raw steel with clear coat
You see the mill scale, grinder marks and weld color. It looks great on interior rails, shelving and range hoods in a modern or industrial house. Not for outside. Clear coat on raw steel will eventually let rust through outdoors.
Hot-dip galvanized
Dipped in molten zinc. The toughest option for exterior steel, especially anything touching the ground like fence posts and farm gates. It looks industrial and dull gray unless it gets powder coated over, which some commercial specs call for.
Infill styles for railings
- Square pickets. Classic, cheapest, works on any house. 1/2" or 5/8" square bar, spaced so a 4" ball can't pass.
- Horizontal bar. Modern look. Fine on decks, but some inspectors frown on it on interior stairs because kids can climb it. Check with your city.
- Cable. Stainless cable run through posts. Keeps the view open on a deck. Needs stiff end posts because the cable pulls hard.
- Panel or mesh. Perforated sheet, woven mesh or laser-cut panels. Good privacy, very modern.
- Glass. We build the steel frame and posts. The glass comes from a glass company.
Not sure what fits your house?
Send a photo. We'll tell you what we'd build and what it'll cost.