Durability is an important quality for construction elements. Aluminium is extremely durable because it naturally forms a layer of aluminium oxide on exposure to air, in a process known as “passivation”, which describes a material becoming “passive” and less affected by its environment. This makes aluminium an excellent choice for your building, including windows, roof lights, doors, curtain walling, cladding systems, roofing and roofline products.

Extruded Aluminium – Mill Finish

Aluminium in its extruded unfinished state is classified as “Mill Finish”.

The term “Mill finish” refers to aluminium as it comes off the rolling or extrusion mill, with no additional surface finishing applied. Here, the aluminium will quickly form a surface layer of aluminium oxide on exposure to air, “passivating” and providing a protective grey oxide coating.

There are two principal methods to further enhance the corrosion resistance of aluminium in construction, and to create decorative and durable finishes.

Anodised Finishes

Anodising is an electrolytic process that forms a stable oxide layer on the aluminium surface. The resulting oxide layer is thicker and stronger than aluminium’s inherent oxide coating. The most basic form of anodising is Natural Anodising, providing a clear look to the surface of the metal.

It is possible to dye the coated surface a variety of colours, electrolytically or with organic dyes, before it is sealed, with bronze shades often used for architectural purposes. Where the colour results from optical effects in the oxide layer, due to absorption and reflection of specific light frequencies, the colour is termed fade-free.

The current UK standard for Anodic Finishes is BS 3987

Current CAB members who provide Anodising finishing services are:

  • Hydro Group
  • United Anodisers

Further information may be found at: Anodising | Council for Aluminium in Building (

Powder Coat Finishes

Powder Coatings are fundamentally different in application to traditional paint that’s applied to components in a wet state and cures to a dry state. Powder coat is applied to aluminium as a dry powder.

Powder coatings are solvent-free paints applied to metals and other conductive surfaces. After suitable pre-treatment of the material to be coated (see our pre-treatment Position Paper), the powder coating is applied electrostatically and is cured under heat to allow flow and formation of a hard finish, tougher than conventional paint.

Polyester is the most widely specified resin system for powder coatings, with enhanced durability polyester being preferred for external application owing to its significantly improved weathering resistance.  Recent advances have meant that the portfolio of finishes available have increased, whereby viable alternatives to anodised aluminium, GRC, timber and corten steel are now possible.

The current UK standard for Powder Coat Finishes is BS EN 12206-1


Photo kindly provided courtesy of AzkoNobel Powder Coatings Ltd.

Current CAB members who provide powder coating services and finishing suppliers are:

  • AMS
  • Barley Chalu
  • Powdertech
  • Superior Paint and Powder
  • Tomburn
  • Vertik-Al
  • AkzoNobel
  • Chemetall
  • Sherwin-Williams

Further information may be found at:

Polyester Powder Coating | Council for Aluminium in Building (

Supplies | Council for Aluminium in Building (

Case studies

The dome of the San Gioacchino in Prati Church, completed in 1897, is the earliest known example of external aluminium cladding still in service. It is in excellent condition after over 120 years, undergoing regular inspection and testing. The architect chose aluminium to clad the dome because it was lightweight, durable and economical in comparison with other materials.

The New Bodleian Library, completed in 1938, boasts anodised aluminium windows. As part of a refurbishment project in 2014, it was only necessary to clean and re-glaze the windows. Based on the durability of anodised aluminium, it is reckoned that the finish is satisfactory for another 60 years or more.

Studies* have shown that polyester powder coated aluminium windows and curtain walling, when appropriately detailed, installed and maintained, can exhibit excellent colour and gloss retention compared with the original coating after more than 40 years.

* Aluminium and Durability. Towards Sustainable Cities. Michael Stacey Architects 2014.