How Can I Make My Steel or Aluminium cladding Look Like Corten Steel cladding?

The most common methods of making steel and aluminum curtain walls look like Corten steel are surface painting and powder coating. We've detailed both processes below so you can determine which one is better for your needs.

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Powder Coating
Polyester Powder Coating (PPC) or powder coating, is one of the most common ways of painting steel and involves applying a dry powder to a piece of steel, which is then transferred permanently onto the steel using an electrostatically charged tool.

Before the powder coating process begins, it's important to prepare the steel. The powder coat will not be attracted to the steel correctly if the steel isn't prepared properly. Any piece of steel that is going to be powder-coated needs to be free of grease and dust.

The dry powder that is now electrostatically charged is drawn to the steel and forms a unique coating that is made permanent by heating the steel at close to 200°C.

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Pros of Powder Coating as a Corten Facade Cladding Alternative
A Wider Visual Choice – PPC provides a wider selection of colors and finishes compared to the usual patina provided by Corten Steel. Things such as planter edgings can be powder coated into any RAL color, as well as specialist coatings which have specific textures and colors. Nothing else comes close to this level of flexibility.
More Value for Money – Powder coating steel costs less than purchasing Corten steel. Although some specialized coatings cost more and should be looked at in a project-specific manner.

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Cons of Powder Coating as a Corten cladding facade Alternative

The Risk of Scratching – Although PPC offers more scratch resistance than ordinary paint, it still will not be durable enough to resist scratches from heavy and hard objects that scrape along the material. This is in contrast to Corten steel, whose color is naturally occurring and does not scratch off.
The Lack of Corrosion Resistance – This 'con' only applies when the steel is pre-coated with a Zinc Primer, as it scratches much more easily, which can expose the steel underneath and corrode. This is not so much of an issue for steel that is hot dip galvanized.

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