Mild Steel vs Stainless Steel: What’s Right for Your Project?
Mild Steel vs Stainless Steel: What’s Right for Your Project?
When choosing the right material for fabrication projects, the decision between mild steel and stainless steel can be more important than many realise. Each type of steel offers its own advantages depending on the application, environment and budget. At BradFabs, we work with both mild and stainless steel across a range of custom metalwork, so we understand how critical it is to pick the right material from the start.
In this blog, we’ll break down the key differences between mild steel and stainless steel, helping you to make the best decision for your next building project.
Understanding Mild Steel
Mild steel, also known as low-carbon steel, contains a small amount of carbon (usually less than 0.25%). This makes it more malleable and easier to work with compared to other types of steel. Mild steel's combination of strength and cost-effectiveness means it’s widely used in more general fabrication projects, such as railings, staircases and structural frameworks.
One of the biggest advantages of mild steel is its affordability. It’s cheaper to produce and buy than stainless steel, which makes it ideal for larger projects where cost and budget can be important. It’s also easier to weld and shape, giving fabricators more flexibility during manufacturing and allowing them to work faster, saving you time and helping you to meet tight deadlines.
Despite this, however, there are also some downsides to using low-carbon steel that you’ll need to keep in mind. Mild steel is not naturally resistant to rust or corrosion, so if it’s needed for outdoor or damp environments, it’ll need to be protected using paint, powder coating or galvanisation. Without this, it can degrade over time and weaken in both appearance and strength.
Exploring Stainless Steel
Stainless steel, conversely, contains a far higher percentage of chromium, usually at least 10.5%, which gives it one major advantage, corrosion resistance. This makes it the preferred choice for applications that will be exposed to moisture, chemicals or harsh weather conditions. This makes stainless steel an ideal choice in areas such as food processing, medical equipment, public spaces, handrails and high-end architecture designed to last a long time.
One key benefit of choosing stainless steel is its appearance. It’s a naturally sleek, clean finish can be polished for a high-end look or brushed for a more brutalist, industrial style. It’s also a “low-maintenance” material, meaning it needs little more than an occasional clean to keep it looking good for years.
Stainless steel is harder and more durable than mild steel, but this also means it can be a more difficult and more expensive material to work with. Fabrication and welding often require specialised equipment and experience to work with stainless steel, which can add to the cost. In most cases, though, the long-term durability and low maintenance costs more than make up for the initial investment.
Where Each Steel Type Works Best
The best material depends on how and where it’ll be used. For indoor projects that don’t face moisture or harsh weather, mild steel is often more than sufficient. With the right coating, it can also be used outdoors, though this may require more upkeep over time.
On the other hand, stainless steel is better suited for outdoor use, public spaces, or any setting where the finish matters and corrosion is a concern. It’s also the right choice when hygiene is essential, such as in kitchens, hospitals or “clean rooms”.
At BradFabs, we take care to advise customers based on both the technical demands and the aesthetic visions of their project. If you're after a budget-friendly option for a standard handrail or a structural frame inside a building, mild steel can be a great choice. But if the structure is exposed to the elements or you’re looking for a more modern, polished look, stainless is worth the extra cost.
Cost Considerations
Budget is always a key factor in any fabrication project. Mild steel is generally less expensive to buy and process, which can keep overall project costs lower. If you're working to a strict budget and the specifics of the project allow for it, mild steel will likely be the most practical option.
Stainless steel costs more upfront and can increase the overall fabrication time, however it will pay off in durability and reduced maintenance. Over the long term, this can more than offset the initial outlay, especially if regular repainting or replacement of mild steel would otherwise be needed.
Maintenance and Lifespan
In terms of longevity, stainless steel has the edge. It resists rust, stains and general wear better than mild steel, particularly when used in exposed or high-traffic areas. It keeps its appearance and strength for longer, even without much in the way of maintenance.
Mild steel, while tough and reliable, will start to show signs of wear without regular treatment. Galvanising or painting it adds a layer of protection, but these coatings can chip or degrade over time, meaning upkeep is essential if appearance and integrity are important.
In Conclusion, Choose with Purpose
At BradFabs, we believe the best material is the one that best meets all of the specific and unique needs of your project. Mild and stainless both have their place in fabrication, but choosing the right one is about more than cost or appearance. It’s about the environment, usage, maintenance and long-term value.
If you're unsure which is right for your job, our experienced team is always on hand to offer advice and help guide you to the best option. Whether you're designing a bespoke staircase, balcony, balustrade or gate, we’ll make sure the material matches your vision and your budget.
Get in touch with us today to discuss your project and discover the BradFabs difference.
