Air conditioner covers: aluminium or steel? The two technologies compared

An air conditioner cover can be made two ways: from aluminium or from steel. Both technologies get you to the same place, namely a unit that is screened from view with airflow intact, but they differ in construction, appearance and character. Below we compare them without the marketing gloss, to make the decision easier.

The aluminium cover

What it is made of

An aluminium cover has a frame of 20×20 T-SLOT aluminium profile (from the V-SLOT system), bolted together in the slots. The frame is filled with aluminium fence profiles, the very same ones used for fencing panels. Slats are available from 20×40 to 20×250 mm, along with diamond profiles. The whole thing is powder coated.

What it does well

• Low weight. Aluminium is light, which makes installation easier, especially in the wall-mounted version.
• Corrosion resistance. Aluminium does not rust, so it takes outdoor conditions in its stride. Powder coating protects the surface on top of that.
• Control over the gaps. By choosing the width of the slats and the spacing between them, you decide how thoroughly the unit is screened and how much room is left for airflow.
• A match for your fencing. If you have aluminium panels from the same family of profiles, the cover will look like a natural extension of them.

When to choose aluminium

An aluminium cover makes sense when you want a light, open enclosure, good ventilation and a match with fencing or other elements made from aluminium profile. It is the all-rounder, and it suits most houses.

The steel cover (the Design line)

What it is made of

A steel cover starts as laser-cut sheet, which is then folded, welded and ground smooth before being powder coated. The decorative panels carry a laser-cut pattern. It is a more “workshop” technology, and it produces a solid, unbroken structure with a decorative motif.

What it does well

• Decorative character. The laser-cut pattern turns the cover into part of the finish of the facade rather than just a screen.
• A solid build. A welded steel frame gives an impression of substance and permanence.
• A pattern of your own. Laser cutting can reproduce all sorts of motifs in the sheet, so the cover can echo the style of the house or the garden.

When to choose steel

A steel cover is the choice when you want a stronger, more ornamental accent on the facade and a finished “plate” with a pattern rather than an open run of slats. It looks right where the cover is meant to be a visible part of the scheme, not simply a technical fix.

What they have in common

Whichever technology you pick, both versions of the cover:

• have an open back so air can move freely,
• are powder coated in RAL 7016 anthracite, RAL 9005 black, RAL 9003 white or any other RAL colour on request,
• are made to measure for a particular unit and a particular spot,
• offer the same range of enclosure options, from a full enclosure of the front with sides and top down to the front on its own,
• can be wall-mounted or free-standing.

How to choose between aluminium and steel

Rather than hunting for the “better” technology, it helps to answer a few questions:

1. How should the cover look? Light and open points to aluminium; an unbroken panel with a pattern points to steel.
2. Do you already have anything made from aluminium profile? If you do, aluminium will tie in with the fencing.
3. How much does the decorative motif matter? If the cover is meant to be an ornament, a patterned steel panel gives you more scope.
4. How is the unit mounted? With wall mounting the weight of the material can matter, which argues for lighter aluminium.

Durability and maintenance

Both technologies are built to work outdoors all year round. Aluminium has the advantage of not corroding by nature, so even a small nick in the coating will not lead to rust. Steel needs an unbroken coating, which is why it is powder coated after the welds have been ground back, giving an even, protected finish. In both cases maintenance comes down to cleaning dust, leaves and grime off the surface every so often.

It is also worth thinking ahead. If you are planning to add aluminium fencing or panels in time, an aluminium cover from the same family of profiles will keep everything consistent. If the cover is meant to be a lasting decorative accent in one spot, a patterned steel panel will serve that purpose well.

Cost and profile availability

An aluminium cover draws on fence profiles that are permanently in stock, so choosing the infill is predictable. A steel cover is cut and welded individually, which gives more freedom in the pattern but involves more labour. You will get an exact quote for either version in reply to your enquiry, because it depends on the dimensions, the extent of the enclosure and the infill or pattern you choose.

In summary

Aluminium means a light, corrosion-resistant, open enclosure with control over the gaps and an easy match with fencing. Steel means a solid, decorative panel with a laser-cut pattern. Both covers are made to measure, powder coated and open at the back. The choice comes down mainly to the visual effect you are after and the way the unit is mounted. If you are torn between the two, describe your situation in your quote request and we will help you choose.