When it comes to building event structures, lighting rigs, or staging systems, the choice of truss material can make or break your project. Two of the most common options are aluminum truss systems and steel truss systems, each offering unique advantages.
Choosing between them depends on your priorities: weight, budget, load capacity, and environmental conditions. Let’s compare aluminum and steel trusses side by side to help you decide which system is best for your next event or installation.
Weight and Handling
One of the most significant differences between aluminum and steel truss systems is their weight. Aluminum truss components are much lighter, often as much as half the weight of similar steel sections. That reduced weight makes them easier to move, lift, and assemble, which is a big advantage for crews working under tight timelines.
Steel trusses, on the other hand, bring more rigidity and mass. They’re better suited for permanent or large-scale installations where structural strength outweighs portability.
For setups that are built and torn down frequently like touring productions, trade shows, or event entranceways, aluminum truss systems typically make more sense thanks to their efficiency and ease of use.
Cost Considerations
Cost can vary depending on project scale and requirements.
- Steel trusses are generally less expensive to manufacture and can be a cost-effective option for permanent structures or installations where mobility isn’t a factor.
- Aluminum truss systems, while slightly higher in upfront cost, can save money long-term through reduced labour, shipping, and maintenance expenses.
Over time, the lightweight and reusable nature of aluminum systems can deliver a better return on investment (ROI) for event companies and rental businesses.
Corrosion Resistance and Maintenance
When it comes to durability, environmental exposure plays a key role.
- Aluminum trusses are naturally resistant to corrosion, which is a significant advantage for outdoor events or installations exposed to humidity and weather.
- Steel trusses, unless properly treated or coated, are susceptible to rust and can require regular maintenance to prevent degradation.
For coastal areas, outdoor festivals, or long-term exterior use, aluminum truss systems outperform steel in longevity and appearance.
Load Capacity and Strength
Steel is known for its exceptional tensile strength allowing it to support very high loads over long spans. That’s why steel truss systems are often used in large, permanent structures like arenas, roof systems, or architectural frameworks.
However, modern aluminum truss systems have come a long way with advanced alloys and precision welding techniques, they can handle impressive loads while maintaining a lightweight frame. For lighting rigs, video walls, and archways, aluminum trusses offer more than enough strength-to-weight performance.
Sustainability and Environmental Impact
Aluminum also wins on sustainability, as it’s 100% recyclable and requires less energy to transport due to its low weight. Many event professionals are turning to modular aluminum truss systems as part of their efforts to reduce carbon footprints and promote greener operations.
Steel is also recyclable, but its production process tends to have a higher carbon output compared to aluminum.
Which Should You Choose?
Here’s a quick comparison summary to guide your decision:
| Factor | Aluminum Truss Systems | Steel Truss Systems |
| Weight | Very lightweight | Heavy |
| Setup Speed | Fast and efficient | Slower, more labour-intensive |
| Cost (Long-Term) | Lower operational cost | Lower upfront cost |
| Corrosion Resistance | Excellent | Requires protection |
| Load Capacity | Strong for portable setups | Superior for heavy-duty, permanent installs |
| Best For | Events, staging, touring, exhibits | Fixed structures, architectural use |
Conclusion
Both aluminum and steel truss systems have their place in the world of structural design. If your focus is on mobility, ease of setup, and corrosion resistance, aluminum truss systems are the ideal choice. However, if your project requires maximum strength and durability, a steel truss system may be a better option.
Contact us today to learn more.