The Lifespan of Custom Metal Products: What to Expect

Whether the need is purely functional, primarily aesthetic, or a mixture of the two, having the product professionally designed and manufactured ensures it will solve your unique challenge, fulfill its intended purpose and be made-to-measure for your space.

Working with specialist custom metal fabrication services is a worthwhile investment as it gives you confidence that you’re getting exactly what you need and provides all the assurances that off-the-shelf products don’t. 

Naturally, when embarking down this route, you’ll want to ensure that your customer metal fabrications will stand the test of time. Here, we explore what to expect from custom sheet metal products and the steps you can take to prolong their lifespan.

Factors that affect the lifespan of metal products 

Custom metal fabrications typically last anywhere between 15-40 years, although some structural steel elements can last way beyond that. However, a product’s lifespan is determined by a number of factors through planning, design, the manufacturing process, and once the product is in situ. 

Type of metal

Some materials are naturally more durable and hard-wearing than others. While competitively priced materials like mild steel, galvanised steel, and aluminium typically have a shorter lifespan than stainless steel or copper, for example, other considerations should come into play when selecting the best material for your project. Factors such as malleability and ease of manipulation can also influence the choice, especially for projects requiring custom shapes or intricate designs.

Just because one metal usually lasts longer than another, it doesn’t automatically make it the best choice for your needs. It all comes down to your specific brief and requirements. Consider consulting an expert to chat through your project so they can point you in the right direction. 

Quality and thickness of materials

The quality and thickness of metal can significantly impact its durability and suitability for a project. Quality metal products fabricated from sheet metal offer flexibility, as it can be purchased at the required thickness and customised to meet specific needs. Specialist fabricators can mill and roll metal to achieve the desired thickness, ensuring it aligns with project requirements.

Once prepared, the metal undergoes a wide range of fabrication processes like laser cutting, CNC machining, forming and welding to achieve the final form.

Metal finishes

There are different ways to ‘finish’ a metal to change the way it looks and performs. For example, steel fabricators can add a protective zinc coating to create galvanised steel, which has high yield strength and is used for structural elements in construction and heavy-duty industrial applications. In the same way, powder coated metals also typically last longer, as the extra layer helps to protect against rust and corrosion. 

For metals like brass, bronze and copper, you can leave them to patina naturally or polish them up and apply a protective lacquer to preserve their brilliant shine. Essentially, your chosen metal and intended use for the finished product determines what type of finish is most suitable.

Structural elements and design considerations

Design and use considerations also impact your product’s lifespan. Products that undergo heavy usage or withstand harsh environments, for example, are likely to deteriorate faster, although you can take measures to give them greater protection. 

In construction, for example, structural components must be capable of withstanding the weight of the structure itself as well as any ‘live’ loads. As such, these elements are made of primary steel, manufactured, reinforced and often coated to ensure they will maintain structural integrity throughout their lifecycle. According to National Steel Buildings, with proper maintenance, a steel-framed building usually has a lifespan of up to 100 years.

Considerations for maintaining your metal products

• Repairing vs replacing – Wear and tear or damage to your product may not necessitate a full replacement. There are ways to mend or reinforce products to extend their lifespan, such as patching with other metals, mig and tig welding, or using robotic welding cells.  It’s worth weighing up your options to find the most cost effective route and consulting experts in precision sheet metal fabrication to explore what’s safe, feasible, and likely to be most effective. 
• Storage and usage – The type and frequency of maintenance you need to carry out also depends on use. For example, for a custom made bar top in a busy venue, you’ll need to clean it regularly and may need to periodically apply a polish or protective lacquer to prevent scuffs or scratches. A decorative feature that isn’t prone to as much contact will naturally require less maintenance. For products that aren’t always in use or situ, investing in good quality storage can reduce exposure to rust and corrosion and prolong their lifespan. 
• Sizes of metal products – A smaller product, like a custom metal countertop, will typically be easier to access and inspect compared to a larger or structural element, like a building beam or column, for example, which may be covered by cladding. Plus, the larger the product, the more points at which damage or wear and tear could take effect, and typically, the more expensive it can be to address. 

While fabricated steel and sheet metal projects are designed to be strong, durable, reliable, and fulfil their intended use, regular cleaning and inspections are usually recommended. When you work with CSM, we issue specific instructions for your custom metal fabrication. We let you know how to care for, clean and maintain your product so you can prolong its lifespan and get the best return on your investment.  

Getting the most from your custom metal products

Various factors can impact how long your metal fabrication will last. It’s often best to seek advice from an expert for your individual product so they can tailor guidance based on the specific material, finish and use. At CSM, we work closely with our customers to create high quality products and ensure they know how to maximise their value. 

Ready to get the ball rolling? With our state of the art machinery and team of skilled designers and craftspeople, we can turn projects around to exacting high standards with relatively short lead times. Learn more about our custom metal fabrications here, or contact our team with any enquiries.