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Ask ten Raleigh homeowners to name a rust‑proof, budget‑friendly door, and half will say aluminum; ask for the strongest bang‑for‑buck panel, and the other half will still swear by classic steel. Both have earned reputations for reliability, but they diverge sharply on dent resistance, insulation, hardware load, and long‑term upkeep.
After more than a decade of RJ Garage Door Services installations and service calls across the Triangle, here is our objective, data‑driven comparison.
Overview
| Category | Aluminum | Steel (Galvanized) |
|---|---|---|
| Impact resistance | Dents on hard blows | High strength; dents easily |
| Panel weight (16 × 7 ft) | ≈ 115 lb | ≈ 165 lb |
| Typical R‑value | R‑6 (foam‑filled) | R‑8 – R‑9 (foam‑filled) |
| Rust potential | None | Low until paint scratches |
| Maintenance | Quarterly rinse; occasional wax | Wash + touch‑up paint as needed |
| Installed price* | $2.6 k (avg.) | $1.85 k (avg.) |
| Noise level | Lighter; nylon rollers advised | Heavier; naturally quiet |
| Recyclability | Infinite alloy loop | Highly recyclable steel scrap |
| Hardware needs | Standard torsion + ½ HP opener | Standard torsion + ½ HP opener |
| Warranty typical | 20 yrs finish/frame | 15 yrs rust‑through |
Strength & Impact Behavior
Aluminum door skins range from 0.040 to 0.060 inch thick. They resist everyday bumps but will crease when a basketball or lawn‑mower handle strikes squarely. Galvanized steel panels, made from 24‑ or 25‑gauge sheet, boast higher tensile strength and less flex, yet ironically dent just as visibly because the metal cannot rebound. Once dented, steel panels hold creases permanently, whereas aluminum’s shallower dents can sometimes be coaxed flat with suction tools. In family driveways with lots of activity, both require caution, but aluminum’s lighter dents are slightly easier on the eye.
Rust, Corrosion & Long‑Term Finish
Aluminum forms a self‑protecting oxide layer, so scratches won’t start corrosion; they merely dull the finish until touched up. Powder‑coat chalking appears after about ten years but wipes away with automotive wax. Steel resists rust thanks to a zinc‑galvanized coat under baked paint, yet once that paint scratches, oxidation creeps beneath, bubbling paint within a season. In humid or coastal environments, diligent touch‑up paint is essential for steel; aluminum all but eliminates corrosion anxiety.
Insulation & Energy Efficiency
Raw metals conduct heat, so both rely on foam cores for thermal performance. Steel doors are thicker (two‑inch sections) and can reach R‑8 – R‑9 thanks to injected polyurethane. Aluminum sections typically include thermal breaks but plateau near R‑6 with similar foam. Our July FLIR scans showed steel interiors 4 °F cooler than aluminum after three hours of full sun. If your garage is conditioned or used as a workshop, steel saves a few HVAC dollars annually.
Weight, Hardware Load & Opener Life
The extra 50 lb a steel door carries translates into marginally heavier torsion springs and greater opener strain over time. Both materials work fine with a ½ HP belt drive, but aluminum cycles more quietly and demands spring re‑balance less often—about 1,500 fewer cycles over a decade in our maintenance logs. If bedrooms sit above the garage, aluminum’s lighter operation keeps morning commutes quieter.
Curb Appeal & Design Flexibility
Aluminum thrives in contemporary architecture—satin black flush panels, anodized bronze frames, or full‑view glass hybrids. Its ability to hold powder‑coat color indefinitely without chipping makes bold hues viable. Steel offers timeless raised‑panel and carriage‑style embossing; its deeper stampings show shadows beautifully, and factory paint palettes cover everything from crisp whites to faux‑wood overlays. For ultra‑modern lines, aluminum wins; for classic curb appeal at a lower price, steel remains king.
Maintenance Routine
Both doors benefit from a quarterly hose rinse and mild soap wash. Aluminum’s job ends there. Steel needs a fast dab of automotive touch‑up paint whenever a scratch reaches bare metal—particularly on the door’s lower two panels, where gravel spray and lawn equipment nick finish first. Skip those touch‑ups and rust can creep beneath paint within six months, necessitating full panel replacement down the line.
Environmental Considerations
Aluminum and steel are both recycling champs: 75 % of all aluminum and nearly 90 % of all steel ever produced is still in circulation. Aluminum production consumes more electricity per ton, but its lighter weight cuts shipping emissions for finished doors. Steel’s higher recycled content (often 30–40 % in door skins) evens the eco‑ledger. Choose either alloy and you’re supporting a robust closed‑loop material stream.
Installed Cost & Resale ROI
Our Raleigh invoices for 2025 place insulated aluminum doors at about $2,600 installed. Foam‑filled steel doors of similar size average $1,850—roughly a 30 % savings. National Cost‑vs‑Value studies peg steel ROI at 93 %, aluminum at 88–92 %. In upscale contemporary builds, appraisers sometimes assign extra value for aluminum’s sleek lines; in traditional subdivisions, buyers gravitate toward budget‑friendly steel without perceiving a quality downgrade.
RJ Garage Door Services Verdict
Choose aluminum if you value rust immunity, lighter hardware loads, modern color options, and don’t mind paying a bit more upfront.
Opt for steel when you want maximum insulation, classic embossing, and the best price‑to‑durability ratio—provided you’re willing to keep touch‑up paint handy for scratches. Whatever you decide, RJ Garage Door Services will size springs correctly, calibrate opener force, and seal perimeter gaps so your new door performs smoothly for years to come.
