Did you know that most corrosion-related failures in metal building panels begin at the cut edges and not the flat surface? Research shows these exposed areas are especially prone to corrosion, as protective coatings are often thinner or missing entirely, making them vulnerable to moisture, pollutants, and long-term environmental damage.
That’s why your choice of coating system matters. When it comes to selecting between painted steel panels and Galvalume Plus™, the real difference lies in performance: how well each system protects against corrosion, how long it lasts, and how much maintenance it will require over the years.
Let’s break down why Galvalume Plus™ steel consistently outperforms painted panels in steel buildings and when painted panels still make sense.
What Really Determines the Lifespan of a Steel Panel?
When evaluating steel panels for a commercial, agricultural, or industrial building, the base metal and coating system are critical. While painted panels might offer aesthetic flexibility, they often rely heavily on the paint film as their primary line of defense.
By contrast, Galvalume Plus™ steel starts with a superior corrosion-resistant substrate, offering built-in protection even when scratched or cut. For specifiers and building owners focused on steel corrosion protection and long-term value, this can be a game-changer.
What Is Galvalume Plus™ Steel?
Galvalume Plus™ is a next-generation steel panel material designed for superior corrosion resistance and long-term performance. It’s widely used in metal buildings for its strength, durability, and low maintenance needs.
Galvalume is a metal-coated steel that combines:
- 55% aluminum
- 43.5% zinc
- 1.5% silicon
This alloy is applied over a steel core through a hot-dip process, resulting in a dual-layer coating that offers both barrier and sacrificial protection.
Galvalume Plus™ goes a step further. It adds an acrylic or resin-based topcoat, which:
- Enhances surface durability
- Reduces staining and fingerprints during handling
- Improves corrosion resistance, especially in edge/cut zones
This multi-layer system provides a self-healing effect at exposed edges: a major weakness of painted panels.
How Painted Steel Panels Work and Their Common Weaknesses
Painted steel panels are commonly used for their aesthetic versatility, but their performance depends heavily on the integrity of their coating system. Here’s a quick look at what makes up a typical painted panel and where its weaknesses can show over time:
What’s in a Painted Panel?
- Steel substrate
- Base coating (galvanized, Galvalume, or bare steel)
- Paint layer (typically PVDF/Kynar 500®, or SMP)
Galvalume Plus™ vs Painted Panels: A Side-by-Side Comparison
| Attribute | Painted Panels | Galvalume Plus™ Steel |
| Corrosion Protection | Dependent on paint and base layer; edges are vulnerable | Alloy + acrylic layer provide superior protection; self-healing at cuts |
| Maintenance | Requires repainting and aesthetic upkeep | Minimal maintenance; topcoat resists staining and oxidation |
| Lifecycle Cost | Higher over time due to repaint and repairs | Lower total cost; lifespan of 40–60 years |
| Appearance Options | Wide range of colors and finishes | Limited to metallic/satin finish (natural look) |
| Best Use Cases | When color is critical | When durability, lifespan, and low maintenance matter most |
| Performance in Humid/Coastal Areas | Paint may degrade quickly | Performs well in most environments; caution in extreme salt exposure |
Why Galvalume Excels at Corrosion Protection
Corrosion protection is where Galvalume Plus™ truly stands out. Its unique alloy coating is engineered to defend against the elements even at vulnerable areas like cut edges offering long-term durability where it matters most.
The Science Behind the Coating
The Al-Zn-Si alloy in Galvalume Plus™ provides two layers of defense:
- Aluminum creates a barrier layer, slowing corrosion
- Zinc offers sacrificial protection, particularly effective at cut edges or scratches
- The silicon improves adhesion and performance at high temperatures
Self-Healing at Cut Edges
Unlike painted systems, Galvalume’s coating actively resists edge rusting. Zinc migrates to protect exposed steel, minimizing “red rust” and extending panel lifespan.
Painted panels? Once the paint chips, the substrate is vulnerable and corrosion spreads fast.
Longevity, Maintenance & Lifecycle Value
A steel panel’s true value is measured over decades, not just the first few years after installation. Understanding how each system performs over time can reveal major differences in durability, upkeep, and total cost of ownership. Here’s how Galvalume Plus™ compares to painted panels over the long term:
How Long Does It Last?
In ideal conditions:
- Galvalume Plus™ can last 40 to 60 years
- Painted steel panels may need repainting within 10–20 years, especially in harsh climates
Maintenance Costs Over Time
| System | Expected Maintenance | Repainting Frequency |
| Galvalume Plus™ | Minimal | Rarely needed |
| Painted Panels | Moderate to high | Every 10–15 years (UV-dependent) |
Real-World Savings: For large-scale steel buildings, roof access for repainting is costly and dangerous. Galvalume’s lower total cost of ownership (TCO) often outweighs its slightly higher upfront investment.
When Painted Panels Might Still Make Sense
While Galvalume Plus™ offers superior durability and corrosion protection, there are certain scenarios where painted steel panels may still be a practical choice particularly when appearance or short-term considerations take priority.
1. When Color and Branding Are a Priority
If your project requires specific colors to match a corporate brand, architectural style, or community design guidelines, painted panels offer a wide range of color options and finishes that Galvalume’s natural metallic look cannot match.
2. For Temporary or Low-Priority Buildings
Painted steel panels may be suitable for short-term structures, such as temporary warehouses, equipment shelters, or utility buildings, where maximum lifespan and minimal maintenance aren’t critical.
3. In Mild Environments with Proactive Maintenance
In regions with low humidity, limited UV exposure, and minimal pollution, painted panels can perform reasonably well especially if regular inspections and maintenance are part of the facility management plan.
Note: If you choose painted panels, be prepared for future repainting cycles and take steps to protect cut edges and exposed fasteners, where corrosion risk is highest.
Specifying Galvalume Plus™ for Steel Buildings
Choosing Galvalume Plus™ is a smart long-term investment, but to get the full benefit, it’s essential to specify the right materials and components during the design and procurement stages. At Buildway, we recommend the following best practices to ensure optimal performance and longevity.
1. Choose the Right Steel Grade and Coating Weight
To ensure long-term corrosion protection:
- Specify AZ-50 or AZ-55 coating weights, depending on environmental exposure.
- Match the steel gauge to the building’s structural requirements: roofing, cladding, or walls.
These coating grades are industry-standard for high-performance building envelope systems and are proven to deliver exceptional durability in diverse climates.
2. Ensure Compatibility with Fasteners and Flashings
Even the best substrate can fail if it’s paired with incompatible components. To avoid galvanic corrosion:
- Use fasteners and flashings that are zinc- or aluminum-compatible
- Avoid direct contact with copper, lead, or graphite, which can accelerate corrosion at connection points
- Confirm all accessory materials are tested and approved for use with Galvalume-coated steel
3. Review Manufacturer Warranties
Top-tier Galvalume products come with warranties of 25 years or more against perforation and structural failure due to corrosion. Always request and review:
- Coating and substrate warranties
- Environmental limitations (e.g., coastal exclusions)
- Proper handling and installation requirements to ensure warranty validity
4. Consider Environment-Specific Protection
In high-salt or marine environments (within 1–2 km of the ocean), standard Galvalume may require enhanced protection:
- Apply a factory-applied topcoat or clear resin layer
- Or, specify stainless steel alternatives for areas with extreme exposure, such as fascia, ridge caps, or roof edges
Buildway Pro Tip: Always consult your panel supplier or system engineer when designing for coastal, agricultural, or industrial applications. Proper material pairing and detailing at the specification stage can prevent premature corrosion and protect your investment for decades.
Why Buildway Is the Smarter Choice for Steel Buildings
At Buildway, we don’t cut corners when it comes to quality or longevity. That’s why every steel building we deliver is made exclusively with Galvalume Plus™ steel, a proven material that offers industry-leading corrosion protection.
Unlike other suppliers who offer painted panels or lower-grade steel, we only use Galvalume Plus™ across all panels and structural components, ensuring your building performs reliably for decades.
Backed by a 50-Year Rust Perforation Warranty
Your investment is protected with our 50-year rust perforation warranty, covering:
- All Galvalume Plus™ wall and roof panels
- Pre-engineered structural steel components
- Factory-applied finishes (with 40–50 year paint warranties)
Choose Buildway if you want the best materials, the longest protection, and real long-term value from your steel building.
Have questions? Call us at +1 (855) 944-1515 or email [email protected]
Conclusion
When it comes to steel building systems, the right material choice makes all the difference, not just in how your building looks today, but in how it performs decades from now.
If your project demands:
- Long-term durability
- Proven corrosion resistance
- Minimal maintenance
- And the best possible lifecycle value
Then Galvalume Plus™ steel panels are the clear, technically superior solution. At Buildway, we make that decision even easier by offering only Galvalume Plus™ products backed by a 50-year rust perforation warranty so you can build with total confidence.
Ready to future-proof your steel building? Download our spec sheet, or contact our team to compare your options and design a system built to last.
Next Steps
- Download our Galvalume Plus™ vs Painted Panel Spec Sheet
- Compare total lifecycle cost before your next project
Glossary
- AZ Coating: Aluminum-Zinc alloy coating (typically AZ-50 or AZ-55)
- Self-Healing Alloy: Coating that repairs minor damage through sacrificial action
- Edge Creep: Corrosion that begins at cut edges and spreads
- SMP: Silicone-Modified Polyester (common paint system)
- PVDF: Polyvinylidene fluoride (premium paint, e.g., Kynar 500®)
FAQs
1. How much longer does Galvalume Plus™ last compared to painted panels?
Galvalume Plus™ can last 2 to 4 times longer than painted steel panels. In many environments, it offers a lifespan of up to 60 years, while painted panels typically last 15 to 25 years, depending on exposure and maintenance.
2. Can you paint over Galvalume Plus™ steel?
Yes, Galvalume can be painted if color is needed later. However, it requires proper surface preparation and the use of compatible primers to ensure long-term adhesion and durability.
3. Is Galvalume suitable for coastal or humid environments?
Galvalume performs well in humid and moderately coastal areas, but caution is advised within 1 to 2 kilometers of the ocean due to salt exposure. In extreme coastal zones, consider using marine-grade coatings or alternative materials for maximum protection.
4. What kind of maintenance does Galvalume Plus™ require?
Galvalume steel panels require minimal maintenance. Recommended upkeep includes:
- Inspecting edges and fasteners
- Removing debris and buildup
- Avoiding contact with incompatible metals like copper or lead (to prevent galvanic corrosion)
5. Is Galvalume more expensive than painted panels?
While Galvalume Plus™ may have a slightly higher upfront cost, it typically offers lower long-term costs due to its extended lifespan and reduced need for repainting or replacement.
Disclaimer: The information provided in this article is intended for general guidance and educational purposes only. While we strive to ensure accuracy, we recommend consulting with local professionals or suppliers for project-specific details. Any external links provided are for convenience only. We do not take responsibility for the accuracy, content, or reliability of third-party websites or resources referenced within this blog. For more details, please read our full disclaimer.
