Once associated with industrial plants and urban neighbourhoods, weathered corten steel now features in a diverse range of settings and applications, from university campuses and rural residences to public artworks. 

The popularity of rusted, aged steel is part of the trend for natural finishes, according to Phil Fisk, Sales Manager for Axalta UK & Ireland. “The look has definitely become more popular over the past five or six years, it’s used not only in facades but also for decorative design and interiors.”

Natural rust 

In corten steel, the transformation of the rust layer from rusted orange to a rich brown hue evolves over time. As Phil notes, this does not always tie in with the architect’s plans. “We’ve had customers ask where they can get hold of corten with an accelerated ageing process,” he says. 

“The fact that corten is only available in steel means you’re working with heavy materials,” says Phil. For building facades, this considerable weight can have implications for the design and even the cost. “Another issue is the fact that water run-off due to rain can leave rust stains. This means you have to choose adjoining colours carefully,” he says. 

Powder coatings offer a stable solution

This is often used for projects to replicate the beauty of weathered steel without some of the drawbacks, Phil explains: “Powder coatings give architects a greater choice of substrates, including aluminium sheet, extrusion and galvanised steel. They offer many of the organic industrial effects, in a full spectrum of colours and finishes, including metallic effects – the possibilities are almost endless.”

As well as creating weathered steel-style facades, it is possible to extend the look to details such as balustrades and trims. “This is a popular option,” says Phil. “Specifying corten for ground-level features such as railings wouldn’t be viable as you’d risk contaminating people’s hands and clothes.”

Consistency and sustainability

While some are attracted to the changing look of corten, Phil says many architects prefer the colour consistency that powder coatings offer: “They want to know their project is going to look the same in 20 years’ time.” 

Seen as a sustainable option, powder coatings contain virtually no VOCs (volatile organic compounds). This can be particularly useful when aiming for green building accreditations such as LEED®.

To explore the options for powder coatings, take a look at Axalta’s collections such as ICONICA, with shades including Timeless Rust, Russet Scarabea and Copper Glimmer. These hues are a starting point for anyone looking to recreate the weathered look in a wide range of shades and finishes.

To explore the ICONICA range in full, click here