What’s the Difference Between Cast and Cast Aluminium Garden Furniture?
What’s the Difference Between Cast and Cast Aluminium Garden Furniture?
When you shop for outdoor furniture, you will often see the terms “cast” and “cast aluminium.” One describes the method, the other the metal. This guide explains the difference, adds Victorian context, and includes expert insight from our Bacup foundry owner and long-time foundryman, Alan Butterworth.
Understanding the distinction helps you choose furniture that matches your lifestyle, preferred maintenance level, and the look you want to create in your garden.
What Do We Mean by “Cast” Furniture?
“Cast” refers to the process of pouring molten metal into a mould, letting it cool, then fettling and finishing the solid piece. The method can be used with several metals, including iron and aluminium. The attraction of casting lies in the detail it allows. Scrolls, grapevine motifs, and crisp latticework are all possible because liquid metal can fill fine features in a mould.
In other words, “cast” tells you how the furniture was made, not what it is made from. You can have cast iron, cast steel, or cast aluminium. The look may be similar, yet the day-to-day experience of owning each type can be quite different.
How the Victorians Made Cast Furniture Famous
Cast garden furniture became widely recognised in the Victorian period. Public parks, railways, promenades, and private gardens embraced cast iron benches and chairs with confident ornamentation. People still use the phrase “Victorian cast furniture” to describe this timeless style.
That heritage matters today because many contemporary designs are inspired by the same motifs. When someone says they want a classic bench, they often picture a Victorian pattern. Modern casting keeps that look alive whilst using materials that better suit contemporary life.
What Is Cast Aluminium Furniture?
Cast aluminium furniture uses the same casting method, but with aluminium as the metal. Aluminium does not rust, which makes it well-suited to the British climate. After casting, pieces are typically powder-coated and oven-baked to create a tough, attractive finish.
Aluminium is also far lighter than iron. You can usually reposition a cast aluminium chair or table on your own. Despite the lower weight, well-designed aluminium furniture feels stable and substantial in daily use.
Cast Iron vs Cast Aluminium: The Key Differences
Weather resistance: Iron can rust if the paint is compromised. Aluminium resists corrosion, so the risk of structural damage is lower and upkeep is simpler. A powder-coated finish protects both, yet aluminium is more forgiving if a chip appears.
Weight and handling: Iron is heavy, which some owners like for permanence. The same weight makes cleaning, rearranging, and storage a challenge. Aluminium strikes a practical balance. It is easier to move yet still reassuringly solid.
How Do They Compare in Maintenance?
Cast iron often requires periodic repainting or at least careful touch-ups where paint chips have appeared. If neglected, rust can spread beneath coatings and spoil the appearance. Some owners enjoy the ritual of restoration, though it does take time.
Cast aluminium usually needs only a wash with warm, soapy water and a rinse. The powder-coated finish is durable, and the metal beneath will not rust. Maintenance is therefore light and predictable across the years.
What About Longevity?
Both materials can last for decades if cared for. Many original Victorian cast-iron benches are still in use after restoration. Aluminium’s advantage is that it avoids corrosion, so long-term appearance tends to be easier to preserve with minimal effort.
Because aluminium maintenance is simpler, owners are more likely to keep on top of it. A quick clean restores the finish and keeps furniture looking fresh without periodic overhauls.
Which One Looks Better?
It comes down to taste. Cast iron has a darker, weighty presence that speaks of Victorian industrial heritage. Cast aluminium can imitate that look in black or shift to lighter heritage tones such as green, bronze, or white through powder coating.
Both capture intricate detail well. With aluminium you gain that classic filigree with a finish that stays brighter for longer and a weight that suits modern patios and terraces.
Environmental Considerations
Aluminium is widely recycled and can be recycled repeatedly without losing quality. Many foundries use recycled aluminium ingots, reducing demand for virgin material and cutting embodied energy compared to repeated repainting cycles.
Fewer intensive maintenance chemicals and paints are needed over the life of cast aluminium furniture. That is a practical environmental win as well as a time saver for owners.
Insights from the Foundry
“When people say ‘cast furniture’ they are often thinking of Victorian cast iron. The process is the same today, but the metal changes the behaviour in the mould. Aluminium runs faster and cools quicker than iron, so you must gate and vent the mould differently. Pour too fast and you can trap gas; too slow and you risk a cold shut where two fronts meet and do not fuse. Getting that right is what gives you crisp scrolls without weak spots.”
Alan Butterworth, Foundry Owner, Bacup
“The thickest sections, like arm junctions and deeper scrolls, hold heat longer. That is why we design the risers and feeders to pull sound metal into those areas as the casting shrinks. It matters for cleaning too. Dirt tends to settle in the same deep sections where the metal is densest, so a soft brush is the most useful tool you will own. Wipe the flats with a cloth, then brush the recesses so nothing hardens in the detail.”
Alan Butterworth
FAQs
Does cast aluminium rust like cast iron?
No. Aluminium does not rust in the way iron does. A powder-coated finish protects the surface, and even if it is chipped, the base metal will not rust. Keep it clean for the best long-term appearance.
Is cast aluminium strong enough compared to iron?
Yes. Well-designed cast aluminium furniture is engineered with appropriate sections and bracing. It feels solid in daily use whilst remaining lighter and easier to move than iron.
Why is Victorian cast iron still popular?
The Victorians popularised ornate casting in public spaces and gardens. The look became synonymous with longevity and civic pride. Many modern designs echo those motifs, now produced in aluminium for easier care.
What maintenance does cast aluminium need?
A gentle wash with warm soapy water, a rinse, and occasional brushing in the recesses. Avoid harsh abrasives. Covers in winter reduce cleaning time further.
Is cast aluminium more sustainable than cast iron?
Aluminium is widely recycled and can be recycled repeatedly. Lower maintenance demand and the use of recycled ingot can reduce environmental impact over the furniture’s life.
Final Thoughts
The difference between “cast” and “cast aluminium” is simple. Cast describes the process; cast aluminium tells you the metal. Cast iron carries undeniable Victorian charm, yet requires more maintenance and is heavy to live with.
Cast aluminium keeps the ornate look that people love, adds easier handling, and reduces upkeep. For most modern British gardens it offers the most practical path to a classic aesthetic that lasts.