Aluminium Fabrication

Master Steel provides full Aluminium fabrication for a wide range of industrial, structural and commercial applications; from stairs, walkways, platforms and enclosures, to architectural components, screens, gates and related work.

We deliver projects requiring a combination of aluminium and another metal such as stainless steel in a single structure. This often involves design and fabrication of the separate components with a bolted assembly.

Our Aluminium Fabrication Services

Aluminium Component Fabrication

We manufacture aluminium components small and large, for outdoor and indoor usage. What is common about the aluminium products we fabricate is the clients’ need for a quality finished product.

To ensure the highest manufacturing standards, all our fabricators are fully Australian qualified and professional boilermakers with experience in projects of all sizes. All fabrication work is supervised by a Certified Welding Supervisor to AS 2214. And our entire manufacturing operation is supervised by a CPEng certified Engineering Manager to ISO 9001.

Aluminium Fabrication Techniques

Our fabrication team employs the full range of techniques required for any aluminium manufacturing project, including:

Crack and weld defect repairs

  • Pre-weld Heat Treatment
  • Post-weld Heat Treatment
  • Cavity excavation
  • Cavity filling
  • Temperature induced stress homogenisation

Non-destructive testing (NDT test)

  • X-ray radiography testing
  • Dye penetrant inspection (DPI)

Aluminium processing

  • Bending
  • Drilling
  • Punching
  • Holing
  • Cutting via plasma, oxy, laser, bevel, abrasive saw, grinding,

Weld preparation

  • Partial Penetration
  • Full penetration
  • Fillet welds

On-site and off-site steel welding

  • Workshop welding - Pulse MIG, MIG, TIG, MMA
  • On-site welding - MMA, Diesel welder for MIG

Surface preparation

  • Sandblasting
  • Polishing and linishing


  • Workshop trial fitting
Site Installation Services

Welding to ISO 9001

Master Steel is an ISO 9001 certified company, providing fusion welding services within a full quality controlled manufacturing process, also known as a “factory production control system”.

AS/NZS ISO 9001 controls the entire lifecycle of the welding process, from design right through to inspection. It considers all aspects that could affect weld quality, making it essential for high quality aluminium fabrication, since it is impossible to undertake complete verification of a welded joint without destroying it.

Factory Fitout

Our manufacturing workshop on the Gold Coast services our clients across Queensland. The 2400 square metre site is set up for 24/7 production flexibility, with 10 individual welding bays, gantry crane for maneuverability and easy access for semi-trailers for us to accept structural members up to 25 metres in length.

  • 24/7 production capability
  • 10x Pulse MIG Welding Machines
  • Spark-free metallic Fusion Welding to ISO 9001
  • 10 individual welding bays with modular layout for productive flexibility
  • 10 tonne Gantry Crane that can help you manoeuvre large items for inspection, welding, and assembly.
  • Amperage load cycle compliance to MRTS78 (Department of Transport and Main Roads standard)
  • 125 tonne hydraulic punch and shear machine
  • Band saw cutting machine for large structural members
  • Capable for receiving 25m long structural steel members
  • 5 tonne forklifts

Quality Inspections

Inspections are conducted throughout the fabrication process to ensure strict quality standards and full traceability of materials used on every project.

All welding fabrication is completed to AS 1665 and structures to AS 1664. As an ISO 9001 certified company, all our products are designed and made in Australia with certified personnel and manufactured to our stringent ISO 9001 compliant quality system.

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Our Aluminium Fabrication Process

Every aluminium fabrication job we undertake follows these stages. It allows us to reliably deliver projects on time, on budget and to the exacting quality standards required by our clients.

Why choose us for Aluminium Fabrication

Companies choose Master Steel for the fabrication of their aluminium because we utilise highly experienced and certified staff working within the weld quality framework of ISO 9001.

  • 30 years metal fabrication experience
  • ISO 9001 Certified
  • Turnkey Service provider
  • Project management

FAQs about Aluminium Fabrication

Here are some common questions we get asked on this topic.

One of the primary advantages of aluminium over stainless steel is weight . Whilst both metals offer strong corrosion and chemical resistance, aluminium has a density of roughly one third that of steel. This makes it particularly advantageous where weight (or the strength to weight ratio) is an important factor in the application.

There are several other reasons for choosing aluminium over stainless steel. It’s aesthetic finish (shiny, clean) keeps it looking good even when exposed to the elements. Aluminium is easier to work with, to cut and form, being more malleable than steel. In terms of temperature, Aluminium is a better conductor of heat, though it can’t be used at temperatures as high as steel.

Welding aluminum introduces some additional complications over welding steel, which require some special considerations and procedures. This includes different melting points, the protective oxide layer on aluminium, thermal conductivity and porosity.

Resulting factors to consider when welding aluminium start with proper storage and thorough cleaning of the base material, selection of the correct filler metal and adherence to proper welding techniques. Read more on this topic on The Fabricator’s blog.

Yes, aluminum is a very good conductor of electricity. By comparison, stainless steel is a relatively poor conductor. Which is why aluminium - and its alloys - are widely used in electrical applications.

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