To the average pedestrian, a street light is simply part of the background scenery. It holds a lamp, it lights the footpath, and it disappears into the urban landscape.
But for a civil engineer, a council asset manager, or an urban designer, a Street light pole is a significant structural asset. It is an investment that needs to stand upright against cyclonic winds, resist corrosive salt spray, and house increasingly complex electrical systems for 25 years or more.
For decades, galvanised steel has been the default choice for infrastructure. However, advances in Street light pole manufacturing have shifted the goalposts. Today, extruded aluminium offers a superior alternative that addresses the biggest pain points of steel: rust, weight, and lack of versatility.
In this deep dive, we explore the engineering differences between these two materials and why modern councils are making the switch.
1. The Manufacturing Process: Extrusion vs. Rolling
The fundamental difference lies in how the pole is born.
Steel: The Rolled Method Traditional steel poles usually start as flat sheets of metal. These sheets are rolled into a tapered tube and then welded along the seam. While effective, this process has limitations. The weld line can become a weak point, and the shape is generally limited to simple circles or octagons.
Aluminium: The Extrusion Method At Multipole, we utilise a process called aluminium extrusion. Think of this like squeezing toothpaste from a tube, but with immense pressure and precision. Heated aluminium billets are pushed through a steel die to create a continuous profile.
This allows us to create complex cross-sections—such as our “Multi-Tech” series—that feature internal tracks and separate cavities for wiring. Because the profile is formed in one piece, there are no welded seams along the shaft to weaken over time. This level of intricacy is simply not possible with traditional rolled steel.
See how our Extrusion Technology works.
2. Fighting the Aussie Elements: Corrosion Resistance
Australia is an island nation. With 85% of our population living within 50km of the coast, salt spray is the number one enemy of infrastructure.
The Weakness of Galvanised Steel: Steel relies on a coating to survive. Hot-dip galvanising adds a layer of zinc to protect the steel underneath. It works well—until it doesn’t. If a stone chips the paint, or a delivery truck scratches the surface, the barrier is broken. Rust begins immediately and spreads underneath the coating (known as “cancer”), often undetected until structural failure looms.
The Strength of Aluminium (Alloys 6063 & 6005) At Multipole, we engineer our poles using specific Marine Grade Structural Alloys (6063 & 6005).
Unlike steel, these alloys do not need a coating to survive. When exposed to oxygen, they form a microscopic, hard oxide layer that seals the metal. If the pole is scratched, this oxide layer instantly reforms, effectively “healing” the wound.
This durability is why the global market is shifting. In fact, over 60% of all new Street light poles in Europe are now aluminium—a testament to their superior longevity and lower lifetime cost.
between replacing a rusted steel pole in 7 years versus having an aluminium pole stand strong for 30.
3. Why “Australian Made Street Lights” Reduce Risk
In the current global climate, supply chains are fragile. We have seen how quickly international shipping can grind to a halt.
Relying on imported poles introduces significant risk to construction schedules. If a shipment is delayed at the docks, your entire streetscape project sits idle. Furthermore, quality control can be inconsistent with overseas mass production.
Choosing Australian made street lights mitigates these risks.
- Lead Times: Local manufacturing means shorter, more predictable delivery windows.
- Spare Parts: Accidents happen. If a driver knocks down a pole in a busy CBD, you cannot wait 12 weeks for a replacement from overseas. A local manufacturer can supply a replacement section in days, restoring safety to the road faster.
4. Weight and Installation Safety (OH&S)
As any Street light pole manufacturer will tell you, the cost of the pole is only half the equation. You also have to pay to install it.
Steel is heavy. Installing a 10-metre steel column often requires a large crane, traffic control to close lanes, and a team of riggers. This adds thousands of dollars to the installation cost and causes major disruption in urban areas.
Aluminium is approximately one-third the weight of steel. A standard aluminium pole can often be lifted by two people or a small hiab truck. This has massive implications for Occupational Health and Safety (OH&S). Lighter loads mean less risk of injury for the installation crew, smaller machinery on-site, and faster installation times.
5. Sustainability: The Green Choice
Sustainability is no longer a “nice to have”—it is a KPI for almost every council tender.
Aluminium is one of the most sustainable materials on the planet. It is infinitely recyclable without losing its properties. In fact, recycling aluminium requires only 5% of the energy needed to produce new aluminium.
Conversely, while steel is recyclable, the energy required to transport heavy steel poles from overseas factories creates a massive carbon footprint. By choosing lightweight, locally extruded poles, you are significantly lowering the “carbon miles” of your project.
Conclusion
When specifying infrastructure, it is easy to copy and paste the specs from the last project. But the technology of Street light pole manufacturing has moved on.
By switching to marine-grade aluminium, you are choosing a material that fights corrosion, protects installation crews, and supports local industry. It is a decision that pays off not just at installation, but for decades to come.
Ready to upgrade your infrastructure specifications? Contact Multipole today to discuss our range of extruded aluminium solutions.