Had a similar issue myself, but honestly, galvanized steel was a bit pricey for my budget at the time. Ended up using aluminum again but added a protective coating this time around...been two years and holding up fine so far. Fingers crossed it stays that way.
"Ended up using aluminum again but added a protective coating this time around...been two years and holding up fine so far."
Glad to hear it's working out for you. Honestly, aluminum with a good protective coat can be surprisingly durable if done right. I faced a similar dilemma last summer—galvanized steel was tempting, but the cost difference just didn't justify it for me either. Went with aluminum flashing again, but this time I prepped the surface meticulously and applied a solid primer before the protective coating. It's only been about a year, but so far no signs of wear or corrosion. I think the key is really in the prep work and making sure the coating adheres properly. Sounds like you nailed it, though...hope it keeps holding strong for you.
Good call on the prep work—it's definitely underrated. I've seen aluminum flashing last years with proper surface prep and coating, but also watched it fail pretty quickly when someone rushed the job. Galvanized steel can be tempting, but honestly, if you're careful with aluminum and use a quality primer and coating, it usually holds up just fine. Curious though, did you go spray-on or brush-on for the coating? I've had mixed results with sprays...
Good points there, especially about the prep. I've found that brushing on the coating usually gives you better control and coverage—sprays can be hit or miss depending on wind, nozzle quality, or just plain luck. If you're careful and patient with a brush, you can really work the coating into seams and edges where sprays sometimes miss. Sounds like you've got the right idea though, aluminum flashing can definitely last if you put in the time upfront.
- Agree on brushing vs. spraying—seen too many spray jobs peel early.
- Inspected a roof last month, homeowner brushed coating into seams; flashing looked solid after 10+ yrs.
- Prep and patience pay off big-time with aluminum flashing repairs.
