Description
EcoSteel™ Colorbond Coil System – Detailed Product Overview
EcoSteel™ is a high-performance fabrication material developed specifically for the production of 3D letters in Australian conditions. It combines 0.4mm Colorbond® steel coil with a proven adhesive system to deliver a robust, long-life alternative to traditional aluminium coil.
Material Specification
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Material: Pre-finished Colorbond® steel
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Thickness: 0.4mm (Similar in handling to 0.8mm Aluminium)
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Finish: Factory-applied coating system engineered for UV resistance and environmental durability
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Mechanical Properties: High tensile strength substrate
The 0.4mm thickness has been selected as a balance between formability and structural rigidity, allowing clean returns while maintaining panel integrity over time. The internal coating colour is a light grey, this will dim LED output slightly, however the difference is not noticeable if its not mixed with other materials.
Fabrication & Processing
EcoSteel™ coil is fully compatible with automated letter bending machines, enabling efficient production of fabricated letters at scale. It can also be processed manually where required.
However, this is not a direct substitute for aluminium coil in terms of handling characteristics.
Key Fabrication Considerations:
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Higher tensile strength:
The steel substrate is significantly stronger than aluminium, which improves durability but increases forming resistance. -
Increased forming force required:
Expect higher load on rollers, tooling, and bending mechanisms. -
Tighter process control needed:
Spring-back behaviour differs from aluminium and must be accounted for in machine settings and operator technique. -
Learning curve for new users:
Operators transitioning from aluminium should expect an adjustment period to refine feed rates, bend pressures, and return consistency.
Weight, Handling & Equipment Considerations
EcoSteel™ is materially heavier than aluminium coil, and this has practical implications across handling, storage, and production workflows.
Key Considerations:
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Increased coil weight:
A 50m roll in 0.4mm thickness can range from ~6kg to 16kg depending on width, with thicker gauges increasing significantly. This impacts transport, storage, and day-to-day usability. -
Manual handling:
Wider or thicker coils may exceed comfortable single-person lifting limits. Consider:-
Two-person lifts for larger rolls
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Mechanical aids (coil dispensers, spindle stands, trolleys)
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Safe handling practices to reduce fatigue and injury risk
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Machine loading:
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Heavier coils place greater demand on feed systems, spindles, and drive motors
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Ensure your letter bender can accommodate the coil weight and inertia without inconsistent feeding or slippage
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Some setups may require upgraded holders, braking systems, or tension control
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Feed consistency:
Higher mass coils can introduce momentum and drag, affecting precision—particularly on smaller letters or intricate profiles.
Letter Bender Compatibility Disclaimer
While EcoSteel™ is suitable for use in letter bending machines, not all machines perform equally.
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Variations in roller design, tooling profiles, drive systems, and calibration will impact results
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Small radius bends and fine detail work will vary depending on machine capability
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Some machines may require parameter tuning or hardware adjustments to achieve optimal results
Users should expect to carry out initial testing and calibration on their specific equipment before full production.
Performance Advantages
EcoSteel™ has been developed to address common long-term failures seen in fabricated letters using aluminium coil, particularly in harsh Australian environments.
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Superior coating adhesion and longevity vs painted aluminium systems
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Improved resistance to UV degradation, chalking, and delamination
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Higher structural rigidity, reducing oil-canning and deformation
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Designed for compatibility with matched adhesive systems to ensure long-term bond integrity
- Recommended for letters 150mm to 1400mm high (Consider strengthening techniques for letters on the large side)
Positioning
EcoSteel™ is not simply a material swap—it is a system-based approach to fabricated letter construction. It prioritises long-term performance and environmental resistance over ease of fabrication.
For fabricators willing to adapt their processes, EcoSteel™ delivers a more durable, stable, and reliable end product—particularly in demanding outdoor applications across Australia.
Summary:
Expect a stronger, heavier, more durable material that requires more control during fabrication and handling. With the correct setup and a short adjustment period, EcoSteel™ provides a significant upgrade in finished product performance.
