Aluminum Generator Access Stairs vs. Steel: The New Standard for Data Centers

Table of Contents

1. Elimination of Heavy Equipment at Install

2. Superior Corrosion Resistance (No Painting Required)

3. Modularity for Future-Proofing

4. The “Zinc Whisker” Threat to Data Centers

Comparison: Aluminum vs. Carbon Steel

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Nick Bishop

My name is Nick Bishop - your aluminum Access Solutions Advisor on the Commercial team. I have 9 years of experience at Upside Innovations. I specialize in access to warehouses, distribution centers and commercial buildings. With my expertise—where aluminum meets access, brilliance follows.

Jan 23, 2026

Estimated reading time: 3 minutes

worker with PPE accessing power generator

Eliminate rust remediation by choosing aluminum, which offers a maintenance-free lifespan that matches the longevity of the generators it serves.

An “industry standard” for backup generator access stairs has been carbon steel—specifically, galvanized or painted systems. It appears on the architectural plans by default, often because it’s a known quantity. However, for infrastructure like data centers, “standard” often means “outdated.”

When accessing massive backup power units from Caterpillar, Cummins, Generac, Kohler, or MTU, a prefabricated aluminum system offers significant advantages over traditional steel. From installation speed to long-term data safety, here is the case for making the switch.

1. Elimination of Heavy Equipment at Install

Steel stairs often require a crane and a welding crew to install, especially for the heights required to access large industrial generators.

Steel Reality: Heavy, single-piece weldments require coordination with crane operators, hot work permits, and production shutdowns.
Aluminum Advantage: Aluminum stair systems are often modular and bolt together. Components are lightweight enough to be carried by hand into tight spaces between generators or inside enclosure yards. A two-person crew can assemble a complete stair tower and platform in hours, not days, with zero heavy machinery.

2. Superior Corrosion Resistance (No Painting Required)

Generators are often exterior and exposed to the elements 24/7.

Steel Reality: Painted carbon steel will eventually chip and rust. Galvanized steel effectively fights rust but is visually industrial and dull. Both require maintenance to prevent structural degradation over 20+ years.
Aluminum Advantage: Aluminum develops a natural oxide film that prevents rust. It requires zero painting or maintenance to maintain its structural integrity, even in wet or coastal environments.

3. Modularity for Future-Proofing

Facilities expand. Generators are swapped. Cooling footprints change.

Steel Reality: A welded steel staircase is a permanent fixture. Moving it requires cutting torches and scrap metal haulers.
Aluminum Advantage: Bolt-together stair systems are reconfigurable. If you need to move a stair to the opposite side of a fuel tank or adjust the platform height for a new generator model, you simply unbolt and reassemble.

4. The “Zinc Whisker” Threat to Data Centers

One of the most overlooked risks of galvanized steel, especially in data center environments, is zinc whisker formation.

The Problem: Over time, galvanized steel surfaces can grow microscopic zinc filaments (whiskers). If these detach and become airborne, they can circulate through cooling systems and land on server motherboards, causing short circuits and catastrophic hardware failure.
The Solution: Aluminum stairs are naturally corrosion-resistant without the need for galvanization. By eliminating the zinc coating, you eliminate the risk of zinc whiskers entirely—a critical safeguard for facility uptime.

Comparison: Aluminum vs. Carbon Steel

Feature	Prefab Aluminum (Upside Solution)	Carbon Steel (Painted/Galvanized)
Corrosion Resistance	Excellent (Natural)	Moderate (Requires coating/maintenance)
Data Center Safety	Zero Zinc Whiskers	High Risk (Galvanized coatings)
Installation	Bolt-together (Hand carry)	Welded (Requires Crane/Heavy Lift)
Modularity	100% Reconfigurable	Fixed / Permanent
Lead Time	Pre-engineered & Ready to Ship	Custom Fabrication (Weeks/Months)