Manufacturing & Craftsmanship

Why Finishes Matter in Outdoor Furniture

Outdoor furniture is exposed to a level of stress no interior material ever experiences. UV radiation, wind-driven rain, salt air, freezing temperatures, and continuous thermal cycling. The finish must not only look beautiful, but also protect the metal beneath for decades in every environment. For these reasons, Powder coating is the global benchmark for long-term outdoor performance, used in architectural applications from window frames to road signs to cladding systems, and in our case – luxury aluminium furniture.

At Oxley’s, we have spent more than three decades refining a specialised high-performance powder coating process for our recycled aluminium furniture. This article explains how the process works, why it outperforms standard industry methods, and what it means for real-world longevity.

1. What Is Powder Coating? A Quick Primer

Powder coating is a dry finishing technique in which electrostatically charged pigment particles are sprayed onto a grounded metal surface and then cured in an oven. During curing, the powder melts, flows, and chemically cross-links to form a single, continuous protective layer.

Key advantages of powder coating

• Highly durable: resists chipping, fading, corrosion, and impact.
• Uniform and architectural: produces a smooth, consistent finish.
• Environmental: contains no solvents and produces minimal waste.
• Colour-flexible: available in almost any RAL shade, matte to textured.

While the principles are universal, the quality of the finish depends entirely on preparation and process control. This is where Oxley’s small batch approach differs from most aluminium furniture mass-producers.

2. Why Powder Coating Is Ideal for Aluminium Outdoor Furniture

Aluminium is an exceptional substrate for powder coating because it naturally resists rust, has a stable oxide layer, and can be engineered into elegant and decorative structural forms. Powder coating enhances these inherent advantages by sealing the metal against moisture and environmental pollutants.

For outdoor furniture, this offers three critical benefits:

• Long-term corrosion resistance. Powder coating prevents moisture and salts from reaching the aluminium surface, ensuring stability even in coastal settings.
• UV and colour stability. High-quality exterior-grade powders retain colour and texture for decades, even in bright sun.
• A low-maintenance surface. Unlike timber, iron, or painted steel, powder-coated aluminium requires almost no upkeep beyond occasional washing.

3. The Oxley’s High-Performance Powder Coating Process

While powder coating is common, the way it is applied varies dramatically. Oxley’s uses a multi-stage process developed specifically for aluminium furniture intended for permanent outdoor use. It is equivalent in discipline to architectural powder coating for building exteriors, far beyond the standard applied to mass-produced outdoor furniture.

Surface preparation: the crucial foundation. Preparing the metal surface is key as it sets a solid foundation for the powder coat to be applied. After welding, each piece is extensively linished by hand to provide a even, smooth surface. We work our way down through hand files and angle grinders to remove excess metal from welding, to our high grit air powdered hand sanders to make sure every surface, edge, and nook is prepared.

Shot blasting. Most furniture manufacturers lightly abrade or wipe the metal before coating. This results in separation between the layer of cured powder and the metal underneath, inevitably leading to cracks and flaking. We go further. Every piece of Oxley’s furniture is individually shot blasted with extremely fine stainless steel shot. This process:

• Triples the effective surface area
• Creates optimal texture for mechanical adhesion
• Ensures the powder can “grip” the metal securely

This step alone is a major differentiator: strong adhesion is the single most important determinant of long-term performance.

Electrostatic powder application. The main event. Pieces are individually hung on our custom-built rail system to ensure a hands-free workflow. Once in our powder-booth the furniture is charged with a negative electrical current. Using an electrostatic gun, powder particles are charged and attracted to the grounded aluminium surface.
This produces:

• An even deposit
• Strong mechanical bond
• Minimal overspray and waste

We work closely with only the leading international suppliers of architectural grade exterior powder to ensure the highest standards of UV, impact, and chemical resistance.

At Oxley’s, we prime our furniture with a basecoat before applying a top coat in our customer’s chosen finish colour. By curing the furniture at multiple stages we ensure an industry leading long lasting finish.

Curing: precision matters. Pieces are then baked in one of our two temperature-controlled oven, allowing the powder to melt and fully bind to the metal.
Fully cured powder coating results in:

• A dense, uniform surface
• Resistance to cracking or peeling
• Excellent longevity in all climates

This curing step is tightly controlled and monitored by our production team because different metal thicknesses and quantities in each cure will have an effect on the temperature and time requirements. Under-cured powder is the leading cause of premature coating failure in cheaper outdoor furniture. Over 30 years of experience and commitment to quality have developed our expertise

4. How Our Finish Performs in the Real World

Weatherproof in every climate. Over the lifetime of our business, Oxley’s Furniture has been installed in a myriad of challenging environments

• Mediterranean sun
• Alpine snow
• Coastal properties with salt-laden air
• Tropical humidity
• Caribbean weather cycles
• Middle-Eastern sandy deserts

The finish remains stable, without warping, chalking, or corrosion.

Decades-long colour integrity. Our architectural-grade powders resist fading far longer than wet-paint alternatives or lower-grade interior powders.

Fits into any design scheme. Powder coating enables ultimate flexibility with a broad palette of refined matte, satin, or textured finishes. Oxley’s core colours are curated for timeless appeal, and our classic finishes add a unique hand-finished patina that adds depth and character to pieces. We also routinely match any RAL colour on request.

5. Sustainability Benefits of Powder Coating

Oxley’s was founded in 1991 on the principle of longevity, durability and circularity. Powder coating complements this mission.

• A solvent-free finish. Unlike liquid paint, powder coating contains no VOCs (volatile organic compounds).
• Minimal waste. Overspray can be reclaimed and reused during the process.
• Extends product lifespan. A product made to lasts decades not seasons will reduce landfill waste and conserve our planet’s resources.
• Perfect alignment with recycled aluminium. All Oxley’s furniture is made from recycled aluminium, and the powder coating process ensures that this material stays in use for generations. Ultimately all our pieces can be reclaimed and recycled for use in another purpose. The same cannot be said for any other material commonly used in outdoor furniture.

6. Maintenance: Minimal by Design

One of the greatest advantages of our powder-coated finish is its ease of care. To maintain its appearance:

• Wash once or twice a year with mild car shampoo
• Wipe with a damp cloth after heavy pollen events or storms
• Avoid abrasive cleaners or scouring pads

No rot. No rust. No re-painting. No oiling. No sealing. No seasonal storage.
This is as close to maintenance-free outdoor furniture as it is possible to achieve.

Common Questions About Powder Coating

• How long does powder coating last outdoors? Architectural-grade powder coating can last multiple decades with negligible fading or corrosion.
• Will powder coating chip or peel? Poorly prepared metal can chip. Our shot blasting ensures exceptional adhesion and our small batch production ensures highest quality.
• Is powder coating safe for coastal environments? Yes, it is the preferred finishing method for coastal aluminium architecture.
• Can I repair powder coating if it becomes damaged? Minor scuffs can be touched up; major repair is rarely required due to the durability of the finish.

Conclusion

A finish is only as good as the process behind it. Powder coating is the industry gold standard for outdoor metalwork, but when combined with Oxley’s intensive preparation and architectural-grade powders, it becomes something more: a protective, low-maintenance, long-lasting finish that enables design freedom without compromising performance.

This is the reason our furniture remains in use, and looking exceptional, years and even decades after installation.

If you are ever in the Cotswolds, you are most welcome to come and see this meticulous process in action, and see first hand the care, attention, and commitment to the highest standard of quality that we take great pride in.