Galvanising, powder coat or both
General weld, coating thickness and adhesion checks are on the iron and steel furniture page; aluminium frames are on the aluminium furniture page. Weathering checks common to all outdoor furniture are on its own page. For outdoor steel sets, the key question is how the frame is protected. There are four common systems, and they behave very differently outside:
| System | What it is | Weak point |
|---|---|---|
| Powder coat on bare steel | Cleaned steel, powder sprayed and oven-cured | Any chip, thin edge or weld pinhole lets rust creep under the coat |
| Pre-galvanised tube, then powder | Tube bought already zinc-coated, then cut, welded and coated | Welding burns the zinc off at every joint, so welds are bare steel under the powder |
| Hot-dip galvanised after welding | Finished frame dipped in molten zinc (the process ISO 1461 covers) | Needs vent and drain holes; drips and spikes of zinc must be removed |
| Duplex: hot-dip, then powder | Galvanised frame powder-coated for colour | Powder can blister or pinhole on zinc without the right pre-treatment |
The system is set in the purchase order and confirmed at a during-production inspection, before frames are coated. Once powder is on, a pre-galvanised frame and a hot-dip frame can look the same.
What we check on outdoor metal sets
| Check | How it is checked | What fails |
|---|---|---|
| Protection system | Cut ends, drain holes and welds inspected for zinc; documents from the galvaniser checked | Pre-galvanised tube where hot-dip after welding was ordered; no galvanising where it was ordered |
| Rust at welds | Every accessible weld checked, including under seats and table frames | Rust bloom, pinholes or bubbles in the coat at welds |
| Drainage holes | Each hollow section checked for a hole at its lowest point in use | Sealed tubes, holes on the top face, holes blocked by powder |
| Seat and table drainage | Water poured on a sampled seat and table top | Water pools on a solid seat or table with no drain path |
| Folding parts | Folding chairs opened and closed; gaps checked where frames cross | Shear or squeeze points that trap fingers; lock that releases under load |
| Colour across the set | Table and all chairs of one set placed side by side in daylight | Different powder batches visible within a set |
| Cushions | Fabric, foam, zips and ties against the specification; cushion fitted to each chair | Indoor fabric or foam, cushions that do not fit, ties missing |
| Set completeness | Sampled sets unpacked in full against the set list | Missing chair, cushion, hardware bag or table part |
Common outdoor metal furniture set defects and how they are classed
| Defect | Class |
|---|---|
| Folding chair lock releases under load | Critical |
| Finger trap at a folding joint | Critical |
| Wrong protection system (no galvanising where ordered) | Major |
| Rust or coating bubbles at welds | Major |
| No drain hole in a hollow section | Major |
| Set incomplete or parts of different sets mixed | Major |
| Colour difference within one set | Major |
| Zinc drips or spikes left on a galvanised frame | Minor (major if sharp) |
| Cushion seam or zip fault | Minor |
Count findings by set when the set is the selling unit. In our Sample 05 report, nesting tables sold as sets of two were inspected as five sets, and faults that applied across the lot were counted once.
Rules and lab tests that apply
- Outdoor furniture standards. EU buyers usually ask for lab reports to the EN 581 series: part 1 general safety, including shear and squeeze points, part 2 seating and part 3 tables. These are lab tests. See EN furniture testing.
- Salt spray. Corrosion resistance is a lab test, usually neutral salt spray to ISO 9227 or ASTM B117. The standard sets the method, not the pass level, so your specification must give the hours and how scribe creep and blistering are judged. The standard's own scope text warns that results are not a direct guide to corrosion resistance in service, so treat it as a comparison and a batch check.
- Cushions and fabric. UK fire rules apply to garden furniture suitable for use in a home; the US federal rule exempts cushions for outdoor use only. See UK fire safety and 16 CFR 1640. Water-repellent fabric finishes fall under the REACH PFHxA restriction, which reaches consumer textiles other than clothing from 10 October 2027.
- Coatings. The US lead-in-paint limit and California Prop 65 apply to the coating; see CPSC and CPSIA rules.
Lightfastness of cushion fabric (ISO 105-B02) is also a lab test. We can pull frames and fabric from production so the lab tests what is shipping.
Set packing, carton labels and loading
A set is often split across two to four cartons: table top, table base, chairs in pairs, cushions. If one carton goes astray in a warehouse, the set cannot be sold. We check:
- Carton marks. Each carton shows the set name, its own content and "1 of 3, 2 of 3" numbering, with the same set code on all.
- Carton counts. Cartons per set match across the lot, and the packing list counts sets and cartons separately.
- Hardware. One bag per set, in a named carton, matching the fitting list.
- Dry packing. Frames dry before wrapping, cushions in their own bags, desiccants for long routes.
- Loading. All cartons of a set loaded together where possible; loading supervision checks counts by set.
What to put in your purchase order
- Protection system: hot-dip galvanised after welding, duplex, or powder only, with minimum thickness.
- Drain hole position and size for every hollow section.
- Salt spray hours and pass criteria, and which batch is tested.
- Cushion fabric type, lightfastness grade, foam type and water-repellent finish declaration.
- Set list: every part, carton numbering and set code.
- Colour rule: one powder batch per set.
For single chairs, see metal chairs; for woven seats, see rope and woven outdoor furniture. Sets for a dining table also share checks with dining tables and dining chairs. To check your next order, book an inspection.