Are Metal Walls Safer for Fire-Rated Interior Applications Than Drywall?

Fire-rated aluminum wall systems are engineered to meet or exceed the performance of Type X gypsum assemblies when tested as complete wall constructions. Unlike gypsum, which relies on bound water to delay heat transfer, aluminum panels remain dimensionally stable and do not off-gas combustible elements. In ANSI/UL 263 or EN 1364-1 tests, aluminum panel systems—paired with mineral wool insulation and fire-rated sealants—achieve two-hour ratings with minimal integrity and insulation loss. The metal face and thermal break layers block both flame spread and smoke penetration.

Furthermore, aluminum produces lower smoke density and fewer toxic byproducts compared to organic binders in gypsum joint compounds and paper facers. This reduces risk during occupant evacuation and supports safer air quality in post-fire scenarios. Sealed, non-combustible joints further prevent fire migration between compartments. For projects prioritizing life-safety—such as hospitals, high-rise residential, or data centers—aluminum walls deliver robust fire performance with streamlined installation and minimal rework.