Materials and construction
Built for here
Forge offers two product ranges with two different material stories. Outdoor kitchens are marine-grade aluminium with sintered stone benchtops. Outdoor fireplaces are cast concrete. Both are specified for outdoor exposure first, looks second. Here is what is in each, and why we built them this way.
Outdoor kitchens
The cabinet structure
Marine-grade 6063-T5 extruded aluminium. The same alloy used in window joinery, marine fittings, and architectural extrusion. Naturally corrosion resistant. Does not rust. Holds dimension through summer-winter swings.
The cabinet panels are 18 mm extruded sections with edge banding. Significantly thicker and stiffer than typical sheet-metal cabinet bodies. Doors, drawer fronts, end panels, and adjustable shelves are full seamless welded units. Not folded sheet metal. Not riveted assemblies.
Finish is powder coat, UV stable, in four standard colours: black, white, khaki, and grey.
Why aluminium and not stainless steel
The default assumption for outdoor metal is stainless. We started there too, then specified differently. A few reasons.
- Stainless pits in coastal salt air. Type 304, the typical grade in outdoor cabinetry, shows pitting within 5 to 10 years on coastal sites. Even 316 marine grade is not immune in NZ exposure.
- Stainless shows every fingerprint and water mark. It does not age gracefully on a daily-use surface.
- Stainless is one colour. Aluminium with powder coat gives colour options that work into a designed outdoor space.
- Aluminium extrusion is dimensionally stable across temperature swings. Sheet-metal cabinet bodies, often 1 to 2 mm thick, flex and rack more over time.
The honest trade-off: aluminium is softer than stainless steel and would dent under heavy sharp impact. We designed around this. The cabinet panels are thick extrusion, not soft sheet. Corners and edges are welded into the structure rather than bolted on as separate trim.
The benchtops
Sintered stone, 12 mm thick. Compressed and heat-treated mineral particles. Non-porous. UV stable. Stain resistant. Harder than granite. Handles direct contact with hot pans without scorching or staining.
We do not seal it. We do not oil it. A damp cloth does it on most days.
The hardware that nobody thinks about
The components that fail first on cheap outdoor kitchens are the ones nobody asks about: the hinges, the screws, and the levelling feet. Cheap outdoor cabinetry uses zinc-plated mild steel here, which corrodes within 3 to 5 years and seizes the doors shut.
- Stainless steel hinges on every door. The hinge pivot is a moisture-prone joint and stainless prevents galling and corrosion.
- Stainless steel connecting screws throughout the assembly. Same logic.
- Zinc metal levelling feet, mushroom-style on the heavier cabinets (kamado, fridge, planter) for load distribution.
How it goes together
Modular does not mean budget. It means each cabinet is a complete welded unit, dimensionally precise. The cabinets then bolt together using a connector system on aligned guides. Two screw types, no on-site fabrication.
The most respected indoor kitchen brands in the world build modular for the same reason. Bulthaup. Boffi. Poliform. Each unit identical to the next, with the same finish, fit, and joint quality. Custom on-site builds, by contrast, often have visible joints, mismatched finishes, and dimensional drift.
Designed in NZ, manufactured at our partner facility
Forge cabinets are designed in New Zealand and manufactured to our specification at our partner facility in Foshan, China. The factory has been making aluminium cabinetry since 2016 and operates a 30,000 sqm extrusion plant.
We chose them because they specialise in extruded aluminium cabinetry, not because they were the cheapest. The configurations, finishes, and hardware we use are agreed with them based on what makes sense for NZ outdoor conditions.
We are honest about this. The alternative is pretending the cabinets are something they are not, and we would rather you bought from us with full information.
Outdoor fireplaces
Why cast concrete
The fireplace range is a different material story to the kitchens. Aluminium handles outdoor exposure without rusting, but it would warp under sustained wood fire heat. Cast concrete handles the heat, holds its dimension, and develops character with use. It is the right material for an outdoor wood-burning fireplace.
Modern architectural concrete, made in New Zealand
The fireplaces are modern architectural concrete pieces, designed and made in New Zealand. Two models, both wood-burning, both semi-customisable. The structure is monolithic cast concrete with twin or single black flue and integrated log storage.
Cast concrete weathers. Marks from rain, splash, and use leave honest character on the surface over time. This is intentional. We are not pretending you are buying a piece that stays factory-fresh. If that matters to you, the fireplace range is not for you.
Browse the fireplace range to see both models.
Care
Most days, a damp cloth handles the kitchen surfaces. Tougher grease, mild soap and water. Within a few hundred metres of the coast, an occasional fresh water rinse to clear salt residue. No sealing. No oiling.
Concrete fireplaces have different care needs, mainly avoiding acidic cleaners that can etch the surface. Full guidance on the Care and maintenance page.
Want to see one?
The technical story matters, but a kitchen has to be felt. Knock on the cabinet panel. Lift it. Open a door and feel the hinge. We can arrange a viewing for serious enquiries. Email hello@forgeoutdoor.co.nz.