A Storehouse of Storage Solutions

With more than an estimated 54,000 storage units spread across the U.S. in 2015, according to IBISWorld, and 2.63 billion square feet of existing rentable self-storage space in 2014, the self-storage industry is booming. In fact, U.S. storage facility revenue topped off at an estimated $29.8 billion in 2014, rising to $31 billion in 2015 and is expected to reach $32.7 billion in 2016. In this growing market, storage builders and facility owners face increased competition and must build and maintain more efficiently and effectively than ever. Metal panels can be a differentiator for this market, especially through multi-story and climate controlled storage facilities.

MBCI Self Storage
Southlake Self Storage in Weatherford, Tex. is a multi-story storage facility utilizing MBCI’s PBU, PBD and PBR metal panels.

Maximizing Sustainable, Rentable Space

Among the cladding and roofing materials available to build these specialized facilities, insulated metal panels (IMPs) are highly energy efficient, deliver a full weather barrier and can be designed without exterior wall framing. This boosts rentable square footage by eliminating exterior wall framing typically built with studs, batt insulation, and liner panels.

Made from 90 percent closed foam, encapsulated inside of two metal panels and impervious to water, IMPs offer a high R-value, which is a big benefit for all storage types, particularly cold storage facilities. Steel panel facings create a vapor barrier and provide long-term thermal stability, virtually eliminating off-gassing found with rigid board insulation. IMPs give design professionals the opportunity to design functional, attractive, sustainable storage facilities, and facility owners the opportunity to lower construction, operating, energy consumption, and maintenance costs throughout the life span of a building.

As an all-in-one air solution—delivering an air, vapor and water barrier with continuous insulation—building teams can strip down the multiple trades to one single application. This means there are no gaps or voids to sap thermal value, and no degradation by air or moisture. Furthermore, IMPs are the most efficient product available, providing an R-value of 7 to 8 per inch vs. the 4.5 for batt insulation, essentially doubling performance. So not only do building teams come away with a thermally superior product, but the IMP storage facility will meet increasing continuous insulation code requirements, such as those mandated by ASHRAE 90.1.

Of course, increasing rentable square footage is one of the biggest draws about IMPs for building owners as those extra four to six inches on the perimeter go straight to the bottom line.

A Modern Style for Storage

Evolving from the standard-looking, plain boxes, today’s storage facilities are taking on a more architectural look to better blend into the office complexes, residential communities and retail complexes surrounding them.

With a variety of high-performance coatings, colors, reveal joints and corrugated sheets with assorted patterns, IMPs offer a large selection of design options to architects looking to create these more trendy designs.

Metal Panels for Self-Storage Buildings
A-AAAKey Mini Storage in utilizes modern colors with 55,000 sq. ft. of MBCI’s Ultra-Dek® metal roof panels.

“The calculated use of smooth, concealed-fastener panels harkens to contemporary design styles with an eye toward the future,” states Ryan Rogers, managing partner, RHW Capital Management Group, Orange, Calif., in an Aug. 2016 issue of Inside Self-Storage. “This can create the perception of innovation and dynamism, communicating to customers that your facility is on the cutting edge of the industry and, as such, a successful leader.”

In order to capitalize on the design and performance options leveraged by IMP panels, architects are advised to integrate these systems from the project’s onset in order to maximize efficiencies and potentially take advantage of longer stands, greater distances and heavier steel gauges.

Multi-Level Storage Facilities

Moving forward, designers can expect to see an increase in multi-story storage facilities, particularly in urban areas, where building owners are being forced onto smaller lots.

Explaining the trend in a Sept. 2016 issue of Commercial Investment Real Estate magazine, Michael Haugh, CCIM, senior director of revenue management, Storage USA, Memphis, states, “Increased land costs have forced developers to build up, particularly in urban markets where land tracks of four or more acres necessary for single-story developments are nonexistent. In some cases, a multistory project can be built on as little as 1.5 acres.”

Or in regions where there is little space for new construction but a high demand for storage, like New York City, storage companies are renovating upward. For example, Stop & Stor partners with door and storage solution company, DBCI to convert existing buildings into high-end, multi-level storage facilities. Using existing building blueprints and outline unit placement, DBCI created a custom storage solution in a space that is both conveniently located and functional For more information, read “Urban Storage Units” in Metal Architecture’s Jan. 2016 issue.

Filling the Storage Niche

From multiple stories to designer-end architecture, IMPs are actively filling an important niche in the self-storage industry as a durable and aesthetic, all-in-one building enclosure solution.

Calculating Cool Roof Energy Savings

Whether it’s providing waterproofing, reducing thermal expansion and contraction, or supplying chemical and damage protection, cool metal roofing has much to offer. Of course, the most substantial benefit is the energy savings gleaned from reduced rooftop heat levels driving down air conditioning loads. In fact, the Lawrence Berkeley National Laboratory’s heat island group projects a whopping $1 billion reduction in cooling costs if cool roofs were to be implemented on a nationwide basis.

To assist architects in determining the kinds of energy savings that can be expected from cool metal roofing, the Oak Ridge National Laboratory (ORNL) has parlayed the data it gathered from a three-year evaluation of metal roofing products into a whole building energy savings calculator.

Cool metal roofs are offered in a variety of colors.
In addition to energy efficiency, cool metal roofs are known for extended durability and longevity.

Cool Roof Calculator

This calculator is called, simply enough, the Cool Roof Calculator. The easy-to-use tool is described as a quick way to compare overall energy costs and savings for a variety of roof and building conditions. Unlike some energy modeling calculators, which are limited to steep slope residential roofs with attics, ORNL’s tool models the typical low slope commercial roof with insulation placed directly over the deck and under the roofing membrane.

To calculate approximate energy savings offered by a cool metal roof, architects are instructed to input the building’s location, proposed roof R-value, roof reflectance and emittance, base energy costs, equipment efficiencies, electrical demand charges and duration.

While experts suggest that it may be difficult to accurately predict the base use and peak demand without detailed construction and cost information, tools such as the ORNL’s cool roof calculator can be a useful way to gather helpful performance estimations for a variety of building types and locations.

Attempting to do just that, the calculator outputs a number of values to offer an approximate estimate of potential energy savings, broken down into cooling energy savings—a calculation of air conditioning savings from base use and peak demand reductions—and cooling season demand savings, an estimate of the peak demand charge reduction enabled by enhanced roof reflectivity.

Accessible at http://rsc.ornl.gov, users can also compare the energy performance offered by a cool roof vs. a conventional black roof.

“It’s a nice tool to give people a feel for where a cool roof would actually help them and have the greatest impact in terms of energy use,” relates Robert A. Zabcik, PE, LEED AP BD+C, director, research and development, NCI Group Inc., Houston, in a Metal Construction News article.

Roof Reflectance Baseline

Roof reflectance and emittance, requirements and options, can be found in energy codes such as IECC, ASHRAE 90.1, California Title 24, and other local codes. Requirements may vary based on roof slope and climate zone, and may allow for either aged or initial solar reflectance, thermal emittance and/or SRI.

Fortunately, MBCI continues to stay current with individual testing and also maintains third-party tested and verified product listings through entities such as the Cool Roof Rating Council, and the U.S. EPA’s ENERGY STAR®.

Part III – Transparency Plus Consensus: A Win-Win for Everyone

Part III transparency plus consensusIt has been a long time since my last blog on this subject. This is not only because I’ve been busy but also because the landscape of green building programs in general has changed significantly since Part II, and I wanted to wait to see how things shook out before I wrote something that might be immediately outdated. If you remember, we left off in Part II talking about how LEED, the most popular green building program in the US, has not been developed through an ANSI accredited consensus process. Furthermore, the resulting lack of transparency was dubiously ironic given that LEED demands a high level of transparency from building product manufacturers min the latest version of their program, LEED v4.

We also discussed the related but more general movement for manufacturers to fully disclose all of the ingredients in their products to a third party who then compares that list to lists of known hazardous substances and disclose any matches on a product label or public disclosure for all to see. This movement has been fueled by several large architecture firms sending letters to building product manufacturers threatening to stop specifying their products unless they participate. Although most manufactures agree that there is merit to disclosure and are anxious to participate in a fair program, they have not been privy to discussions regarding the logistics of such a program nor have they been allowed to participate in any kind of a standard development governing the disclosure process. This makes manufacturers reluctant to participate, given their vulnerability in such a situation. This risk is leveraged by the fact that currently the only standards that dictate the rules of such a program are under the control of consortiums who have little to no scientific expertise and, frankly, have not been friendly to the building products industry in the past.

I also mentioned that there are alternative programs to LEED that have been developed through a valid consensus process. Specifically, the International Green Construction Code (IgCC), ASHRAE 189.1 and Green Building Assessment Protocol for Commercial Buildings (also known as Green Globes) are ANSI standards that outline the relevant requirements for anyone to view. However, the USGBC marketing machine and resulting popularity of LEED prevented wide use of these standards. Thus, they remained largely unutilized. That is until this year, when the USGBC, IgCC and ASHRAE signed a Memorandum of Understanding, promising to work together and create a favorable consensus by eliminating duplication of provisions and assigning an area of responsibility for each group to maintain separately.

Although no documents have yet to be created, it appears that the administration and enforcement provisions of the new standard will come from the IgCC, and the technical content will come from ASHRAE 189.1, both of which are consensus based. Meanwhile, LEED will require compliance with 189.1 as a prerequisite to an upcoming interim version of LEED. This approach allows an Authority Having Jurisdiction (AHJ) to adopt the IgCC as a minimum standard of construction; dropping any reference to LEED they might currently have as minimum project requirements for all buildings. This leaves LEED to evolve as a completely voluntary program going forward and push the envelope of green building, which is their core mission. Meanwhile, Green Globes remains ANSI accredited and still exists as a commercial competitor to LEED. This environment should result in a more user friendly application process, the lack of which been a ubiquitous criticism of LEED for years, because Green Globes is much more user-oriented.

So, it appears that the most popular green building programs are poised to move in the
direction of a true consensus, which is fantastic news for everyone involved. However, the creation and development of disclosure programs, which will not be in the initial technical requirements provided by ASHRAE 189.1, remains largely a one-sided affair with no seat for manufacturers at the table. Besides the contentious nature of the subject in general, there are major philosophical questions that have to be addressed before Health Product Declarations (HPDs), or any type of disclosure in general, can be brought into the main stream. That subject is beyond the scope of this blog, but I encourage you to read a very good article on the trappings of HPDs called “Disclosure: The Newest Dimension of Green Building” by Jim Hoff.

The good news is that there may be a viable alternative to HPDs on the horizon. ASTM has a current open work item to develop a true consensus based standard guiding the issuance of a Product Transparency Declaration (PTD), which has much the same intent as an HPD. As discussed in Part I, the development of ASTM standards is a highly transparent process that allows everyone, including manufacturers, to come to the table. I encourage every designer to join ASTM and get involved in this process, especially those firms who participated in the letter writing campaign, and forgo HPDs until PTDs are available.

Yes, it will take a little longer; the reality that the development of consensus based standards takes time. But just like the development of the laws that govern this country, there is far too much risk involved in getting it wrong. Instead, having these standards developed by a consensus-based process is the only way the finished product will be truly useful and meaningful.

Demand for Roofing: Something to be Happy About

DSC00994

With the economic troubles of Greece and now China filling our news feeds, it’s nice to come across good news.  And let’s face it—over the last several years, particularly since 2009, there hasn’t been a whole lot of good news for roofers or the construction industry overall.

Recession Effects & A Positive Outlook

Roofing demand fell between 2009 and 2014 as nonresidential building construction spending and residential reroofing activity declined due to the recession, according to an article recently published on Building-Products.com. But this same article says U.S. demand for roofing is projected to rise 3.9 percent annually to 252 million squares in 2019, valued at $21.4 billion, according to a new Freedonia Group study.

Metal Roofing Outlook

In particular, metal roofing will see above-average demand gains through 2019. The article goes on to say metal roofing demand will be helped by its durability and ability to support solar panels used to generate electricity.  Building Products also sites metal roofing systems provide additional insulation as a boost to energy savings.

New building construction activity is expected to account for increased demand for roofing through 2019. New non-residential demand will come in the areas of office and commercial construction. Demand in the institutional and industrial segments will also increase as more schools, hospitals and manufacturing sites are built, correlating to an increased demand for such low slope products as metal roofing.

All Those Sustainability Acronyms Mean Something, Right?

PCR, LCA, EPDBy now I’m sure you’ve heard about PCRs, LCAs, and EPDs.  Simply put, a PCR is a set of product category rules; an LCA is a life cycle analysis; and an EPD is an environmental product disclosure.  But what do they mean and what’s the purpose of it all?  In the broadest sense, these are mechanisms used for the sustainability movement.  The most granular is the EPD, which is a product-based discussion (i.e., disclosure) of the environmental effects caused by a specific product or product type.   Architects and building designers use EPDs to compare products in order to select the most environmentally friendly products to be used in environmentally friendly buildings.

Developing an EPD can only happen after the creation of a set of product category rules (PCR).  A PCR sets the rules for creating LCAs and EPDs.  An example of a PCR is “Product Category Rules for Preparing an Environmental Product Declaration (EPD) for Product Group: Insulated Metal Panels & Metal Composite Panels, and Metal Cladding: Roof and Wall Panels,” which was developed by UL through the efforts of the Metal Construction Association (MCA).

Only after a PCR is developed can a verifiable LCA or EPD be developed.  An LCmA and EPD are similar but different.  An LCA uses industry-average data, and an EPD is specific to a product or product type.  For example, “LCA of Metal Construction Association Production Processes, Metal Roof and Wall Panel Products” provides industry-average information about the environmental aspects of three key products: steel insulated metal panels, aluminum metal composite material panels, and steel roll-formed claddings.  This LCA is based on 24-gauge material.

EPDs are typically more product specific.  (An EPD is typically based on an LCA, so most often LCAs are developed prior to EPDs.)  For example, the EPD titled “Roll Formed Steel Panels For Roof and Walls” provides similar environmental data as an LCA, but includes information about 29-, 26-, 24-, 22-, 20- and 18-gauge materials.  This provides additional product specific information that can be used by designers when an industry average is not adequate.  And importantly, more LEED points are garnered from a product-specific EPD than an LCA because of the specificity.  LEED is certainly a driver of this!

LCAs and EPDs used in the roof industry are often focused on cradle-to-gate analysis, and exclude the use phase and end-of-life phase.  Ideally, an LCA or EPD should include the use and end-of-life phases so architects and designers have a complete cradle-to-grave analysis.  Without the use phase, designers are allowed to freely select the service life of a metal roofing product, for better or worse, without industry guidance.  And, the advantages gained through metal recycling at the end of life are also omitted from MCA’s LCA.

It’s all about standardized disclosure of environmentally based product data.

Learn more about MBCI’s LCA, EPDs and other sustainability efforts, here.

Choosing the Right Metal Roof System for the Job

It should be no surprise that I’m a strong advocate of the outstanding benefits of metal roofing. It is extremely, durable, low maintenance, energy efficient, recyclable –yes, I could go on and on. And it’s not just functional; it’s attractive. Its versatility is a designers dream when it comes to achieving today’s architectural elements—hips, valleys, slope changes, transitions and dormers are all possible.MBCI's 7.2 Panel

But as great as these roofs are, care must be taken to select the right type of metal roof system for the job at hand. In fact, the designer must specify a roof panel that can be used in each of the design elements he or she intends to incorporate into the roof project. Design, coupled with the choice of roof slopes, trim details and how the panel is to be fastened to the substructure are deciding factors in choosing the proper roof. When the roof system chosen isn’t the right one for the job, the result can be a roof that leaks and doesn’t function as designed.

Though most metal roofing manufacturers are able and willing to discuss the application parameters for each of their products, it would be wise to arm yourself with at least a general idea about the parameters of some of the most common profiles. To arm you as simply as possible, I’ll separate metal roofing into two broad categories—through fastened and standing seam.

Through-Fastened Roof Systems

Exposed, or through-fastened panels, are available in a variety of widths, usually from two to three feet wide. They also come in various rib shapes, heights and spacings. Typical gauges are 29 and 26, but they also come in 24 and 22 gauge.

There are structural and non-structural through-fastened panels. Structural panels are capable of spanning across purlins or other secondary framing members such as joists or beams. Non-structural panels must be installed over a solid deck.

Through-fastened roofs generally have two great advantages: (1) they are relatively inexpensive and (2) they are simple to install. Structural though-fastened panels have the additional advantage of providing a diaphragm, which is important in the wind bracing of metal buildings.

But most through-fastened roofs also have two big disadvantages: (1) they can leak if not fully seated to the panel or if the purlin is missed, and (2) they do not allow the roof to float during thermal movement. This can cause the roof panel to tear around the fasteners, causing leaks and possible roof blow off.

For this reason, through-fastened roofs are best suited to small- and medium-sized metal buildings and residential applications. In both instances, the panel runs are limited to shorter lengths where thermal movement is typically not a problem.

I’ll discuss the best uses for standing seal metal roofing systems in detail in my next two posts.

To support our customers’ design flexibility, MBCI offers 11 different metal roofing panels with exposed fasteners, each with its own unique profile. Most of these roof panels can also be used in wall applications and designed for both vertical and horizontal installation. Read more.

Code Requirements for Cool Roofs with Climate Zone Specifics

There is still a lot of discussion—some agreeable and some not so agreeable—about the necessary color of our rooftops.  One side of the discussion revolves around keeping the surfaces of our built environment “cool,” so there’s a movement to make all rooftops “cool” by making them white, or at least light-colored.  Those on the other side of the discussion claim that cool roofs are necessary to reduce a building’s energy use.  Cool roofs can be a really good idea, but let’s not mix up the reasons why cool roofs matter—are we cooling the urban areas (that is, reducing urban heat islands), or are we saving energy costs for individual buildings? Cool Roofs
h
The average building height in the United States is less than two stories, but “white roofs” are mostly desired in dense, urban areas…and how many buildings here are less than two stories?  Tall buildings are typically found in dense, urban areas, with shorter buildings dominating the fringe urban areas.  In the suburbs and rural areas, one- and two-story buildings are more the norm.  So we have a mix of building heights in the United States, but the conflict is that the “cool roof” focus is often where the tallest buildings exist.

And unfortunately, a cool roof on a 20-story building isn’t going to reduce its energy use, especially if the code-required amount of insulation exists on that roof.  Rather, reducing energy use of a 20-story building hinges on the energy efficiency of the 20-story-tall walls—R-value of walls, percentage of windows, and solar blocking eaves, just to name a few items.  Conversely, the energy efficiency of a one-story big-box store comes down to its roof.  And for these buildings, roof color definitely can make a difference.  However, our building codes don’t differentiate based on building proportions, but only on geographic location—and that’s problematic.  But as designers, we can improve on the code requirements.

The 2015 International Energy Conservation Code provides specific information about cool roofs, which are required to be installed in Climate Zones 1, 2, and 3 on low-slope roofs (<2:12) directly above cooled conditioned spaces.  There are two ways to prescriptively comply with this requirement: use roofs that have a 3-year-aged solar reflectance of 0.55 and a 3-year-aged emittance of 0.75.   Notice that initial (i.e., new) reflectance and emittance are not specified; long-term values are more important.  The second method to comply is to have a 3-year aged solar reflectance index (SRI) of 64.  SRI is a calculated value based on reflectivity and emittance.  It’s important to understand why a cool roof is desired and to make appropriate design decisions.

To locate metal roof products that meet the IECC requirements, go to http://coolroofs.org/products/results and use the search function to narrow your results or view our finishes’ SRI ratings on our Cool Metal Roofing page.

When It Comes to Roofing Expertise, It Doesn’t Hurt to Diversify

As is often the case when it comes to your investments, it’s always a good idea to diversify. This also applies to the investment of your construction expertise as a roofing contractor. Even with the mild uptick in new construction activity of late, contractors are smart to explore the additional revenue stream that can come from roof renovations and retrofits.

Example of Retrofit Metal Panel, NuRoofMost metal roof retrofit work entails adding slope to an existing flat- or low-sloped roof.  According to a 2013 article in Metal Construction News, about 25 percent of U.S. commercial, institutional and public buildings are 55 years old or older and consist of flat-roof stock that has reached the end of its service life. Two years later, that percentage is surely higher.

To transition from a flat roof to a sloped roof is a good move, because it will result in lower energy and maintenance costs for years to come.  It is also environmentally smart, because metal is one of the most recycled materials used in construction, and metal roofing is 100 percent recyclable at the end of its service life. A metal roofing system provides for additional insulation, as well as the installation of solar panels that reduce reliance on electricity. And in most circumstances, a new metal roof can be installed without having to remove the existing flat roof. A metal retrofit may carry a higher initial cost, but when total life-cycle cost is considered, a metal retrofit will end up being the lowest cost alternative.

A large number of buildings with flat membrane or built-up roofs require a framing system to produce an adequate slope. But this particular type of retrofit can be challenging. In general, the retrofit market is more specialized and much more technical than what roofing contractors are likely used to in the existing metal building market. At the same time, the retrofit market can be very profitable and is worth getting up to speed on.

Whether you’re doing a small retrofit project or a complete renovation, MBCI can assist you with developing a preliminary budget, estimating, engineering, as well as providing a complete set of shop drawings for your retrofit project.

Stay tuned for future posts where we’ll provide some guidelines on how to successfully navigate the design process of retrofitting a flat or inadequately sloped built-up or membrane roof.  Adding this diversity to your portfolio of roofing skills will likely net a high return on investment.

Metal Roofs & Walls a Big Plus When It Comes to Net Zero Energy

Kickapoo Tribe Government & Community Building
Kickapoo Tribe Government & Community Building features MBCI’s CF Architectural Insulated Metal Panel

Are you familiar with “Net Zero Energy?” No, it’s not that sense of power you got from using that early dial-up Internet browser of the 1990’s (The company, by the way, is still in existence, and comes up in searches for the term Net Zero. Who knew?). The Net Zero Energy I’m speaking of is the enviable, sustainable state achieved when the creation and use of energy within the same building system are equal.

Though achievable, the cost and capacity for producing energy within a building system is greater than that of creating energy efficiency in one. The good news is that metal roofing and ,a href=”http://www.mbci.com/products/wall-products/”>wall panels are extremely useful on both sides of the equation.

On the energy efficiency side, insulated metal panels (IMPs) provide roof and wall systems with the thermal and radiative performance needed for sustainable design. Insulated wall and roof panels provide continuous insulation and eliminate thermal bridges. As building and energy codes become increasingly more stringent, insulated metal panels are an ideal choice for thermally efficient building envelopes.

Baker Hughes features MBCI’s CF Mesa Insulated Metal Panels

On the other side of the equation, a common method of generating energy is through the use of photovoltaics (PVs), and metal roofs provide the best possible surface to host a photovoltaic (PV) array. Solar photovoltaic systems and solar water heating systems can be installed on a metal roof, penetration-free, resulting in high performance with minimal risk. Both the use of IMPs and the installation of PVs on metal roofs can be used with proper designs to maximize building energy efficiency.

Of course, metal roofing, known to last 40 years or longer, is the only type of roof that can be expected to outlive the PV system mounted on it, which results in virtually zero maintenance and a very low in-place cost for the roof and PV system together.  A sustainability win, a durability win, and, of course, an aesthetic win.  The result is anything but a zero sum game.

Find out more about MBCI’s Insulated Metal Panels

Find a sales representative