metal roof Archives | Page 3 of 9

Types of Standing Seam Metal Roof Clips & Why They’re Essential

Posted on December 1, 2020 by MBCI

A successful standing seam metal roof project goes beyond the obvious panels, substrate and frame. In order for the roof to look great and perform properly, don’t neglect the importance of selecting the proper roof clips for your given project. What may seem like a minor detail is, quite literally, what’s holding it all together. Here we’ll take a look at the key factors that go into selecting the correct clip type and see why this is so essential for the well-being of any standing seam metal roof.

When you are looking at the installation manual or if you’re ordering your materials directly—or even if you’re submitting the order to MBCI to do the engineering for you—you’re going to need to know and identify certain details. The roof clip selection criteria will be based predominantly on two main factors: 1. What is your insulation system and 2. What are the expansion and contraction requirements for your roof? You’ll also need to know your project’s roof geometry and how the panel you’ve selected is able to meet the roof clip range on a particular plane, because the distance the panel spans impacts what type of clip you would use. Additionally, the type of substrate you are attaching the clip to will dictate what type of clip you should use. Is it going over wood, metal decking, open framing?

With that information in hand, you’re ready to do your due diligence. MBCI classifies clips in two ways: high or low; fixed or floating.

The high and low clips are predominantly determined by insulation systems. For a low clip, for instance, MBCI will typically will go up to a maximum of four inches of insulation; a high clip will go up to six inches of insulation.

Here’s a bit of a caveat. What we’re referring to is how much insulation you’re trying to compress between the roof panel and the substrate—and particularly the purlins or the steel frame you’re attaching it to. The clips are designed with a “stand-off” that elevates the roof panel above the substrate to permit insulation to pass between the roof panel and the substrate at the structural attachment points. A low clip is typically a 3/8-inch stand-off; a high clip, depending on panel type, can be 1-inch, 1-3/8-inch or even possibly 2-inch.

Knowing this helps determine whether you’re choosing the right clip because, let’s say, you go with too tall of a clip or not tall enough to accommodate your insulation system, then the system’s going to be difficult to install and will not perform correctly. And watch out for roof systems that have roof clips with no stand-off that do not permit fiberglass insulation to be installed or is discouraged from being installed at the clip lines due to impact on the panel appearance.

Another factor here is if you are putting the roof over a solid substrate, such as wood or metal decking. In this case, we will typically default customers to a low clip system because they don’t need to accommodate for any sort of fiberglass insulation systems. We’re assuming the insulation is occurring elsewhere below the decking or incorporated with the decking, such as rigid board insulation. In the case of rigid board insulation over decking, a low clip is still utilized but with an added bearing plate. The clip is attached through the rigid board insulation into the decking or structure below.

The more particulars you know of your intended insulation system to determine the clip height needed, the better prepared you will be in determining the right clips. Will there be fiberglass insulation or rigid board insulation or no insulation? What is the insulation thickness? What type of insulation system? Share these details with your MBCI sales rep to help you get started selecting the right clip height.

You can also find much of this information on the MBCI website by searching the roof type and then reviewing the corresponding installation manual and details to determine what clip height to use based on your insulation and substrate.

Which brings us to the other main factor in selecting the right clip. A fixed or floating clip is dependent on the substrate and how much anticipated movement is needed for the roof size.

With fixed clip systems, there are no moving parts in the clip. The ability for that clip to expand and contract as the roof expands and contracts is dependent on the substrate. In layman’s terms, if you were to screw that clip to a purlin, as the purlin heats up and cools down, it’s going to allow for some of the movement of that roof. Generally, when a fixed clip is installed over a metal building purlin, the manufacturer advises a limit of 100-foot maximum on a single roof surface. This is an average and can be impacted also by roof color and geographic location of the roof install that control temperature swing ranges, i.e., 100-foot maximum is a guide.

It is advised that the fixed clip always be installed over open framing in order to permit the greatest ability to accommodate roof panel expansion/contraction. It is not advised to use fixed clips attached to a solid substructure because those don’t accommodate roof panel movement.

If the roof needs to be installed over a solid substrate OR if the roof plane is over a slope more than 100 feet, then the manufacturer would prescribe a floating clip system. [Note: A floating clip can also be used even if the slope is less than 100 feet.] The floating clip system permits the roof panel to move (expand/contract) independent of the substrate to which the clip is installed. The system either contains a clip with a tab seamed into the roof panel rib that is able to float/slide where it attaches to the clip, or the clip is such that when it engages the panel seam is doesn’t restrict the panel movement. The only thing controlling for floating clips is the maximum range of the clips that allows it to float. In other words, how far can the clip tab or panel slide at the clip attachment. The panel manufacturer again will have information as to this amount. You will need to make sure they’re aware of what the maximum single panel run distance is from low side to high side.

One more thing to note is that not every roof system is available with fixed clips and not all systems have high and low clips (although the majority do). That said, educating yourself and researching the panel you’re looking at will give you the information you need to make the determination as to which clip will not only work best, but potentially will work at all. Every panel has its own roof clips, so the roof clips are not interchangeable across all systems. An essential part of selecting a roof panel is verifying that its clip attachment is suitable for your project.

It might not be immediately obvious that you have the wrong clip. For instance, let’s say you ordered an Ultra-Dek® roof and you ordered an Ultra-Dek® clip. That sounds straightforward, but did you order the RIGHT Ultra-Dek® clip for your particular project? The roof may even be able to be installed regardless, but, after installation you may discover it doesn’t perform properly or as intended due to the wrong combination of clips, insulation and substrate. That’s why it is so critical to check with the manufacturer that you have the right clip before you purchase or start putting down the roof.

For more information, reach out to your local sales rep or go to the MBCI Ask An Expert site to confirm the clip you need to make your project a success.

Protecting Metal Panels from Rust

Posted on October 29, 2020 by MBCI

One of the many benefits of metal panels that contributes to their strengths is the fact that there are so many rust-resistant coating options with different levels of protection, making them a great option for virtually any environment or any budget. That said, though, missteps during storage, as well as during and after installation, can leave you with unwanted corrosion, i.e. rust. Factors such as improper storage, improper cutting, or other elements the metal might come in contact with can wreak havoc that are beyond the manufacturer’s control.

Regardless of the finish you have—painted, unpainted, high-end coatings or standard coatings—here are some simple installation and care instructions that can help further maintain the longevity of your metal panel product.

Preventing Rust When Materials Are Delivered

Proper material delivery/site storage is the first step to preventing rust. Be certain to check your panels while uncrating after storage on site for any early signs of corrosion, such as black discoloration or white rust/residue on them. This is a sure sign that that panel has been improperly stored and water has not been able to properly evacuate the panel bundles. Do not install any panel on which this has occurred, as the panel finish has most likely been compromised due to improper storage. If you go ahead and install it, that panel is going to continue to corrode and eventually lead to further rust/corrosion.

Make sure that you’re not trapping any sort of moisture in between the metal panels or restricting them from being able to drain when stored on site. Although the panel itself is corrosion-resistant, if you subject it to repeated and significant water being trapped in between the sheets by either not storing the material out of the mud and ground water, or if you’re not sloping the material bundles in such a manner that they can drain, then the result can yield “wet storage stains.” Therefore, if you want to prevent any sort of damage due to improper site storage, you must make sure that the panel is able to drain while stored and, if possible, tarp to resist heavy moisture concentrations such as snow and ice during inclement weather if necessary.

Preventing Rust During Installation

Next, let’s look at some installation no-no’s that WILL most definitely eventually lead to rust—and things to avoid. The first is the accumulation of drill shavings. Whether it’s a roof panel or a wall panel, when you’re installing the screws, even if you’re pre-drilling for the screws, you’re going to generate metal shavings. If those metal shavings are not removed and left to sit or cling to the sheeting those shavings will rust and will stain the roof or wall sheets. The shavings are uncoated/raw metal with no corrosion protection that can and will rust quickly. Eventually, the shavings may wash off or be blown off the roof or wall, but might not be until after they’ve stained the sheeting, thus leaving you with an issue to remedy and, since the “culprit” is gone, questioning if it’s just a stain or something more serious.

Drill shavings

Remove the shavings as soon as you can to mitigate this issue. Additionally, if you’re going to do any field cutting, you need to do so via a shearing process utilizing the proper tools, such as electric nibblers, hand snips or electric shears. Any other type of cutting can cause the edge of the base material to become exposed and no longer protected by the Galvalume and painted coatings as they become disrupted. Using tools such as a “hot” saw, abrasive blades or even a reciprocating saw leads to a tearing motion rather than shearing motion, which will strip the metal of that protective coating; over time it can start to rust.

Improper field cutting of panels with abrasive blade

Graphite is another corrosive element that should be avoided as it is not a friend to Galvalume metals. Therefore, stay away from writing on your Galvalume material with pencils because over time the graphite will react, break down that protective layer, and lead to corrosion. If you do write on the panels with a pencil, make sure you clean it off. The best solution is to use permanent markers/Sharpies or dry erase markers.

Graphite

Watch out for overspray from any adjacent wall coatings or finish systems like Stucco or similar masonry products, which can also damage panels if not removed promptly. And be certain not to rest the base of any metal panel in direct contact with material that is corrosive, such as concrete, or in such a manner that water can become trapped behind the panel and not able to drain. Industry recommendation is to maintain an eighth of an inch to a quarter-inch gap at the base of all your wall panels for not only expansion/contraction but for proper drainage and to prevent contact with dissimilar/corrosive materials.

Masonry products

Preventing Rust After Installation

Although Galvalume—whether bare or painted—is highly corrosive-resistant by nature, it too has its Kryptonite. Post-installation, the most important thing is to make sure you’re not adding something to the roof that’s going to react chemically/negatively with the Galvalume finish/coatings. For instance, many people don’t recognize that if they have mechanical units on a roof, the condensation that comes out of those mechanical units, when deposited directly onto a Galvalume panel over time, will lead to corrosion and rust. This condensate should either be filtered before exited onto the roof panel or drained via piping and not directly onto the sheeting.

Contact with dissimilar metals, whether it be via incorrect type or method attachment from metal signage, solar panels and snow retention can be another major factor in post-installation corrosion. Panels must not come in contact with or be exposed to the runoff from the following metals: copper (lightning arrest systems, flashing, roof jacks, HVAC drainage); lead (roof jacks, pipe flashing); iron (pipes or soil); and, as previously noted, metal shavings.

Copper

Post-installation, panels must also not come in contact with or be exposed to the runoff from chemicals, such as acid from batteries and acid washing brick, and even pressure-treated lumber.

Treated lumber

What To Do In Case of Rust

Let’s face it. Sometimes, despite all your efforts…someone didn’t get the memo and rust happens. Now what do you do? How can you safely can attempt to repair it or remove it without causing more damage?

First off, here’s what NOT to do. Heavy solvents that are meant to remove paint or stains can/will adversely affect the metal. If you witness a rust stain on the roof, don’t go up there with paint remover, acetone or any other toxic solvents and start scrubbing on it because you most likely could make matters worse. You might remove the stain along with the finish entirely, leading to bigger problems. (If you’re an end user, check your finish warranty and manufacturer maintenance documentation supplied to you by your builder/installer for guidance on cleaning and repairs.)

The key is to identify if the rust is just a stain /discoloration or it’s more systemic. Is the catalyst (ex.: a shaving) causing the rust still present? If it’s just a surface stain and the coating hasn’t been damaged, it might just be a matter of getting some mild detergents or something else to remedy the situation. Some good options are Formula 409 or Simple Green and Soft Scrub without bleach or something similar. and it may require a trial and error process to determine which is most effective based on the condition you’re trying to remedy. Products such as Rid O’ Rust or similar whose key ingredient is oxalic acid can be used diluted with water. With any of these products, test a small area first and wait to see results before proceeding to larger areas. And always be certain to fully rinse/flush areas of cleaning products to ensure no residues /films remain.

Always start light. Don’t break out any steel wool and/or metal grinders and start trying to get the rust off the panel that way. If it looks to be more than just a stain—perhaps you clean it and a few weeks later it comes back—that most likely means that the panel has actually been damaged and you’re not just going to get rid of the “stain” by cleaning it as it’ll return. It may require touchup paint or even a panel replacement. It depends on the severity of the damage. If this is the case, be certain to check with your installer, maintenance manual, and panel supplier for further instructions on how to address.

For more information on panel maintenance and warranties, see the MBCI website resource center.

Benefits of Metal Panels For Agricultural Applications

Posted on September 20, 2020March 29, 2022 by Tyler Roose

Agricultural applications need building solutions that are durable, effective, cost-efficient and versatile, which is why MBCI’s high-quality metal building products undergo rigorous testing to ensure they will meet or exceed the aesthetic and structural requirements of any agricultural building initiative—from general farm facilities to barns, pole barns, sheds, horse stables, riding arenas, ranches, livestock stables, crop storage buildings, machinery storage and garages, animal shelters and more.

Why use metal panels on agricultural applications?

Metal is an excellent choice for agricultural applications because of its durability and longevity, ease of installation on new or existing buildings, its ability to provide a weathertight seal and its low maintenance requirements.

The lifespan of metal roofs and siding can be up to 60+ years. MBCI’s metal panels are built with high-quality material and are backed by some of the industry’s leading warranties. Durable and low-maintenance agricultural steel panels are a perfect fit for the demanding nature of farm and ranch buildings, offering resistance and strength under extreme temperatures, high winds, heavy snowfall, strong storms and other harsh weather conditions. In fact, during hot summers, metal panels can help keep your building cool and energy costs low, while in the winter they shed ice and water to prevent damage. Metal, indeed, has a distinct advantage in its ability withstand the elements and not rot or warp over time.

MBCI’s agricultural metal roof and wall panels are also sustainable—made from recycled materials and are 100% recyclable at the end of the building’s life.

As far as design options go, you can choose from a variety of styles, profiles and colors for your metal barn siding, pole barn siding, metal shed roofing and more. Exposed fastener panels are the most commonly used on agricultural buildings because of their economical pricing and durability. MBCI offers up to 10 different exposed fastened panel profiles to choose from, depending on your preference and the region you’re in. Examples include: Rain Guard®, Perma-Clad®, WeatherSafe®, and Stormproof®, which can be used with DripStop technology to control condensation.

What to Consider

Once you’ve made the decision to use metal for your agricultural building, determining the particulars will depend on a number of factors. Here are some preliminary questions to consider.

Purpose: What are you using the building for? For instance, is it for equipment storage? Livestock? Is it a hobby building or a workshop?
Size: How much lot size do you have available?
Entry points: Where are your entry points? How big do the doors need to be? Do you need certain types of doors? For example, if the building is being used for equipment storage, what are you going to be moving in and out of there?
Aesthetics: What “look” are you trying to achieve?

Design Trends

As far as aesthetics, metal panels come in a multitude of colors (MBCI offer approximately 25 color options), so you have a lot of versatility with the color scheme for your agricultural project. Traditionally, what we see is a single color for the roof panels and then an alternate color on the walls, and the trim typically matches the roof panel. Another trend is a wainscot panel or a designer panel, which is basically a smaller strip around the base of the building to add an accent color. From there, many customers will wrap that with stone or masonry, too, to make it more decorative. Plus, with the merger of MBCI’s parent company with Ply Gem, our customers now have access to stone products as well.

Beyond Panels

Metal building options don’t end with roof and wall panels. To that point, MBCI prides itself on being a complete building envelope solution. If a steel frame building is your desire, then MBCI has that covered as well. From new construction to repair and remodel, MBCI offers a vast line of primary and secondary steel structural products and resources to meet the project’s needs. MBCI also partners with many great customers nationwide to offer componentized steel structures that can benefit any agricultural application.

Additionally, with the recent Ply Gem merger previously mentioned, MBCI is better positioned to give customers access to windows, walk doors, stone, and many other components needed to further enhance agricultural projects—all from a single source supplier.

Whether you need a complete structure, metal roof or wall panels, or simply components for a repair or addition, MBCI has the right products and accessories to meet any agricultural building requirement.

For information about MBCI’s agricultural metal building products and solutions, contact your local sales representative.

Measuring for a Metal Roof: Considerations and Tips

Posted on August 25, 2020March 29, 2022 by Michael Fuselier

Getting an accurate measurement for your metal roofing panels may seem like a no-brainer, but it’s not quite as simple as length x width. The many complexities of a roof must be taken into consideration in order to ensure your numbers add up. For instance, anything that intrudes upon a roof plane needs to be included in drawings with labeled measurements as these conditions will all affect the measurement but are sometimes overlooked.

Let’s look at some specific conditions to consider before getting out the measuring tape as well as some handy tips for installers.

Building Conditions to Consider Before Measuring

The type of roof system

Is it going to be a standing seam roof system or an exposed fastener system? Once you’ve decided on your roof type, we recommend reviewing all of the conditions/details on the roof. If it’s a standing seam roof, will the roof system need to float? If so, where will it be pinned, and what direction will it float?

At MBCI, we have published installation technical manuals for installers and erectors to utilize in order to familiarize themselves with how to adjust for ridge conditions or end lap conditions, for instance.

Is it a new or existing metal building?

If it is an existing building, are there new or updated building codes to consider? This could possibly dictate panel type, gauge, or width, or require additional framing members that could impact the final measurements.

What is the purlin spacing?

The panel break at the purlin for an endlap condition will need to be considered.

Are there extensions, overhangs or penetrations?

Include any roof extensions or overhangs that may not be apparent at first glance. Any and all roof conditions should be considered when calculating panel and trim length, including any roof penetrations such as pipes, roof curbs, skylight hatches, etc.

The manufacturer’s details will aid in determining such things as panel hold back at the ridge, or panel overhang at the eave or gutter. Also, roof or slope transitions, and panel hems should be considered.

Insulation

The thickness of the insulation could determine or dictate the fastener type used.

Measuring Tips

Field verify the roof slope. The contractor should gather the field dimensions so measure when the framing is in place. While you can measure off of a set of plans, it’s not a definitive way to do things because things change in the field.
The structure should be square while you’re measuring. Scaling from plans may get you close, but measuring erected framing that is plumb and square is the most accurate.
You should measure multiple spots.
It’s a good idea to use a plan view of the roof or sketch a bird’s eye view to record your measurements.
Record your measurements in the units of measure that your manufacturer uses, typically feet and inches, to avoid errors.
The erector may elect to add a few inches to the length of the panels at a hip or valley to remedy any cutting mishaps since these panels will be field cut to the hip or valley angle.
Some contractors include one or two extra panels at the longest length for any errors or jobsite damage.

Ultimately, the takeaway is that any differential when measuring metal panels for installation could affect a building’s performance, so it’s important to keep all potential scenarios that could affect measurement accuracy in mind—throughout the entire process. To find out more about the proper way to measure a roof for metal buildings or to schedule training, contact your local MBCI representative.

Five Installer Responsibilities for Weathertightness Warranties

Posted on August 6, 2020 by MBCI

Every metal roof installation comes with an implied warranty: the roof shouldn’t leak. This is true even if your customer didn’t buy a “manufacturer’s weathertightness warranty.” It’s just the very basic expectation. Any details we send out, any materials, whatever the manufacturer supplies the installer…all go to that simple premise that you are buying a quality roof system from the get go.

Beyond that, though, a purchased manufacturer’s weathertightness warranty takes it a step further. It’s added insurance. In order to get the full value and peace of mind from a warranty, there are certain considerations the installer needs to keep in mind. Let’s take a look at five key installer responsibilities on projects with manufacturer weathertightness warranties—beyond, of course, putting down the roof correctly!

1. Understanding the weathertightness warranty type selected for the project.

MBCI sells two types of weathertightness warranties: Standard and Single Source. The approval process up front is the same for both but it is crucial to know the scope of the project’s warranty. With a standard warranty, the only real expectation is that the roof will remain watertight for 20 years. It is a very basic, very inexpensive warranty in which the manufacturer and the installer jointly warranty the roof for that period of time. The manufacturer covers all the materials and the details, and the installer is covering the installation.

The opposite end of that spectrum is the single source warranty, which is purchased when the customer wants not only the roof warrantied, but prefers everything associated with the roof—any accessories, anything else penetrating the roof—to be 100 percent covered by the manufacturer, if applicable. These warranties do cost more, require inspections, and require an installer to have completed the manufacturer’s certified installer training program.

It’s important for the installer to know what warranty was sold, particularly because he/she may not have been the one involved from the start. They may be coming in to bid the job as the installer only. Therefore, he/she needs to ask questions because they may or may not have the personnel on their crew that meets the requirements to install that roof for the weathertightness warranty purchased.

2. Obtaining/confirming building geometry approval for warranty.

Beyond the type of warranty, it is simultaneously necessary to investigate whether there are additional procedures related to the building geometry. Has everything been correctly noted so that the warranty itself will be valid? Is the manufacturer aware of transitions, edge conditions, roof penetrations, roof accessories (snow guards, solar, etc.)? It is extremely important to make sure that the geometry—or the conditions of the roof—are covered within a particular warranty.

MBCI, for instance, will review your roof plan and see the eave gutters, the ridge, the rake, etc. and we can survey what’s going on. Is that roof tying into something else? Will there be materials on that roof that aren’t provided by us or not being installed by the roof installer? As the manufacturer, we would be taking a cursory view to say, yes, we can warranty the roof or no, revisions are needed. If there is anything that we can’t warranty, we’re going to spell that out upfront. We will give as much direction as possible to get the project to a point it can be warranted.

That said, it’s the installer’s and customer’s responsibility to make sure that the manufacturer knows what’s happening. Think about it this way. Many times, there are other trades involved outside of the roofing contract. Along comes someone who says, “I need to run something through your roof,” or six months down the road the owner wants a satellite dish on the roof and the installer incorrectly penetrates the roof., causing a leak. Guess who they’re going to call? The installer/customer/owner needs to get that approved by the manufacturer. Otherwise, the warranty could be voided.

The main takeaways here: Do not make modifications to that roof without the manufacturer’s approval because the roof installer can end up inheriting the liability for that if they do. And, communicate the criteria or the requirements of the warranty to the customer. Don’t just hand them the paperwork. Make sure they understand what’s in it and their responsibilities as metal roof owners.

3. Ensure proper installer certification and training as required by the warranty type.

This sounds self-explanatory, but it goes back to the warranty type and the necessity to make sure the warranty selected is appropriate for the job. Verify whether or not the job requires a certified installer and if so, ensure certifications are current. If the installer is not certified, then they need to take the steps to get certified in order to meet that warranty requirement.

A common situation: A warranty gets sold by a general contractor and he/she subs it out to another roofing contractor. That sub comes in and says not to worry, “we know how to put the roof on. We’re certified.” Then, MBCI gets ready to issue the warranties or schedule inspections and finds out the subcontractor doesn’t know our system that well. And remember—for certain types of weathertightness warranties the installer needs to be certified via our training program.

4. The installer is responsible for correct installation per manufacturer’s details.

The onus is on the installer to follow the details and directions provided by the manufacturer. If you install the roof per those details, and then there’s a problem, the responsibility falls back on the manufacturer unless determined otherwise. If, however, the installer doesn’t follow the details provided and the manufacturer comes out to do a warranty claim or warranty inspection, then the installer is going to be responsible for correcting it. The installer can’t put it in wrong and just say, “oh, well, that’s covered by the warranty.” It’s not. A manufacturer’s warranty is not for covering a bad installation—particularly in the case of a standard warranty. If the installer does a poor install and the roof leaks, that’s not covered by the standard warranty; it falls back on the installer. Of note, this scenario can be different with a single source warranty, since the manufacturer will be out there doing ongoing inspections and ultimately can become responsible for the installation as well.

And, it goes without saying, the warranty doesn’t cover the interior contents of a building that may be damaged due to an installation issue.

5. Do not make adds or changes to an installed system once completed and the warranty has been issued without first getting manufacturer approval.

The warranty only covers the installed product per details, as mentioned. It does not cover additional materials added to the roof or any changes made, at least without the manufacturer’s prior approval—after the install is complete.

Some examples would be adding a mechanical unit to the roof, a plumbing vent added through the roof, or the satellite TV cable through the roof. Putting a penetration, fasteners, holes of any kind, into a previously installed roof system, unless approved by the manufacturer, will void the warranty in that location. If the manufacturer does not give approval, the installer, along with the customer, would need to make the decision—is it worth the risk to proceed knowing that if the roof leaks, that location would no longer by covered by the warranty.

To find out more about MBCI warranties and installer certification, contact your local MBCI representative or visit our website.

Metal Roofing Considerations for Coastal Areas

Posted on July 13, 2020 by Randy Tweedt

Whether it is wind speed, sun exposure or the proximity to a coastline, these factors would be the major considerations when choosing metal roofing for a project in coastal areas. The good news is that metal panels can be used in just about any coastal area so long as you find the right product profile and finish that meets your specific requirements to maximize performance given the variables of the environment.

There are a number of special considerations given the environmental conditions inherent to a coastal area, including the impact to paint systems and certain unique maintenance requirements, wind ratings, hurricane conditions and certifications/regulatory product approvals that will limit the panels you can you use within specific coastal areas, for instance Dade County, the state of Florida, and the Texas Coast.

Finishes: The 1,500-Foot Rule

Metal components can be a great roofing choice, even in a coastal area, whether a bay, gulf, or ocean water. Key is how you manage the finish on the products and how close you are to the actual salt environment. Simply stated, if you’re outside of a 1,500-foot range from the coastline or salt water, then standard metal roofing would be suitable, but if you’re closer to the coastline there are special paint options or finishes you’d need for the product to withstand the coastal environment.

At MBCI, we use Flurothane Coastal coil coating system* as our standard solution to the challenge of salt spray and harsh coastal environments. This coating is a premium fluoropolymer (PVDF) system developed for use in the most extreme coastal environments. This system is unique in its use of an innovative thick film primer. The two-coat system has a total dry film thickness (DFT) of 1.7 to 2.0 mils.

Choosing an appropriate coastal finish can also affect your product’s warranty. If, for example, your project is within the 1,500-foot range and you don’t choose the required coastal finish, if the panels were to rust there would be no warranty offered and it could affect your warranty for weathertightness as well.

Suitable Panel Types and Additional Coastal Conditions

Overall, roof failures are the largest hurricane loss due to wind and water damage. For this reason, metal roofing is a highly recommended option for coastal regions where hurricanes and high force winds are prevalent. The appropriate metal panel type for these areas is mainly contingent upon what you want to accomplish. Because MBCI does have high wind ratings for most of our panels, whether it be a screw down (aka through-fastened) panel or a standing seam profile panel, selections should be determined by the complexity of the roof itself and the roof conditions. There are standing seam panels and through-fastened panels that can be approved for both roof and wall applications in many coastal areas.

Also, of note, different types of coastal areas may receive higher wind speeds. There is obviously a wide difference in wind speeds between the East Coast and the West Coast, for example, although both are coastal communities. In an area with higher wind speeds and/or hurricane conditions, you would want to consider panels that achieve higher wind ratings. Since there are many different panel options, and some may not be able to achieve as high wind ratings as others, you should look at what those values would be for wind and what testing has been done. MBCI’s metal wall panels and roofing systems are able to resist and withstand extreme environmental conditions, such as those in Florida or the Texas coast where strict product approval and testing processes are required.

MBCI has panels that meet requirements for Florida Approval, Dade County and Broward County for instance, where you need to have an NOA (Notice of Acceptance) for those county areas, as well as products that are TDI approved (Texas Department of Insurance), which is usually seen in the Texas coastal area.

Additionally, sun exposure and color can have an impact as far as solar reflectance, so that is another consideration. Somewhere like Florida gets a lot of sun yet a coastal area in Washington State would be mostly cloudy. If you are in an area that has more sun, then you may want to consider a panel with a higher solar reflectance value.

Maintenance Requirements

If you have metal roofing in a coastal area, you’re going to follow much of the same maintenance as you would on any metal roof, but you would want to inspect it for damage, especially after a wind event or storms. One of the main differences, though, especially if you’re within the 1,500-foot limit where you needed a special finish, is that you’re going to have to do a fresh water rinse regularly on the panels a couple of times a year. What this means is you are basically hosing it off with fresh water to get the potentially corrosive salt spray residue off of it.

For more on metal roof and wall panels and finishes for use in coastal areas, contact your local MBCI representative.

* (1) All substrates must be properly pretreated. (2) American Society for Testing and Materials. (3) Flurothane Coastal system is not designed to bridge cracks in the substrate. (4) Varies by color. (5) Flurothane Coastal system will generally meet the requirements for most post-painted fabrication processes. However, variations in metal quality, thickness or cleaning/pretreatment applications can lead to diminished flexibility.
SOURCE: Valspar Corporation

Maintaining Panel Modularity and Square When Installing a Metal Roof

Posted on June 15, 2020 by MBCI

Most metal roofing system installers know the importance of keeping panels on module, i.e., holding the width of the panel. But holding module alone isn’t enough; keeping panels square is equally important as the two go hand in hand. When proper attention is paid to both, you will have a faster install—ensuring longevity and functionality of the roof system so that it will be able to properly expand and contract as designed—not to mention improved appearance.

The ability to hold panel modularity is directly dependent upon several factors, including:

Skillset of the installer
Frequency that modularity is checked
Substrate deficiencies
Insulation system
Appropriate methods being used to hold panel modularity during panel installation
Keeping symmetry/maintaining squareness

Here are some important considerations for ensuring success for panel alignment.

The Relationship Between Holding Module and Squareness

The roof panel is not going to “hold itself” 100% on module and square by installing just as received using only the hardware components supplied from the manufacturer. It is the installer’s responsibility to ensure the proper alignment and squareness of the panel install in order to hold panel module. For example, if you’re working with a 16-inch panel, installers need to keep the spacing of the panel ribs at 16 inches. In this way, the panel doesn’t become stretched or compressed. So, holding module is key along with holding square; the two are connected. If an installer doesn’t start the building out square, it will make it even harder to keep module with regards to the alignment of the panel.

As far as the overall appearance and performance, the success of the metal roof is going to be heavily dependent on how square it is installed and an ability to maintain proper modularity. There are a number of suggested methods for doing so outlined below. Installers must decide which method works best for their them and their roof panel application.

Methods to Ensure Success

The key method is measuring ahead and monitoring your installation so you know where you should be along that roof install. The metal panel is typically 24-gauge or 26-gauge material and therefore it’s easy enough to pull it ahead or have it become crowded during installation if you’re not staying close to your marks, and therefore it’s easy to get the panel out of module. The bigger impact, aside from just aesthetics of being on or off module is the performance of the system itself, to where it could become under stress or it could go through extra deformation due to being out of module and out of square. Its important to verify/measure the panels leading edge and adjust as needed via roof clips or other panel hardware. Some suggested methods include:

Run a string line from eave to ridge square to the eave and measure from the string back to each panel run. The string line is moved ahead as the roof installation progresses. If installing over solid substrate, snap chalk lines for alignment points along the roof.
Use a metal measuring tape permanently secured to the substrate at panel endlap locations, ridge and other intermediate points for permanent reference to check module.
Mark the eave line for every rib installation to ensure the panel stays on module. Trapezoid panels offer metal closures for proper placement at the eaves to assist in holding module while vertical rib panels do not.
Pre-drill substrates at the endlaps and ridge locations for clip alignment ahead of roof panel installation. A hole can be located at the leading edge of clip location so that an awl or punch can be inserted into the hold to align the clip and adjust accordingly. The holes drilled ahead of the panel at the corresponding panel module.

To assist with holding the panels’ shape when checking modularity, utilize outside panel closures or cut wood blocking to the panel’s correct width and insert between panel ribs. Note that a bad roof substrate that is out of tolerance for “flatness” will not be hidden or magically corrected by the panel installation. The alignment and tolerance of the substructure are equally critical to the panels’ squareness and being able to hold module. Substrate should be should be installed to a level plane tolerance that is no more than ¼” in 20-ft or 3/8” in 40-ft variance.

Do not stand in panel and/or keep as much weight as possible out of panel while installing clips. Not only is it unsafe but it changes the width of the panel and thus impacts modularity.

Use the correct combination of roof clip heights, insulation thickness and thermal spacers to maintain level panel installation and prevent panels from gaining or losing module. MBCI provides recommendations in its installation manuals regarding most common types of insulation thickness and means of attachment to various substrates. Additionally of note:

Trimming of insulation or adjusting thermal block thickness can help control/modify panel modularity as needed.
Alignment straps for trapezoid panels can be purchased from the manufacturer and installed on top of purlins before insulation. These set the clip spacing at 2-0” o.c and can be utilized at the endlap and ridge locations minimum or added at other locations.

At MBCI, we recommend that installers check module/square every three to four panels. If the panel grows or shrinks 1/8th of an inch or 3/16th of an inch with three or four panels or shows signs of being out of square, there’s time to recover from it by making adjustments to correct. If an installer just blindly puts the roof on for 50 feet or so and then realize they’re off module or out of square, it will likely be past the point of return to hold module and keep square.

For more information on installing metal roof panels to hold module, see our previous blog post on the topic.

For more information on our installer training sessions, click here, or submit your technical or installation questions by filling out our Ask An Expert form here.

Tips for Selecting and Field Applying Touch-Up Paint

Posted on November 14, 2019 by kbuchinger

Metal roofing and wall panels routinely come from the factory pre-finished a durable, baked-on paint finish that covers the Galvalume^®-coated steel surface. This production occurs in a controlled environment, which helps create a consistent product, and allows metal panels to last decades with minimal maintenance. It turns out, however, that the biggest threat to a metal panel’s paint coating can happen during panel installation. Tools, fasteners and other installation-related items and activities can scratch or damage the finish, requiring touch-ups to the paint. If you experience this, here are some touch-up paint tips to keep in mind.

Assess the Damage

First, determine how noticeable the scratch is. Do you have to be close to see it, or can you see it easily from several feet away? Generally, if the scratch isn’t noticeable and has not penetrated the Galvalume coating, its best to refrain from doing a paint touch-up. This is because touch-up paint can’t match the fade resistance of the original baked-on pre-finish, and if the Galvalume is still intact, it will still protect the steel beneath the scratch.

On dark or bright colors in particular, the touch-up paint will fade much more quickly than the original paint. Often, the end result is that touch-up paint is more noticeable than if the scratch is left alone. On the other hand, if the scratch is noticeable and needs a touch-up, there are some best practices to follow. It’s important to note though, that if a large area of the panel is damaged (more than 10–15%), then it’s best to just replace the panel.

Getting the right touch-up paint

Metal panel manufacturers recognize that there may be a need for minor paint touch-ups in the field. So, most offer small containers of paint conducive to field work. These paints are specifically formulated to match standard color offerings, and have properties that make them compatible with the factory finish. Therefore, it’s important to always buy touch-up paint from the manufacturer that produced the original panels. Never ask a paint store to match colors based on a piece of panel or trim. Doing so may get a color match, but it won’t contain the other protective properties of the paint coating you receive from a manufacturer.

Choice of touch-up paint application

Touch-up paint for field application is often available in three types of containers: paint pens, small bottles and spray cans. Usually, the best choice for a scratch is a paint pen. Touch-up paint pens have small, precise tips that can fit into scratches, allowing it to only apply paint where needed. For larger scratches or scuffs, manufacturers offer bottles of paint (with a small brush) similar to those used for nail polish. Generally, these are best for dings on the panel.

Spray cans are also available, and are ideal for painting small accessories like plumbing vent pipes. Don’t use spray cans to conceal a scratch because they apply much more paint than necessary. This can cause unsatisfactory results as the paint weathers and fades differently than the original paint.

Using touch-up paint

When performing a paint touch-up, it’s important to make sure the area in and around the scratch is clean and dry. Wipe down the area as needed, then dry it completely before applying any paint. Afterward, paint the surface using the least amount of paint necessary. This eliminates excess paint on the pre-finished panel. Paint pens are ideal for this since they apply less paint than a nail polish-type bottle or spray can. Once the touch-up paint is on the panel, it will need time to dry. During drying, make sure that dust or other contaminants do not embed into the wet paint.

Consult the metal panel manufacturer

To ensure you or your maintenance professional properly select and apply touch-up paint, be sure to check all warranty and installation requirements and resources with the metal panel manufacturer. They can help ensure you get touch-up paint that matches the paint originally used on your panels and that you take the right steps to ensure warranties remain intact. MBCI offers metal panel touch-up paint for industries and applications including:

For more on metal roof and wall panel finishes, colors and touch-up paint techniques, contact your local MBCI representative.

Cutting Metal Panels Properly On Site

Posted on October 17, 2019 by kbuchinger

Cutting metal panels on site is an often-necessary part of installing metal roofing and wall panels. However, using the right tools and methods to ensure the panels remain damage-free is vital. Using the wrong tools can result in rust, rust stains, the voiding of warranties and diminished building service life. In this blog post, we’ll share several common field-cutting techniques and best practices that help ensure good results.

Maintaining Longevity When Cutting Metal Panels On Site

When metal panels are made in a manufacturing facility, the tools and methods used to cut the coated metal coil help protect the cut edge from deterioration like corrosion. When cutting metal panels on a jobsite or in the field, protecting any cut edges is just as important. To understand how to field-cut metal panels without sacrificing the quality and protection delivered from the manufacturing facility, you must first understand the what protects the panels. Most often, metal roof and wall panels are fabricated from Galvalume®-coated steel coil because of its proven longevity. Not only does the Galvalume coating protect the surface area of the metal panels, it has also been shown to be effective along the thin edges of the metal too, as long as those edges are cut properly.

During fabrication, the Galvalume metal panels are cut to length either by shearing while flat before entering the roll former, or by means of a profile shear as the panels exit the roll former. Either method tends to “wipe” the Galvalume coating across the cut edge of the metal panels. This provides superior cut-edge protection from corrosion.

Likewise, when panels arrive on site, any needed field cutting should address the same concerns of protecting the edge of the steel from corrosion. Of course, there are ways of doing the field cutting correctly. However, there are also poor strategies that can lead to real problems. The following are examples of common field cutting tools and the best practices for good results.

Common Tools and Methods for Cutting Metal Panels On Site:

Aviation Snips

Red and green aviation snips are a good choice for small cuts on metal panels, such as around pipe penetrations. These snips will wipe the Galvalume® coating in the same way as factory shears, making them a good choice.

Electric Shears

Electric shears are optimal when making lengthier cuts along the steel, such as cutting a wall panel at a corner or at a door opening. These shears take a ¼” strip of metal out of the panel during the cutting process, which tends to leave both sides of the panel smooth and flat along the cut. Like the aviation snips and factory shears, electric shears will wipe the Galvalume coating and protect the edges.

Mechanical Shears

Mechanical shears are an add-on tool that fit onto a battery-operated impact or screw gun. These shears do not take any metal out of the panel and will leave a slightly wavy edge. Mechanical shears are an excellent choice for bevel cutting standing-seam panels at hips and valleys, since they too wipe the Galvalume coating over the cut edges to offer protection.

Nibblers

A nibbler is a great tool for cutting across corrugations in wall panels to create openings for windows, doors and similar structural additions. A good nibbler typically costs $500-$700 (currently), but is well worth it if you often cut corrugated metal panels. The punch and die in the nibbler tends to wipe the Galvalume across the cut edge as it punches out small, half-moon shaped pieces of panel. However, because these little metal pieces will fall away from the cut, it’s important to contain them so no one walks on them. Otherwise, they can embed in the soles of installer’s shoes and create scratches in roof panels when they walk on the roof.

Skill Saw

Skill saws are an ideal tool for cutting metal panels because of their versatility. This tool can cut either across or parallel to corrugations, whether straight or at an angle. When using a skill saw, it is critical to use a saw blade that cuts cool. Otherwise, the Galvalume coating can melt along the cut edge and become ineffective. In particular, do not use an abrasive blade, which will generate heat and damage the coating.

Panels cut with abrasive blades corrode. A cool-cutting blade leaves a smooth edge.

Additionally, its vital to avoid cutting panels on the roof or above other panels. A skill saw blade will throw considerable amounts of steel debris into the air and down onto any panels below. This debris, called swarf, will quickly rust and ultimately cause rust spots in the panels. If enough swarf gathers in one spot, it can rust through the panel.

Steel swarf, like this collected at the ridge will rust through the panel.

Which Tools Should To Avoid When Cutting Metal Panels On Site:

Tools that should never be used include:

Torches
Cut-off saws
Reciprocating saws
Hacksaws
Grinders

All of these tools will melt the Galvalume^® coating, causing edge rust just like an abrasive blade would. These tools also throw a lot of steel debris (swarf) onto the panels they cut. This debris will be hot and will embed into the panel coating. This can cause rust spots and bigger problems down the road.

In conclusion, using the right tools and following metal panel manufacturer recommendations when cutting metal on site will help ensure that the panels remain damage-free and the final installation will be a fairly seamless process. Using the wrong tools can result in rust, rust stains, and the voiding of warranties. For more on best practices and recommendations for on-site cutting and installation of metal panels contact your local MBCI representative.

Are Metal Panels An Ideal Low-Slope Roofing Material?

Posted on July 22, 2019 by MBCI

Many large, commercial, low-rise buildings often don’t benefit from steeply-sloped roofs the way residences and small commercial buildings might. This is because a steep roof slope would add unwanted height and unnecessary construction cost. Buildings like warehouses, retail stores, etc. are more appropriately built with low-slope roofing, commonly known as “flat roofs”. The National Roofing Contractors Association (NRCA) defines low-slope roofs as those with “a slope at or less than 3:12″. Anything steeper qualifies as a “high-slope roof”. With this in mind, let’s look at some key points to consider when designing and constructing a low-slope roof.

Low-Slope Roofing Materials

When it comes to selecting low-slope roofing products, there are generally three fundamental choices:

Asphalt/ Bituminuous Products: The traditional commercial roofing norm for many years, the use of asphalt/bituminous products has dwindled as newer, more appealing options have emerged.
Flexible Membrane Roofing: This roofing material can be made from a variety of types of plastic/polymer-based materials (commonly known as EPDM, TPO, PVC, etc.). Rolls of the chosen membrane are laid out on the roof structure and secured in place either with mechanical fasteners (screws with large washers) or with a continuous layer of adhesive.
Metal Roofing: Sometimes overlooked, metal roofing is suitable for different roof slopes. Many metal roofs that use standing-seam systems are rated for use with a pitch as low as ½:12.

When considering which type of roofing material to use for a building project, there are a number of significant differences that illustrate why metal roofing is often the ideal choice.

Engineered For Superior Performance

Standing-seam metal roofing is made specifically for use on low-slope roofs as it meets a number of performance requirements:

Water resistance: Precipitation doesn’t penetrate through metal or through the standing seams where the metal panels join together. This is why they can tolerate such low slopes, allowing the water to drain away slowly and predictably without leakage.
Rigidity: The rigid nature of metal means that there is less opportunity for ponding (standing water). This is not always the case with asphalt/bituminous or membrane roofing systems.
Drainage: Metal roofs carry water to the building’s edge toward gutters and downspouts that carry it away from the building. Other roofing systems rely on drainage piped inside the building. This takes up space and has the potential to leak water inside the building and cause damage.
Wind Resistance: Standardized uplift testing shows that metal roofing performs as well or better in extreme weather than mechanically-fastened or fully-adhered membrane systems.
Durability: The most cited advantage of metal roofing is its long-term strength and durability. Engineered design and use of high-quality coatings ensures a longer lifespan—50 years or more. In contrast, other roofing types typically feature lifespan ratings of 20 or 30 years.
Puncture Resistance: Low-slope metal roofing is more puncture-resistant than asphalt/bituminous or membrane roofing. This makes it better able to tolerate foot traffic, hail and other puncture-inducing hazards.
Construction/ Installation Ease: Metal roofing panels are custom-made to suit specific building sizes and end uses. This customization typically means it takes less time to place and install metal roofing in the field. Further, metal panels can tolerate a wide range of temperatures and weather conditions and still install and perform as intended. Low-slope roofs are also safer to walk on with less risk of slips, falls and other hazards.

Cost-Effectiveness

Using metal roofing on low-slope roofing systems can be cost effective in a number of ways:

Fewer labor hours as a result of the ease of installation saves money during construction.
Competitive material costs, particularly if the metal roofing is part of a total metal building package from a single manufacturer.
Minimal maintenance requirements and aversion to rusting, mold growth and decay that save the building owner money over time.

This all adds up to a very favorable life-cycle cost.

The performance, cost-effectiveness and life-cycle benefits of metal roofing panels make them a viable option for low-slope roofing systems. Manufacturers like MBCI can help you select the right metal roofing products and provide information and resources to help ensure proper installation.

View examples of low-slope metal roofing projects and contact your local MBCI representative to start your project today.