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Sealing the Deal: The Importance of Properly Sealing the Building Envelope Using IMPs and Single-Skin Panels

Posted on June 29, 2018March 30, 2022 by MBCI

The primary purpose of a building’s envelope (roof and walls) is to protect the building’s interior spaces from the exterior environment and provide the desired exterior aesthetics. Whether choosing insulated metal panels (IMPs) for their superior performance or, instead, looking to the wide range of aesthetic choices available with single-skin panels—or some combination of the two—the common goal must always be to protect the building from the potential ravages of water, air, vapor, and thermal/heat. By ensuring proper installation of metal panels and, thereby, properly sealing the building envelope, problems can be mitigated, efficiencies maximized, and the integrity of the building protected.

Here, we’ll briefly consider the benefits of each panel, and some key considerations relative to their sealant needs and capabilities.

Insulated Metal Panels (IMPs)

IMPs are lightweight, composite exterior wall and roof panels that have metal skins and an insulating foam core. They have superior insulating properties, excellent spanning capabilities, and shorter installation time and cost savings due to the all-in-one insulation and cladding. In effect, IMPs serve as an all-in-one air and water barrier, and are an excellent option for retrofits and new construction. With their continuous insulation, roof and wall IMPs provide performance and durability, as well as many aesthetic benefits.

IMPs offer excellent R-value and improve energy efficiency to the building envelope.

Generally speaking, because of the nature of the joinery, it is easier to get a good seal in place with IMPs given their relative simplicity (i.e., putting the two pieces together with the sealant). They require great attention, though, in terms of air and vapor sealing—aspects largely controlled by the installers on a given project. As an example, vapor sealing in cold climates or applications is critical to the overall soundness of a building. Consider the damage a building could incur if moisture seeps into a panel and becomes trapped; it if freezes, it could push panels out of alignment. This would result in not just an unattractive aesthetic, but a performance failure as well. In order to be effective, all sealant and caulking must be fully continuous.

Single-Skin Panels

Single-skin panels, alternatively, offer the advantage of an expansive array of colors, textures and profiles. They are also thought to have more “sophisticated” aesthetics than IMPs. Single-skin panels are available in both concealed fastener and exposed fastener varieties, and are part of an assembly. They can be used alone or in combination with IMPs, and as long as the needed insulation is incorporated, single-skin panels can meet technical and code requirements, depending on the application. Single-skin products offer a wide range of metal roof systems and wall systems as well.

Getting the proper seal on single-skin panels may require extra sealants or closures, and have more parts and pieces that have to come together to create the seal. However, when properly installed and sealed, they can provide excellent performance in their own right. Some key caveats include ensuring panel laps are properly sealed with either tape or gun butyl sealants, and carefully inspecting air and water barriers for proper installation as well as penetrations through the wall for sealing/fire caulking prior to panel.

In most cases, following the details for the most common conditions will give you a successful and high-performing outcome.

Regardless of the type of metal panel used, taking the time and effort to ensure the sealing and caulking details are properly handled, metal buildings can protect the built environment and provide long-lasting quality and performance.

Best Practices for Ensuring Metal Roof Accessories are Properly Installed

Posted on June 22, 2018 by kbuchinger

Best practices for roofing contractors, general contractors…and even architects—from spec’d work to pre-roofing conferences.

Many metal roofs have roof penetrations for accessories installed by other trades. Unfortunately, oftentimes, these penetrations are improperly made or the accessory material is incompatible with the standing seam roof. A properly installed Galvalume standing seam roof, for instance, can be expected to last 60 years or longer. However, improper work on the roof by other trades can result in leaks and possibly a roof service life far less than 60 years. In order to achieve the best results, the roofing contractor needs to coordinate with the general contractor, the architect, and the building owner to ensure proper installation.

In most cases, it is the roofing contractor who is held responsible for all things roof! If armed with a clear checklist as he or she walks into a pre-roofing meeting with the architect, there will be a significantly greater likelihood of a well thought out and successful process. Here are some suggestions for the roofing contractor (in conjunction with the entire team) to consider.

A reminder to specifiers to put in the project specifications that all roof penetrations and roof accessory installation must be coordinated with the roofing contractor. Beyond the obvious issue of maximizing performance, if a manufacturer’s weathertightness warranty is specified, the roof manufacturer must preapprove any work performed on the roof by other contractors.
If the above is not in the project specifications, the roofing contractor should initiate the conversation during the pre-roofing conference with the architect and the general contractor.
Roof curbs should ideally be supplied by the roofing contractor and they should definitely be installed by the roofing contractor. Welded aluminum curbs should be used as specified by the roofing manufacturer. See tips for installing roof curbs, here.

Be sure to use the proper roof curb to ensure a well-installed, weathertight condition.

Pipe penetrations for vent pipes, heater flues, gas and electric, etc. as well as penetrations associated with lightning protection air terminals and cable management should be coordinated with the roofing contractor and with the roofing manufacturer if there is a weathertightness warranty. Rubber roof jacks should always be used.

The above example is a high temperature rubber roof jack. Pipe penetrations allow for a long-term performance of the roof.

Ensure that dissimilar materials such as copper, lead, and graphite are not used on the roof. This includes treated wood, which contains copper. Condensate from roof top AC units must be piped off the roof as it contains dissolved copper.

This is an example of wood and HVAC condensation on a metal roof.

The roof must be protected from spills of any harmful chemicals or masonry products.

The above represents just an overview of some of the best practices the roofing contractor should consider when entering into a job with other trades. As the roofing contractor, anything that involves the roof will likely be seen as YOUR purview. After all, if there’s a leak, who are they going to call? That said, being proactive regarding roof accessory installation—regardless of who is doing the actual work—will serve all parties in the end. Get in front of any potential issues and ensure everyone is reading from the same playbook. For more information, contact your local sales representative.

Reducing Peak Demand Costs with Cool Metal Roofs

Posted on May 9, 2017 by Candy McNamee

Among the many benefits offered by cool roofs—including a decrease in urban heat island effect or increased roof system longevity—perhaps the most significant is a reduction in peak demand energy usage which directly affects building expenses.

Peak demand is the highest point in the day at which a building draws electrical consumption. A facility’s monthly utility rates are largely determined by the power usage level at this time, so anything that can be done to drive usage down will significantly reduce utility costs. As evidenced by their test values, cool roofs are an effective way to decrease air conditioning loads during peak demand times.

Cool roof values are expressed in terms of solar reflectance and thermal emissivity. The combination of these values is used to determine how hot a surface will become by its ability to reflect solar energy and radiate heat away from itself. Cool roofsare capable of reflecting solar heat away from a building by more than 70 percent. In fact, the U.S. Environmental Protection Agency estimates that ENERGY STAR® qualified roofing products can lower roof surface temperatures by up to 50°F.

According to Jeff Steuben, executive director, and Carolyn Richter, communications manager, Cool Roof Rating Council (CRRC), in a recent Florida Roofing article, “Building occupants can experience improved comfort as compared to a conventional dark roof, as the building’s interior is subject to less thermal flux and stays cooler during warm seasons,” and, “Reduced indoor temperatures lead to energy savings from reduced cooling energy loads.”

Along these lines, contractors can also access a CRRC-provided listing of cool roof rebates, codes and voluntary cool roof programs at: www.coolroofs.org/resources/rebates-and-codes.

Cool Roofing Longevity

In addition to energy efficiency, cool metal roofs are known for extended durability and longevity, with most products offering a 40-year finish warranty.

In fact, a well-noted extensive study, Natural Exposure Testing in California, conducted by the Oak Ridge National Laboratory, found that pre-painted metal roofing maintained higher levels of reflectance, over a three-year period, due to its ability to shed particulate matter, as compared to conventional roofing materials. Further, pre-painted metal roofing has been found to retain 95 percent of its initial solar reflectance over this same three-year period.
Increasing performance and energy savings, solar reflective pigments in cool metal roofs offer higher total solar reflectance and thermal emittance, even in darker colors. With cool roof technology, the ability for the roof to store heat and radiate that heat into the building after sundown is dramatically reduced.

Heitmann Residence featuring a Cool Metal Roof

Cool metal roofs are proven to deliver environmental and performance benefits, of which the most significant to building owners is their contribution to the bottom line. Although savings will vary based upon geography, materials and insulation, the U.S. Environmental Protection Agency estimates that reflective roofs can save up to 40 percent of a building’s cooling energy costs.

When utilizing the U.S. Department of Energy’s Cool Roof Peak Calculator, contractors will discover that the total value of energy savings offered by a cool roof averages more than $1,000 annually in most climate zones for a typical commercial building. Furthermore, this applies to both cool roofing installed over both existing roof insulation and new insulation.

Proven Strategy

As established by documented study and significant heat build-up reduction levels, cool roofs are a proven strategy for supporting longer lasting roofs, reducing both utility costs and decreasing a building’s environmental footprint as Steuben and Richter conclude, “cool roofs are one of the most effective ways to obtain energy savings and environmental rewards through building envelope design and re-roofing projects.”

Knowing When to Call the Metal Manufacturer: Part 2

Posted on May 1, 2017August 15, 2024 by MBCI

As stated in Part 1 of this series, the success of a metal roof or metal wall project can rest on the installer knowing when something isn’t working or just doesn’t seem right. When that happens, a call to the manufacturer is not just suggested but is really imperative to ensure any potential problem is averted before it’s too late. In addition to the previously discussed scenarios, such as damage to the physical panel or problems with the fasteners, let’s take a closer look at a few other common circumstances under which MBCI recommends immediately reaching out to the manufacturer:

Alignment and Substrate Issues

It is the installer’s responsibility to verify the substrate and check for proper alignment before attaching any sheeting materials. If the installer notices any issues of this sort (either before installation or once they start putting on the sheeting), they should stop and address them immediately. This might include oil canning or other irregularity in the appearance of the panel. The installer should investigate the source. If unable to identify and properly remedy the situation on their own, then a call to the manufacturer’s support team is recommended. They may be able to suggest items to check to help locate the source of the problem—whether it be installation or manufacturing—and from there make suggestions as to the best possible means to address the situation.

Accessories

When physically getting ready to modify a panel system by adding things to the roof (such as snow guards or mechanical curbs) or to walls by installing doors, windows and louvers, these penetrations can have an impact on the system and its weather-tightness and appearance. Oftentimes, other trades—who may or may not have knowledge of the sheeting system—are coming onto the job to perform the accessory installation. It’s wise to visit with manufacturer prior to installation and/or alert the non-metal panel installer of precautions to take when adding accessories.

The pipe penetration shown here is not the correct type of piping for metal roofing, and not the correct installation. This can lead to issues with roof performance, including leaking and water damage.

Coordination regarding material types of accessories, fasteners and placement is critical. There are materials that can react negatively with the installed system and lead to damage as well as void manufacturers warranties. Accessories should always be discussed prior to installation. Read more about different types of roof accessories and penetrations in MBCI’s blog article, Roof Penetrations Made By Non-Roofing Contractors.

Panel Engagement

Panel systems have an engineered means by which the panels attach and engage one another as shown in the manufacturer’s installation manuals and project drawings. If at any point the panel will not engage as depicted in the details, installation should be halted and reviewed to determine the cause. This can require a call to the manufacturer to help determine if the matter is site and substrate related or potentially a manufacturing issue.

Do not continue to install the system if the laps are not nesting properly, clips are not engaging as detailed, panel modularity cannot be controlled or if the overall panel is not “resting” on the substrate such that there is excessive bowing and stress in the panel. This is the time to call the manufacturer, as once the material is completely installed, it is much more difficult to determine the cause of a problem and is potentially more expensive to remedy. Additionally, in many cases, full installation constitutes acceptance of the product and the manufacturer’s hands could be tied or extremely limited in being able to assist in remedying after the fact.

By knowing when to be proactive with a call to the manufacturer, installers can mitigate many types of potential pitfalls. And if you’re just not sure, it’s best to call.

For more information on metal roof and wall products and training, MBCI offers courses through its Metal Institute. These courses are available for general training purposes or for those seeking installer certification.

Combatting Thermal Bridging with Insulated Metal Panels

Posted on March 23, 2017 by MBCI

When using compressible insulation, say for instance fiberglass batt, consideration must be given to how that insulation is going to be deployed in the actual wall or roof. For instance, installers might place the insulation across the framing members and then smash it down with the cladding and run a screw through to the underlying structure. The problem here is that the insulation is rated with some R-value—and that R-value is determined by an ASTM procedure that also determines what its tested density is. So in essence, it’s ‘fluffy’ insulation.

One manufacturer’s insulation, however, might be thicker than another’s. The contractor is buying an R-value, not a density or a thickness. The insulation is tested to that R-value at whatever thickness and density¹ is needed to achieve it. Let’s say R-19 fiberglass batt is specified, but then it is put in an assembly and smashed down flat… now it’s not R-19 anymore; it’s now R-something else. That’s a thermal bridge—when the insulation’s R-value has been compromised.

Manufacturers have the ability to run long length panels that minimize the number of end joints. This continuity provides significant advantages over traditional insulated materials when designing for energy efficiency. This image illustrates the difference between fiberglass batting made discontinuous by compression between panel and framing members and the continuous insulation provided by insulated metal panels.

Unfortunately, thermal bridging is almost impossible to eliminate. In the example above, another choice might be to put it between studs. Except in this situation, the studs break the insulation. While it’s not pinched, the studs are separating it. Whether the studs are metal or wood, in either case it’s still a significant thermal short circuit or a thermal bridge.

Even with the highest quality insulation systems—insulated metal panels, for example—a joint is required. Building is not possible without putting neighboring panels together. Therefore, insulation is discontinuous. While it’s impossible to avoid thermal bridging, there are two requirements to ensure the building performs the way it needs to perform.

Thermal bridging must be mitigated. In other words, the designer or installer has to try to eliminate as much of it as possible.
If thermal bridging is unavoidable, it must be accounted for in some fashion, which usually means putting more insulation somewhere to make up the difference. This is called a “trade-off” and is allowed by most building energy efficiency codes.²

Why Insulated Metal Panels?

Insulated metal panels then are the best bet, because although the joint is a thermal bridge, in effect, it is not nearly as impactful as breaking a line of fiberglass with a stud or smashing the fiberglass between the panel and a framing member. In the illustration below, R-value doesn’t just vary at that point where the panel and the stud meet. The entire insulation line gets smashed and one would have to go some distance from the stud before the insulation returns to its normal, fluffy thickness. These issues need to be mitigated and accounted for.

Continuous insulation is critically important to an efficient envelope design. Insulated metal panels, with their side laps designed for concealed fasteners, eliminate the possibility of gaps in the insulation and thermal bridges. Continuous insulation is important because thermal bridges and discontinuities introduced by compressing non-rigid insulations cause the in-place R-Value of the assembly to be less than the tested R-Value of the insulation used. This effect has become a focus in newer energy efficiency codes such as ASHRAE 90.1 and IECC.

Manufacturers such as MBCI and Metl-Span publish insulated metal panels as U-factors because the joint is tested as part of the assembly (both mitigating and accounting for the aforementioned issues). These values can be found on product data sheets and technical bulletins, such as Metl-Span’s Insulation Values technical bulletin, published January 2017.

References

ASTM C 665 – 12, Standard Specification for Mineral-Fiber Blanket Thermal Insulation for Light Frame Construction and Manufactured Housing, Table 1, Footnote c.
ASHRAE 90.1 – 13, Energy Standard for Buildings Except Low-Ride Residential Buildings, Section 5.6
High Performance Green Building Products – INSMP2A (CEU)

Beauty and Braun: The Benefits of Mixing Insulated Metal Panels with Single-Skin Panels in Commercial Design

Posted on November 30, 2016 by Joe Moore

Commercial projects aren’t one size fits all. By bringing in metal panel products to suit the individual need, designers and architects can provide custom solutions for a variety of applications. Single-skin metal panels and insulated metal panels (IMPs), if used correctly, can together add both aesthetic and functional value to your projects.

While IMPs can provide superior performance with regard to water control, air control, vapor control and thermal control, you may sometimes find your project requires—from an aesthetic perspective—the greater range of choices available in single-skin profiles. Let’s spend a little time looking at some of the reasons behind the growing trend of specifying a combination of insulated metal and single-skin panels.

Benefits of Insulated Metal Panels

Insulated metal panels are lightweight, composite exterior wall and roof panels that have metal skins and an insulating foam core. Their much-touted benefits include:

Superior insulating properties
Excellent spanning capabilities
Insulation and cladding all in one, which often equates to a shorter installation time and cost savings

Benefits of Single Skin

Single-skin panels, on the other hand, with their expansive array of colors, textures and profiles, may have more sophisticated aesthetics. They can be used on their own or in combination with IMPs. It should be noted, too, that single-skin panels can—in their own right (as long as the necessary insulation is incorporated) —satisfy technical and code requirements, depending on the application.

Beyond aesthetics, when it comes to design options, single-skin products offer a wide range of metal roof systems, including standing seam roof panel, curved, and even through-fastened systems. As for wall systems, those may include concealed fastened panels, interior wall and liner panels, and even canopies and soffits, not to mention exposed fastened systems. Therefore, you have a wide range of not only aesthetics options but VE (Value Engineering) options as well.

Why Mix?

So, in what situations might the designer or architect choose to combine the two panel types? Let’s examine a couple of specific scenarios related to the automotive or self-storage worlds as a means of illustration. In both of these types of applications, it is not uncommon for the designer to recognize the importance of wanting to keep the “look” of the building consistent with branding or to bring in other design elements.

The Coalville Wastewater Treatment Facility in Logan, Utah combines the insulated CFR panel with the single-skin Artison L-12 panel.

Single-skin panels can be used as a rain screen system in the front of the building or over the office area, and would provide the greater number of design options. In the rest of the building, designers can take advantage of the strength, durability and insulation benefits of IMPs. Although you could use one or the other for these examples, the advantage of mixing the two would be achieving a certain look afforded by the profiles of single-skin, while still adhering to stringent building codes and reducing installation time—which is the practical part of using IMPs.

Focus on HPCI IMP Systems

One great example of a current trend we’re seeing at MBCI is the use of the HPCI-barrier IMP system, along with single-skin panels. The High Performance Continuous Insulation (HPCI) system is a single system that is a practical and effective replacement for the numerous barrier components found in traditional building envelopes.

The HPCI Insulated Metal Panel is quick and easy to install and provides an economical solution to conventional air, water, thermal and vapor control without sacrificing thermal efficiency.

A big benefit to using the HPCI system is that the barrier wall is already in place. In terms of schedule, the HPCI barrier system is typically installed by contractors who are also installing the single-skin system, eliminating the need for multiple work crews, and thereby minimizing construction debris and reducing the likelihood of improper installation. With a general lead time of four to six weeks for the HPCI and a week or two for the single-skin, the installation goes fairly quickly. Therefore, it appeals as the best of all worlds—a single system meeting air, water, thermal and vapor codes (ex.: IBC 2016, NSTA fire standards) plus the design flexibility of a single-skin rain screen product. (Note: The HPCI panel must be separated from the interior of the building by an approved thermal barrier of 0.5″ (12.7mm) gypsum wallboard to meet IBC requirements.)

Bottom line, HPCI design features and benefits include the following:

• Provides air, water, thermal and vapor barrier in one step
• Allows you to use multiple façade options while maintaining thermal efficiency
• Easy and fast installation, with reduced construction and labor costs

Conclusion

As designers, architects and owners are getting smarter about a “fewer steps, smarter dollars” concept and an increased awareness of applicable codes and standards, not to mention lifecycle costs, the trend towards maximizing the strengths of available systems will continue to grow. Whether the right choice is an IMP system, single-skin or some combination, the possibilities are virtually endless.

Selecting Metal Panels Based on Roof Slope

Posted on November 1, 2016July 29, 2024 by Jason Allen

If you’re reading this article, then you are probably already aware that metal roofing can provide many benefits, including longevity, durability and water shedding—not to mention the aesthetic features of today’s metal roof products. When specifying a metal roof system, choosing the correct panel is a key factor. Roof slope is critical in determining that choice. Let’s take a look at some of the main things to consider when choosing a metal roof panel with regard to roof slope, including building codes, minimum slope requirements and typical applications.

Building Codes

Building codes are perhaps the most important driving force dictating the roof slope to choose. Different types of roofs have distinct specifications for installation. According to the 2012 International Building Code (1507.4.2 Deck slope), minimum slopes for roof panels need to comply with the following:

The minimum slope for lapped, non-soldered seam metal roofs without applied lap sealant shall be three units vertical in 12 units horizontal (25-percent slope).
The minimum slope for lapped, non-soldered seam metal roofs with applied lap sealant shall be one-half unit vertical in 12 units horizontal (4-percent slope). Lap sealants shall be applied in accordance with the approved manufacturer’s installation instructions.
The minimum slope for standing seam of roof systems shall be one-quarter unit vertical in 12 units horizontal (2-percent slope).

Minimum Roof Slope Requirements

Depending on the roof profile, there are minimum roof slope requirements for each panel, which need to be considered. The profile refers to the shape the metal sheets take when they bend to form panels. Metal roof slope is expressed by a ratio indicating the roof pitch, which notes the vertical rise of the roof (in inches) for every 12 inches the roof runs horizontally—in other words, dividing the vertical rise and its horizontal span. The most common slopes are: 3:12, 1/2:12 and 1/4:12. When looking at metal roofing panel, you will need to consult with the manufacturer to ensure that the metal panel you selected will work for your application.

Applications: Low Slope or Steep Slope

Commercial Application– Low Slope Roofs

A low-slope roof is one whose slope is less than 3:12. Low slope roofs have several benefits. They have simpler geometry that is often much less expensive to construct and low slope metal roofs require fewer materials than a steep slope, which reduce material costs. Metal roofing panels are excellent solutions for roofs with low slopes. Commercial roofs are typically low slope (less than a 3:12 slope), and larger than residential roofs. This is due to low slope metal roofs being a bit easier to build on large structures.

Cecilia Junior High in Cecilia, Louisiana uses 7,180 sq. ft. of MBCI’s SuperLok®. This panel requires a minimum slope of 1/2:12.

Residential Application– Steep Slope Roofs

A steep slope roof is one whose slope is greater than 3:12. Steeper slopes are ideal for areas that have higher snow loads and will also prevent the possibility of ponding water on the roof. When it comes to residential construction, your roof is a visible part of the structure. Choosing a metal roof for residential construction involves choosing a panel profile that will be aesthetically pleasing.

It is common to use steep slopes in residential applications, such as this home in Guntersville, Alabama that utilizes MBCI’s LokSeam® (requiring a minimum slope of 3:12).

Conclusion

Regardless of whether you’re choosing metal panels for a commercial or residential structure, slope matters. Following common standards, doing your research and paying attention to manufacturer guidelines regarding minimum slope will ensure you’re reaping the full benefit of your metal panel selection.

For More Information

To learn more about metal roof slopes, check out:

Fastener Compatibility with Metal Roof and Wall Panels

Posted on October 19, 2016March 29, 2022 by MBCI

The installation of a new metal roof or wall panel on a residential home, business or commercial building takes care, precision and—of course—the right tools. Regardless of the structure, you’ll likely find that choosing the correct mechanical fastener plays a key role in the long-term performance, durability and efficacy of the project.

Many metal roof and wall panels, in fact, rely upon the use of quality mechanical fasteners to secure components to a structure. In order to guarantee a resilient and weather-tight attachment, it behooves the user to select an appropriately compatible fastener type for the specific metal construction, thereby ensuring expected benefits, such as energy efficiency, extended life cycle, and even lowering insurance bills for the owner. In other words, once the decision has been made to use metal building materials for your roof or wall project, the next step is figuring out how to hold it all together.

Know Your Fastener Options

Before selecting fasteners for the project, it is important for the designer or installer to understand the various materials and options available. Typically, this involves the following considerations:

What type of material and coating is appropriate?
What type of head do I need? Does it need to be painted?
Do I need a washer? If so, what material should I use?
Should I use self-tapping or self-drilling screws?
What thread count should I specify?
How long does the fastener need to be?

The MCA provides a summary of the different types of fasteners in their technical bulletin, Fastener Compatibility with Profiled Metal Roof and Wall Panels.

Select a Fastener on the Basis of Material

Most fasteners are made from coated metal but both the type of metal and coating must be chosen on the basis of the materials the fastener is bringing together. Galvanic action between dissimilar metals can cause premature fastener failure and lead to leakage. Even stainless steel screws will corrode severely under the right (or actually wrong) conditions. In extreme exposure, sometimes the best option is to use galvanized screws and plan on replacing them at a later date with a larger screw once the zinc has been depleted.

Considerations for Self-Drilling Screws

Self-drilling screws have a drill bit built in and don’t require a pre-drilled hole. Although self-drillers save the installer the step of drilling a hole, they are not always a good idea. The available space between the back of the hole and the next physical restriction must be at least as big as the bit itself or the threads will not engage. Also, drilling a hole allows a quick inspection to ensure the hole is in the correct location and plies are aligned and parallel. Generally, self-drillers are used when going through thin gauge steel into thicker gauge steel and self-tappers are used when fastening two thin gauge plies.

Washers

Fasteners may be used with or without washers. While plastic washers help prevent leaks, they are not required on purely structural connections. When using washers, it is important to visually inspect the screw after installation to be sure they are properly compressed and not kinked. Exposed plastics generally degrade when exposed to ultraviolet light. Furthermore, use of neoprene washers may be prevented by restricted material lists, or “red lists.” Fastener heads themselves may be made of different materials than the rest of the screw, long-life ZAC heads being the most common example.

Fastener Profiles

Fasteners have different profiles. Flat or “pancake” screws are used when low profile installation is necessary and may have Philips, hex, or Torx sockets. Which socket to use is usually an installer’s preference based on accessibility restrictions. Another common feature is an over-sized dome beneath the head to encompass a larger washer. Also called shoulder screws, these screws are useful when thermal movement might distort the holes.

Fasteners can also be colored to match the roof or wall panel.

Thread Count per Inch

Thread count per inch, or TPI, must also be considered. Most commonly, fasteners are installed through the thinner ply first and grip in the thicker ply, pulling the plies together. Therefore, TPI selection is usually driven by the thickness of the thicker ply. Generally, the TPI is close to the gauge of the metal for gauge steel and higher for plate and sheet.

Length

The fastener must also be long enough to fully engage all plies of material, plus the length of the drill bit in the case of self-drillers. Generally, this is rounded up to the next half or quarter inch. However, the longer the screw, the more torsional strain is produced during driving and in the case of very long fasteners, this can break the fastener or introduce wobble, leading to poor installation. Therefore, stainless steel with over-sized washers is often used for long screws for added strength and protection.

For More Information on Fastener Compatibility

To learn more about fasteners and their compatibility with different types of metal roof or wall panels, check out Metal Construction Association’s recently published technical bulletin, Fastener Compatibility with Profiled Metal Roof and Wall Panels.

A Storehouse of Storage Solutions

Posted on October 7, 2016March 29, 2022 by Jeremy Silverstein

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.

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.

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.

Nice Curves! Stunning Architecture with Curved Roofing and Walls

Posted on September 30, 2016March 29, 2022 by Shelby Shipman

Breaking away from simpler panels, more and more architects are experimenting with arched and curved metal roofing and wall panels to upgrade their designs. This enables designers to incorporate exciting elements like concave and convex curving, not as feasible with other cladding materials.

Combined with unique angles, increased edge finishing options, appealing gutter options and greater compatibility with shingle types, architects now have access to a greater assortment of mix-and-match options.

For example, at Owens Community College in Findlay, Ohio, a regal red, double-curved canopy crowns the curtainwall with 15,500 square feet of 22-gauge curved metal roof panels. Designed by Rooney Clinger Murray Architects, the structural roofing panel system, fabricated by MBCI, is ASTM tested for air infiltration and water penetration, and incorporates a 2-inch tall standing seam that was field seamed during the installation process. The contractor, Charles Construction Services, won the American General Contractors (AGC) Build Ohio Award for “New Construction Under $10 Million.”

For Owens Community College, the Curved BattenLok® metal panels in red accentuate the arch of the campus, making it the focal point of the building.

Another noteworthy curved design example is the Central Los Angeles Area High School #9, designed by HMC Architects. “Metal enabled us to clad buildings of different geometries, including curved geometries, in one material, while also giving them a special appearance,” reported Kerstin Kohl, spokesperson for the project’s design architect, COOP HIMMELB(L)AU, in a Metal Construction Association case study, Steeling Art for Students.

Using CAD and BIM for Curved Metal Panels

For designing and fine-tuning curved metal creations, the latest CAD and BIM features are key tools for architects.

In creating the “geometry that has been freed from the relentlessness of the orthogonal layout,” as described by Mark Dewalt, AIA, principal at Valerio Dewalt Train, in a recent article in Metal Architecture magazine, New Trends in Metal Architecture, designers are using CAD in shop drawings to support unique façade fabrication.

“The use of computer design to warp and twist and perforate will give metal greater longevity, added Kevin Marshall, AIA, LEED AP BD+C, associate architect, Integrated Design Solutions.

Similarly, BIM software is further supporting enhanced compatibility with metal roof and wall designs with newer features such as automated light gauge steel wall framing work and the ability to more easily configure supporting structures, openings, complex L or T connections and service hole positions while providing photorealistic renderings so that the client can see exactly how their building will look once built.

West Haven City Hall combines MBCI’s Curved BattenLok® in Copper Metallic with Artisan® Series and Flat Sheet.

Ensuring a Tight Building Enclosure with Curves

As with any roofing type, designing and installing a tight building enclosure for curved roofing and walls is essential for delivering a high performing building.

For starters, architects must choose an appropriate vapor retarder, especially in cooler climates and interior relative humidity levels of 45 percent or greater. Also, buildings with high humidity interiors and construction elements that may release moisture after the roof is installed–such as interior concrete and masonry, plaster finishes and fuel-burning heater– require special considerations when choosing vapor retarders.

With utility clips, some curved panels will lay tight to the wood deck, but if tin tabs are used to attach the moisture barrier to the wood deck, then they will need to be covered to prevent the tabs from rusting the back side of the panels. Similarly, plastic washers may not be the best option as they run the risk of impacting the panels, resulting in undesired aesthetics. Rather, peel and stick membranes are a preferred underlayment because they eliminate the potential of underlayment fasteners penetrating or dimpling the panels.

A Savvy Look for Design

Whether it’s wavy, circular or some other exciting soft geometric shape, curved metal roofing and walls open up all kinds of new design possibilities. Out of the box, literally, architects are actively producing exciting, eye-catching creations with these welcomed capabilities.