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Alignment Tolerances of Substrates for Metal Panels

Posted on March 8, 2017 by MBCI

Installers take note! It is your responsibility to ensure the substrate material over which you place the metal panels is in proper alignment before beginning installation. Otherwise, you can suffer some significant negative impacts on the overall appearance of the system.

As we’ve discussed in a previous blog article, Choosing Proper Substrates for Metal Roofing Systems, the substrate (or substructure) rests underneath the metal panels is a key part of the roofing or wall system. It serves two main functions: to act as a base to which the metal material is attached and to serve as a structural member to transfer loads to the primary framing system.

Knowledge is Power

Too many times, inexperienced metal building sheeting installers or sheeting-only contractors may not realize how big an impact alignment can have; it’s very easy to get too far into the process before recognizing there’s a problem. The issues must be dealt with at the very beginning of the process as well as the way through the installation of the panel system, whether it’s roof or wall panel installation, and must be checked frequently.

Major Misconception

One common misconception, especially for those new to the panel system, is that aesthetic anomalies are a result of panel quality. When troubleshooting, the manufacturer will ask a series of questions about the installation and alignment. However, by that stage, the installer may be beyond the point where it’s an easy fix, depending on the circumstances.

Key Considerations

Understand the general panel installation characteristics by reading the installation manual. Become familiar with which screws and clips to use, and how the panels physically connect as well as types of insulation systems that work well with the panel system and if there are any limitations related to insulation types or thicknesses.
Installers must be certain that the substrate material they’re installing over, whether metal or wood or something else, has been properly erected and properly aligned before panel installation begins.
As they’re putting the panels over the substrate, installers should be checking the alignment, whether vertically/horizontally along the leading edge of the panel or inward and outward on the panel itself. With most metal panels, major variances in the substructure will cause the panel to accentuate any errors. As a result, the panels will look unattractive and be difficult to install.
When the panel installation first begins, the installer might not immediately recognize there’s a problem. A variance in the steel or in the substructure can have a big impact, which won’t be known until it’s too late. As an example, consider erecting half a wall on a cloudy day without checking alignment. At the end of the day, it looks fine, but the next day when the sun is shining on it, the “aesthetic delights” due to misalignment are obvious.
Check panels during installation for any damage due to handling, surface irregularities and how it engages or lays on the steel. Do not install any “suspect” panels and contact the manufacturer as needed.

Types of Problems with Alignment

Different types of panels can react differently to a substructure out of alignment. Some are more forgiving, and some are terribly unforgiving.
Overdriving fasteners combined with improper alignment is a killer 1-2 punch.
If alignment is not properly addressed/corrected prior, installers often try to push and pull the panel out of plane, resulting in “oil canning,” a common rippling effect that occurs with improper installation. It should be noted, this often is a direct result of the substrate and/or improper installation and does not have any bearing on performance, weather-tightness and warranty. It doesn’t look nice but is not a cause for rejection.
If the steel is out of alignment, the panels can be difficult to engage and perform the way they should.

What Can You Do?

Using a level, laser or a string line, an installer can measure/check the amount that the substructure is either going in or out of plane and correct as needed. For instance, the plane is zero mark-perfectly plumb, perfectly level. There’s an allowable tolerance that the substructure can be out of plane and still be acceptable. Manufacturers often publish recommended tolerances that should always be reviewed. The preferred tolerance being convex (outward) and never concave (inward).

Other Considerations

The main takeaway here is that steps should be taken to prepare a substructure to properly receive the metal panels. Then, diligently check as panels are being installed to ensure proper alignment is maintained and the installer is not inadvertently pushing and pulling them out of alignment, which could result in less than favorable final appearance.

Tips for Installing Metal Roof Curbs

Posted on January 25, 2017 by kbuchinger

Metal roofs made from galvalume-coated steel provide great corrosion resistance and can readily satisfy a 20-year weather-tightness warranty. However, when a large penetration in the roof is needed, such as a large exhaust fan or other equipment, the integrity of the roof can be compromised if not addressed properly. The common method of dealing with large penetrations (i.e., spanning over one or more standing seams) is to install roof curbs that form the transition between the roof and the equipment being installed.

Of course, like most aspects of building construction, there are choices available in materials, methods, techniques, and styles of installing a roof curb. When the key objective is to provide a curb that will perform for the entire life of the standing seam roof, there are four key points to keep in mind.

Roof Curbs for Standing Seam Metal Roofs

Pick the Proper Material:

A galvalume-coated roof doesn’t mean that a galvanized steel roof curb is the best thing to use – in fact, galvanized roof curbs are known to rust, corrode, and leak, particularly along weld joints, as soon as a year after installation. Instead, a curb made from aluminum (preferred) or stainless steel should be used to prevent premature corrosion. To put any concerns about dissimilar materials and galvanic corrosion to rest, keep in mind that galvalume is approximately 80 percent aluminum by volume, so they are highly compatible.

Rusted Welds on a Galvalume Roof Curb

Use the Proper Roof Curb Type:

It is not uncommon for a roofer to choose a curb type referred to an an “over/over” curb, meaning that, after the opening is cut, the curb is installed over the roofing on both the upslope and the downslope sides. This might be the easiest to install during construction, but it will very likely create more work and callbacks when the upslope side starts to get water into or under the joint, and leaks. Instead, it is well worth taking a few extra minutes to install an “under/over” curb, which places the upslope side under the roofing in a true shingled lap between the curb and the roof. This way, the upslope edge is much more protected and less likely to leak using the same shingled condition occurring on the downslope side – all creating a properly water-shedding, weathertight condition.

Provide the Proper Water Flow Clearance:

We all know that water seeks the path of least resistance, so the key to keep water flowing down a roof is to avoid creating pockets of resistance. This is particularly true on the upslope end of a curb as well as on the two sides parallel to the slope of the roof. A curb with a minimum clearance of 12 inches between it and any other object on the upslope end will give water enough room to flow around the curb easily. Similarly, once the water reaches the two sides, at least 6 inches of free clearance is needed (i.e., without being encumbered by standing seams or other features) to allow the water to keep going and not back up to create a water head at the upslope end of the curb. Simply put, clearance means free-flowing drainage; lack of clearance can mean water buildup and leaks.

Install Roof Curbs Rib to Rib:

Installing curbs that rest in the flat, lower, panel area of metal roofing invites water tightness problems since the curb now has to be installed and sealed in the most vulnerable area – the surface where rainwater flows. Instead, coordinating the curb size with the rib spacing to provide a rib-to-rib curb eliminates fasteners down both sides of the curb in the pan of the roof panels. Placing the curb on and attaching it to the ribs also allows better transitioning from under the roofing on the upslope end to cover the roof on the downslope end. This type of curb has the added benefit of being able to be installed either during the roof installation of after the roof is finished.

Taking these four points into account in your next metal roofing project where roof curbs are required will help assure a well-installed, weathertight condition that should last just as long as the metal roofing system itself.

Roof Penetrations Made by Non-roofing Contractors

Posted on December 20, 2016May 2, 2023 by kbuchinger

In our last two posts, we have looked at the proper ways for roofing contractors to address different types of penetrations in metal roofing in order to assure that a watertight seal is achieved from the outset, as well as over the life of the roof. But what happens when another contractor, such as a plumber, electrician, or other trade needs to penetrate the roof? How is the watertightness of the roof assured then?

Warranty Control for a Metal Roof

Most metal roofing warranties are very specific about what is included or not included should a roof leak occur. Therefore, the manufacturer’s warranty should be the first thing that is checked for a particular project to determine whether a seemingly innocent bit of work on the roof has the potential for a loss of warranty coverage. Commonly, qualified roofing contractors need to do the work and it needs to be inspected, but in some cases, supervised work may be acceptable too. Either way, any penetration installed by a trade contractor other than a roofing contractor should be fully coordinated with the architect or owner’s representative, the roofing manufacturer’s representative, the general contractor, and the roofing contractor. Once reviewed, there may be several options on how to proceed.

Guided Installation

For a single or simple penetration, say for a single small mechanical or electrical line, it may be possible to simply work with the trade contractor on the location of the penetration, review in advance that the proper materials are being used, and check the quality of the work for water tightness when complete. (Note: following the guidelines in our prior post on Pipe and Flute Penetrations will provide a good checklist of things to cover.) If everything is appropriately done, then it may be possible to have the roofing manufacturer add the new penetration to the list of items covered under the warranty.

Lightning Rod Application for Metal Panels

Coordinated Installation

In some cases, numerous penetrations may be required, such as the installation of multiple lightning rods across a roof. In this case, it might be more prudent to consider a coordinated, cooperative effort to allow each trade to do what it does best and keep the warranty in effect. Instead of an electrician being responsible for the roof penetrations and for lightning rods, let him focus on the lightning protection and wiring aspects of the work. But first, bring in a roofing contractor to advise on the proper locations of the lightning rods and to be the one responsible for the watertight seal. Location advice would include things like avoiding valleys, standing seams, or other areas that are difficult to seal or flash around. The electrician could then make the needed lightning rod penetrations in the agreed-upon locations and complete his work. Following right behind, the roofing contractor could install retrofit rubber roof jacks around the lightning rods and assure that they are sealed properly. Alternatively, the roofing contractor could make the penetration and allow the electrician to install the lightning rod, while the roofing contractor installs an appropriate rubber roof jack over or around it. Either way, the two trades need to review the process ahead of time and be sure that everyone is on board to produce the best results for everyone involved.

Bottom Line: Think Through Penetrations

Standing Seam Roof Penetration

Standing seam metal roofs have become more complex in recent years, with more and varied types of roof penetrations. This simply magnifies the need for better communication between the design professional, roof manufacturer, general contractor, roofing contractor, and any of the various trades that might be working on the roof.

When everyone takes the time to plan up front and think through their own needs and the options to get there, everyone wins. The architect/owner representative can ensure that his or her clients get a roof that will perform long-term. The roof manufacturer is able to provide expertise that has been gained over a long period of time through working with similar details on roofs all over the country. The roofing contractor can leave the project knowing that the details are long-term and will mean little chance for leak callbacks. Plus, the general contractor and the building owner can quickly resolve any arguments over which trade is responsible for repairing a roof leak.

Structural Penetrations in Standing Seam Metal Roofs

Posted on December 8, 2016 by kbuchinger

In our prior post on “Pipe Penetrations in Standing Seam Metal Roofs,” we identified important guidelines for when pipe penetrations are made to metal roofing systems, typically after the metal roofing is installed. That means an opening is cut in the metal roofing, it is properly flashed or sealed, and the penetrating member is passed through it. However, some penetrations are already in place before the roofing contractor shows up. These can be things like vertical members resting on the building structure that support a platform for HVAC equipment above the sloped roof. Or, it can be parapet wall with offsets or other conditions that are already in place. In cases like this, a different approach is needed to assure that the roof remains watertight.

Equipment Platforms for Structural Penetrations

Structural Penetrations in Standing Seam Metal Roofs

From the standpoint of a roofer, a structural equipment platform is a pre-existing condition. The metal roofing industry already recognizes the need to address such situations, particularly on existing buildings, by offering retrofit flashing and curb products. The same, proven approach can be used when pre-existing conditions are encountered on new buildings as well. For example, when structural posts for equipment platforms are encountered running up through the roof plane, roof jacks and curbs specifically designed for retrofit applications should be used. The retrofit roof jack, or boot, should be made out of rubber and be designed to install around the penetration, rather than over it. The boot should ideally rest on a two-piece retrofit pipe curb which can span across one or more standing seams and create a smooth, flat surface for the boot to be attached and sealed. The two-piece design allows for the pipe curb to be properly shingled on the up slope and down slope side of the roofing, thus preventing a “backwater lap,” which will leak. Trying to use only products intended for new construction on such conditions will require unwarranted field modifications or an over-reliance on caulking and sealant, all of which can be prone to problems and failure of the watertight abilities of the roofing.

Parapets

The use of parapet walls around some or all of a perimeter of a building is a common condition. However, if the building shape varies, and the parapet along with it, then there may be some rather uncommon conditions in which the roofing meets an offset or irregularly shaped parapet walls. The issue is that water coming down the sloped roof runs into the offset or other obstruction, causing a buildup of water and a potential leak. The typical approach is to provide a cricket, which is flashed into the parapet wall and diverts water away from the corner created by the offset. It is important, in this case, to be aware that standard sheet metal crickets have not proven to be effective. Instead, welded aluminum crickets and fixtures are recommended to create a truly watertight seal. Also, the welded cricket can be “shingled” into the roof to prevent “backwater laps.” The key is to provide a complete seal at the corners by welding the material, which cannot be done with sheet metal crickets.

Design Planning

The best way to address all of the structural roof penetration issues described here is with proper upfront planning. Avoiding any of these conditions would of course be ideal, and perhaps they can be designed out of some projects. However, if they’re unavoidable, then the roofing contractor and the design professionals need to review the conditions together ahead of time. This advance design planning is the best way to assure that the best, most effective detailing is employed and the proper materials are available on site.

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, 2016May 25, 2023 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.

Proper Care and Usage of Roof Seamers

Posted on May 25, 2016 by kbuchinger

As more standing seam metal roofs are being installed than ever before, it is imperative for roofing contractors to have the proper tools when quoting jobs. Remember, a properly formed seam is important for aesthetics, weathertightness and wind uplift. With the right tools in hand for these complex installations, you can get the job done faster, better and with greater cost efficiency than your competitors.

Know Your Type

Seamer use depends on the type of metal standing seam panels on the project: double lock seam, symmetrical seam, one-piece snap-lock interlock and two-piece snap-lock interlock. You will need to identify the type of panel in order to choose the right seamer and confirm that you are using the right seamer for the job. The double lock seam, also known as a Pittsburgh seam, is double-folded, meaning the finishing seam is 180 or 360 degrees. This applies to MBCI’s Double-Lok® and SuperLok® panels. A single-lock seam is 45 or 90 degrees, such as MBCI’s BattenLok® HS and Curved BattenLok®.

Follow Manufacturer Instructions Explicitly

Adherence to the field manual instructions is critical to ensure proper installation that will not result in damage to the seamer and/or panels. It is critical to carefully read the manufacturer’s manual thoroughly before beginning the seaming operation, whether renting or buying the equipment. Not only will this give you the best possible result, but it can also save you the headache of incurring costs of replacing or repairing the seamer due to misuse.

Step-by-Step Guide to Pre-Seaming

Locate field manual in the seamer box and review operational procedures.
Locate power source and check against power requirements in field manual.
Check seams for proper engagement.
Clean dirt, debris and excess sealant from seams and panel surfaces to avoid interfering with the seaming operation.
Panels should be seamed with an electric seaming tool as panels are being installed.

Keys to Seaming Success

The seamer should be supplied or recommended by the manufacturer. Don’t assume another manufacturer’s seamer will work on the panels you are installing. For example, other manufacturers may have a panel similar to MBCI’s BattenLok® HS but that doesn’t mean that an MBCI seamer would work on any of those panels. It is important to use the seamer recommended for the specific product. It must be the proper seam for the engineering. That is if you don’t seam it properly, the manufacturer won’t know if its load charts and tables are accurate.As previously stated, carefully read and follow seamer instructions for proper results. You will need a properly formed seam to ensure you achieve the desired aesthetics and weathertightness as well as mitigating risk from wind uplift. The seamers are miniature roll formers and need to be installed in a very specific way.
Take care of the seamer—don’t leave it out in the rain or in other weather conditions where it could suffer damage.
If not forming seams properly, stop immediately and call the manufacturer or company providing the seamer
If renting, when returning the seamer make sure all equipment is returned, i.e. hand crimpers or hand seamers.

For more information on MBCI seamers, please review the manuals for specific panel types.

Using Wind Clamps to Improve Wind Uplift on Standing Seam Metal Roofs

Posted on May 16, 2016 by Jason Allen

Among the most important factors to account for when specifying a standing seam metal roof are wind control and wind uplift. It is imperative to take the necessary measures to ensure the safety and efficacy of the metal roof. The wind clamp—an extruded piece of aluminum that is placed on the panel seams at clip locations—is one accessory that can be used to improve wind uplift characteristics on metal roofs, delivering substantial time and cost savings as these devices help mitigate risk of wind uplift and improve overall wind design.

Standing Seam Panel Deflection as a Result of Wind Uplift

Why Use a Wind Clamp

A typical failure mode of a standing seam metal roof panel is the clip top pulling out of the panel seam when the panels are subjected to high winds. With a standard install of a standing seam panel, the seams just fold into each other. With enough pressure, wind will force seams to come apart—be it a vertical failure, horizontal movement of the seam or from clip disengagement. The clip top can then pull out of the panel seam.

The wind clamp resists the panel seam being opened, allowing for higher uplift loads. The purpose of wind clamps, in fact, is to prevent failures at the seam openings due to any deflection of the panel. The wind clamps provide more strength, thereby dramatically improving wind uplift performance.

The clamp is installed over the panel seam at clip locations, in the edge and corner zones of the roof. This allows the roof to resist the higher wind pressures in these zones, usually eliminating the need for additional purlins or joists. On large roofs, the savings can be substantial.

Another benefit is shorter installation time. Since additional purlins or joists are typically not required at the edge or corner zones of the roof, the building can be erected faster.

Choosing Wind Clamps

When choosing the type of wind clamp, it is important to consider the type of panel and the special features of the clamps. MBCI, for example, uses S-5!’s patented wind clamps, which work for two panel types—Ultra-Dek® and Double-Lok®. The S-5! wind clamps do not penetrate the steel, thereby eliminating the risks of corrosion and water leakage that can be introduced by a hole in the steel. Since the screws are hidden from the weather elements, it helps to maintain waterproofing.

Quantitative Difference with Wind Clamps

One of the biggest benefits of using wind clamps in the edge and corner zones is that usage minimizes the quantity of purlins needed, resulting in substantial cost savings. For example, let’s look at a comparison using MBCI’s Double-Lok 24” – 24 ga. panels with and without wind clamps.

In this example:

The use of wind clamps in the edge and corner zones eliminated 3,800 linear feet of purlins.
Assuming 8” x 2-1/2” Zee 14 ga. purlins were used, there would be a cost savings of $10,400.

Conclusion

Utilizing wind clamps to protect the investment of a standing seam metal roof can increase strength, make installation faster and lower overall cost.