1. Introduction
Just 24 hours ago, a major storm system swept across the Midwest, causing widespread damage to commercial and residential structures—many of which featured metal clad exteriors. Reports from contractors in Illinois and Indiana highlighted recurring failures in poorly installed corrugated steel facades and standing seam roofs, reigniting discussions about proper metal cladding maintenance and selection. If you’re dealing with metal clad materials—whether it’s a metal clad house, shed, or even electrical wiring—knowing how to troubleshoot common issues can save time, money, and future headaches.
Metal clad (or metalclad) refers broadly to any structure or component where a base material is covered or reinforced with a layer of metal. This includes everything from clad steel beams and metal clad wall panels to aluminum clad pipe insulation and copper siding. Understanding the clad metal meaning helps you choose the right fix for the right problem.
2. Rust and Corrosion on Exterior Metal Clad Surfaces
One of the top complaints with metal clad siding—especially corten steel siding or corrugated steel facade—is premature rusting or staining, even on so-called ‘weathering’ steel.
2.1. Identify the Metal Type
First, confirm whether your metal is truly designed to rust (like corten steel plate) or if corrosion is a defect. Corten siding cost may be higher, but it forms a protective patina. If you see flaking or pitting on stainless steel plate or aluminum clad sheet, that’s abnormal.
2.2. Clean and Seal
- For non-weathering metals like zinc metal siding or aluminum diamond plate, gently clean with a mild detergent and water.
- Rinse thoroughly and apply a clear protective sealant rated for exterior metal use.
- Avoid abrasive pads—they scratch the surface and accelerate future corrosion.
3. Leaks in Metal Clad Roofs
Standing seam metal siding and pac clad standing seam roofs are popular for durability, but improper installation often leads to leaks around seams, flashings, or penetrations.
3.1. Inspect Flashing and Coping
Check pac clad coping and column covers for gaps. Re-seal with butyl tape or compatible metal roof sealant.
3.2. Tighten or Replace Fasteners
Over time, thermal expansion can loosen fasteners in colorbond standing seam or vertical standing seam metal siding. Replace any missing or corroded screws with neoprene-washed variants designed for metal roofs.
4. Electrical Issues with Metal Clad Wiring
Metal clad electrical wire (often called MC cable) is common in commercial buildings, including in Pennsylvania where code permits its use. But problems arise when it’s mishandled.
4.1. Avoid Cutting Damage
When cutting metal-clad cable, use a rotary cutter—not a hacksaw—to prevent nicking the internal conductors. Damaged insulation can cause shorts or ground faults.
4.2. Proper Grounding
Ensure the metal sheath is properly bonded to the grounding system at both ends. Aluminum clad steel wire or cu clad wire must never be used as the sole grounding path unless code-compliant.
5. Paint Peeling or Fading on Metal Clad Walls
Whether it’s a steel clad house or a metal clad shed, paint failure is common if surface prep is skipped.
5.1. Prep Before Repainting
- Remove all loose paint with a wire brush or scraper.
- Clean with TSP (trisodium phosphate) solution to remove oils and chalk.
- Prime with a metal-specific primer (e.g., zinc-rich for steel).
- Use high-quality acrylic or urethane topcoats rated for exterior metal.
6. Thermal Bridging and Condensation in Metal Clad Buildings
Metal conducts heat, so uninsulated metal clad walls or roofs can lead to condensation inside walls—especially in humid climates.
6.1. Add Continuous Insulation
Install metal clad insulation (like rigid foam or mineral wool) on the exterior side of the structural frame before applying the metal skin. This breaks the thermal bridge and reduces moisture buildup.
6.2. Use Vapor Barriers Wisely
Place vapor retarders on the warm-in-winter side of the assembly—never sandwich vapor barriers between two impermeable layers.
7. Choosing the Right Clad Metal Type for Your Project
Not all clad metals are equal. Aluminum clad stainless steel offers corrosion resistance with strength, while titanium clad or inconel 625 overlay suits extreme environments. For residential aesthetics, consider zinc clad dormer accents or copper siding for timeless appeal.
7.1. Match Material to Environment
- Coastal areas: Use 316 stainless steel plate or aluminum 5052 sheet (resistant to salt).
- Industrial zones: Corten steel plate or zinc nickel alloy coatings hold up better.
- High-traffic exteriors: Diamond plate steel or stainless steel checker plate adds durability and slip resistance.
8. Conclusion
Metal clad systems—whether used in a steel clad building, pac clad hwp roof, or even as metal clad wire—offer strength, longevity, and modern aesthetics when properly selected and maintained. By addressing rust, leaks, electrical safety, and insulation early, you’ll extend the life of your investment and avoid costly repairs. Always verify local codes, especially when using metal clad type wiring or installing a metal facade in regulated districts.
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