1. Introduction
Metal clad building components—like metal clad walls, roofs, and siding—are increasingly popular for everything from sleek steel clad houses to industrial metal clad sheds. Whether you’re working with corten steel facade panels, zinc clad dormers, or aluminum clad electrical wire, these materials offer strength and style. But they also bring unique challenges. From corrosion concerns to wiring code compliance, knowing how to troubleshoot common problems saves time, money, and headaches.
2. Problem: Rust or Corrosion on Metal Clad Surfaces
Even durable options like clad steel or corrugated steel facade can develop rust if improperly installed or exposed to harsh environments without proper protection.
- Always choose the right metal clad type for your climate (e.g., zinc metal siding or copper siding for coastal areas).
- For existing rust, clean the area with a wire brush, apply a rust converter, then repaint with a high-quality metal primer and topcoat.
- Consider pre-finished options like Colorbond standing seam or PAC Clad HWP, which include factory-applied protective coatings.
3. Problem: Condensation Behind Metal Clad Walls or Roofs
Metal clad insulation is critical to prevent moisture buildup, especially in metal clad buildings with poor ventilation.
- Install a vapor barrier between the interior wall and the metal cladding.
- Use insulated metal panels or add rigid foam insulation behind exterior corrugated metal siding.
- Ensure adequate roof ventilation if you have a metal clad roof—ridge vents and soffit vents help airflow.
4. Problem: Difficulty Installing or Cutting Metal Clad Components
Working with thick steel plate or aluminum clad sheet can be tricky without the right tools.
- Use a metal-cutting circular saw or nibbler for clean cuts on metal clad siding or vertical standing seam metal siding.
- Wear safety gear—metal shards and sharp edges are common hazards.
- For precision, mark cut lines clearly and clamp the material securely before cutting.
5. Problem: Electrical Code Confusion with Metal Clad Wiring
Many DIYers wonder: ‘Can metal clad wire be used outside?’ or ‘Do I need AFCI breakers with armored metal clad cable?’
- Metal clad electrical wire (often called MC cable) is approved for both indoor and outdoor use when rated for wet locations.
- In commercial buildings (including Pennsylvania), MC cable is generally permitted per NEC Article 330—but always check local codes.
- Yes, AFCI protection may still be required on circuits—even if they’re in metal conduit or MC cable—depending on the room and local amendments.
6. Problem: Fading or Chalking on Painted Metal Clad Finishes
Over time, sun exposure can degrade finishes on steel facade panels or aluminum clad steel siding.
- Choose PVDF-coated products like PAC Clad standing seam roof systems or zinc clad roof panels—they resist UV damage better than standard paints.
- Clean surfaces annually with mild soap and water; avoid abrasive cleaners.
- Repaint only with coatings specifically formulated for metal substrates to ensure adhesion and longevity.
7. Problem: High Cost of Premium Materials Like Corten Steel Siding
Corten siding cost can be prohibitive—sometimes double that of standard steel options.
- Use corten steel plate selectively as an accent (e.g., on a feature wall or column covers) rather than full coverage.
- Consider alternatives like pre-rusted finishes or textured powder-coated steel that mimic the look at lower cost.
- Get multiple quotes from suppliers of stainless steel plate or clad metals—prices vary widely based on thickness (e.g., 1/8 inch steel plate vs. 3/16 metal plate).
8. Problem: Poor Aesthetics from Mismatched Cladding Elements
Mixing materials like a zinc facade with copper siding or PAC Clad coping can look disjointed if not planned carefully.
- Stick to 2–3 complementary metals max (e.g., aluminum clad stainless steel trim with a steel clad house body).
- Use consistent panel profiles—pair standing seam facade with vertical standing seam metal siding for visual harmony.
- Mock up a small section before full installation to test color and texture interactions in natural light.
9. Conclusion
Metal clad materials—from titanium clad accents to everyday aluminum clad pipe insulation—offer unmatched versatility in modern design. By anticipating these common issues and applying the right fixes, you’ll ensure your metal clad building performs beautifully for decades. Always prioritize proper installation, climate-appropriate material selection, and code compliance to get the most out of your investment.
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