1. Introduction
Just 24 hours ago, a major storm system swept across the Midwest, leaving thousands of metal clad buildings with damaged roofs and compromised siding. Homeowners are now scrambling to assess whether their metal facade held up—or if they’re facing costly repairs. If you own a metal clad house, shed, or commercial structure, knowing how to troubleshoot common problems can save time, money, and stress.
Metal clad systems—whether used for walls, roofs, or wiring—are prized for durability, modern aesthetics, and low maintenance. But they’re not immune to issues. In this guide, we’ll walk through seven frequent problems and provide actionable, step-by-step solutions.
2. Leaky Metal Clad Roof? Check Your Seams and Flashing
Standing seam metal siding and roofs like Colorbond standing seam or PAC CLAD HWP are popular for their sleek look and weather resistance. But leaks often occur at seams, penetrations, or where the roof meets walls (coping).
- Inspect all seams for gaps or lifted panels.
- Ensure PAC CLAD coping and column covers are properly sealed with compatible sealant.
- Replace worn gaskets around vents or skylights.
If you have a zinc clad roof or corrugated steel facade, make sure fasteners aren’t over-tightened—this can deform panels and create entry points for water.
3. Rust or Corrosion on Corten Steel Siding
Corten steel siding is designed to develop a protective rust patina—but sometimes it corrodes unevenly or stains adjacent surfaces. This is especially common in humid climates or near saltwater.
First, confirm it’s true Corten (ASTM A588) and not regular steel mistakenly labeled as such. If corrosion is excessive:
- Clean gently with a soft brush and mild detergent—never use acid-based cleaners.
- Install drip edges to prevent runoff from staining concrete or wood below.
- Consider applying a clear sealant if staining is unacceptable (though this alters the natural aging process).
Note: Corten siding cost is higher than standard steel, so proper installation matters. Always allow airflow behind the metal clad wall to prevent moisture trapping.
4. Electrical Issues with Metal Clad Wiring
Metal clad electrical wire (often called MC cable) is common in commercial builds and some residential retrofits. But mistakes happen—especially when running it through exterior walls or connecting to boxes.
- Never use metal clad wire outdoors unless it’s rated for wet locations (check jacket labeling).
- When connecting to a junction box, use an approved MC cable connector—don’t just shove it in.
- In Pennsylvania and many other states, MC cable can be surface-mounted indoors but must be protected from physical damage.
Also, remember: MC cable doesn’t eliminate the need for AFCI protection in bedrooms or living areas per current NEC codes.
5. Paint Peeling or Fading on Metal Clad Surfaces
Whether it’s a steel clad house or aluminum clad sheet siding, UV exposure and thermal cycling can cause paint failure. Vertical standing seam metal siding may show chalking or flaking at panel edges.
Solution:
- Sand affected areas lightly.
- Clean with TSP (trisodium phosphate) to remove chalk and grease.
- Prime with a metal-specific bonding primer.
- Top-coat with a high-quality acrylic or PVDF finish rated for exterior metal.
For copper siding or zinc metal siding, avoid painting altogether—they’re meant to age naturally.
6. Condensation and Insulation Problems
Metal clad buildings often suffer from interior condensation if not properly insulated. This is especially true for metal clad sheds or warehouses without vapor barriers.
Use metal clad insulation designed for your climate zone. Aluminum clad pipe insulation helps on HVAC lines, but walls and roofs need continuous insulation—like rigid foam behind the metal skin.
Never trap moisture between the metal and substrate. Always include a drainage plane or rainscreen gap for metal clad wall systems.
7. Choosing the Right Clad Metal Type for Your Project
Confused by terms like ‘clad metal meaning’ or ‘alloy clad’? Clad metals combine two materials—like aluminum clad stainless steel or titanium clad—for enhanced performance.
Examples:
- Stainless clad aluminum offers corrosion resistance with lightweight properties.
- Copper nickel clad is used in marine environments.
- 2024-T3 clad aluminum plate is common in aerospace but overkill for homes.
For most residential uses, stick with proven options: corten steel plate for rustic looks, zinc clad dormer for elegance, or exterior corrugated metal siding for affordability.
8. Conclusion
Metal clad systems offer strength, style, and sustainability—but only if installed and maintained correctly. From fixing a leaky PAC CLAD standing seam roof to safely routing metal clad electrical wire, small details make a big difference. Whether you’re building a steel clad inc structure or refreshing a metal clad house, understanding these common pitfalls ensures your investment lasts decades.
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