1. Introduction
In the past 48 hours, a major construction firm in Texas halted work on a high-profile commercial project due to premature corrosion on its corten steel facade—a reminder of how critical proper handling and installation of metal clad systems truly are. As architects and builders increasingly specify materials like zinc clad dormers, colorbond standing seam roofs, and stainless clad aluminum panels for their durability and modern aesthetics, understanding common pitfalls is essential.
Metal clad—often referred to as metal cladding—encompasses a wide range of applications, from metal clad walls and roofs to electrical wiring and insulated piping. Whether you’re working with a metal clad house, a steel clad building, or even aluminum clad pipe insulation, knowing how to troubleshoot typical issues can save time, money, and structural integrity.
2. Problem 1: Rust and Corrosion on Exposed Metal Clad Surfaces
Corrosion is a frequent issue with untreated or improperly sealed metal clad siding, especially in coastal or high-humidity environments.
- Always verify the base material: corten steel plate is designed to form a protective rust layer, but standard mild steel plate will degrade without protection.
- For long-term performance, opt for pre-finished systems like zinc metal siding or copper siding, which develop natural patinas that resist further corrosion.
- If using exterior corrugated metal siding, ensure it’s zinc coated or features a factory-applied coating such as Colorbond.
3. Problem 2: Improper Installation of Metal Clad Electrical Wire
Metal clad electrical wire (often labeled MC cable) is widely used in commercial buildings, including in Pennsylvania, but incorrect installation can violate code and create fire hazards.
- Confirm that the metal clad type matches local electrical codes—some jurisdictions require MC cable with an internal bonding strip.
- When running metal clad wire through an exterior wall, use listed fittings and ensure the cable is sealed against moisture ingress.
- Never use aluminum clad steel wire in place of copper-clad (cu clad wire) for grounding unless explicitly permitted by code.
4. Problem 3: Poor Drainage and Water Intrusion Behind Metal Facade Panels
A metal facade may look sleek, but without proper detailing, it can trap water against the substrate, leading to mold or structural decay.
- Install a rainscreen gap behind all metal clad wall systems, including corrugated steel facade and standing seam facade panels.
- Use PAC CLAD coping and column covers with integrated drip edges to direct water away from joints.
- Seal penetrations with compatible sealants rated for metal movement and UV exposure.
5. Problem 4: Thermal Bridging in Metal Clad Insulation Systems
Metal conducts heat efficiently, which can undermine energy efficiency if not addressed in metal clad insulation assemblies.
- Specify continuous insulation (ci) behind aluminum clad sheet or stainless steel metal plate cladding.
- Avoid direct contact between interior framing and exterior metal by using thermal breaks.
- For aluminum clad stainless steel or stainless clad aluminum composites, ensure the insulation layer meets local R-value requirements.
6. Problem 5: Mismatched Expansion Rates Causing Panel Warping
Different metals expand and contract at varying rates. Combining, for example, a titanium clad element with a zinc clad roof without allowances can lead to buckling.
- Use compatible fasteners and allow for movement in all directions—especially with vertical standing seam metal siding.
- Avoid rigidly fixing large metal plate sections; instead, use slotted holes or sliding clips.
- When working with alloy clad materials like 2024-T3 clad or 7075-T6 clad aluminum, consult manufacturer guidelines for thermal movement allowances.
7. Problem 6: Aesthetic Inconsistencies in Mixed Metal Clad Applications
Combining materials like corten steel siding and a zinc clad dormer can create visual discord if not planned carefully.
- Create a mock-up before full installation to assess color, texture, and weathering compatibility.
- Understand long-term appearance: corten siding cost may be justified by its evolving rust patina, but it won’t match the bluish-gray of a zinc facade over time.
- Use consistent joint detailing across all metal weatherboard and metal clad siding elements for a cohesive look.
8. Problem 7: Difficulty Sourcing or Cutting Specialty Metal Plates
Projects often stall due to confusion around metal plate specifications—such as 1/8 inch steel plate versus 3/16 metal plate—or inability to cut thick steel plate accurately.
- Source from reputable stainless steel plate distributors who provide mill test reports for grades like 316L SS plate or ASTM A387.
- Use CNC metal sheet cutting services for precision on materials like aluminum diamond tread plate or perforated plate.
- For on-site modifications, use cold-cutting tools to avoid warping heat-treated plates like 4140 steel plate or Inconel 718 plate.
9. Conclusion
Whether you’re constructing a steel clad house, retrofitting a metal clad shed, or installing PAC CLAD HWP roof systems, anticipating and solving these common problems ensures longevity and performance. Always verify the clad metal meaning in your context—whether it refers to architectural cladding, electrical wiring, or composite metal sheets—and select materials like aluminum clad steel or copper nickel clad based on environment, code, and design intent. With careful planning and attention to detail, metal clad systems deliver unmatched durability and modern appeal.
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