1. Introduction
Just 24 hours ago, a major construction firm in Texas halted work on a $12M commercial complex due to premature corrosion on its newly installed metal clad facade—highlighting how critical proper material selection and installation are. Whether you’re building a metal clad house, renovating a metal clad shed, or installing a standing seam siding system, mistakes can lead to costly repairs.
Metal clad systems offer durability, modern aesthetics, and low maintenance—but only if you avoid common pitfalls. In this guide, we’ll walk you through seven frequent problems and their practical, field-tested solutions.
2. Rust and Corrosion on Exposed Steel
Many DIYers assume all steel is weatherproof. But untreated mild steel plate or boiler plate steel used in a metal clad wall can rust within months—especially in humid or coastal areas.
- Always opt for corrosion-resistant options like corten steel plate, zinc coated steel, or aluminum clad steel for exterior applications.
- For high-moisture zones, consider a zinc clad roof or copper siding—they naturally develop protective patinas.
- Avoid mixing dissimilar metals (e.g., aluminum and steel) without dielectric insulation to prevent galvanic corrosion.
3. Poor Insulation Leading to Condensation
A metal clad building without proper insulation traps moisture, causing interior condensation, mold, and energy loss. This is especially common with metal clad sheds or uninsulated metal clad wall assemblies.
- Use metal clad insulation with a vapor barrier, such as aluminum clad pipe insulation or foil-faced rigid boards.
- Ensure there’s an air gap behind the cladding to allow ventilation—critical for corrugated steel facade or vertical standing seam metal siding.
- Seal all penetrations (vents, windows, doors) with compatible flashing like PAC Clad coping or column covers.
4. Incorrect Fastening and Panel Alignment
Wavy panels, loose seams, or buckling often stem from improper fastening during installation of standing seam siding or exterior corrugated metal siding.
- Use manufacturer-recommended clips (e.g., Snap Clad clips) and allow for thermal expansion—especially with aluminum or zinc metal siding.
- Never over-tighten fasteners; this restricts movement and can crack the metal or coating.
- For PAC Clad HWP or Colorbond standing seam systems, follow exact overlap and clip spacing specs.
5. Mismatched Materials and Aesthetic Clashes
Combining a corten steel facade with a shiny aluminum clad sheet can look jarring. Worse, incompatible metals can accelerate degradation.
- Stick to cohesive palettes: e.g., zinc clad dormer with a zinc clad roof, or stainless clad aluminum accents with a steel facade.
- Understand clad metal meaning: it refers to a composite material (like aluminum clad stainless steel or titanium clad) where a thin layer of one metal protects a stronger, cheaper base.
- When in doubt, request samples of 6061 T6 aluminum plate or 316 stainless steel plate to test color and texture in natural light.
6. Electrical and Safety Code Violations
Using metal clad electrical wire incorrectly is a frequent code violation—especially in commercial builds in states like Pennsylvania.
- Metal clad wire (including aluminum clad steel wire or CU clad wire) must be properly grounded and connected to boxes with listed fittings.
- Surface mounting is allowed, but exposed runs need protection from physical damage.
- Confirm local codes: some jurisdictions require AFCI breakers even with armored metal clad cable.
7. Maintenance Neglect on Specialty Finishes
Corten siding cost may be higher upfront, but skipping maintenance on finishes like electroplating, chromium plate, or gold coating leads to premature failure.
- Clean metal weatherboard or metal clad siding annually with mild soap—never abrasive pads.
- Inspect seams, fasteners, and flashings every 6 months; replace corroded stainless steel metal plate or diamond plate steel as needed.
- For engraved brass plates or nameplates, use non-acidic cleaners to preserve detail.
8. Conclusion
Metal clad systems—from steel clad houses to zinc facade installations—offer unmatched longevity when installed and maintained correctly. By avoiding these seven common mistakes, you’ll protect your investment and enjoy a sleek, modern look for decades. Always verify material specs (like ASTM A387 for alloy plate) and consult professionals for complex builds like steel clad buildings or PAC Clad column covers.
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