1. Introduction
Just 24 hours ago, a major construction firm in Texas halted work on a high-profile metal clad building after unexpected corrosion appeared on its corten steel facade—sparking renewed concern among architects about material selection and maintenance. With metal clad systems growing in popularity for everything from sheds to luxury homes, knowing how to troubleshoot common issues is more critical than ever.
Whether you’re installing a metal clad roof, running metal clad electrical wire, or cladding your home in zinc or aluminum, problems like improper sealing, galvanic corrosion, or cable routing errors can derail your project. This guide walks you through seven real-world problems—and their practical, actionable solutions.
2. Rust and Staining on Corten Steel Siding
Corten steel siding is prized for its weathered look, but premature rust streaks or uneven patina can ruin curb appeal—especially if runoff stains adjacent surfaces.
- Allow proper drainage: Install gutters and drip edges to direct water away from the metal clad wall.
- Use sacrificial barriers: Place non-reactive spacers (like rubber or plastic) between corten and dissimilar metals to prevent galvanic corrosion.
- Accept the process: True corten steel takes 18–36 months to stabilize. Avoid sealants unless specified by the manufacturer—they can trap moisture and worsen staining.
3. Installing and Routing Metal Clad Electrical Wire
Metal clad (MC) electrical cable—often called metal clad wire—is common in commercial and residential builds, but improper installation risks code violations or fire hazards.
- Always use listed MC cable rated for your environment (e.g., wet locations require specific jacketing).
- Secure every 6 feet with approved clamps; never staple through the armor.
- When running through an exterior wall, use a listed fitting (like a compression connector) and seal the penetration with fire-rated caulk to maintain the building envelope.
- Confirm local codes: In Pennsylvania and many states, MC cable is permitted in commercial buildings—but AFCI protection may still be required depending on circuit use.
4. Leaks in Metal Clad Roofs and Facades
Standing seam systems like PAC Clad standing seam or Colorbond standing seam are durable, but poor flashing or seam alignment causes leaks.
- Inspect seams: Vertical standing seam metal siding must be locked correctly—gaps indicate improper tooling.
- Flash penetrations: Use PAC Clad coping or custom flashings at dormers, chimneys, and valleys. A zinc clad dormer, for example, needs compatible sealants to avoid chemical reactions.
- Slope matters: Corrugated steel facade or exterior corrugated metal siding should have a minimum 3:12 pitch unless using specialized low-slope profiles.
5. Painting and Repainting Metal Clad Surfaces
Can you paint metal clad windows or a steel clad house? Yes—but preparation is key.
- Clean thoroughly: Remove chalk, oil, and oxidation with TSP or a metal-specific degreaser.
- Prime properly: Use a rust-inhibiting primer for steel; for aluminum clad steel or zinc metal siding, choose a self-etching primer.
- Topcoat wisely: Acrylic latex or PVDF-based paints (like those used on Colorbond) offer the best UV and fade resistance.
6. Galvanic Corrosion Between Dissimilar Clad Metals
Clad metal meaning refers to layers of different metals bonded together (e.g., aluminum clad stainless steel or copper nickel clad). But when dissimilar metals touch in wet conditions, corrosion accelerates.
- Isolate materials: Never directly fasten stainless plate to aluminum diamond plate without a dielectric barrier.
- Choose compatible systems: A titanium clad or inconel 625 overlay is fine next to stainless steel, but avoid pairing zinc plate with copper siding.
- Use coated fasteners: Stainless steel screws with non-conductive washers reduce risk in mixed-metal assemblies like a zinc facade next to a steel base plate.
7. Cutting and Fabricating Metal Clad Components
Whether you’re trimming a metal clad shed or cutting aluminum clad sheet for column covers, precision matters.
- Use the right tools: For metal sheet cutting, opt for aviation snips (thin gauge) or a plasma cutter (thick steel plate). Avoid abrasive blades—they smear coatings.
- Mind the edges: After cutting 1/8 inch steel plate or 316 stainless steel plate, deburr edges to prevent coating failure.
- Store properly: Keep aluminum 6061 T6 plate and brass plates for engraving dry and separated to avoid surface transfer or staining.
8. Conclusion
Metal clad systems offer unmatched durability, modern aesthetics, and design flexibility—from corten steel siding to PAC Clad HWP roofs. But success hinges on understanding material behavior, following code requirements, and addressing issues early. With these seven solutions, you’ll avoid costly callbacks and ensure your metal clad building stands strong for decades.
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