1. Introduction
Just 24 hours ago, a major architectural firm in Chicago unveiled a new sustainable office tower featuring a striking corten steel facade paired with vertical standing seam metal siding—sparking renewed interest in high-performance metal clad systems. As designers and builders seek durable, low-maintenance, and visually distinctive exteriors, understanding the nuances between different metal clad types has never been more critical.
Metal clad isn’t just one thing—it’s a broad category covering everything from building envelopes to electrical cables and industrial piping. In this deep dive, we’ll compare seven major metal clad applications, unpacking their materials, performance, costs, and real-world uses.
2. What Does ‘Metal Clad’ Actually Mean?
Before comparing types, let’s clarify the metal clad meaning. ‘Clad metals’ refer to composite materials where a base metal (like carbon steel) is bonded—mechanically or metallurgically—to a more corrosion-resistant or decorative metal (like stainless steel, copper, or zinc). This process, known as cladding, combines cost-efficiency with enhanced performance.
The term ‘metalclad’ (often written as one word in technical specs) appears across industries—from architecture (‘metal clad wall’, ‘metal clad roof’) to electrical engineering (‘metal clad electrical wire’) and industrial manufacturing (‘clad steel’, ‘aluminum clad stainless steel’).
3. Architectural Metal Clad Systems
3.1 Corten Steel Facade and Siding
Corten steel siding has surged in popularity for its rust-like appearance that stabilizes over time, eliminating the need for painting. A corten steel facade offers exceptional weather resistance and a bold industrial aesthetic.
However, corten siding cost remains high—typically $8–$15 per square foot installed—making it a premium choice. It’s ideal for statement buildings but requires proper drainage to avoid staining adjacent surfaces.
3.2 Zinc and Copper Cladding
Zinc facade systems, including zinc clad dormer and zinc clad roof applications, provide a sleek, modern look with natural patina development. Zinc metal siding is lightweight, 100% recyclable, and lasts 80+ years.
Copper siding shares similar longevity but develops a distinctive green patina. Both are more expensive than steel but offer unmatched elegance and minimal upkeep.
3.3 Aluminum and Steel Standing Seam Systems
Colorbond standing seam and PAC Clad standing seam roof systems dominate commercial and residential metal clad building projects. These use aluminum clad steel or pre-painted steel sheets in vertical standing seam metal siding configurations.
Benefits include excellent water shedding, thermal efficiency, and compatibility with solar panel mounting. PAC Clad HWP (High-Performance Wall) panels and PAC Clad column covers are increasingly used in mixed-material facades.
3.4 Corrugated and Weatherboard Options
Exterior corrugated metal siding and metal weatherboard offer rustic or industrial charm at lower costs. Corrugated steel facade panels are durable and easy to install, often used in metal clad sheds or steel clad houses.
While less refined than standing seam, they’re practical for agricultural or budget-conscious builds. Aluminum diamond tread plate or steel checker plate may also be repurposed for accent cladding.
4. Industrial and Structural Clad Metals
4.1 Clad Steel Plates and Sheets
In heavy industry, clad metal meaning shifts toward performance. Stainless clad aluminum, aluminum clad stainless steel, and titanium clad plates combine strength with corrosion resistance.
Common base materials include mild steel plate or carbon steel plate, overlaid with 316 stainless steel plate, Inconel 625, or nickel alloys. These are used in chemical plants, boilers (boiler plate steel), and marine environments.
Specifications like ASTM A387 govern pressure vessel grades, while alloy plate types—such as 6061 T6 aluminum plate or 7075 T6 clad—serve aerospace and defense sectors.
4.2 Clad Pipes and Insulation
Aluminum clad pipe insulation protects HVAC and industrial piping from moisture and UV damage. The aluminum clad sheet reflects heat and resists weathering, extending system life.
Similarly, aluminum clad steel wire and aluminum clad wire are used in fencing and reinforcement where galvanic corrosion must be minimized.
5. Electrical and Specialty Metal Clad Applications
5.1 Metal Clad Electrical Wire
Metal clad electrical wire (MC cable) features insulated conductors wrapped in an interlocked armor—often aluminum or steel. It’s widely used in commercial buildings, including in Pennsylvania, where code permits surface mounting.
Variants include CU clad wire (copper-clad aluminum) for cost savings, and aluminum clad steel wire for added tensile strength. Always verify local codes—some jurisdictions require AFCI breakers even with metal-clad circuits.
5.2 Other Niche Uses
From metal nameplates made of brass plates for engraving to diamond plate steel sheets for non-slip surfaces, clad metals appear everywhere. Even cookware like All-Clad pans uses aluminum core sandwiched between stainless layers—though that’s a different ‘clad’ context.
6. Cost and Material Comparison Snapshot
- Corten steel siding cost: $8–$15/sq ft
- Zinc metal siding: $12–$20/sq ft
- Colorbond standing seam: $7–$12/sq ft
- Corrugated steel facade: $3–$6/sq ft
- Clad steel plate (e.g., stainless over carbon): 20–50% pricier than base steel
- Metal clad electrical wire: ~$1–$2/ft depending on gauge
7. Conclusion
Whether you’re designing a steel clad building, selecting exterior corrugated metal siding, or specifying clad steel for a refinery, the right metal clad type balances aesthetics, environment, budget, and longevity. From corten steel plate to PAC Clad coping and aluminum clad stainless steel, today’s clad metals offer smarter, more sustainable solutions than ever before.
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