1. Introduction
In the past 48 hours, a surge in sustainable building practices has spotlighted metal clad exteriors as a top choice for architects and builders seeking durability and low maintenance. With rising demand for energy-efficient and weather-resistant envelopes, understanding how to properly install and maintain metal clad systems is more critical than ever.
Metal clad—also referred to as metalclad—encompasses a broad category of construction materials where one metal is bonded or layered over another to enhance performance, aesthetics, or cost-efficiency. Whether you’re working on a metal clad house, commercial metal clad building, or retrofitting a metal clad shed, this guide delivers actionable steps for successful implementation and upkeep.
2. Understanding Metal Clad Materials and Applications
Before installation, it’s essential to grasp the clad metal meaning. Clad metals combine two or more metals—such as aluminum clad stainless steel or stainless clad aluminum—to leverage the strengths of each. Common types include titanium clad, copper nickel clad, and alloy clad sheets like 2024 T3 clad or 7075 T6 clad used in aerospace and architecture.
For exteriors, popular choices include:
- Corten steel facade and corten steel siding (known for rust-like patina and minimal maintenance)
- Zinc metal siding and zinc clad roof (offering longevity and self-healing properties)
- Copper siding and vertical standing seam metal siding (for premium aesthetics)
- Exterior corrugated metal siding and corrugated steel facade (ideal for industrial looks)
- Colorbond standing seam and PAC CLAD standing seam roof systems (pre-finished, durable options)
Each material serves different climates, budgets, and design goals. For instance, corten siding cost may be higher upfront but reduces long-term maintenance, while aluminum clad steel offers corrosion resistance at a lower price point.
3. Step-by-Step Installation of a Metal Clad Wall System
Installing a metal clad wall requires precision to ensure weather-tightness and structural integrity. Follow these steps:
3.1 Prepare the Substrate
Ensure the wall structure is level, dry, and free of debris. Install a vapor barrier or metal clad insulation (e.g., aluminum clad pipe insulation for thermal breaks) if required by local codes.
3.2 Install Furring Channels or Battens
Attach horizontal or vertical battens to create an air gap behind the cladding. This promotes drainage and ventilation—critical for preventing moisture buildup behind steel facade panels.
3.3 Cut and Fit Panels
Use proper tools for metal sheet cutting. Measure carefully for elements like zinc clad dormer sections or PAC CLAD column covers. Always wear PPE when handling sharp edges of steel plate or aluminum diamond tread plate.
3.4 Secure Cladding
Fasten panels using concealed clips for standing seam systems or exposed fasteners for corrugated profiles. Avoid over-tightening to allow for thermal expansion. Use compatible fasteners to prevent galvanic corrosion—especially when joining dissimilar metals like aluminum clad sheet to stainless steel plate.
3.5 Seal Joints and Edges
Apply sealant at seams, corners, and penetrations. For coping details, use PAC CLAD coping profiles designed for your system. Ensure all joints accommodate movement without cracking.
4. Common Problems and Maintenance Tips
Even high-quality metal clad systems face challenges over time. Here’s how to address them:
4.1 Corrosion and Staining
Galvanic corrosion can occur when dissimilar metals contact in wet conditions. Prevent this by using isolation membranes or selecting compatible alloys like aluminum clad steel wire instead of bare copper near aluminum.
For corten steel siding, avoid runoff onto concrete or light-colored surfaces—it can stain. Install drip edges or gutters to manage water flow.
4.2 Paint Fading or Chalking
Pre-painted systems like Colorbond may fade in UV-heavy climates. Clean annually with mild detergent and inspect for coating damage. Repaint only with manufacturer-approved products.
4.3 Insulation and Condensation
In cold climates, condensation can form behind non-vented cladding. Always integrate breathable membranes and ensure adequate cavity ventilation—especially in metal clad buildings with steel plate substrates.
4.4 Electrical and Safety Considerations
When running metal clad electrical wire through walls, use listed fittings and ensure grounding per NEC standards. Note: metal clad wire (including aluminum clad steel wire or CU clad wire) is permitted in commercial buildings in Pennsylvania and most U.S. jurisdictions when installed correctly.
5. Conclusion
Metal clad exteriors offer unmatched durability, design flexibility, and sustainability when installed and maintained properly. From corten steel facade installations to PAC CLAD HWP roofing systems, understanding material compatibility, proper detailing, and regional code requirements ensures long-term performance. Whether you’re constructing a steel clad house or upgrading a metal clad shed, following these practical steps will help you achieve a professional, weather-resistant finish that stands the test of time.
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