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Roofs and Walls: The Metal Option

Building Operating Management, Sep 2005

Life-cycle costs, aesthetics make metal worth a close look

Most facilities executives know that metal is strong and durable. Few, however, are aware of metal's other important facility-related qualities. When used for construction projects, metal is attractive, long-lasting, environmentally responsible and requires little maintenance. Equally important, the cost of installing and maintaining a metal roof or wall system compares quite favorably with other materials when total life-cycle costs are considered.

About 20 percent of U.S. commercial roofs and 23 percent of walls are metal, says Greg Crawford. executive director with the Cool Metal Roofing Coalition and vice president of operations with the Steel Recycling Institute.

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The fact that metal has a lower market share than other roof types is a result of various factors. In some parts of the country, metal simply hasn't developed the following that other building materials have, says Toy Henson, general manager with MBCI. In the southwestern United States, for instance, metal is used in many building applications. On the other hand, builders in the Northeast and Upper Midwest aren't as accustomed to using metal in their projects.

More significantly, some facilities executives have formed misperceptions about metal. Many assume that it is more costly than other materials - an assumption that doesn't hold when life-cycle costs are considered. Few facility executives are aware of the range of colors and designs in which metal is available. Some assume that it will rust within a year or two; in reality, metal roofs can last for decades. Finally, few facilities executives realize how little maintenance metal roofs require.

One of metal's qualities that most facilities executives do understand is its durability. It's not unusual for metal roofs to last well over 30 years, says Dave Evers, vice president of research and development with Butler Manufacturing.

In fact, some metal roofs still are going strong after a century, says Kevin Corcoran, vice president of business development with Englert.

According to a low-slope roofing life-cycle cost analysis completed by Ducker Worldwide in October 2004, the expected service life of a metal roof was 40 years. That compares with 23.2 years for built-up/modified bitumen roofs and 19.6 years for single-ply roofs.

The Right Coating

Usually, rust doesn't play a significant role in shortening the life of steel roof and wall systems. That is, as long as the metal used in a building project has a quality, galvanized coating appropriate for the environment, it should remain rust-free, says Dick Bus, president of ATAS International and president of the Metal Construction Association.

Facilities executives will want to look for what's known as a G90 galvanized coating, says Bus. During galvanization, a coat of melted zinc is applied directly to the steel, protecting it from corrosion.

Choosing the proper type of metal with the appropriate coating is critical to ensuring a long life. For instance, metal roofs or walls on facilities that will be located within environments exposed to salt, such as those near an ocean, should use aluminum or a steel coating with a zinc and aluminum alloy - known as galvalume. Buildings located in industrial areas, where they'll be subject to acid rain, should be coated with either aluminum, zinc or copper, says Bus.

Also contributing to metal's durability is its ability to withstand impact. Roofing materials are classified by Underwriters Laboratory according to their ability to resist impact; Class 4 roofing materials rank highest. All metal roofs are Class 4, says Bus. Some insurers offer a discount from premiums when insuring buildings with Class 4 roofs, Bus says.

Little Work

Another benefit of metal roofs and wall systems is that they require little maintenance. Most of the precipitation with which the roof or exterior wall system is likely to come into contact will simply run right off, provided the metal is installed at an appropriate slope, says John Pflugh, senior product engineer with CENTRIA.

Snow and rain don't stick to the metal surface because of the durability of the coatings, says Crawford. "It's due to the hardness of the surface at the atomic level, where there's very tight bonding that resists soiling."

As a result, maintaining a metal roof or wall system only requires facilities executives to inspect the metal twice each year. One inspection should occur in the spring to determine whether winter's ice and snow have damaged the roof. Another inspection should occur at the end of the summer. Here, the inspector is looking for any indications that summer storms or winds have loosened the fastenings connecting the roof to the rest of the building.

The differing maintenance requirements of various roofing materials have a direct impact on the bottom line. Some surveys have shown that the cost of maintaining asphalt roofs ranges from 5 to 15 cents per square foot, per year with costs typicalIy rising as the roof gets older. That compares with about a penny per square foot for many metal roofs.

Business Services Industry

Roofs and Walls: The Metal Option

Building Operating Management, Sep 2005

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