Metal Wall Panels
By Kenneth King

Metal is a beautiful, versatile, and durable choice for exterior wall cladding. The stunning elegance of metal enhances a design’s enduring appeal with a wide range of panel profiles, materials, colors, and finishes. Additionally, since metal can be curved and formed in ways that traditional wall materials cannot, designers can achieve truly unique aesthetics at an economical price.

Metal roofs have been used in construction for centuries, but metal wall panels are a more recent trend. When metal wall systems became popular in the 1970s, they were typically used in agricultural and industrial settings. Now, however, metal wall panels are enhancing the beauty of all types of structures.
 

Ageless Appeal

Over the years more aesthetically pleasing profiles have been developed and some designs combine aesthetics with functionality. Most wall panels today are available in galvanized steel, galvalume, aluminum and stainless steel. Some are available in more exotic materials, such as copper and zinc.

Material coatings for wall panels offer various aesthetic and functional benefits. Most manufacturers offer a wide variety of standard and custom colors with warranted, weather-resistant coatings such as Kynar®.
 

Panel Types

Most wall panels today are designed to install either vertically or horizontally, with a few exceptions that can be installed in either direction. There are generally two types of metal wall panels - concealed fastener and exposed fastener.

Concealed fastener systems can accommodate thermal expansion and contraction while providing a flush, seamless look. They can be installed over solid substrate or furring channels, and can feature mechanical stiffening plateaus or other mechanical finishes.

Exposed fastener systems offer a variety of profile choices and larger standard coverage widths. When exposed fastener profiles are used, they should be installed with corrosion-resistant steel or stainless steel screws with the heads painted to match the panel color.

Insulated and un-insulated panel systems are also available. An insulated panel, in addition to its added benefit of energy efficiency, also enhances to “smoothness” of the installed panel. Generally, insulated panels are more expensive. However, panels manufactured with a factory-adhered backer-board, such as polystyrene, offer a lower-cost alternative than traditional composite panels to achieve an extremely “flat” installed appearance. This is particularly desirable when designers choose a flush panel profile for the walls of a building.
 

Performance Characteristics

Metal wall panels provide resistance to weather, energy efficiency, acoustic reduction and fire protection.

Panels should be tested in accordance with ASTM E 283 test for air infiltration and ASTM E 331 test for water penetration. Specifications should also require that wall panels withstand the wind loads determined by a manufacturer’s or independent engineer for each individual building.

Some manufacturers offer fire rated wall panels that have UL ratings from 1 hour to 4 hours. These rated panels are not only an integral part of an exterior application, but an important life-safety component for an interior space as well. In some instances where a building houses hazardous or explosive materials, a “pressure release” metal wall system may be used, where the wall is installed with restraining cables to prevent it from scattering during an event, and damaging other parts of the building or surrounding property. Try accomplishing that with a typical drywall or masonry wall construction!
 

Summary

With the total life cycle cost of metal being roughly half that of other construction product, its suitability for roofs and walls continues to grow, particularly on facilities that serve certain industries such as healthcare, education, and government. Metal’s durability, versatility and longevity are extremely attractive benefits to building owners and facilities executive who are driving metal’s exponentially increasing market share.

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