June Construction Slips 3 Percent

 

New construction starts in June dropped 3% to a seasonally adjusted annual rate of $385.7 billion, according to McGraw-Hill Construction, a division of The McGraw-Hill Companies. Declines were reported for two of construction’s three main sectors – housing and nonbuilding construction. Meanwhile, nonresidential building advanced in June, continuing to show some improvement after extremely weak activity earlier in the year. During the first six months of 2010, total construction starts on an unadjusted basis came in at $199.6 billion, down 4% from the same period a year ago.


The June data lowered the Dodge Index to 82 (2000=100), compared to a revised 84 for May. The Dodge Index had witnessed an extended decline from mid-2006 through early 2009, and since then it has hovered in the range of 82 to 95. “The pattern of construction starts can still be viewed as showing low-level stability, although barely, as June came in at the bottom of the recent range of activity,” stated Robert A. Murray, vice president of economic affairs for McGraw-Hill Construction. “The improvement shown by single family housing over the past year has stalled, at least for the present. With regard to nonbuilding construction, the dollar amount of new electric utility projects has retreated, and it appears that the lift provided to transportation public works from the stimulus funding is leveling off. For nonresidential building, the recent pickup in May and now June suggests that the worst of this sector’s decline may be over. However, renewed expansion for nonresidential building on a sustained basis is not likely in the near term, given such ongoing constraints as tight bank lending, eroding state and local budgets, and sluggish employment growth.”


Residential building in June fell 5% to $118.9 billion (annual rate), with single family housing receding 1% while multifamily housing dropped 24%. From the spring of 2009 through the first quarter of this year, single family housing had shown steady improvement, but during the second quarter activity retreated. Murray noted, “Some of the improvement for single family housing may have been accelerated with the homebuyer tax credits, and their expiration has led to a near-term pause in what is still believed to be an upward trend for homebuilding.” The decline for multifamily housing in June followed four straight months of gains after very depressed contracting at the outset of 2010. The largest multifamily project reported as a June start was the $60 million apartment portion of a $90 million mixed-use building in Washington DC. For the first six months of 2010, residential building was up 23% in dollar terms relative to 2009, with single family housing climbing 27% while multifamily housing edged up 2%. The year-todate increase for multifamily housing was due mostly to a greater volume of renovation work.


Nonbuilding construction, at $110.5 billion (annual rate), decreased 13% in June. Much of June’s decline reflected a sharply lower amount of electric utility construction, which fell 64% relative to a strong May. While June did include the start of a $367 million wind farm in Wisconsin and a $200 million gas-fired power plant in Texas, the boost arising from large projects was down substantially from May. For the public works categories, reduced activity in June was shown by river/harbor development, down 27%; and miscellaneous public works, down 11%. The miscellaneous public works category, which covers such diverse project types as site work and pipelines, did include the June start of a $1.1 billion natural gas pipeline in Louisiana and Texas. On the plus side in June, highway and bridge construction advanced 3%, while larger gains were reported for sewers, up 18%; and water supply systems, up 34%. Through the first six months of 2010, nonbuilding construction was down 10% from the prior year, with electric utilities sliding 35% while the public works categories registered a smaller 5% decline.


Nonresidential building in June grew 9% to $156.3 billion (annual rate). On the institutional side of the nonresidential market, healthcare facilities jumped 59%, boosted by the June start of five projects valued each in excess of $100 million, located in Kansas ($324 million), California ($200 million), Texas ($176 million), Kentucky ($121 million), and New Jersey ($120 million). Murray indicated, “After the steep 33% correction in 2009, the healthcare facilities category is strengthening once again in 2010, helped by healthcare chains bringing deferred projects to groundbreaking, as well as the start of more governmentowned hospitals.” The amusement-related category also had a strong June, surging 85%, with the boost coming from the start of a $500 million renovation project at Madison Square Garden in New York NY. The educational building category in June lost momentum, falling 7%, with the decline cushioned by the start of such large projects as a $177 million medical research laboratory in Worcester MA and a $125 million high school addition and renovation in Mastic Beach NY. Also slipping back in June were transportation terminals, down 5%; and the public buildings category, down 12%.


On the commercial side of the nonresidential market, office construction in June dropped a modest 4%. Large office projects that reached groundbreaking in June included a $70 million data center in Cheyenne WY for the National Center for Atmospheric Research, a $62 million data center in Lakewood CO for the U.S. General Services Administration, and a $54 million upgrade to a federal office building in Chicago IL. More substantial declines in June were reported for stores and shopping centers, down 19%; and warehouses, down 26%. The depressed hotel category was able to report a 61% increase in June, coming as the result of a $172 million post-flood restoration project at the Opryland Resort Hotel in Nashville TN. Also reporting a gain in June was the manufacturing plant category, climbing 55% with the lift coming from the start of a $150 million sugar refinery in Louisiana.


During the first six months of 2010, nonresidential building was down 15% from the same period a year ago. By major segment, the institutional categories fell a comparatively modest 5%, while more sizeable declines were reported for commercial buildings, down 29%; and manufacturing buildings, down 54%.


The 4% shortfall for total construction starts at the U.S. level during the first six months of 2010 compared to last year reflected a varied performance by region. Greater year-to-date activity was reported in the Northeast, up 5%; and the South Central, up 2%. Diminished year-to-date activity was reported in the South Atlantic, down 6%; and the West and Midwest, each down 8%.

 

Source: McGraw-Hill Construction Research & Analytics

 

 

 

Update from the Government Relations Committee of Metal Construction Association

 

 

-- The Senate may take up a bill aimed at small businesses that could include extensions to the cool metal roofing tax credits.


-- Another "extender bill" of some sort is expected during the lame duck session of Congress following the fall elections. If our tax credit has not already been extended by then, it could be in this bill.


-- Sen. Binghamton has introduced an energy bill that contains code language better than what the Home Star bill uses.
 
-- Sen. Lugar has also introduced an energy bill. His office has a good relationship with Sen. Merkley of Oregon. Tom Coleman, MCA's contracted lobbyist on Capital Hill, will inform them of the IMP energy benefit and try to get language in Lugar's bill.
 
-- The Building Star bill is languishing. There is some thought that it might be combined with the Home Star bill. Tom will be working with Sen. Lincoln's office since she sits on two influential committees overseeing these bills.
 
-- There will likely be no appropriation bills signed until after the November elections.
 
-- The REEP bill, first introduced by Rep. Welch, VT, has been combined into the Home Star bill.
 
The Safe Chemicals Act bill is getting more attention now, thanks to the BP oil crisis in the Gulf.  There is growing interest in all types of regulatory legislation, especially on potentially toxic chemicals.  Tom believes this bill will move forward, but not quickly. He is also representing the chemical industry that would be impacted by passage of this bill.  Tom is currently coordinating efforts with the chemical industry and MCA.

 

Source: MCA e-News June 30, 2010

 

 

Color Me Sustainable

Green design would benefit from a richer palette.

By Lance Hosey

 

“Architects are afraid of color,” says Janine James, polymath designer and the founder of the New York multidisciplinary firm The Moderns. “And when architects fear something, they call it uncool.” Whether or not we all suffer from some form of chromophobia, it’s true that architects tend to avoid most of the visible spectrum, with their models of white foam board, gray chipboard, and pale wood, and buildings of concrete, steel … and pale wood. Few architecture curricula even offer, much less require, a course in color theory, a foundational subject of study in most other design disciplines.

 

Sustainability seeks to make design more compatible with nature—and nature without color is, well, virtually nonexistent. Most living things depend on a rich palette to navigate their worlds, and people are no different. Advertisements in color are read up to 42 percent more often than the same ads in black and white, and the human eye can distinguish more than 10 million hues, so it stands to reason that color perception serves a biological purpose. In the mid-1990s, researchers at Texas A&M University studied perceptions of scenic beauty in forest landscapes and found that people invariably were drawn to the green-yellow range of the spectrum. Apparently, we associate verdant colors with food-bearing vegetation—shades that literally nourish.

 

Color can be a subtle persuader or a powerful lure, influencing health, well-being, and mood. In Color and Human Response, Faber Birren notes that red can raise blood pressure, pulse rate, tension, respiration, and perspiration, while blue has the reverse effect. An experiment by interior designer Shashi Caan during a 2006 design show found that the color of a room can influence how much people socialize in it. Other research indicates that people’s perception of temperature can change with the color of a space: Blue-green can lower the comfort range, while red-orange can raise it, by as much as 10 degrees in either direction. Could a savvy color palette reduce reliance on air conditioning and save electricity?

 

But color can aid energy conservation more directly. On a summer day in the South, the surface temperature of a white roof can be 80 degrees lower than that of a black roof, and studies in Florida show that surface reflectivity alone can cut a building’s cooling costs by a quarter. U.S. Secretary of Energy Steven Chu estimates that lightening up the colors of all the roofs and pavement in the U.S. would slash emissions by the same amount as banning all cars for 11 years, a staggering claim.

 

Color can benefit the entire triple bottom line of people, planet, and profit. So why is color selection not normally considered pertinent to sustainable design?

 

Source: architectmagazine.com

 

What Solar Power Has to Offer

 

By Leah B. Garris

 

What makes solar power so appealing?

 

In Wales, while working on ways to make steel more resistant to degradation in sunlight, a Swansea University student discovered a way to make paint harness energy and convert it into electricity. Dr. Dave Worsley, a reader in the Materials Research Centre at Swansea University's School of Engineering, is now investigating ways of painting solar cells onto flexible steel surfaces used for cladding.


In Newark, NJ, New Jersey Institute of Technology (NJIT) researchers developed a solar cell that can be painted or printed on flexible plastic sheets. "The process is simple," says lead researcher and author Somenath Mitra, professor and acting chair of NJIT's Department of Chemistry and Environmental Sciences. He says that consumers will print sheets of these solar cells with inexpensive inkjet printers to create their own power stations.


When it comes to renewable energy, solar power is definitely picking up speed. With more and more buildings taking on this new technology, solar power is becoming realizable for many facilities professionals.


What makes solar power so appealing? For starters, its list of advantages continues to grow. A big one on the list: utility cost stability. "The price of sunlight cannot be raised, unlike the price of oil and gas," says Steven Strong, founder and president of Harvard, MA-based Solar Design Associates. Solar power also leads to pollution prevention if it's a point source, says Gregg Casarrini, market research manager at Conergy Americas, Denver. And, as another added plus, you're not using utility power. You can also take advantage of peak shaving if your load is highest during peak energy-use hours.


Besides the bottom-line and environmental benefits, your organization's corporate image can also profit when you show an interest in renewable energy.


In terms of cost, solar power, according to Casarrini, is more expensive than other renewable options. "But, significant cost reductions are being achieved every year," he emphasizes. "The key is that it can be deployed almost anywhere, whether it's on a customer site or on a utility site. Wind, geothermal, and hydro cannot." Strong addresses the issue of cost by saying that solar power is expensive when you compare it to the cheapest electricity available (from dirty coal). "But, if the system is partly paid through the marketing budget, the media attention per dollar can outpace other marketing techniques, and it generates clean electricity." It's all in how you look at it. Of all renewable-energy options, Strong points out that solar is the most widely distributed when it comes to customer-sited options.


State and local incentive programs can help fund solar projects, but these programs differ significantly. (Strong recommends visiting www.dsireusa.org to learn about these solar programs.) In states that don't offer incentives, initial costs can be pretty high. So, it's a good idea to investigate incentives before you decide whether or not you can afford solar power.


When it comes to knowing whether or not solar will work on your site, Strong says that a "clear, single plane of roof with an unobstructed, un-shadowed view of the southern sky (in the northern hemisphere)" is the best configuration for solar-panel installation. Even though an unobstructed plane is ideal, he says that, with today's modern systems and options, most solar panels can work around some obstructions without severely impacting performance. Strong's helpful hint: Each peak kilowatt of solar-rooftop generation requires between 100 and 120 square feet of roof space.


Casarrini points out that strange or difficult roof angles or gables could complicate installation. "Flat roofs are fine; mounting systems can easily be tilted to the optimal angle," he says.

 

Source: Buildings magazine

 

 

Metal Walls Panels - What's Ahead for IMPs

 

An Industry Perspective - Part III
By Marge O'Connor


In general, the market challenges for metal wall panels are similar to what they have always been – stay a step ahead of the competition, educate buyers and code officials, and support industry research and product testing. But different needs and opportunities lie ahead for specific wall panel segments, say our experts.


“Our industry’s ongoing challenge is staying competitive with other construction products as the cost of all building materials increases. For architects, metal offers what they really want – a high performing product that fits into their design. For installers, metal is easy to use. And for building owners, the driving force is the enhanced building performance and energy efficiency of metal systems. As more people use the Internet to do their product research, metal will be specified in building design and incorporated into the building envelope in many different ways,” says Ken Buchinger, vice president of business development and research and development for MBCI, Houston.


Doug Pickens, vice president of marketing for Metl-Span LLC, Lewisville, TX says that the future is particularly bright for IMPs. “We stand to grow at an even faster rate than that of the last few years, where we had close to 20 percent growth per year before the recession hit. We may see even faster growth rates when the economy comes back, and for a number of years running. But increased government regulation is the biggest challenge for IMPs going forward, particularly in regard to chemical components. Right now chemical companies are working on the next generation blowing agent, which is not a VOC, has virtually zero global warming potential and continues to provide high R values.”


Brandon Wyatt, Marketing Manager, 3A Composites USA (formerly Alcan Composites USA, Inc.), Charlotte, NC, notes that there’s also a great future for MCM panels in saving energy because the finishes have coatings that help create a cooler building. “The evolution of the product will be a driving force for the future of the market – especially in regard to solar reflectivity and energy savings. You see it in MCM on roofs now, but wall panels will become a stronger force in the future.”


Jim Bush, vice president of sales for ATAS International, Allentown, PA also points to sustainability and code requirements as key factors in future opportunities. “We need to stay on top of these, especially in regard to how all of the building materials and components integrate with each other and how, when assembled together, they comply with codes. We need to raise awareness of the science behind wall panel assemblies, such as rainscreens, and create an understanding of the overall building design and how metal wall panels play a role in keeping moisture out and energy efficiency in. When you look at some of the work now being done by ORNL [Oak Ridge National Laboratory] on building envelope research, you see that members of our industry continue to step up to be part of this association-led research that no single manufacturer could possibly do alone.”


For several reasons, renovation and retrofit are prevalent trends for metal wall panels.


Funding to make buildings more energy efficient is more readily available and developers are realizing how retrofit can easily bring an existing building up to code while dramatically improving its appearance.


Bush, who chairs the Metal Construction Association’s Retrofit Task Force, emphasizes that metal is very competitive in retrofit because compared to other methods and materials it is more reliable, installs faster and is less expensive. “Metal wall panels make it easier to add insulation materials to help bring existing buildings into compliance with new energy codes. An existing industrial building can be brought up to standards for mixed use and office space, particularly in areas that are being renovated or gentrified,” he says.


“We are seeing more progressive developers acquiring properties that are in financial trouble and renovating them to bring them up to newer standards and codes. They are turning old commercial properties into new retail or mixed use with residential. As long as the financial situation is good retrofit will remain prominent because it helps developers make better use of existing property,” Bush adds.


The future for metal in retrofit is very bright. From a marketing standpoint, however, when multiple decision makers are involved, reaching the right ones can be a more fragmented, challenging process.


It also opens up business opportunities. “With renovation and retrofit the architects still make decisions because they are pulled into the design. But we usually need to reach all of the players - architects, owners, contractors and developers. Many times contractors are brought in first on retrofits, which opens up a whole new avenue for them to be consultants on these projects. As they work more on the design of retrofit, they have more opportunity to talk with building owners about using it. This also lets them initiate the discussion about using metal wall cladding on the project,” notes Bush.


Along with retrofit, the green building movement is a prime area for metal wall panels, which also are part of “cool” technology. “We’ve heard a lot about cool roofs, but there also are wall systems, such as our Inspire Wall, that add energy savings. In these systems, metal panels are used to collect solar energy for preheating ventilation air providing renewable energy. In this case metal panel systems can provide a payback within 3 to 5 years of installation. So, the metal wall panel actually pays the building owner back,” adds Bush.


But our industry needs to keep metal visible in green building. “Metal is at the forefront of the whole green building movement, and many of us are doing a lot to keep metal there. But more needs to be done in some areas. LCA (Life Cycle Assessment), for example, is more of a challenge for metal products. But that’s where the whole design and build industry is going, so we’ll need to work heavily on that,” says Rick Brow, director of marketing for CENTRIA, Moon Township, PA.


He also points to how our industry needs to play its strong card. “Our industry has always been innovative, but our biggest challenge is gaining acceptance for the innovation. When price becomes a motivator, as it tends to be in this kind of economy, you have to convince the decision makers that metal is a better value than what’s out there,” Brow says.


No matter the challenges and the opportunities the best thing the metal construction market has is the cooperative effort among its many facets to keep metal the best of all construction materials. And the individual manufacturers are maintaining that competitive edge in the way they create products, carry out their marketing programs and continue to keep research and education top priorities.

 

Source: DesignandBuildwithMetal.com

 

 

 

 

 

 

 

Readying Tomorrow’s Architects For The Challenges Of Sustainable Building Design

 

By Scott Kriner, Green Metal Consulting

 

It’s been estimated that 80% of a product’s environmental impact can be determined in the design stage. This is no different in building design. The building industry is looking to designers to lower the impact of the construction phase, the products used, and the long-term operation of structures. Where are these designers? How will tomorrow’s architects become versed in sustainable building design?


Sustainability has been synonymous with “green” for some time. We know that there are big differences between the two words. ASTM defines sustainability as “development that meets the needs of the present without compromising the ability of future generations to meet their own needs”. The “green” market is but one part of an overall sustainability program. And sustainability is definitely becoming more of a Main Street concept. This is especially true as we watch WalMart getting closer to introducing their Sustainability Index on all of their products sold in the stores. One of WalMart’s environmental goals is to cut 20 million tons of greenhouse gas emissions from their supply chain in five years.


To answer the question of how tomorrow’s architects will be equipped to deal in a sustainable world, I traveled to Philadelphia University where my older son is studying Architecture. Actually, the visit was an impromptu thought I had while driving nearby.


As many of you know, stopping in unannounced to see your son or daughter at college can prove to be very interesting – for parent and student. But this visit was a pleasure. My son met me on campus and took me to the design studio where he has been practically living, eating and sleeping for the past four years. There I saw the project he was currently working on. It included a very large and impressive 3-D topographical model of a large wooded area and the models of a dwelling and observation building set in the wooded terrain. Next stop was the computer lab where the Revit images of the structures were revealed, with my son talking about the BIM features of the software. The design of the building included natural ventilation, passive solar heating, sustainable site considerations, natural daylighting and rapidly renewable products. Needless to say, I was a very proud father that afternoon.


Philadelphia University is no different than many other architectural schools across the country. As the green building market emerged, universities adapted by introducing more and more curricula in the field. Colleges began to award Masters degrees in Sustainable Building Design as part of their Architecture programs.


An article in a recent issue of Sustainable Industries magazine showcased several colleges, universities and institutes that had introduced these types of classes and degrees. A list of college courses offered in today’s Architecture program includes titles such as:


• Productivity and Health of Buildings
• Urban Agriculture
• Environmental Economics
• Building Performance Modeling
• Bio Mimicry
• Green Packaging
• Business Case for Sustainability


Dozens of colleges and universities also offer “green chemistry” programs and even provide Ecological Design certification programs. Today’s schools of Architecture offer a variety of themes such as Landscape Architecture, Planning and Public Policy, Indoor Design, and Historic Preservation. In fact, my son has expressed an interest in historic preservation and renovation of buildings as the application of his Architecture education.


The Sustainable Building Design concept has transformed the construction market and also the higher education system in this country. There is hope for the future and it’s in the form of the graduating college classes of 2010 and years to come. One can only dream of what today’s young architects will do with new products, new technologies, new systems and new thinking when it comes to the design of tomorrow’s buildings and renovations. I’m confident that our society will see wonderful and amazing structures that will sustain the sustainable building design concept.

 

Source: DesignandBuildWithMetal.com

 

Targeting Decision Makers


An Industry Perspective – Part 2
By Marge O'Connor


The changing perception of metal panels among decision makers has been influenced by manufacturers’ promotional efforts. These include educating decision makers about metal and delivering messages through the standard methods of advertising, public relations, trade shows, sales calls, lunch-and-learn sessions, and more recently extending it to a wider scope of electronic media.


“Manufacturers in our industry are all astute marketers and have been doing a great job for a long time. But electronic communication now is a very important part of the mix and will continue to be. Five years ago it was less than 15 percent of our marketing program; today it’s substantially more,” notes Doug Pickens, vice president of marketing for Metl-Span LLC, Lewisville, TX.


He also noted several reasons why electronic marketing is growing. “Electronic marketing is faster and typically generates a better return than direct mail, where a 1.5 percent response rate is normal and 6 percent is high. Email open rates are about 25 to 30 for architects and contractors. Targeted emails to an existing customer base can have an open rate as high as 40 percent.”


Brandon Wyatt, Marketing Manager, 3A Composites USA (formerly Alcan Composites USA, Inc.), Charlotte, NC, agrees. He said the new paths being taken to reach decision makers are based in large part on the different methods now available. “The libraries in architectural firms are smaller because specs and design applications are now being data-based and accessed online. The hard cover binders and literature are becoming more scarce as they can go online or pick up a CD or memory stick at a trade show with all the information in downloadable format. One click away is a lot closer than a walk to the archive.”


In addition to communication vehicles, changes in the education needs of decision makers have also occurred. “The AIA’s increased learning requirements have been a good thing. Metal sustainability, for example, is not, specifically taught in all schools and neither is any kind of performance technology for walls and roofs. So manufacturers have been helping to fill that gap with continuing education programs,” says Rick Brow, director of marketing for CENTRIA, Moon Township, PA.


Sometimes, delivering the right message to decision makers requires a mix of old and new tools. For example, if a building owner or contractor does not use the Internet regularly, manufacturers still have to reach them through print magazines or direct mail.


Keeping all options open is important, says Julie Pawuk, Marketing Communications Manager, for CENTRIA. “Many seem to be focused on online communication, but that’s only part of the way to get your message across. Direct mail, trade shows, sponsorships, samples, and literature are still required. It’s a total process of which electronic is only one part.”


No matter the method, educating the building owners and contractors is still a key process, notes Wyatt. “Although the majority of decision-making power rests with the architect, they may be influenced in final product selection by building owners or contractors when the market becomes more cost based as it is in this economy. This has architects researching products when a contractor wants to do a substitution. Or a general contractor may have experience with certain products and encourages the architect to switch out.”


Architects role in the process has had its own evolution, according to Brow. “About 20 years ago, decision-making changed when the emphasis shifted to using contractors’ project managers to oversee the actual construction part of a project. At that point, architects began to focus solely on design. Today architects have moved back into total performance and the science of how to build walls and roofs to meet performance. They also have formed building envelope councils, which are local or regional groups that meet about once a month to discuss how to create better performing buildings.” (Note: The Building Enclosure Council’s Web site is www.bec-national.org)


To get the right message to the right decision makers, manufacturers need to understand the special needs of each group. “Owners rely on performance; architects also want performance but usually put more emphasis on aesthetics. General contractors are ultimately responsible for performance but must follow the specs, so they look at price and liability, along with meeting project specifications. When we design products we consider how they will meet the top three decision factors – aesthetics, performance and sustainability -- to make them attractive to a broader mass of decision makers,” adds Brow.


Jim Bush, vice president of sales for ATAS International, Allentown, PA notes the increased opportunities when contractors are involved. “Sometimes the process includes contractors who specialize in maintenance, and showing them how metal can be used and how they can help building owners with this information. This opens up more opportunities for manufacturers because it goes beyond our traditional sales channels. Add to this the boom in electronic media. That makes our decisions on where to put marketing dollars more challenging. We need to determine how to reach all of the decision makers and that varies by who they are.”


The message is also determined by what materials or products metal may be competing with in a given market.


“In wall cladding we compete with EIFS, masonry, precast, GFRC (glass fiber reinforced concrete) and glass curtainwall. If you compare some metal panel systems to each of these on price only, you’re forgetting the importance of the weight of foundation and framing in certain situations. That changes the price when you look at the total cost of all of the related components. Long-term durability is another big plus for metal; with most precast, for example, you’ll eventually have to repaint and reseal the exterior,” adds Brow.


Pickens agrees: “We may compete with other metal wall products, but brick, block, tilt-up and precast materials are our real competition. For IMPs, energy conservation is the best selling point against these materials because insulation has to be added to each of them and they are composed of multiple components. Both of these factors add cost, particularly for installation/labor. What’s really driving the increase in market share for IMPs, however, is their ability to provide long-term energy conservation. As the cost of energy to operate a building continues to soar, the market for IMPs will grow,” notes Pickens.

 

Source:  DesignandBuildwithMetal.com

 

Wonder Walls - Metal Wall Systems Offer Aesthetics, Durability and Efficiency

 

By Jim Schneider

 

TALKING about metal walls once conjured images of corrugated sheds and rusted-out industrial parks. Those days have long since passed. Today, designers are using architectural metal wall panels to create impressive façades and offer superior performance on buildings of all kinds and in all markets. The benefits of these systems range from aesthetics to durability and energy efficiency.

Several different types of metal wall systems are available to suit the needs of any project. Following are some of the major types of architectural metal wall panel systems available to designers today. Each has its own attributes and advantages to consider when specifying your next job.

PREFORMED PANELS

One of the oldest types of metal wall systems, pre-formed metal wall panels, also known as single-skin metal wall panels, have been in use at least since the 1940s. The panels are most commonly manufactured from coated steel but can incorporate a variety of metal substrates, such as aluminum, copper and zinc.

Typically, a metal sheet is run through rollforming equipment to add ribs or some kind of profile to the material. This shape provides greater strength to the panels and can add aesthetic appeal. To further protect against the elements, metal panels include durable coatings or paint systems that are factory-applied before the panels are formed. The pre-formed and pre-coated panels then are affixed to a building’s structure.

There are two basic types of pre-formed metal wall panels: exposed-fastener panels and concealed-fastener panels. Exposed- fastener panels, because they have visible fasteners, typically are used in industrial applications. Concealed-fastener panels tend to be used in projects with a greater focus on aesthetics.

The panels often are made from a high percentage of recycled content and are themselves fully recyclable. With proper coatings and maintenance, this durable wall system can have a service life of 20 to 30 years. Varied profiles, such as batten, integral batten, corrugated and stepped, can be used to create unique aesthetic looks, giving architects a deep palette of design options. They can be installed horizontally or vertically to achieve a number of different looks.

One of the major advantages of this wall system option is its economy. Because the panels can be installed so quickly, a preformed metal wall system generally is lower in installed costs than a comparable brick, precast or tilt-up application. All-weather installation capability cuts down on construction delays and aids in getting the building in the dry more quickly.

METAL COMPOSITE MATERIAL

Projects seeking a more flat, sleek appearance often turn to metal composite material, or MCM, panels. The panels consist of two relatively thin metal skins bonded to a thin engineered plastic core. The bonding process, which requires precise temperature, pressure and tension conditions, takes place in the plant. Panels are purchased bonded and then routed for forming in the field. A variety of metals, such as stainless steel, zinc, copper and titanium, can be used as the skins on these panels, but the predominant metal used is aluminum.

The core generally is made from a low- density polyethylene. This supporting core helps keep the MCM sheets flat and free of oil canning and other texture imperfections. The panels do not have insulation properties because keeping the temperature the same on the outside and inside surfaces allows the panels to remain flat in all temperature conditions. Temperature variances in the panel can cause thermal bowing. The metal skins can be finished in an array of colors and coatings to achieve the look sought by the project designer.

Because of the precision and consistency MCM has to offer, it often is utilized by designers as an architectural element. However, the material has many other attributes, as well. The panels provide excellent resistance against the elements and, with proper coatings and maintenance, can last for decades and still maintain their original appearance.

The plastic core also means less material is used in the creation of the panels. They are lighter in weight than brick or precast panels, meaning less structural steel is required to support this wall system. In addition, approximately 70 percent of the material used to make an MCM panel is recycled content. In the past, MCM only was used on high- end architectural projects. Today, however, improvements in manufacturing have made the panels more flexible and affordable, so they are seen on a wide array of building types and often are used in conjunction with other materials, such as brick or precast.

 

INSULATED METAL PANELS

At a time when energy efficiency is very much on the minds of building owners, insulated metal panels, or IMPs, are an increasingly attractive option to designers and developers. The excellent thermal qualities of these panels make them a preferred solution for numerous building types, particularly industrial/ commercial applications, cold-storage and high-end architectural projects. Because the insulation is factory-installed under controlled circumstances, the panels are able to provide efficient, uniform thermal performance throughout the entire structure.

 

Insulated metal panels are made up of an exterior metal panel and an interior metal panel with a layer of insulation between, creating a sandwich-like finished product. The core typically is 2- to 6-inches (51- to 152-mm) thick. It is a total-wall system that provides the vapor barrier, air barrier and insulation in one unit. IMPs are available in a multitude of widths, lengths, thicknesses, gauges and finishes. Easy and quick installation attracts many designers and builders to IMP systems. The panels arrive ready to install and are much lighter than tilt-up or precast. They can be erected by a single installer, rather than using multiple trades to install the exterior, insulation and other pieces of the wall system. Because IMPs can be installed quickly, even during inclement weather, construction times and labor costs can be reduced. The panels also are very durable and require little maintenance. High-performance coatings generally are applied to the exterior to protect the panels from the elements. There are two major types of insulated metal panels. One is called a laminated IMP, which consists of a cut piece of rigid polyisocyanurate insulation sandwiched and glued in place between the interior and exterior panels. The insulation is foamed outside the panel and allowed to set into a solid state like a loaf of bread. After it fully cures, it is cut into slabs and installed in the panel with industrial adhesives. The other type, known as foamed-in-place metal panels, involves filling the void between the interior and exterior panels with a type of liquid polyurethane foam insulation, which hardens in place, bonding the panels and forming the completed product.

Although both types offer similar thermal performance—approximately R-7 for every inch of thickness—there are a few differences. The foamed-in-place process lends itself well to the kind of repetitious panel construction found in industrial/ commercial and cold-storage applications. Because the insulation literally is poured into the panel and hardens there, it fills cavities and crevices, which minimizes voids.

 

Laminated IMPs lend themselves well to flat, high-end architectural applications. The insulation is allowed to fully cure before being precision-cut into slabs and then bonded under controlled pressure conditions. This can create a very flat, even surface. Also, if the panel requires a great deal of fabrication, shapes or curves, laminated IMPs are the more common choice.

 

Some myths exist about IMPs. For example, some believe the insulation core absorbs water like a sponge. This is false because the closed-cell structure of the foam in both types of IMPs prevents the panels from absorbing water. Absorption tests have been run on both types of insulation and show less than 1/10 of 1 percent absorption. Another myth is that a laminated IMP will delaminate. The bonding is done with structural urethane adhesives, which are made up of 100 percent solids, as opposed to contact adhesives, which consist of 5 percent solids, so they do not delaminate.

 

Like other metal wall systems, IMPs contain a high level of recycled content and are available in an increasingly wide array of colors, profiles and finishes. The panels can be installed vertically or horizontally to suit the aesthetic needs of a project. Adding to their sustainable appeal, the panels can be removed and actually reused on another project, which prevents them being landfilled.

 

WALL OR NOTHING

Every project has its own sets of goals and requirements, and no one system fits every occasion. Architects, owners and builders must determine what best suits the needs of a particular project. When examining the options, it is clear that metal wall systems, whether pre-formed, MCM or IMP, can offer flexibility and durability and look great while doing it.

 

Source: Metalmag.com

 

Metal Wall Panels — Going from Simple to Spectacular

An Industry Perspective - Part 1

By Marge O'Connor 

 

From their early utilitarian use across America’s farmland to their visibility in today’s architectural masterpieces, metal wall panels have helped build structures and commerce for more than 40 years.

 

The first designs were basic, and communication between suppliers and designers was fairly simple, with education being a key part of the sale. Today the entire process and the end result are much more sophisticated.

 

Designs are highly creative and vibrant. Metal wall panel products are innovative, there is a wider variety to choose from and they are designed to meet today’s high performance building needs. Marketing and communication is multi-layered and in many cases instant. Education remains a huge part of marketing – but is quite comprehensive and delivered through a variety of media.

 

Design Trends

Yes, the industry and its products have come a long way. “In the early years, metal wall panels were typically applied in a vertical manner. There was nothing exciting about these panels for them to compete against other products that were more architecturally pleasing. Now designs are much more interesting. Metal panels are used in all kinds of directions, with multiple profiles placed on one wall. Single skins are combined with MCM, or different styles of panels are used to give a design more definition,” says Jim Bush, vice president of sales for ATAS International, Allentown, PA.

 

The types of panels have grown from just one or two simple styles to a wide variety of different profiles, sizes, colors, metals, and gauges with a much broader spectrum of finishes and coatings.

 

Applications have also expanded going from plain wall panels to unique architectural elements. Metal panels now clad entire building exteriors, frequently using one or several types of panels. They also are combined with other building materials, or applied as a metal-on-metal accent.

 

“One project might use five or six different types of wall material along with glass. These designs mix and match two or three panel types, such as flat and profile, to impart a sense of texture on the exterior walls and improve the building’s energy efficiency,” notes Doug Pickens, vice president of marketing for Metl-Span LLC, Lewisville, Texas.

 

“Another new concept is to utilize trim components to accent the wall and do reveals to offset the metal panel system. This breaks up the wall cladding with metal accents and creates a whole new spectrum of ideas. The designs are also enhanced by the variety of color options and flexibility of coatings that are now available for wall systems,” Bush adds.

 

Along with new panel types, the use of different metals has created more design opportunities. Aluminum composite material (ACM) was the first successful metal composite in the marketplace. But according to Brandon Wyatt, Marketing Manager, 3A Composites USA (formerly Alcan Composites USA, Inc.), Charlotte, NC, the reference changed to the current metal composite material (MCM) as different types of metals began to be used for various panel applications. 3A Composites remains focused on aluminum composite materials as its Alubobond product marks its 40th year in the market this year.

 

“Designs are definitely more creative with metal since architects realize that it allows them more options for curves, vivid colors, transitional paints and colors that change in the sunlight, such as Alucobond Spectra which actually shifts in the light. Depending upon the pigment type and viewing angle, different wavelengths of light are reflected back to the viewer resulting in an ever-changing color gradient with iridescent highlights,” Wyatt notes.

 

This transitional paint look is growing in popularity and has been used in children’s hospitals, the interior and exterior of retail clothing stores, and sports complexes where custom colors have been created to meet the vision of the architect or designer.

 

The market has also expanded for certain types of panels. In the last five years, for example, insulated metal panels (IMPs) have been chosen for all kinds of applications and a wider field of projects.

 

“Historically, IMPs have been used for cold storage applications, warehouses, freezers, coolers and food processing facilities. Now their use is more broad-based because they can fit the needs of any non-residential structure. They are also ideal for retrofit applications,” says Pickens, noting that the type of IMP used does not limit the design.

 

“New patterns that use IMPs with other panels are extremely creative. They are being used in more horizontal applications than ever before. The running bond pattern is particularly popular. It looks like staggered vertical joints and can combine different colors or shades of a single color scheme,” he adds.

 

Market Evolution

Creativity is not the only factor affecting designs. Other influences include new technology for design, manufacturing, testing and marketing; more stringent energy codes; the national push for more energy efficient buildings; results from ongoing product testing and technical research; and increased marketing by competing materials providers.

 

Changing codes and standards have affected the entire design and build process in the last several years and will continue to do so. Rick Brow, director of marketing for CENTRIA, Moon Township, PA, notes: “Decisions today are heavily influenced by energy codes. Additional insulation in exterior walls and roofs is required and additional thermal requirements are expected in future codes. The trend to move insulation outside of the metal stud cavity has also resulted in a variety of new products/solutions.”

 

Brow also notes that certain changes in codes have helped improve the market for wall panels. “We’re getting away from the true barrier wall, and using more rainscreen techniques, where walls are back ventilated or pressure equalized. This has allowed metal panels to be used in more projects.”

 

The metal industry also has increasingly used technology to meet specific needs and to produce better products.

 

“The design community is reinventing the use of metal panels. We have had jobs where architects wanted something unique and each time we were able to custom produce it. From a manufacturing point we now have more flexibility to produce custom panels; current technology makes it a lot easier. This ability also makes metal more competitive from a design standpoint because the design can be more flexible without adding a lot of cost to the wall assembly,” says Bush.

 

The depth of the research produced by the metal industry also has helped expand the market by showing how metal performs in a variety of situations.

 

“Metal is probably the most tested and well understood construction material there is because of what our industry has done in testing and research. We fully understand how metal reacts in extreme weather conditions, such as high wind, rain, and hail; in seismic zones; and, how it reacts thermally in hot and cold climates. Because of all this research, architects can be assured that there are metal products that will perform well in most environmental applications. This testing and overall product performance is critical to ensuring that the building performs as the architect intended during design,” says Ken Buchinger, vice president of business development and research and development for MBCI, Houston.

 

The testing also has increased the understanding of the types of products and proper installation details to use in given applications, which also aids metal panel installers and fabricators, who play a key role in achieving the ideal outcome on a project.

 

As the market has matured, new opportunities also have surfaced for metal panels. In the last 12 years, environmental needs have become one of the strongest issues for the construction industry, and the green building movement has been positive for the role of metal wall panels in building design.

 

“A number of criteria affect the overall design of the building envelope, including the architect’s vision, the building owner’s needs, zoning laws, energy codes and the architectural look of other buildings in the vicinity. As energy codes become more stringent, architects are being required to design building envelopes that are much more efficient. For better building performance, they’re looking at IMPs as an effective solution while giving the building a great looking exterior. As the energy efficiency of building envelopes becomes a greater priority, the market for insulated wall panels will get even bigger,” Buchinger says.

 

About four years ago the growing emphasis on sustainability and a building’s long-term energy efficiency began to increase the demand for IMPs and change their market position. “This also reversed the perception that IMPs were expensive when compared to other construction materials. Now, designers and owners who once thought IMPs were too expensive are realizing their value in reducing operating costs. As energy expenses increase and more companies and organizations become environmentally sensitive, IMPs are increasingly being used,” Pickens says.

 

Source: DesignandBuildWithMetal.com