Since 1940, Rigidized® Metals Corporation has been the leader of producing engineered metal surfaces and panels. The metal texturing process adds strength, durability and beauty to any project.

Beth Neel

The Beauty of Exotic Metal Shines Through

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As metal roofing becomes more popular, its aesthetic appeal is better appreciated and receives more attention. The need for a better quality, and a better looking, metal roofing product and accompanying advances in metal processing methods, have pushed the popularity of metal roofing far beyond the industrial plants, barns and tobacco sheds of yesterday.

Advances in color palettes and finishes have allowed this time-tested material to take on the look of more traditional products while still boasting all of its own desirable characteristics. Metal shingles designed to have the look of cedar shakes and any color imaginable, including those custom designed to be consistent with a corporate brand, have advanced metal roofing’s aesthetics. Those products are amazing and can help any project achieve a desired aesthetic while offering all of the benefits of metal.

But, what if the product you need isn’t a copy cat. What if you want a roof that stands up proudly as natural, unpainted metal and easily moves past the sea of disguised products? An exotic metal roof makes an incomparable aesthetic statement.

An exotic metal in its true form is striking. Metals such as zinc, stainless steel, titanium and copper demand and deserve the attention they receive for being themselves and for being different. These materials are often referred to as exotic because the appearance of a well-executed natural metal is magnificent, and the metal itself exudes a mystique.

And while the material remains true to itself, a finish is often necessary to allow the most functionality and performance while still delivering exotic beauty. Finishes can be rolled in, abrasive, colorized or embossed and offer many different, subtle appearances.

In addition the material’s aesthetics at the time of installation, long-term performance is also essential. Corrosion resistance and durability are important for both performance and aesthetics, as is the resistance to mold. When exotic metals are properly specified and installed they can last the life of the building with little maintenance. In going the distance, these materials not only provide an environmentally sensible solution, they are cheaper in the long run as compared to materials that require replacement.

A rusted, dented or algae covered metal roof panel is not visually appealing and means many problems for the building’s architect, owner and facility manager. Specifying a metal and finish that will perform for at least the useful life of the building is critical.

A finish, such as those we produce at Contrarian Metal Resources, creates an interesting visual and a high level of functionality. That translates into the ability to make an aesthetic statement while achieving the necessary level of performance to ensure those aesthetics remain intact.

Architectural metal finishes eliminate the need to compromise beauty for performance.

For example, an architect might desire the beauty and sleek nature of exotic metal for the roof of a technology center along a major interstate. The aesthetic of stainless steel might be just right for a high tech look but a highly reflective material isn’t appropriate in a high traffic area. A solution is to specify the exotic metal but with a low glare finish. The reduced reflectivity is suitable for the location and the stunning metal crowns the building just as the architect desired.

Beth Neel

The Do's and Don'ts of Stainless Steel Roofing

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For the architect, panel manufacturer, fabricator, installer or contractor considering a stainless steel roof, you can expect a beautiful, permanent roof system that will be very economical in the long run—if you rely on a competent architectural metal supplier and don’t make the assumption that stainless is like any other metal. Here are some do’s and don’ts to guide you:

Do…
Recommend stainless steel where sustainability is important because it will last. On buildings that are designed to last longer than the anticipated life of other roofing materials, stainless steel is less expensive in the long run. While stainless steel may not make economic sense on a strip mall, for example, it is possible to install a permanent stainless steel roof that will save the owner repair and replacement costs in the future. When life cycle costing is conducted, including acquisition, maintenance, service disruption and disposal costs in present value terms, stainless steel is hard to beat.

Use a low glare stainless steel finish, like Contrarian Metal Resources’ InvaiMatte® where a highly reflective surface, as most stainless steel finishes are, will pose a problem. InvariMatte® has been used on a number of airport terminals where glare poses a safety risk. In addition to promoting safety, a low glare finish will be less apt to show oil canning, or shape deviations in the panel work.

Use a uniform surface finish that is designed for architectural applications. Aside from having a low glare property, InvariMatte® is also quite uniform, allowing for a good-looking bare metal installation.

Use a grade of stainless steel that is appropriate for the environment. Coastal environments and sites where deicing salt is used in close proximity will usually require Type 316 stainless steel. Type 304 is appropriate in most other locations. The low carbon versions of these grades (T316L/T304L) should be specified on parts that will be welded. Other grades may be considered, depending on the environment. If you follow our earlier advice with regard to selecting a competent supplier, you can rely on their expertise in grade selection. If you choose to work with Contrarian Metal Resources, a 30-year limited corrosion warranty will back up our material recommendation.

Detail the system so that it drains well. While stainless steel is very forgiving when it is exposed to moist conditions, good water and vapor management will promote the longevity of all of the affected materials in the system.

Use proper tooling for stainless steel fabrication. The mechanical properties of stainless steel are higher than mild carbon steel, aluminum and other metals that are used for roofing. The most significant difference the panel manufacturer or fabricator will notice during forming is a higher modulus of elasticity or greater “spring back”. In order to overcome this issue it is often necessary to have a combination of more horsepower and more tool sets in the roll forming operation. It is also important to have sufficient tooling harness so that the work rolls do not wear prematurely. Further, seaming tools need to be of sufficient capability to form stainless steel.

Monitor tool wear to ensure good results. Worn tooling bears the risk that free iron molecules will imbed in the surface of the stainless steel. If this occurs, it will cause the stainless steel to corrode, manifesting as red rust on the surface of the material. It is necessary in this case to remove the rust with a solution like dilute citric acid.

Remove heat tint from welding operations. Left untreated, this carbide-rich scale will propagate corrosion. Cryogenic blasting is an excellent method of scale removal. Pickling paste is also effective. Fabricators and installers often grind the scale off, but this method is not as effective and the repair area is much more reflective than the parent metal surface, particularly if a low glare finish has been used.

Strip the protective vinyl film at the earliest opportunity in the field, once other subcontractors are out of the area. First of all, a good architectural metal supplier will apply a strippable film that is capable of withstanding outdoor exposure for a period of weeks. This is not to say that you can leave the film on indefinitely. Assuming exterior-grade vinyl has been supplied, it is prudent to leave the film on the panel work throughout the installation process in order to protect the surface from contamination by construction debris, including wasted carbon steel fasteners, welding swarf, tar and paint. Strip the film as soon as the risk of contamination has passed. This will minimize the need for final clean-up activity upon owner inspection.

Don’t…
Abut dissimilar metals without evaluating the risk of bi-metallic, or galvanic corrosion. This is of particular concern where moisture can reside and where the metals are substantially different in terms of electrode potential. Fasteners should be stainless steel of equal or nobler grade.

Rely on solder for strength. While stainless steel is solderable, it is best to use solder for small connections that need to be made for water management purposes. However, in a shear condition, a stainless steel solder joint will fail.

Use muriatic acid, chloride-based cleaners or abrasives when cleaning stainless steel. Instead, you should use a mild detergent (ammonia –based is fine) and rinse for general clean-up. Acetone will address grease, tar and fresh paint. Use MEK on dried paint. Free iron contamination (rust) will sometimes respond to mineral oil, but imbedded iron particles will likely require dilute citric acid, followed by a rinse.

If you start with a competent architectural metal supplier that can help you select a grade and finish that is appropriate for the application, and follow these dos and don’ts, you can be assured of good results. While stainless steel costs more up front, in the long run the owner can be spared the cost and inconvenience of replacing the roof.

Beth Neel

The Use of Metal on Airport Exteriors is Taking Off

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Metal is showing up more frequently on newly-constructed airport exteriors across the country. The trend signals a see-and-avoid juncture for airport construction specifiers mindful that some metal products are less suitable for airport settings than others – those that have reflective properties, require paint, or corrode when exposed to jet fuel emissions. Not so with Contrarian Metal Resources’ InvariMatte®, a corrosion-resistant, uncoated stainless steel finish with low glare and a long lifecycle.

The InvariMatte® finish recently has been used on several major airport projects in the United States, including the Jamaica AirTrain JFK Terminal in New York, an expansion at Detroit Metropolitan Wayne County Airport in Michigan, and the Scottsdale Aircenter in Arizona. InvariMatte® was chosen for these projects because of its dependable characteristics and uniform appearance.

In addition to sun, wind and precipitation, airport exteriors are continually exposed to jet fuel residue, earth-rumbling engines and the repercussions of heavy traffic. The materials used to construct these exteriors must stand up to these elements and maintain an aesthetic standard. Stainless steel accomplishes both goals.

Corrosion-Resistance
InvariMatte® resists the threat of corrosion from atmospheric conditions and trapped moisture.

Data collected from the Nickel Development Institute indicates that aluminum, a common alternative to stainless steel, corrodes several times faster. While a layer of paint is effective for extending the life of an aluminum panel, it can actually have a detrimental effect on corrosion resistance if that layer is breached and moisture is trapped at the metal interface. Incidental damage to roof panels – punctures in the paint, or dents and dings – can easily occur from routine maintenance or weather events, such as hailstorms. If moisture and contaminants – like sulfur dioxide and chlorides – are trapped at the metal surface, rapid deterioration, known as crevice corrosion, will occur.

Fortunately, with InvariMatte®, no paint is needed, allowing the natural beauty of stainless steel to shine through.

No Chance for Paint Deterioration
Aside from physical damage done to them, painted surfaces do not stand up well in an airport environment because of jet fuel residue. Kerosene-based fuels will act as solvents when particles come in contact with painted exteriors. While some floor paint formulations are resistant to jet fuel, none is available for coil-coated applications. More to the point, however, is the fact that “resistance” to jet fuel does not equate with “imperviousness.” The InvariMatte® finish is able to make the claim that it is impervious to jet fuel.

Low Glare
In addition to being visually uniform, Contrarian’s InvariMatte® has low reflectivity compared to typical stainless steel finishes. For that reason, it can be used on airports as prominently visible exterior walls and roofs with no risk of glare or reflection that could compromise a pilot’s sight. InvariMatte® has lower gloss (<20 at 85 degrees Fahrenheit) than many paint finishes.

Low Lifecycle Cost
Considering the high cost of service disruption at an air terminal, not to mention security issues, a permanent stainless steel roof system is a logical and cost-effective choice. While titanium will perform beautifully from a sustainability standpoint, it’s expensive in comparison to stainless steel. Likewise, a less costly alternative, aluminum, painted or not, requires maintenance or replacement at some point during its lifecycle, which makes it more costly overall.

Type 304 or 304L InvariMatte® stainless steel can be expected to last the useful life of an air terminal building with little maintenance. Gutters should be kept clear and panels may need to be cleaned for cosmetic reasons, but these are minimal necessities as compared to alternative products.

Recent Airport Applications for InvariMatte®
Jamaica AirTrain JFK Terminal in New York is a $389 million multimodal transfer point that links the new light rail system from JFK International Airport to the Long Island Railroad, New York City Transit subway lines, and ground transportation centers. About 8,500 of the airport’s 32,000 daily passengers arrive or depart from the terminal.

Reflectivity was a concern not only for pilots and airport personnel, but also for those who live and work in surrounding high-rise buildings and condominiums. “InvariMatte® is a sensible choice as a cladding material in dense urban environments,” says Contrarian Metal Resources President Jim Halliday. “While stainless steel addresses corrosion and paint failure concerns due to smog and jet fuel residue, other stainless steel finishes are just too bright to be used in glare-sensitive locations like transportation centers.”

InvariMatte® was also specified for its longevity and low-reflectivity at Detroit Metroploitan Wayne County Airport and Scottsdale Aircenter. When construction began in 2001 at the $1.2 billion Edward H. McNamara Terminal at Detroit Metro, it was one of the largest construction projects in the United States. The redevelopment and expansion project solves operational and structural problems and readied the airport for forecasted growth in air traffic and passengers.

Scottsdale Aircenter, a full-service Fixed Base Operator at Scottsdale Airport, opened in 2003. Construction is underway on an expansion project that will add more than 100,000 square feet of hangar and office space.

InvariMatte® is a non-directional, low gloss, uniformly textured stainless steel finish designed for architectural applications. While its lower reflectivity lends itself to roofing applications, it can be applied to wall panels, coping and trim. The superb consistency of this finish results in excellent panel-to-panel matching. Since InvariMatte® has no coatings to deteriorate, it will last indefinitely with little maintenance. InvariMatte® is readily welded or soldered and available in coils and cut lengths up to 288 inches and widths ranging from 0.75 to 49 inches. Because stainless steel is dimensionally stable up to 2000-degrees Fahrenheit, InvariMatte® provides an added measure of protection in the event of a fire. Contrarian Metal Resources offers a 30-year warranty on Grades 304, 304L, 316, and 316L.

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