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A Simple Solution to Metal Panel Condensation

Posted on December 27, 2016May 31, 2023 by Tyler Roose

If you’ve ever gone outside before sunrise, you’ve likely noticed dew on the grass or on your car windows. This is condensation. While we may have learned the basics of this naturally occurring phenomenon in science class, we may need a quick refresher.

Condensation occurs when there’s more water vapor (the invisible, gaseous phase of water) than the air can hold. When the water vapor is cooled off or compressed to its saturation limit—at which point the vapor’s molecular density reaches its maximum threshold—it turns into liquid. Warm air can hold more moisture, but as it cools it reaches its saturation limit and water droplets form. While not a problem on the grass or your car (once you wipe the water away), condensation on metal panels CAN be a problem for your customers. The good news is there’s a simple solution.

What causes condensation on metal panels?

When temperature and humidity conditions reach dew point, moisture can condense on the underside of metal roofing and potentially cause water damage to the inside of your customer’s building. Those drips from ceilings and surface moisture occur when warm air comes in contact with the cooler roofline or walls.

High interior humidity—a common cause of condensation in metal buildings—can result from heating and air conditioning systems, how the building is used, gas-fired heating components, improper construction techniques or even human respiration, as these all give off moisture vapor.

Effects of condensation on different types of panels:

If there is an abundance of condensation, water droplets will form and can cause damage. In metal buildings, there are a few possible consequences of trapped moisture in wall and roof systems:

Corrosion of metal components, even on surface-treated metal: When exposed to moisture, metal components can oxidize and weaken, decreasing the life of your customer’s building.
Degradation/ reduced effectiveness of the thermal performance of insulation
Mold or mildew growth, which can cause unpleasant odors and increase health risks, particularly for those with allergies or asthma
Insect infestations

Note: The probability of significant problems will depend on the location and usage of your customer’s building.

Controlling Condensation: What is the Solution?.

Traditionally, condensation is managed by insulating the metal roof so that the panel temperature never reaches the dew point. This is often accomplished using vinyl-backed fiberglass insulation to prevent humid air from coming into contact with the cooler metal roof (which may be at or below the dew point). If your customers are heating or cooling their building, adding insulation is certainly worth consideration. If they aren’t, there is another option to consider besides the installation of vinyl-backed insulation.

Your customers can consider installing Drip Stop, a patented condensation control membrane, to prevent damage from moisture. Drip Stop (manufactured by ABC) is a felt-like material with a rubber backer that can be applied to the back side of metal panels. The material literally traps and holds the moisture resulting from condensation. When conditions change, the ambient air temperature usually rises, thereby raising the dew point. The moisture is then released from the Drip Stop material back into the air in the form of normal humidity. Drip Stop can be applied to the back of metal coils (either Galvalume^® Plus or painted) and then the metal can be roll-formed onto panels.

What are the benefits of this alternative condensation control method?

Drip Stop offers several advantages for your customers:

Durability: Drip Stop is a very tough, light gray anti-condensation felt that is not susceptible to ripping, tearing or deterioration unlike standard insulation and vapor barriers.
Low Maintenance: Drip Stop resists dirt and grime, is antimicrobial and is very easy to clean with a hose or pressure washer.
Corrosion Protection: The rubber backer on the material helps protect the back side of the panel from corrosion (although there is no protection at the panel’s cut edges).
Easy to Handle: There is no need to roll a vapor barrier over purlins and then seal with tape, which can reduce labor hours and cost. Additionally, the use of Drip Stop is not hindered by windy conditions.
Safety and Insurance: The material is approved for smoke generation and flame spread per UL^® 723 for insurance specifications.
Acoustic Benefits: Drip Stop helps dampen sound from either inside or outside the building.
Versatility: Drip Stop is approved for use in residences, warehouses, industrial plants, sports arenas, schools, storage buildings, garages, animal confinement facilities and more.
Cost-Savings: Drip Stop is up to 25 percent less expensive as compared to traditional solutions.
Warranty-Backed: Drip Stop features a 20-year adhesion warranty to ensure longevity.

The Bottom Line:

There’s no need for the damaging effects of condensation to put a damper on your customer’s metal building project. With a simple solution like Drip Stop, you customers can protect their assets and prevent costly and time-consuming repairs.

For more information on Drip Stop and how it can be applied to ABC’s PBR, Imperial Rib® and Retro-R® panels, visit our website or contact your local sales representative.

Safety and Savings Courtesy of Metal Panels

Posted on November 2, 2016May 31, 2023 by Tyler Roose

Most people understand that buildings outfitted with secure, storm-resistant roofing material like metal are less prone to damage from hurricanes, hail storms and other damaging weather events. Not only does this strength provide safety and security for the building owner, but those qualities also translate into cost-savings outside of what’s saved due the longer lifespan and lower maintenance requirements of metal panels.

Safety in Strength

Metal roofs are made to last. Thick panels, properly installed and maintained, have a lifespan of up to 50 years under normal circumstances—double that of most asphalt shingle roofs. To ensure that lifespan, metal roofing manufacturers perform rigorous tests (according to strict ASTM standards) that document performance under a range of environmental traumas. These tests confirm that, compared to other surfaces, metal offers superior performance when subjected to the following:

Hail

Even the most basic metal roof is a shield against hail damage, but of course some products and roof designs offer even greater protection. To protect against hail damage, the optimal option is a heavy-gauge metal panel roof installed over solid plywood or oriented strand board (OSB) sheathing. Two of the most comprehensive post-storm studies found that such roofs survived even the biggest hailstones without punctures or leakage.[i] In the worst cases, the damage to the metal was only cosmetic.

Wind and water

Metal roofs can withstand wind gusts as strong as 140 mph. Because they consist of large interlocking panels, they’re less susceptible to uplift than individual asphalt shingles and offer fewer entry points for water.

In addition, the synthetic underlayments used by professional roofers are 20 times stronger than felt, so in the unlikely event that the roof is punctured there is a much lower chance that water will get into the structure. (Synthetic underlayments also stay as much as 25 degrees cooler on a hot, sunny day and include an anti-skid coating that keeps roofers safer during installation.)

Wildfire

We’ve all seen pictures of metal-roofed homes that have survived wildfires while the surrounding structures burned to the ground.[ii] It makes sense: metal panels hold a Class A fire-resistant rating (the highest possible), making a metal roof installed over a fire-resistant cap sheet the optimal combination in fire-prone areas. In fact, a publication from the UCLA School of Architecture urges homeowners rebuilding in wildfire zones to use non-combustible roofing and siding. It also cautions against the use of clay tiles, which can develop cracks that allow wind to drive burning embers into the attic.[iii]

Lightning

Many people ask about metal roofing’s lightning resistance: does its conductivity make it more susceptible to strikes? The answer is no: not only is a home with a metal roof no more prone to this than any other structure, but if it is struck by lightning the large metal surface will do a good job of safely dispersing that energy.[iv] And because metal is not flammable, a strike is much less likely to start a fire, which is often the most devastating result of a lightning strike.

Continual Savings

Confirmation of metal’s durability and safety comes from a third party business with a real stake in the matter: the insurance industry. Some insurance companies offer lower premiums for the use of qualifying wind- and impact-resistant roofing materials like metal. These include large national insurers like State Farm and Nationwide, which offer discounts in 26 states plus one Canadian province for certain roofing products with Class 4 wind ratings. Most metal roofing manufacturers, including American Building Components, have several products on their lists.

For more information on ABC’s roof products, please visit our website or contact your local representative today.

[i] http://www.constructionmagnet.com/metal-roofing-magazine/metal-vs-mother-nature-hail

[ii] http://photoblog.nbcnews.com/_news/2012/08/16/13314843-lone-house-surrounded-by-scorched-earth-survives-wildfire?lite

[iii] http://www.energy-design-tools.aud.ucla.edu/FIRES.html

[iv] http://www.metalroofing.com/v2/content/guide/newsletters/04-0701.cfm

Maintaining, Cleaning & Repairing Metal Panels

Posted on September 23, 2016May 31, 2023 by Tyler Roose

Understanding the maintenance requirements of your metal panels is essential to maximizing the longevity of your investment with the least amount of hassle. While metal panels have been engineered to provide decades of trouble-free protection, they can suffer damage from the build-up of debris as well as storm-related traumas like hail stones, falling branches and ice dams. To extend the lifespan and strength of metal panels, maintenance consists mostly of preventing and correcting these issues.

The importance of regular inspections

Regular inspections are critical to identifying damaged panels and accumulated debris that can trap moisture, causing corrosion over time. To prevent this, a visual inspection should be performed in the spring and the fall of each year, as well as after major weather events to identify issues. Take a walk around the structure and look for leaves, branches and other debris piled up on the roof, including in valleys, gutters and downspouts, as well as behind chimneys and/or other protrusions. While you can perform this type of inspection yourself, please keep in mind that metal panels—particularly metal roofs—should be professionally inspected every four to five years depending on your geographic location. If you live in a coastal or humid area more prone to corrosion and rust, professional inspections should be done more frequently to prevent the rust from spreading and causing structural damage to the panels.

In addition to debris, keep an eye out for scratched or dented areas, as well as for loose screws and seams that look like they are separating. (If you can’t make out the details from the ground, try using a pair of binoculars.). Use the manufacturer’s recommended touch-up paint to correct scratches as they can quickly degrade the surface protection and jeopardize the longevity of metal panels. If the panels have separating seams or holes, first check to see if the repair is partly or fully covered by your warranty. Unless you are experienced in metal roof repair and possess a thorough knowledge of the products and techniques that can be used without voiding the warranty, it is recommended that you engage a metal panel repair specialist to make the repairs. If you decide to undertake the work yourself, it is also important to remember that these fixes are, at best, temporary and should be addressed by a professional recommended by the metal panel manufacturer.

Cleaning metal panels

Keeping metal panels clean is one of the best ways to ensure they last as long as possible. When cleaning metal roofs and walls, using a non-pressure cleaning method with detergents recommended by the metal panel manufacturer is ideal. It is not advisable to use metal tools such as rakes to remove debris. This is likely to scratch the paint, reducing the panels protection from the elements and other damaging factors. Using a leaf blower to remove debris is a common choice, but a long-handled push-broom or a telescoping pole with a window cleaning brush will also do the job. Ideally, the tool should be one that lets you do the removal from the ground, but if you absolutely must walk on the roof then only step on the flat areas. If there are areas you can’t access yourself—particularly slanted areas that have been made slippery with cleaning solutions—hiring a professional service to do this once or twice a year is the safest option.

To reduce the chance of further damage and keep your panels cleaner over longer periods of time, trim tree branches as far back from the building as possible. This is especially important for large, unhealthy branches that could break off during high winds and cause damage.

Proper snow removal

There are—of course—considerations that must be made for metal buildings located in colder climates. After a winter storm, it’s a good idea to remove standing snow from the roof. This is doubly important on older homes where poor attic insulation can lead to ice dams. An ice dam forms when heat escaping from inside the attic warms the roof and melts the bottom layer of snow. The snowmelt then re-freezes, creating a dam that traps water which can work its way into seams between panels and around flashings.

Warranty considerations

It’s always smart to reference the metal panel manufacturer’s warranty to be sure you don’t use any products or tools that will void your warranty. They should also provide instructions and advice specific to the panels and application(s) you’ve selected to ensure you get the most out of their products with the least hassle.

For more information on metal panels, check out ABC’s FAQ page. For more on our metal panels and accessories, please visit our product pages or contact your local representative today.

Cool Metal Roofs Save Energy and Cost

Posted on August 24, 2016April 29, 2024 by Candy McNamee

Metal panels are a cool addition to your building in more ways than one. Besides looking great, a metal roof is a simple and effective way to make you more comfortable in warmer months while cutting your energy use and providing potential tax savings.

What is a cool roof?

A “cool roof” is one that’s both reflective and emissive. That is, it reflects sunlight and re-radiates absorbed heat back to the sky before that heat can work its way into the structure. Measured surface temperatures of cool roofs are as much as 50 degrees lower than those of conventional roofs [1] so the building’s interior is less prone to heat up, as are any ducts running through the structure. The benefits are obvious: your rooms are naturally cooler and don’t require the air conditioner to work as hard, and you enjoy lower electric bills. In fact, the US Department of Energy (DOE) reports energy savings as high as 15 percent for homes with cool roofs.[2]

And if you’re building a new home, a cool roof may reduce construction costs by letting you install a smaller air conditioning system.

Cool Metal Roofs are both reflective and emissive.

How it works

In technical terms, these benefits are thanks to cool metal roofing’s high solar reflectance and high emissivity. The solar reflectance is used in determining ENERGY STAR® compliance. When solar reflectance is calculated with thermal emissivity, in accordance with ASTM E1980, the result is the solar reflectance index or SRI. SRI is stated in whole numbers from 0 to 100, with the higher numbers indicating better performance. Tests done at Lawrence Berkeley National Lab (LBNL) found that metal roofs painted with white coatings have SRIs from 71 to 82. By contrast, white asphalt shingles earn at maximum an SRI range of just 21 to 40.[3] This indicates cool metal roofs perform three to four times better than white asphalt shingles.

The LBNL data is for white roofs, but metal has a much wider range of cool colors. Yes, white is more naturally reflective—you will feel cooler on a hot, sunny day when wearing a white shirt as opposed to a black one—but with metal panels, it’s not just about color. A broad range of paints for metal panels have chemical additives that increase their cool properties.

Tax benefits

If you need any more incentive, there’s another benefit to installing a cool roof. As mentioned in our metal roof tax credits blog, if you re-roof your primary residence using an ENERGY STAR® certified metal roofing product before Dec. 31, 2016, you are eligible to receive a tax credit. And in fact, ABC has 28 colors that are ENERGY STAR qualified for steep-slope roofs. Simply include a copy of the manufacturer’s Certification Statement for those panels with Tax Form 5695 with your tax return to qualify for a $500 tax credit.

For more information on ABC’s cool roof products, please visit our website or contact your local representative today.

References:

[1] http://energy.gov/energysaver/cool-roofs

[2] https://www.youtube.com/watch?v=urbpBy_Z5lE

[3] http://energy.lbl.gov/coolroof/

Metal Roofing Gauges: What Are The Best Gauges For Metal Roofs?

Posted on August 15, 2016May 31, 2023 by Tyler Roose

When your customers decide to use metal panels for their building project, they’ll need to make several decisions to choose the best panel. One of the first decisions they’ll make is what gauge or thickness they need. There are a variety of metal roof and wall panel profiles to choose from, and they are all available in several gauge thicknesses … but what does that really mean to your customers and how does that affect your business?

Metal Panel Gauges Deciphered

U.S. manufacturers express the thickness of metal panels as their ‘gauge’, with 22-gauge being the thickest and 29-gauge the thinnest of traditionally-sold metal roof and wall panels. Each gauge represents a nominal decimal range. For example, a 26-gauge steel panel can range between 0.0179 and 0.0217 inches thick according to a University of North Carolina at Chapel Hill resource.

This means that while a 26-gauge panel from one manufacturer could measure 0.027 in. thick, a 26-gauge panel from another manufacturer could measure only 0.0179 in., but both are sold as 26-gauge panels. Although those seem like small numbers, they represent a noticeable difference in panel stiffness and strength.

So how do you and your customers know if the metal panel manufacturer has used thinner sheeting and made up the difference with a coat of paint? When ordering inventory, you should look beyond the gauge number to the manufacturer’s specifications on metal thickness. This will give you peace of mind that you’re providing your customers with the gauge they’re paying for and the quality they need to get the job done.

Costs of 26-Gauge Panels vs. 29-Gauge Panels

Expect to pay more for thicker panels. The cost of a 26-gauge product will be about 15 percent higher than a 29-gauge with the same profile from the same manufacturer. While some people insist that the extra cost is always worth it, that may be misleading. Yes, thicker panels are stronger, but the importance of that added strength depends on the type of building construction as well as the customer’s priorities and location.

When To Choose a Thicker Metal Roofing Gauge

There are instances where thicker gauges always earn their keep. The most common of these is the post-frame building, or pole barn: an open-framed structure used for barns, garages and warehouses. Post-frames generally lack structural sheathing, so the roof and wall panels must span between the supporting trusses or purlins. Because 22-, 24- or 26-gauge sheeting is thicker, and will, therefore, remain more structurally sound over a longer span than a 29-gauge, the building needs fewer supports, which saves your customers money. For post-frame structures like this, it is important for your customers to consider the potential snow load the roof may need to support when choosing the metal panel gauge. Lighter-gauge (thicker) panels may save your customers from structural collapse in the winter months!

Lighter gauge (thicker) metal is also more forgiving of installation errors such as the over-tightening of screws, and it won’t be as likely to transfer bumps and waves in the sheathing. (The latter is more likely when re-paneling an older home.) Thicker trim pieces will also lay more accurately, so some homeowners and contractors opt for 29-gauge roof and wall panels with 26-gauge trim, a combination that is common and cost-effective.

When To Choose a Thinner Metal Roofing Gauge

Span isn’t always a concern in the residential market. Nearly all homes have a layer of plywood or oriented strand board sheathing covered by a weather-resistant barrier. The metal panels are affixed to the sheathing and serve no structural role in these instances; their job is to keep the sheathing dry. A quality 29-gauge panel is more than adequate for this—which is why it’s used on nearly 80 percent of homes with metal panels.

Despite this, thicker (lighter-gauge) panels can make sense for buildings in hail-prone areas, but not because of structural integrity. A 29-gauge metal panel can have the same impact-resistance rating from Underwriters’ Laboratory (UL) as a 26-gauge panel; the advantage of thicker metal panels in this case is that they are less prone to denting. If your customer lives in a place like Cheyenne, Wyoming (the hail capital of North America) and is concerned about long-term appearance, thicker panels may be the better option.

Let ABC Help You Choose the Right Metal Panel Gauge!

For more information about metal panel gauges, check out our panel selection chart or contact your local ABC representative today. Additionally, use our online ordering tool to find accurate pricing, create quotes and place orders for metal building products anytime, anywhere and from any device. If you don’t already have an account, register for access today!

Your Guide to Steel-Curtain Roll-Up Doors

Posted on July 29, 2016March 24, 2023 by Jessica Taylor

No building is complete without a door. In this blog, we investigate steel-curtain roll-up doors and how they deliver form and function across a wide variety of uses.

What are Steel-Curtain Roll-Up Doors?

You see them everywhere. They’re used at your local schools, recreation and retail centers, and government, medical and office buildings. They provide access and security for storage units whether applied in backyard sheds, residential garages or commercial storage facilities. And, they are also an integral part of agricultural structures, transit stations, freight buildings and warehouses.

Made of a curtain (sheet) of durable, secure steel and designed to provide quick, easy access to both commercial and residential buildings, these doors open by traveling vertically, but gather into a roll at the top of the door instead of sliding along tracks. And while they can be used in a myriad of applications, with so many door options available in the marketplace today, why are so many people opting for steel curtain roll-up doors?

Why Steel Roll-Up Doors?

Long-term Value:
Roll-up doors made of steel are generally less expense to purchase initially and they save money over the course of their lifespan. Not only do they last longer, but they also require fewer, less expensive repairs and are more durable than wood, aluminum or fiberglass products—particularly in challenging environments. In addition, steel is more energy-efficient, saving on heating and electricity costs throughout the year.

Security:
Exterior doors are inherently the most vulnerable points of many buildings, so reducing the likelihood of theft, fire, vandalism and contamination is the best way to keep your property secure. More impenetrable than doors made from wood, fiberglass or aluminum, steel doors with standard stainless steel latches are better able to protect against unwanted entry, fire, noise, vandalism and contamination from exterior elements, providing reliable security and peace-of-mind.

Durability:
Steel is a resilient material manufactured to protect against extreme weather conditions and harsh usage environments. Unlike doors made from other materials, steel roll-up doors can endure the wear and tear of heavy traffic usage and can be outfitted with rust-resistant components including spring coatings and bottom bars to further extend their longevity.

Longevity:
While wood doors are susceptible to warping and rotting, aluminum doors can quickly become dented and fiberglass can easily crack—all of which require replacement—with proper installation and maintenance, metal doors can last 30 years or longer. The high-quality primers and paint coatings used on steel doors protect against chipping and scratching, keeping the doors looking better longer.

Easy Maintenance:
Steel roll-up doors require little-to-no maintenance and are easily replaceable—making them one of the most reliable, cost-effective options in the industry. ABC’s doors are unique in that they feature gear-driven tensioning brackets that ensure safe and easy adjustments that can be made on site and with minimal down time.

Appearance:
Steel roll-up doors are available in a wide variety of sizes, styles and colors. In addition, manufacturing improvements and advances in coating and paint products enables customization to suit even the most unique aesthetic requirements.

Space-Savings:
Because roll-up doors open vertically and are gathered into a roll instead of sliding along tracks, they take up little overhead space while enabling convenient and easy access.

How to Select the Right Steel Roll-Up Door:

Whether you are replacing doors on an existing building or sourcing them for a new project, be sure to consider the below factors before purchasing:

Use:
The door you need will depend on its intended use. Light-duty doors are manufactured to meet the specific and unique demands of small structures, portable buildings or recreational facilities while heavy-duty doors meet the needs of more demanding environments like commercial freight and utility buildings, warehouses and agricultural facilities.

Environment:
It is vital to consider your geography when selecting steel roll-up doors. If your project is located in a region susceptible to high winds from weather events including hurricanes, tropical storms and tornadoes, a wind-rated door tested in accordance with International Building Codes and that complies with your insurance requirements should be considered. Check both local and national building codes to understand if you need wind-certified doors, which can dramatically reduce maintenance and replacement costs as well as minimize downtime.

Warranties:
Be sure that you are familiar with and fully understand the warranty options available on the products purchased. It is common for doors and door components to be covered by a product warranty, while the coil coatings and paint are warranted under a second that should include considerations for film integrity as well as both chalk and fade.

To learn about ABC’s roll-up door solutions, visit our Roll-Up Doors product page or contact your local sales representative.

Galvalume® vs. Galvanized Metal Roofing

Posted on June 14, 2016May 31, 2023 by Jessica Taylor

Galvalume^®vs. Galvanized Metal Roofing

Selecting metal panels made from high-quality materials is essential to the longevity and success of your customer’s metal roofing system—from the steel sheets to the fasteners. Although the quality of the paint system applied to metal roofing panels provides an essential level of protection (as discussed in our recent ‘Decoding Your Warranty’ blog series), not to be overlooked is the coating used on metal roofing panels. Two coatings are commonly used on steel sheeting in the metal panel industry today: Galvalume^® and Galvanized. Both products are manufactured to adhere to carbon sheeting and provide a barrier that resists corrosion. Additionally, they enhance long-term water-tightness and durability, ensuring resilience through damaging weather conditions. But what exactly are the differences between Galvalume^® and Galvanized?

What is Galvalume^®metal?

Introduced into the construction marketplace by Bethlehem Steel in 1972 and now widely available around the world, Galvalume^® is carbon steel sheeting coated with aluminum-zinc alloy by a continuous hot-dip process. Composed of 55 percent aluminum and approximately 45 percent zinc, this coating combines the best properties of both metals. It has the corrosion resistance, high temperature oxidation resistance and heat reflectivity typical of aluminum coatings, with the formability and galvanic protection of cut edges characteristic of zinc coatings. This combination makes it ideal for most types of roofing and siding. In addition, the coating also contains a small but significant amount of silicon in the alloy—not to enhance the corrosion performance, but to ensure optimal coating adhesion to the steel substrate when roll-formed, drawn or bent during fabrication.

What is Galvanized metal?

Galvanized Sheet is carbon steel sheet coated with zinc on two sides by a continuous hot-dip process. This method tightly adheres the coating to the steel with an iron-zinc alloy bonding layer formed by a diffusion process while the heated steel strip is in contact with the molten zinc.

What is the difference between Galvalume^® & Galvanized roofing?

While both products were developed to essentially sacrifice themselves to protect the steel sheeting they coat, the above exposure comparison shows that Galvalume^® performs (up to nine times) better in fighting corrosion as compared to Galvanized coating. While Galvalume^® can initially show signs of corrosion faster than Galvanized, it has a sacrificial property that will prevent the corrosion from growing whereas once corrosion has started on a Galvanized panel, it can continue to corrode until panel integrity is lost. According to a study released by the Metal Construction and Zinc Aluminum Coaters associations, the longevity of a low-slope unpainted Galvalume^® standing-seam roof is 60 years (See the full report.) Additionally, primer and paint adhere better to Galvalume^®-coated panels and they carry a 20-year limited warranty while galvanized panels do not, making them a smarter long-term investment for your customers’ homes, agricultural buildings or commercial properties.

Important Facts About Galvalume^®

Galvalume^® should not come in direct contact with: standing water, dissimilar metals (copper, lead, iron), harsh chemicals, graphite pencil, masonry products or treated lumber.
Proper roof inspections and maintenance is still required, as with any other roof system.

Its versatility, ease of use, aesthetic appeal and long-term, service life-extending performance makes Galvalume-coated steel roof panels the most economical and sustainable coating option for your customers’ new and retrofit applications. To learn more about Galvalume^®, please visit http://www.galvalume.com/. To view ABC’s Galvalume^® Plus products, which are easy to form and install safely due to the thin, clear acrylic coating that allows them to be roll-formed dry without vanishing oil, please see our color resources and Galvalume^® warranty information.

Spotlight on Underlayment: Synthetic vs Felt

Posted on May 13, 2016May 31, 2023 by Jessica Taylor

What’s under your customer’s metal roof matters.

Roof underlayment is the first layer of material laid prior to the metal roofing panels. It separates the roof covering from the roof deck, thus protecting it from detrimental resins, unevenness and—in re-roofing applications—fasteners and other old building materials. This water-shedding layer also provides secondary protection from weather, shields the roof deck during construction and is often required for warranty adherence and for roofs that must meet Underwriter’s Laboratory (UL) fire ratings. Outside of its traditional use, synthetic underlayment can also offer a myriad of benefits for your customers.

Synthetic vs Felt

Felt underlayment, also known as “felt paper” has been the traditional underlayment of choice for decades. It was used to prevent damage to the roof covering caused by sap leakage from wooden building materials, however—as even most wood structures are now constructed using plywood or other, non-wood materials—this is no longer an issue. Felt underlayment is saturated with asphalt composed of volatile compounds that dissipate over time. This makes it more fragile and likely to absorb moisture, which further weakens the roof. This deterioration is accelerated when asphalt is exposed to UV rays, heat, poor ventilation and less energy-efficient roof coverings. Additionally, the crude oil refining techniques that previously resulted in the creation of asphalt as a byproduct, now extract the maximum amount of product from the crude resource. As a result of this advancement in the refining process, only a powder-like residue that is not conducive to the development of asphalt is generated. Consequently, more customers are turning to a synthetic alternative for a longer-lasting, economically-efficient solution.

Compared to traditional organic felt, synthetic underlayment is significantly more lightweight, permitting many more squares per roll, which makes it an economical solution for your customers. While non-woven materials are generally moisture permeable, woven scrim synthetic roof underlayment greatly enhances tear resistance and ease of installation. While it can be designed to be moisture-permeable, synthetic underlayment is typically manufactured as a barrier that doesn’t absorb moisture, making it resistant to fungal growth and wrinkling.

Underlayment Requirements and Resources

Although synthetic underlayment may be the superior choice for your customers, it is imperative that its use does not violate building code requirements or manufacturer’s warranties for the intended roof covering and that it is installed according to the manufacturer’s provided instructions.

The International Code Council (ICC) has developed a single set of comprehensive and coordinated national model codes and standards used in the design, build and compliance processes to ensure the safe, sustainable and affordable construction of structures. The ICC’s set of International Codes (I-Codes) are available for purchase, and include, among others:
· International Building Code (IBC)

International Energy Conservation Code (IECC)
International Fire Code (IFC)
International Green Construction Code (IgCC)
International Residential Code (IRC)

Of particular importance to the roofing industry are the IRC and IBC I-Codes. These codes include specific underlayment requirements and installation/ attachment directions for simple enforcement by inspectors. Provided in Chapter 9 of the 2015 IRC and Chapter 15 of the IBC, they cover material types, application and attachment requirements, including specific information for metal panels with denotations for variances specific to high-wind areas.

Because of the wide variety of underlayment and metal panel styles, the IRC and IBC require installation according to manufacturer’s instructions. In the absence of manufacturers’ instructions and/ or when using alternative materials, the specific requirements outlined in the IRC and IBC I-Codes should be used where applicable. Remember, a metal roof is designed to have a long service life, and the underlayment’s service life should at least match that of the metal roof. Don’t allow your customers to be shortsighted when designing for longevity by using an underlayment not guaranteed to last for the duration of their roof.

Advantages of Underlayment

Woven, coated polypropylene synthetic underlayment fabric is not only designed to protect against weather damage, but also provides greater strength, a longer UV exposure window and more secure surface for installation safety. Some underlayment options are 100 percent recyclable and up to 25 degrees cooler than asphalt felt, which can result in decreasing energy costs for your customers. At one-fourth the weight of traditional felt, but up to 20 times stronger, it ensures longevity that can’t be matched using traditional felt, particularly in areas that experience extreme heat and weather events. To prevent downhill slide during installation, underlayment is manufactured with anti-skid coating on both sides, ensuring a more sure-footed feel is achieved once attached. In addition, underlayment is certified to withstand up to six months of exposure to the sun and other weather elements before the final roofing material must be laid.

Learn More

For more information on ABC’s metal roof and wall products and for more tips on underlayment, please contact your local ABC sales representative.

Decoding Your Warranty: Paint Chalking

Posted on April 29, 2016April 29, 2024 by Heather Hollis

The third and final element of our “Decoding Your Warranty” blog series covers paint chalking. As with fading, chalking is an expected occurrence with any paint system that is subjected to outdoor exposure, and while it may be preferable to other issues such as cracking or peeling, it is still important to the metal roofing industry and its customers. As a result, similar questions should be asked about how this is addressed in paint system warranties to ensure chalking isn’t the cause of premature damage to your metal roof system.

What is paint chalking?

Also referred to as “powdering”, chalking happens when the resin (binder) of the paint system is compromised. The resin is the substance that holds the paint pigment together. It also ensures the color is evenly distributed and provides glossiness, durability and flexibility. In addition, resin has the very important job of adhering the pigment to the metal surface it’s applied to and protecting the finish against damage.

When the resin at the surface of the paint finish deteriorates, most often as a result of exposure to ultraviolet (UV) rays, the embedded pigment particles lose their adhesion to the paint film (resulting in color fading) and the resin particles take on a white (chalky) appearance that is easy to wipe off of the surface. In addition, chalking can erode the film resulting in a loss of substrate protection and run down onto the underlying structure, further degrading the appearance of your structure.

How can you protect against paint chalking?

Climates that are exposed to more intense UV rays for longer periods of time will experience chalking sooner as the environment plays a big role in how painted metal will perform. While you may not be able to control how much UV or moisture exposure your roof gets, you can choose a paint system that is not over-thinned or over-spread and that uses high quality components. ABC’s Signature® 200 system incorporates a 30 percent SMP Resin—one of the strongest in the marketplace—to help reduce the amount of chalking experienced.

Similar to the fading section of the warranty, paint system warranties allow for an acceptable amount of chalking. Chalking is measured in accordance with the standard procedures as defined by the “Standard Methods of Evaluating Degree of Chalking of Exterior Paints”, ASTM D4214. ABC guarantees the level of chalk on vertical panel applications will not chalk in excess of a numerical rating of eight (the higher the numerical rating, the better) for 30 years for our Premium paint system colors and 25 years for our Select40 paint system colors. For non-vertical panel applications, ABC guarantees a rating of 6 for 30 years for our Premium paint system and 25 years for our Select40 paint system. Consumers should be aware of these numbers, and expect them to be expressed in sample warranties.

Check out ABC’s metal color resources and warranty information to learn more!

Missed parts one and two of the “Decoding Your Warranty” blog series? Start reading now!

Decoding Your Warranty: Paint Fade Protection

Posted on April 14, 2016March 24, 2023 by Casey Walker

Will a Metal Roof Lose its Color?

Paint fading is one of the biggest concerns voiced by metal roofing customers. Over time, all paint systems will fade so it’s important for your customers to understand how warranties can protect their investment. Buying a red roof that prematurely fades to pink is unfortunate enough, but this is made even worse by a warranty that doesn’t adequately protect their purchase.

ABC WARRANTY INFORMATION: PAINT FADING

Why does paint fading matter?

The paint on your customer’s metal roof or wall isn’t just for decoration. In addition to providing color, the paint finish also protects the panels from corrosion, temperature, moisture and other detrimental environmental elements. Fading is the most common source of color change over time and happens when environmental elements deteriorate the paint’s pigment (granular particles that give the paint its color). This deterioration also reduces the paint’s effectiveness in protecting metal panels.

Paint fading is measured by the American Society of Testing Materials’ (ASTM’s) Hunter unit (∆E) standard, which compares the faded color to the original. In accordance with ASTM Standard D2244, one Hunter Unit is equal to the smallest amount of change visible to the naked eye.

What do you need to look for in your warranty?

Selecting a product with a 40-year warranty is a great start, but not all panels, paint systems and warranties are created equal. Your customers should make sure that the manufacturer provides a warranty which clearly defines the number of Hunter units the paint system is allowed to change for both vertical (wall) and horizontal (roof) applications. This is critical when comparing one painted metal roof or wall against another. The lower the number of Hunter Units expressed in the warranty, the better the paint system will resist fading.

ABC’s Premium paint system warranty guarantees paint will not fade in excess of five units in vertical applications and seven units for non-vertical applications over the course of 30 years, with the exception of Radiant Red. ABC’s fading specification on all colors available in our Select40 paint system guarantees protection for the same degree of fade as guaranteed in the Premium system, but for 25 years. Check out ABC’s color resources and warranty information to learn more!

What’s next?

Understanding the film integrity and fading for metal panels is very important, but it doesn’t end there. In the final installment of our “Decoding Your Warranty” blog, we will uncover a third consideration that can help you and your customers understand metal roofing and siding warranties: chalking.

<img decoding="async" class="aligncenter wp-image-447 size-large" src="https://www.abcmetalroofing.com/wp-content/uploads/2020/07/dripstop-1024x279-updated.jpg" alt="ABC Drip Stop for metal panel condensation" width="1024" height="279" />What causes condensation on metal panels?