Corrugated Metals Blog

Corrugated Metal Interior Application

Posted by Ken Carlton

Sep 8, 2016 9:40:58 AM


Traditionally, corrugated metal has been used as exterior cladding on buildings. 

However, cutting-edge interior design firms are utilizing corrugated metal in a wide variety of material types, profiles and applications. There are many good reasons to use corrugated metal for interior use, but among the most prevalent are a clean, sleek appearance, strength, product life-cycle, cost efficiency, and the ability to give interior spaces a unique appearance. 

The photo below illustrates the use of corrugated metal on a residential interior, which was designed by SCNZ Architects, New Orleans.

Contact CMI today for further information about uses of corrugated metal for interior design!

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Interior_use2.jpg

Designed by SCNZ Architects, New Orleans.

CMI's 2.67 x 7/8" profile - 24 GA Galvalume Acrylic Coated Steel



 

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Topics: corrugated metals, Steel, Sinewave, Interior, 2.67 x 7/8

Cedar Rapids, IA Parking Garage

Posted by Ken Carlton

Aug 7, 2014 1:53:00 PM


This architecturally pleasing parking garage is a new addition to downtown Cedar Rapids, IA. CMI is proud to be a supplier for this high profile job.

CedarRapidsParkingGarageA

 

Corrugated Metals, Inc. and our sales representative in Iowa, RW Brimeyer Sales closed the deal to supply the siding panels for the Cedar Rapids Parking Garage in Cedar Rapids, IA. This unique project designed by OPN Architects from Cedar Rapids, IA, managed by Knutson Construction and erected by Rushton Sheet Metal out of Iowa City, IA, encompassed our Bold Rib I profile made out of 0.080 Non-Clad perforated aluminum. The design started with perforated .25” diameter x .437” staggered center holes supplied by Accurate Perforating Company, Inc from Chicago, IL. CMI formed the metal in our Bold Rib I siding profile that comes 33.5” wide. We cut the panels to custom lengths dictated by our customer. After the product was formed into CMI’s Bold Rib I profile it was post painted by Crystal Finishing Systems, Inc. in 4 different colors on both sides. The colors used for this project were blue and various shades of gray. Detailed inspections of all critical dimensions ensured the integrity of this 25,000 sq-ft project.

Construction for this project commenced in January 2013 and was completed in June 2014.

Corrugated and perforated panels are a simple yet elegant solution for creating striking designs that give depth and texture to a building exterior, and our precision workmanship brought life to this architect’s aesthetic expression. 

 

For additional information on this project or CMI's architectural capabilities, click the Featured Projects link below.

Featured Projects


And if you have questions or would like to learn more about all of our products, contact us here.

 




 

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Topics: corrugated metals, aluminum, Bold Rib, Parking Garage

5 Steps to Ensure Design Efficiency for Your Construction Project

Posted by Ken Carlton

Jun 25, 2014 9:29:53 AM

denver-convention-3From the Colosseum to the Empire State Building, from a local courthouse to the local corner store, buildings and architecture make up a central part of our lives and consciousness. Perhaps no one is more aware of this than people in the construction business. This is an area that has seen more than its fair share of challenges in recent years, with the economic crisis of 2008 still looming in the background.

While construction has seen moderate growth since then, leaders in this industry continue to focus on improving the efficiency of construction projects. Making construction more efficient can not only directly contribute to a company’s bottom line, but also represents an investment for future sustainability and energy savings.

Choosing the Best Site

Designing and constructing energy efficient buildings begins with choosing the most appropriate site. There are a number of factors to consider when determining the most efficient use of a construction location. For maximum sustainability, it is best to choose sites where the least amount of land disturbance is needed.

Preserving the existing topography of a construction site minimizes excavation and allows for the conservation of trees, topsoil, and grass. Purchasing replacements for these can increase final construction cost. Also, a site that has been clear cut will often increase storm water runoff during construction, resulting in the loss of valuable topsoil and other erosion issues.

There are many other considerations involved as well. The access of the structure to sunlight could affect the building’s heating and cooling requirements. How windy the area is will also play a role in heating and cooling. This includes the direction of the prevailing wind, as well as the effect that cold winter winds or cooling summer breezes will have on energy efficiency.

A location’s current water drainage patterns should also be examined to ensure that the maximum amount of natural drainage will remain after construction. This will retain the current site’s topography while minimizing possible water damage in the future.

Optimal Building Design

Architects and designers can take steps such as locating spaces with no HVAC requirements toward a building’s colder areas, along with limiting the number and size of north/south side windows on buildings in cold climates. Making sure that windows in each room provide cross ventilation will give free cooling during the spring and fall. Designing buildings that provide maximum daylight can reduce the amount of artificial lighting that is required.

General contractors and sub-contractors can also contribute to efficient building design. Air and vapor barriers should be appropriately installed. These products, which inhibit the movement of airflow and water vapor inside a structure, need to be well secured and sealed to inhibit any possible damage done to them during construction.

In addition, contractors can ensure that air leaks in a building’s thermal envelope are properly sealed. This has been shown to save energy expenses by up to 50%. Finally, contractors can make sure that insulation is installed precisely according to the manufacturer’s instructions. When insulation is inappropriately installed, it reduces energy efficiency and can even be detrimental to the building.

Resource Efficiency

Efficient building design makes the best use of resources. The construction of new buildings can produce a fair amount of debris and waste, so using resources efficiently is very important to keep the industry sustainable. There are many ways to accomplish this.

These include techniques known as “optimum value engineering” that reduce the amount of wood needed for construction. Building with wood is a sustainable method in general. When wood is taken from sustainable sources, it provides more energy efficiency than working with cement or steel.

Another familiar practice that helps make the most out of resources is recycling. Much of the waste created in the construction process could be recycled, but simply isn’t. Salvaging and recycling this waste requires some planning, but ultimately saves money while protecting the environment.

In addition to using and recycling construction materials, new buildings should incorporate features that make it convenient for consumer goods to be recycled throughout the building, further helping to save space in landfills and foster sustainability.

Saving Time and Money

As the construction industry continues to gain economic stability, it’s important for different sectors of the industry to employ time and money-saving techniques. There are a vast number of techniques for this purpose, including purchasing materials in bulk. With the volatile nature of the material costs, bulk purchases can be made that save time and money.

Many seasoned contractors have close contact and knowledge of the marketplace for their supplies and are able to navigate cost spikes with bulk purchasing. Another time and money-saving technique in construction is to purchase locally. Purchasing within a 500 mile radius can bring many logistical advantages that include less fuel consumption and faster delivery times, as well as decreasing a company’s carbon footprint.

A Growing Field

The art of maximizing design efficiency in construction has grown a great deal in recent years, and continues to do so today. In an economic climate that can be filled with uncertainty, making time and money-saving choices that lead to better overall sustainability is always a smart choice.

Working with the best sites, building designs and most efficient use of resources not only aids the bottom line of the construction company. Efficient design and construction contribute to an economy that will ensure high performance and sustainable buildings to help the environment for years to come.

To read more about our products and the processes we utilize and recommend for optimizing efficiency, visit our Architect's Corner and select from our wide range of data sheets, CAD files, and more. 

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Topics: corrugated metals, American Construction, design efficiency

Aluminum and the LEED Revolution

Posted by Ken Carlton

Mar 10, 2014 7:42:00 AM

aluminum_bitsSince its introduction in 1993, the U.S. Green Building Council (USGBC) has been promoting sustainability in America’s building industry. Its most well known initiative is the Leadership in Energy and Environmental Design (or LEED) green-building rating system. According to the USGBC website, LEED provides: “a framework that gives project teams the ability to choose solutions that contribute to aggregate environmental progress.”

When it comes to actual building materials, aluminum finds its way into many LEED-rated projects. In 2008, aluminum producers claimed that approximately 85% of domestically produced, flat rolled products for the construction market were made of recycled content. This high level of recyclability is not a surprise when it comes to aluminum. Not only does both post-consumer and post-industrial aluminum contain high percentages of recycled content, but also aluminum itself is 100% recyclable. Other amazing eco-friendly qualities of aluminum include:

  • Aluminum from recycled materials requires only around 5% of the energy required to produce aluminum from bauxite ore.
  • Using recycled over raw materials to create aluminum reduces air pollution by 95% and water pollution by 97%.
  • There is no limit to how many times aluminum can be recycled, so it never loses quality. Therefore, even after it long lifespan, it can be quickly reintroduced into the material stream.
  • LEED buildings, many of which feature recycled aluminum, use 25% less energy than the national average, which adds up to $675.26 per employee!

It is clear that the LEED rating system is becoming a critical part of the American construction industry. As more construction professionals discover the benefits of LEED-rated buildings, the more it becomes clear just how eco-friendly and versatile aluminum can be.  

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Topics: corrugated metals, aluminum, American Construction

The Benefits of Weathering Steel

Posted by Ken Carlton

Feb 24, 2014 7:39:00 AM

Rust is a phenomenon that most engineers seek to avoid, but is actually desirable in weathering steel. Also known as Corten steel, weathering steel is characterized by what the American Institute of Steel Construction (AISC) describes as “useful corrosion,” in which naturally occurring rust not only lengthens the lifecycle of a weathering steel structure, but also saves the time and money associated with painting and maintenance.  Rust on weathering steel sheets is not a sign of deterioration as with corrosive steel sheets; in fact, it is just the opposite.

Corten, which was trademarked by the United States Steel Corporation (USS), is the well-known brand name of weathering steel. Corten originally received the ASTM standard designation of A242, but is now recognized by the newer ASTM grade for steel sheets and coils, A606. Weathering steel was specifically developed with small amounts of copper, phosphorus, chromium, nickel and silicon. These materials allow Corten steel sheets to form a layer of rust when exposed to weather, excluding the need for paint.

weathered_steelInstead of ruining the metal, however, rust actually serves to protect Corten from further corrosion. Weathering steel sheets, which initially look rather unremarkable, form a protective barrier of rust when exposed to moisture and oxygen.   That barrier eventually seals the exposed Corten steel sheets against the very elements that caused them to rust in the first place. According to AISC, “this stable barrier layer greatly resists further corrosion, reducing it to a low value.”

Weathering steel is also conveniently high strength, low maintenance, and cost effective. The abundant benefits of weathering steel make Corten steel sheets ideal for structural and architectural applications such as bridges, roofing and open-framed buildings. Bridges built with Corten have been known to last up to 120 years with minimal maintenance, which involves regular inspections and cleaning. Because weathering steel does not require paint, builders can also avoid the health issues concerning volatile organic compounds found in certain paints.

The popularity of weathering steel may also be explained, in part, by its attractive appearance. Structures built with Corten steel sheets take on the reddish, orange color of rust. As the rust deepens with further exposure to the environment, the steel sheets develop a deep russet patina that many people find appealing. The unusual appearance of weathering steel was featured in the New York Times a few weeks before the Barclays Center, built with Corten, opened. Weathering steel structures, the article observed, “can look suspiciously unfinished to the casual observer, [yet] has many fans in the world of art and architecture.”

Corten steel has been well-received by a community of architects and design engineers because of its considerable benefits. Weathering steel has a proven ability to withstand use over the long term, while requiring minimal upkeep. Structures built with Corten steel sheets do not require paint, which is good for the environment and the bottom line. Weathering steel sheets also develop a patina of rust that does not harm the Corten, but rather beautifies it. Beautiful and practical, weathering steel is an excellent building material. 

 

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Topics: corrugated metals, Steel, Rust

How Steel Made the Modern World

Posted by Ken Carlton

Feb 10, 2014 7:39:00 AM

metal_structureHere is a hard-to-argue fact: Without steel there would be no modern industrial world. Though the art of steel making dates back to 4000 B.C., the steel we rely so heavily on today was made possible by the development of the Bessemer process in 1856 and the first usage of the galvanizing process in 1836. These groundbreaking scientific discoveries allowed for the production of large quantities of high-quality steel at lower costs. It also marked the beginning of a switch from iron to steel and, more importantly, the start of the Second Industrial Revolution.

As has been widely documented, this boom in steel production allowed for the creation of transcontinental railroads both in America and around the globe. The connecting of once remote lands via 30,000 miles of new rails also allowed for a new era in agriculture and manufacturing. As cities grew out of this transformation, steel also allowed for the creation of high-rise living and skyscraper-filled financial districts. It was and still is a wave of overwhelming change that has little match in the history of humanity. Other interesting facts about the birth and blossoming of the modern steel industry include:

  • 60% of the world’s steel is produced using the Basic Oxygen Steelmaking Process.
  • Worldwide steel production has more than tripled since 1943.
  • China is now the world leader in steel consumption with an amazing 623.9 million tons of steel per year. To put that number into perspective, the U.S. is second with 89.1 million tons.
  • One-quarter of an average computer is made of steel!
  • Steel has a great deal to do with the growth of modern medicine thanks to its role in surgical and hygienic safety equipment.
  • Steel is incredibly sustainable. Over 80% of steel products are recycled.

There is no way to overstate the importance of modern steel. Its amazing combination of strength, formability and versatility, allows steel, especially galvanized steel, to continue to build the world of the present and future.  If you want to learn more about the history of steel, you can always check out the website of our friends at the American Iron and Steel Institute (AISI). 

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Topics: corrugated metals, Steel, AISI

Steel vs. Aluminum: What’s Right for Your Trailer?

Posted by Ken Carlton

Jan 14, 2014 8:37:00 AM

trailer_hauling_livestockHere’s a question that has been plaguing manufacturers for decades: Do you use steel or aluminum for your product? As you might imagine, the choice is critical on a wide range of levels. Issues like weight, strength, corrosion-resistance, carbon footprint and cost all play roles in deciding which direction to go. When it comes to trailers (the ones used to transport horses, cars, livestock and other products and materials) most of the industry’s leaders are fans of aluminum. So how did all the biggest names in trailers conclude that aluminum was far superior to steel for their products?

Corrugated Metals - Comparing Aluminum and Steel

While there are many factors involved when choosing between aluminum and steel, the following five factors stand out:

  • Weight - There isn’t much argument that aluminum weighs less than classic steel. While the price of a steel trailer might be lower when purchased, the second you get an aluminum trailer out of the road you instantly begin saving money. Whatever weight the steel adds to the trailer is pounds of cargo that you don’t carry.  This is especially a big deal to over-the-road truckers who must constantly battle with weight restrictions.
  • Strength - Don’t be fooled, modern aluminum is tough and strong. While it cannot match steel’s yield and ultimate strengths, aluminum can certainly hold its own. In addition, aluminum has a better strength-to-weight ratio.
  • Corrosion - In general, aluminum is much more corrosion resistant than regular steel. Some of the extremely expensive and difficult-to-work with stainless steels do offer excellent corrosion protection. However, they are heavy and absolutely cost prohibitive for use in trailers. 
  • Green Benefits - According to the Aluminum Association: “one pound of aluminum in place of 1.5 lbs. of steel in a typical bus or truck application reduces greenhouse gas emissions by almost 90 lbs. over the lifetime of the bus or truck.”
  • Cost - This one isn’t as clear cut as the issues above. The initial cost, what you pay to have a trailer manufactured, will most likely be higher with aluminum. Steel does have a number of cost benefits (upkeep, repairs); but if you crunch the numbers, the costs associated with aluminum and steel equal out in the end, or even in favor of aluminum.

After looking at these factors, and many more, it starts to become clear that when it comes to trailers, aluminum is your best bet. Of course, this is not the case for all situations, and you should always share your unique needs with your trailer manufacturer or salesperson; but in general, aluminum is the perfect corrugated metal material for your next trailer. 

Interested in learning more about our full line of corrugated metal products? Download our full product brochure to get started:

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Topics: corrugated metals, Steel, aluminum, Trailers

The True Beauty of Corrugated Metal

Posted by Ken Carlton

Nov 25, 2013 1:18:00 PM

corrugated_metal_redOne of the biggest myths about corrugated metal siding and roofing is that it is ugly and drab. Visions of poorly designed Quonset huts and mundane backyard sheds might even come to mind.  In reality, corrugated metal is a versatile, innovative, and often stunningly beautiful building material that is at the vanguard of the modern architectural movement.

Invented by Henry Palmer in the 1820’s, corrugated metal is to this day a common building material all throughout the world. Its staying power comes from a combination of durability (they last 2 to 3 times longer than asphalt shingles), utility, manageable weight, corrosion-resistance, and cost. For years, it got the reputation as an inexpensive and bland alternative to other roofing and siding materials, like wood, tile, and stone. However, over the past decade, designers and architects have fallen in love with the versatility of corrugated metal. 

corrugated_metal_blueThe fact of the matter is that corrugated metal roofs and siding have now attained “coolness.” It has found its way into all environments. Whether it is found in the middle of the hippest new urban neighborhood, on a beach, or down a classic country road; corrugated metal stands out as unique and attractive. Some of the biggest names in modern architecture, including Frank Gehry, Renzo Piano, and Glenn Murcutt, all have and continue to rely heavily on corrugated metal siding and roofs to create some of the most iconic buildings the world has seen.

Another reason for the corrugated metal renaissance is its unique ability to be energy efficient. Being “Green” is a major part of modern architecture. Properly coated corrugated metal roofs are not only appealing to the eye, but can also cut heating and cooling costs dramatically.

One can only hope the myths surrounding corrugated metal will vanish as more architects, designers, and building owners discover its true beauty.

 

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Topics: corrugated metals, roofing and siding

Protect Your Company from Purchasing Counterfeit Metals

Posted by Ken Carlton

Nov 11, 2013 8:15:00 AM

It has been said that “imitation is the sincerest form of flattery” and in some cases that may be correct.  However, when it comes to construction materials that are counterfeits to the real deal, that imitation may cause great harm to life and property.

counterfeit_wordcloudThe Construction Industry Institute (CII) recently sponsored a study, “Product Integrity Concerns in Low-Cost Sourcing Countries,” about the counterfeit construction materials.  The report included a reference to a 2003 study on the overall market of counterfeits.  It found that the market was valued at about $1 trillion, which included the knock-off Fendi bags and Rolex watches, but also the metals, fasteners, and other materials used in American construction.

This Issue at Hand

The CII study notes: “Although there are many areas of concern related to product integrity, the potential impact of counterfeit products to plant performance, plant life cycle, safety, [and] structural and product integrity was the focus of this investigation. While there is much literature on counterfeiting in general, there is almost nothing documented on counterfeiting relative to the construction industry. For example, the counterfeit ‘industry’ does hundreds of billions of dollars of business annually; however, the scope of counterfeiting within construction is unknown. What is known is that counterfeit products have caused significant negative impacts to safety, project schedules, overall costs and quality of construction.”

welderThe study focused on interviews with approximately 187 construction industry officials, as well as members of various governments.   The CII research was conducted in China, Taiwan, Hong Kong, the United Kingdom, Pakistan, Canada and the United States.

The report delved into the Class A through C counterfeit types.  Class A counterfeit products are of high quality but obviously flawed, materials or products with a Class C designation are literally unusable or at least should not be used.  Other types of forgeries include products with labels or stamps from legitimate testing or licensing authorities, such as the Underwriters Laboratories or other similar organizations.  These cause the greatest concern because of the false sense of security that they are legitimate and have been tested in some manner.

The CII provided a list of the top 10 counterfeit construction materials and products.  These are listed in the chart below:

chart

Recommendations and Efforts to Educate Manufacturers and the Supply Chain

Supplier pre-qualification, manufacturing surveillance, resident inspection, third-party verification, and unscheduled in-process inspections are all activities that manufacturers need to diligently perform or procure if they are to maintain supply chain integrity. Here are a few recommendations from the CII that are contained in our eBook (LINK to eBook!) for the industry and the individual contractor to fight the problem:

  • Confirm and verify that every link in the supply chain is secure and observed. Responsible manufacturers have designed and implemented highly reliable and secure distribution networks that ensure product integrity. For branded products, trust only manufacturer-authorized distributors.
  • The industry as a whole should adopt a zero-tolerance policy regarding counterfeiting. Report all incidences of counterfeiting to the appropriate authorities and never fail to support any law enforcement agency’s effort to prosecute to the full extent of the law.
  • Train/educate customs officials and other law enforcement agency personnel regarding measures against counterfeit construction goods and materials—not just the higher-profile retail

Our Stand on Counterfeit Materials

At Corrugated Metals, we adhere to the strictest guidelines in securing our lines of supply against counterfeit materials. We sell only prime aluminum and steel products. Every product we manufacture is accompanied by mill certification reports, which document the quality of the metal. Every product is checked for gauge, length, width, coverage, surface, and other quality parameters. And we make it our business to be the best-informed and most proactive company in the roll forming and corrugated metal field.

Want to learn how you can protect 
your business from counterfeit materials?

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Topics: corrugated metals, Counterfeit Metals, Premium Aluminum

Frightened About Freight Laws? Corrugated Metals' Shipping Saver Can Help

Posted by Ken Carlton

Oct 28, 2013 1:18:00 PM

Earlier this year, new regulations set by the Federal DOT regarding hours of service for drivers went into effect. The new Hours-of-Service (HOS) Regulations have been poised to change the landscape of shipping in the United States since 2011. Freight carriers are now adjusting to the consequences of reduced capacity and productivity.

saving_money_buttonThe HOS regulations enforce stricter limitations on the number of hours that a driver can drive consecutively, and per day. They also set limitations on minimum 34-hour restarts. Prior to these regulations, there were no rules regarding mandatory rest breaks, consecutive driving hours or restarts.

When the rules were first proposed three days before Christmas in 2011, they met with strong opposition from organizations such as the American Trucking Association. To many members of the trucking and shipping industry, the rules anticipated an overall reduction of capacity which, in addition to the current shortage of drivers, would especially hurt the industry during this time of year.

In response these regulations, Corrugated Metals is happy to announce our Shipping Saver Program, a service designed to help purchasing managers and estimators cut costs on shipping during the predicted squeeze after the regulations took effect.

Just put your name on our list, and we’ll give you a call when our delivery trucks are scheduled to pass by your plant or facility. You can place an order at the same time, and we’ll load it onto the truck and deliver it to you for a reduced shipping fee. It’s a win-win situation for all.

To make this program work, all we need is your contact information. If you’re interested in saving money on shipping, especially during the year-end holidays, please visit our website today. 

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Topics: corrugated metals, Freight Carriers, Shipping, HOS Regulations