IEQ MATTERS: THE BENEFITS OF METAL WALLS AND CEILINGS

Indoor environmental quality (IEQ) has become a top priority in a time when awareness of health, safety, and well-being is more acute than ever. Metal walls and roofs can provide solutions that consider IEQ and sustainability goals.

IEQ refers to the quality of a building's interior environment in relation to the health and well-being of those who occupy it. Components of IEQ include indoor air quality, lighting and daylighting, aesthetics, and acoustics, all of which are vital elements for architects to consider. When IEQ is poor, occupants suffer long-term and short-term physical and mental effects. According to the EPA, Americans spend, on average, about 90% of their time indoors. For this reason, IEQ design becomes even more crucial.

Furthermore, the people most susceptible to adverse effects of poorly designed spaces—the very young, older adults, and people with medical conditions—tend to spend even more time indoors. Within these indoor environments, issues such as too much noise, bad air, and poor lighting can interfere with daily activities. Lack of communication, concentration, and sleep lead to stress responses such as high blood pressure and anxiety. Noise can impact mood and well-being for all those occupying the space.

Metal walls and roofs can address a variety of these IEQ components. New low-VOC coatings can assure that any metal elements will reduce the release of toxins into the air. Metal products come in a variety of shapes, colors, sizes, and patterns that provide aesthetic design that makes homes and commercial buildings feel comforting. They may provide biophilic design that evokes elements of nature and has proven positive effects on occupant health. And metal walls can integrate with window, door, and lighting designs to help bring natural light into a space in inventive ways that support good sleep cycles and, during the day, productivity and elevated moods.

It may seem like a strange material to associate with acoustics, but when it is combined with other materials, it can provide quality sound absorption. One example is perforated metal acoustical ceiling and wall panels. Since they are metal, they are highly durable, and with the array of painting and patterns that are now associated with metal, they can be aesthetically appealing.

Metal sound-absorbing panels are often added to existing metal barriers to reduce reverb and lower reflected sound. They can be attached to walls and ceilings, including as absorptive baffles.

Perforated metal was developed for the mining industry about 150 years ago as a way to filter coal. Now it’s being used in a variety of mainstream applications for sound control including restaurants, airports, concert halls, offices, retail, and manufacturing facilities.

The manufacturing process for perforating metal starts with sheet metal, which can be cut and bent into different shapes. The most common method for perforation is using a rotary pinned roller that features sharp needles that punch holes in the metal. Metal can also be perforated through die and punch methods and by laser.

PIKES PEAK SUMMIT COMPLEX

Photo courtesy of Metl-Span

Pikes Peak Summit Complex met the rigid requirements for the Living Building Challenge using metal for its roofing system.

Location: Colorado Springs
Project Goals: Living Building Challenge and load requirements for the roof

The Pikes Peak Summit Complex was the highest ongoing construction site in North America during its construction. This challenging project created a facility that takes advantage of the inspiring views and natural beauty of Pikes Peak, also known as America’s Mountain. The building had several unique challenges because of its location on Pikes Peak, which has an elevation of 14,114’[ML1] .

At this elevation, it’s difficult to walk without getting out of breath due to the high elevation and low air pressure. The area is prone to heavy snow, even in summer, and the near year-round weather makes for a short construction window. The wind speed can get up to 170 mph, which was a challenge for installers hanging panels.

On top of the load-bearing challenges of the complex, the project aimed to meet the Living Building Challenge. They needed a metal roofing system that could meet both of those requirements. It involved early planning in which the engineering team had to show the panels would stand against the extreme conditions. LBC data were submitted for all roof components including sealants, butyl, clips, roof panel, backplates, seam sealant, snow guards, and sheets to make sure they met the LBC’s stringent requirements.

The roof has a 1:12 pitch and is shaped like a trapezoid, with panels as long as 115’. The panels tie into a gutter that borders the perimeter of the roof, which is made from a ¼" plate to support the snow load. The project started with high-density expanded polystyrene (EPS) insulation with ¾" plywood mechanically attached to structural metal decking. An ice and water shield was installed and trim details that tied into the gutter system were completed. Clips fixed the metal panels, allowing for thermal movement toward the eave. A crane lifted the roll former onto the roof so the metal panels could run the full length of the roof system. Clips were installed and the roof panels were seamed as they were being installed to avoid any issues if a wind event at this elevation were to occur. The peak detail was installed to complete the roof, and finally, a snow guard system was installed.

VAIL ELEMENTARY SCHOOL

Photo courtesy of MillerClapperton

Vail Elementary School’s pre-engineered design was constructed quickly, thanks to its preapproved building system made up of insulated roof and wall panels.

Location: Santa Ana, California
Project: Pre-engineered metal building system

For the construction of Vail Elementary School, a lot of planning went on behind the scenes. The construction company had already developed pre-engineered building systems of various sizes that were pre-approved by the Division of State Architect (DSA). Once they began the project, they were able to choose one of the pre-approved building systems that fit the size they needed. The system already had pre-sourced and pre-verified materials and components, including insulated metal roofing and wall panels.

The advantage to being preapproved with the DSA is that the structural components did not have to be submitted again under the site-specific plan review. All the work and approvals were done, and they were able to break ground and build the school in a shorter timeline, saving the school district six months.

Despite the pre-engineered style, the manufacturer still provided flexibility for location of doors and windows. And the system allowed the client to choose color, style, and thickness for the insulated roof and wall panels. That kind of choice allowed the school to select options that met their needs, including school aesthetics.

The panels the school chose featured an exterior finish in a light color that emulated stucco.

The 36”-wide panels with a 2½” urethane core boast an 18 R-value; 5,766 square feet of wall panels and 6,844 square feet of insulated roofing panels featured a Terra Cotta finish. The 42”-wide roof panels are 3” thick.

Even toward the end of the project when the construction crew was getting ready to work on ductwork, doors, and windows, there was no question about what they needed to do in terms of energy efficiency. The pre-engineered design had already taken into account components such as IMPs, which would achieve the energy codes for heating and cooling in California.