May. 27, 2024
Construction
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If you&#;re going through the process of choosing the right metal roof material for your project, you&#;ll see that two of the most common choices are steel (Galvalume®) and aluminum.
Both are great options for standing seam metal roofing projects, but there are some situations when Galvalume is the better choice and some when aluminum will work best.
Sheffield Metals is a leading metal sheet and coil distributor &#; in both Galvalume and aluminum substrate options &#; for the architecturally-driven metal roof and wall industry. We&#;ve helped hundreds of home and property owners, contractors, architects, and manufacturers choose the right metal for their project(s).
That&#;s why we believe comparing Galvalume vs. aluminum and the pros and cons of using each material is important.
Galvalume, a flat rolled steel-based metal roofing material, combines three of the most high-performing metallic coatings used in roofing today &#; steel, aluminum, and zinc. To create Galvalume, mills begin with a cold-rolled carbon steel base sheet that is then continuously hot-dipped with aluminum and zinc alloys (AZ) until it reaches a coating of 55% aluminum, 43.4% zinc, and 1.6% silicone. This process allows Galvalume to have some of the best characteristics of each metal, which is why it&#;s one of the most popular metals used in metal roofing.
Galvalume can be utilized as a roof, wall, trim, accent, and more in most building applications. Plus, it&#;s suitable for use in some extreme environments, such as non-coastal hurricane zones, high rain or snowfall locations, high-temperature regions, and more.
Here&#;s a selection of some of the most common applications that use Galvalume:
In standing seam metal roofing, the most common thickness of Galvalume is 24-gauge, but anywhere from 22 to 29-gauge material is standard. Galvalume is sometimes referred to by its coating weights, AZ-50 and AZ-55. Here&#;s a breakdown of these two terms:
Warrantied product &#; One of the main selling points of Galvalume is the 25.5-year warranty on the substrate, which is sometimes referred to as a perforation warranty. Galvalume systems also often come with paint warranties that further protect your investment and provide peace of mind that the roof or wall system will last. Plus, non-residential property owners can buy a weathertight warranty for their Galvalume roofing structure, which ensures the roof was installed correctly and adheres to strict installation details. (Note: Substrate or paint warranties are NOT available for Galvalume products within 1,500 feet of a coast.)
Corrosion resistance & self-healing properties &#; Galvalume&#;s coating formula combines zinc&#;s strength and self-healing characteristics with the rust-resisting properties of aluminum. These characteristics help control the red rusting at exposed edges of Galvalume panels. Most steel-based products will experience typical edge creep from the exposed steel, but it will eventually stop with Galvalume. These characteristics make failure in the roof field less likely with Galvalume systems.
Easy to handle & install &#; Another benefit of Galvalume is that it&#;s not as temperamental as other metals used in the roofing industry. Installers don&#;t have to worry as much about leaving fingerprints, dents, deep scratches, etc., on Galvalume panels because they&#;re tougher and more tolerable. It also doesn&#;t have many strict ventilation or air gap requirements like some other metals &#; including aluminum. Galvalume is a standard metal roofing product and often doesn&#;t have special installation details or requirements.
Economical & competitively priced &#; For the most part, Galvalume is reasonably priced and one of the most affordable metal materials available for roofing products &#; especially when compared to aluminum. Here are average price ranges for just Galvalume coil; these numbers do NOT account for installation, other thicknesses, rollforming, finishes, colors, locations, or special orders:
Keep in mind that into mid-, steel prices are continually fluctuating, so the price can vary dramatically.
Not recommended in coastal environments &#; The coating of Galvalume will not stand up to the conditions associated with a coastal environment, including properties up against breaking surfs, large bays, marshes, and other coastlines. Specifically, saltwater will degrade the Galvalume coating and lead to premature damage to the roof or wall. It&#;s recommended that properties within a certain distance of a coast use an engineered aluminum roof system, as aluminum resists corrosion and rusting from saltwater for much longer.
Not suitable for most animal enclosures/buildings &#; Galvalume is not suitable for use on buildings where animals are housed or held. Animal waste products put off ammonia gas, which over time reacts with the Galvalume coating and leads to degradation of the metal. However, Galvalume is sometimes used on modern chicken houses with a vapor barrier between the chicken area and the roof for appropriate ventilation. It&#;s best to check with the manufacturer before putting Galvalume on any animal confinement building, as it&#;s often dependent on the structure&#;s use and design.
Heavier than aluminum &#; When looking at the weight of a roofing product, there are pros (durability, ease of installation, etc.) and cons (stress on the building structure, etc.) to heavier materials. Overall, metal roofing is significantly lighter than asphalt shingles, tiles, and most other roofing materials. When compared to Galvalume, aluminum is more lightweight. A typical 24-gauge Galvalume roof weighs anywhere from 1 to 1.5 pounds per square foot for a finished panel, and a .032 aluminum roof weighs less than half of that same 24-gauge Galvalume panel.
Interactions with other materials &#; Galvalume performs best when not in contact with specific building materials, including concrete, treated lumber, copper, lead, bricks, and iron. If Galvalume is in contact with one of these and is then introduced to an electrolyte such as water, it can lead to galvanic corrosion of the metal and potential failure of the roof system.
Also, if you are using multiple types of building products, be sure to confirm with manufacturers that their products are compatible. For instance, let&#;s say you want a metal roof with wood shingles. Some wood shingles are &#;treated,&#; and often times the treatment can react adversely with the metal roof.
Aluminum is a lightweight, silver-white metal that is element 13 on the periodic table and is the third most abundant element on Earth. However, aluminum never occurs in its metallic form in nature. Its compounds, usually aluminum sulfates, are chemically broken down using electrolysis/electrolytic reduction to produce the aluminum metal material.
Aluminum sheet and coil products used to make panels are sold according to the thickness in inches (usually in decimal form), so the higher the number/decimal, the thicker the aluminum material. There are varying thicknesses of aluminum, but the size to purchase is often dependent on the use or application:
Plus, aluminum typically comes in similar (if not the same) color, finish, and paint system options as Galvalume.
Overall, aluminum is suitable as a roof, wall, trim, and more in several different environments, including coastal environments, hurricane zones, locations with high rain or snowfall, high-temperature regions, and more. Here are some ordinary aluminum roofing applications:
Self-healing & no red rust &#; Aluminum is unique in how it handles the minimal corrosion it experiences. When it begins to corrode, it doesn&#;t red rust as steel products do; instead, it oxides and forms hard oxidation (or oxide film) on its coating, which protects the metal. This helps to preserve the material and make it last in corrosive environments, like coastlines. Plus, the oxidation forms rather quickly, so there&#;s no edge creep or red-rust formation that can happen with steel material.
Suitable for use in coastal environments &#; One of aluminum&#;s most significant selling points is that it performs well in coastal environments. As we mentioned, aluminum has much better corrosion resistance than steel products, especially in harsh coastal environments where saltwater can wreak havoc on a roof system. Because aluminum oxidizes as it starts to corrode, it makes it stronger and prolongs the system&#;s life on the coast. This makes aluminum the metal roofing material most commonly installed in the Caribbean Islands, on the Atlantic coastline, the Gulf Coast, and the Pacific Coast. Best of all, aluminum roofing systems still carry a PVDF paint warranty when installed in coastal areas.
Warrantied product &#; Aluminum metal roofs come with various warranty options, including paint, substrate, and weathertight warranties, which help protect your investment and provide peace of mind that the roof or wall system will last. There are even paint warranties available on aluminum products used in coastal applications. For example, Sheffield Metals offers a 25-year PVDF paint warranty for coastal properties and a 20-year PVDF paint warranty for Caribbean properties. Or, if your property is NOT in a coastal environment, our standard 40-year PVDF warranty applies to aluminum roofs as well.
Suppose you&#;re a commercial property owner and your building is on a coast. In that case, you even have the option to buy a weathertight warranty for an aluminum roofing structure, which ensures the roof was installed correctly and adheres to strict installation details. Learn more about Sheffield Metals&#; weathertight warranties in this comprehensive article.
Lightweight &#; As we discussed, metal roofing is one of the lighter roofing materials, which helps reduce the added stress on a building&#;s frame. Aluminum is one of the most lightweight metal materials, which makes it easier for contractors to transport, handle, and get panels onto the building. Plus, if you&#;re running panels on-site with a portable rollforming machine, a lighter coil can be easier to transport and puts less stress on the rollformer. (Note: Because .032&#; aluminum is thicker than 24-gauge Galvalume, aluminum coils will be slightly less lineal footage).
Highly recyclable &#; Metal is almost always recyclable in one way or another, and aluminum is one of the world&#;s most reusable and sustainable metals. About 95% of all aluminum roofing systems installed worldwide are made from previously recycled aluminum materials. At Sheffield Metals, we use a series aluminum alloy () primarily made from previously recycled materials and very little pure aluminum. Aluminum&#;s high recyclability and reusability are why many people choose aluminum for their projects, especially those looking to meet LEED certification requirements.
Thicker materials available vs. steel &#; Thicker aluminum is more readily available than steel, which is a distinct advantage for larger copings. Galvalume is typically readily available in thicknesses up to 22-gauge (approximately .030&#;), and aluminum is generally available in thicknesses of .050&#; and .063&#;, depending on the metal supplier. This allows contractors to have larger copings and fascias while minimizing the appearance of oil canning.
Easier to bend and dent &#; This drawback is both a benefit and a disadvantage of aluminum. On the one hand, aluminum is more malleable than steel, which means it can be easily bent and fabricated without experiencing any breaks or cracks. This is especially helpful during the rollforming and fabrication of panels. However, since aluminum is a little softer and lighter, it has been known to dent easier than other metals during and after the installation. Contractors should use extra caution when handling, removing PVC, and installing aluminum panels. Improper handling can cause imperfections and/or oil canning to be visible in the finished installed panel. Additionally, if a structure is beneath trees or other objects that could fall on the roof, another type of metal material may be a better option to help preserve the roof&#;s look.
Luckily, the tensile strength of aluminum is comparable to steel, but aluminum is more susceptible to surface denting.
Medium to high price point &#; Aluminum is in the mid to high price range for material cost, which makes it not the most affordable metal material option. On average, aluminum sheets and coil (not accounting for rollforming, installation, finishes, color, location, etc.) comes in at about $2.20 to $3.00 per square foot. Similar to Galvalume, aluminum is also experiencing price fluctuations in .
Requires more space for thermal movement &#; Aluminum expands and contracts roughly twice as much as a steel roof. This is something that contractors need to be aware of during the installation to allow enough room for the thermal movement of the panels. This is especially important when using a mechanically seamed profile in panel lengths greater than 15-20 feet. It&#;s recommended that an expansion clip be used per the applicable engineering for panels of a longer length. Restricted expansion and contraction of an aluminum roof can cause oil canning, increased noise, and more required maintenance on any exposed fasteners.
Natural color &#; It&#;s typically not recommended to use a bare aluminum product with its natural silver-gray color. As the metal ages, experiences weathering, and oxidizes (white rust), it doesn&#;t hold its original mill-finished color and often becomes washed out and spotty. The best way to overcome this issue is to buy painted roofing coils or panels, which will age much cleaner over time because the paint covers any metal color changes.
To help with the decision process, we wanted to lay out some common scenarios that might influence the material you choose for your project.
Best material choice: Aluminum
Explanation: Galvalume/steel materials will corrode when exposed to saltwater environments and lead to the premature failure of your roof. On the other hand, as aluminum is exposed to saltwater/coastal conditions, the material begins to oxidize, making it stronger and prolonging the system&#;s life. You will undoubtedly want to choose an aluminum metal roofing system for coastal properties. You then qualify for more warranty options, including paint and weathertight warranties.
Best material choice: Galvalume or aluminum, but usually Galvalume
Explanation: For the most part, homes and properties that are not on the coast will end up choosing a Galvalume metal roofing system. It&#;s more common/readily available, has standard installation details, and is the more economical choice. However, aluminum is still an option for non-coastal projects as well.
Best material choice: Galvalume
Explanation: Acrylic-coated Galvalume (AZ-55 or Galvalume Plus) is an excellent option for those looking for a natural bare metal finish. Bare aluminum is usually not a color or material option, as the metal will become washed out and spotty over time. Galvalume and aluminum can also be coated in paint systems similar to bare metal colors/finishes, such as Silver Metallic, Copper Metallic, and Medium Bronze.
Best material choice: Both Galvalume and aluminum
Explanation: As we discussed, Galvalume and aluminum have various warranty options, including paint and weathertight. The level of coverage will vary based on your location, paint system, panel profile, etc. However, there are still warranty options available for Galvalume and aluminum products installed according to the manufacturer&#;s warranty requirements.
Best material choice: Neither (or choose a striation or rib-roller for the flat of the panel)
Contact us to discuss your requirements of Galvalume Steel Coil for LED backlights. Our experienced sales team can help you identify the options that best suit your needs.
Explanation: Oil canning is an inherent characteristic of light-gauge, cold-formed metal products &#; including Galvalume and aluminum. It is a visual phenomenon seen as waviness or distortion in the flat surfaces of metal panels. Luckily, oil canning is only an aesthetic concern that does not affect the strength or performance of the system.
Plus, there are methods to minimize the appearance of oil canning, including:
So, is Galvalume or aluminum the better material? It depends.
When choosing between materials for your project, a qualified, skilled, and knowledgeable contractor or manufacturer is the best place to start. They will be able to recommend the material that is best based on your project attributes, which may include (but is not limited to):
Sheffield Metals is dedicated to educating customers and potential buyers to make the most informed decision about the best metal material for their roofing project &#; Galvalume, aluminum, or otherwise. Whether you&#;re a contractor, architect, manufacturer, property owner, or beyond, we can work with you to choose the right product.
Contact one of our knowledgeable metal roofing specialists today to ask your questions about Galvalume, aluminum, or any other metal roof type!
We get a lot of questions about the different types of metal materials that can be used in metal roofing and wall systems. There is one question that comes up more often than others:
What is the difference between Galvalume® and galvanized metal?
These two metals, which are technically coatings applied to a steel core, aren&#;t all that different from one another by definition. However, the benefits and drawbacks of Galvalume and galvanized metal significantly differ, including how long each one lasts, the expectations of how each one will perform, and more.
While our main product focus at Sheffield Metals is painted or bare 24-gauge Galvalume coils and sheets used in the standing seam metal roof and wall industry, we sell galvanized metal products as well. In essence, we believe it&#;s important that you know the different attributes of these two materials so you can make the best choice for your project.
In this article, expect to learn:
Bethlehem Steel introduced the Galvalume coating to the construction industry in the early s. Galvalume roofing material combines three of the most important metals used in roofing today&#;steel, aluminum, and zinc. Manufacturers begin with a carbon steel base sheet that is then continuously hot-dipped with aluminum and zinc alloys until it reaches a coating consisting of 55% aluminum, 43.4% zinc, and 1.6% silicone. This process allows for one material to have some of the best characteristics of each metal, which is why it&#;s become one of the most popular materials in today&#;s roofing market.
Galvalume is also referred to by its coating weights, AZ-50 and AZ-55. Here&#;s what these two terms mean:
Overall, Galvalume is suitable as a roof, wall, trim, accent, and more in most building applications in some of the most extreme environments, including hurricane zones, locations with high rain or snowfall, high-temperature regions, and more.
Some common uses for Galvalume include:
However, there are some situations where Galvalume is NOT recommended for use. In these situations below, the main concern is that the coating will prematurely break down and cause the roof or wall system to fail quicker than if it were not in that location. Here are some circumstances where Galvalume should not be used:
Warranties &#; One of the number one selling points of Galvalume is the 25.5-year warranty on the substrate, which is sometimes referred to as a perforation warranty. Galvalume systems also often come with paint warranties that further protect your investment and provide peace of mind that the roof or wall system will last. (Note: Substrate or paint warranties are NOT available for Galvalume products within 1,500 feet of a coast.) Plus, commercial property owners can buy a weathertight warranty for their Galvalume roofing structure, which ensures the roof was installed correctly and adheres to strict installation details.
Corrosion resistance &#; When compared to galvanized metal, Galvalume&#;s corrosion resistance is about two to four times better. Galvalume&#;s formula was designed to combine the toughness and strength of zinc with the rust resistance of aluminum. Research conducted by the Metal Construction Association (MCA) indicates that Galvalume roofing could last as long as 40 to 50+ years without any extreme signs of corrosion.
Self-healing properties &#; All steel-based products have some degree of edge creep from the exposed steel when the coil is cut, but it can be offset by hemming or touching up exposed edges with paint pens. An advantage of Galvalume that stems from this concept is the fact that it has self-healing characteristics that help control the red rusting at the cut/exposed edges. (Note: A small degree of red rusting at cut edges is normal, but with a Galvalume coating, the red rust will eventually stop.)
Economically priced &#; For the most part, Galvalume is reasonably priced and one of the more affordable metal materials available for roofing products. Depending upon the thickness, color, and quality of the desired Galvalume panels, pricing ranges anywhere from $5.00 to $15.00 per square foot. Keep in mind that in and , steel prices are continually fluctuating, so the price can vary dramatically.
Oil canning &#; Oil canning is an inherent characteristic of light-gauge, cold-formed metal products, especially products with broad, flat areas. It&#;s a visual phenomenon seen as waviness or distortion in the flat surfaces of metal panels. Luckily, oil canning is only an aesthetic concern that doesn&#;t affect the performance of the roof system. This occurrence is possible with any metal roof or wall type, including Galvalume. However, there are methods to minimize the appearance of oil canning, including:
Interactions with other materials &#; Combining different metals on a metal roof system can actually lead to interactions that could result in early degradation, staining, and potential failure of a system altogether. Galvalume performs best when not in contact with copper, lead, bricks, treated lumber, iron, and concrete. If Galvalume is in contact with one of these and is then introduced to an electrolyte, such as water, it can lead to galvanic corrosion of the metal.
Unpainted Galvalume scuffing concerns &#; When installing a non-painted Galvalume, the acrylic coating on the top of the panels is susceptible to scuffing, especially in high-traffic areas. Once the coating is scuffed, there&#;s not much that can be done to fix the issue other than immediately replacing the scuffed panels. If scuffed unpainted Galvalume is left on the roof, it may become splotchy as the scuffed/exposed parts of the roof age and weather quicker. To avoid this issue, it&#;s important to limit foot traffic on installed panels and be aware of foot, boot, and ladder placement.
Galvanized metal products have been around since the 17th century, but the process of &#;galvanizing&#; materials became a widespread practice in the early 19th century. Galvanization (commonly referred to as galvanized) is a protective zinc coating that is applied to a steel or iron substrate through a hot-dip galvanizing process. Before the introduction of Galvalume to the metal roofing industry in the late 20th century, using galvanized sheet and coil was a common practice. However, because of the superior durability and corrosion resistance of Galvalume, 90+ percent of the metal roofing and wall industry in the early s transitioned from galvanized substrates to a Galvalume substrate.
Additionally, galvanized metal sheet/coil may also be called G-90, which refers to the coating weight.
Galvanized metal is used in similar applications as Galvalume, especially for agricultural projects. However, the most significant thing to keep in mind is that galvanized is a little more challenging to find and might depend on what area your project is in (more details on that below). As mentioned, most manufacturers have stepped toward using Galvalume as the majority of their product offerings because it lasts longer and provides more benefits for property owners.
At Sheffield Metals, we do carry one product that has a galvanized substrate, Vintage® from Steelscape. To this day, Vintage is a popular sheet and coil, especially for architectural applications where an aged metallic look is desired.
Additionally, galvanized products will not stand up to the conditions associated with a coastal environment, including properties up against coastlines with breaking surfs, large bays, and marshes. Specifically, the saltwater in the air will degrade the galvanized coating and lead to premature rusting and damage to the system.
Better suited for animal confinement &#; One of the most notable benefits of galvanized steel is that it can be used on structures that house animals. Galvalume is not suitable for animal confinement because manure from the animals breaks down into ammonia gas over time and then reacts with the Galvalume coating. However, an adequately ventilated galvanized roof system can perform well for several animal confinement applications. It&#;s best to check with the manufacturer before putting galvanized steel roof on an animal confinement building; plus, they might offer some specific design recommendations.
Better formability &#; Galvanized steel is more malleable than Galvalume, meaning that it will bend and form a little easier than other metal types. This is why galvanized is sometimes used more often in stamped metal shingles or stamped vent flashings, as galvanized allows for more concise bends.
Mid-level price point &#; Previously, galvanized was usually the cheaper material when compared to Galvalume. However, in the last 10+ years, the pricing of these two materials has fluctuated back and forth, but predictions in show galvanized material is now about 6% higher in price over Galvalume. Typical G-90 galvanized standing seam metal roofs cost anywhere from $8.00 to $16.00 per square foot and fluctuate further based on your location, the installer, the material color, thickness, and more. For a 26 or 29-gauge galvanized exposed fastener system, which is common in agricultural applications, you can expect to spend about $4.50 to $7.50 per square foot. Keep in mind that prices continue to fluctuate in , so these costs could quickly change.
No substrate warranties &#; Arguably the most significant disadvantage to galvanized metal systems is the fact that the substrate doesn&#;t have a warranty. Most galvanized systems have the potential to be unpredictable in specific environments and use, meaning that most manufacturers don&#;t offer warranties on most galvanized products.
Not self-healing & red rust &#; The zinc coating on galvanized sheet/coil does a good job protecting the steel core for the first decade or so of use. Though once any part of the steel core is exposed, the metal will start to red rust, which is both unsightly and will eat away at the metal over time. As we discussed, all steel products inherently have some degree of edge creep near cuts and exposed edges. The problem with galvanized metal (painted or not) is that once it starts to red rust, it doesn&#;t eventually stop as Galvalume does. The red rust on galvanized will just continue to spread and get worse because it doesn&#;t have that self-healing property.
Shorter longevity &#; Studies have shown that galvanized metal roofs will last around 15-20 years in the right environment. This may seem like a long time, but you would expect it to last as long if you&#;re spending the same amount or more for a galvanized roof than for a Galvalume roof. However, Galvalume roofs can last 40+ years, which is over double the lifespan of a galvanized roof.
Availability issues &#; When compared to Galvalume sheet and coil products, galvanized metal roofing products aren&#;t always as accessible. Galvanized is a very regional product, meaning that it&#;s easier to find and purchase in specific areas of the U.S., including those with a higher concentration of agriculture and animal confinement. Since Galvalume tends to perform better and lasts quite a bit longer, it&#;s easier to find and purchase nationwide.
Oil canning &#; Like Galvalume, galvanized metal can also develop oil canning in the flat areas of the panel.
Even though Galvalume and galvanized are generally similar in the way they&#;re created, they have different characteristics that affect how each one should be used in metal roof and wall projects.
Here&#;s a recap of what we discussed:
Galvalume is:
Galvanized is:
At Sheffield Metals, we are dedicated to providing and educating our customers with the information they need to make the best and most informed decision. Contractors, architects, distributors, homeowners &#; we&#;re available to help with your metal roofing project.
Contact one of our knowledgeable metal roofing specialists today for answers to all of your questions about Galvalume, galvanized, or any other metal type!
For more information, please visit Galvalume Steel Coil for Agriculture.
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