5 Problems With Corrugated Metal Panels

Let’s say you’re looking for a low cost, easy to find a metal panel with a simple installation. So simple that you might even be tempted to do it yourself. Under these circumstances, all roads would lead you to corrugated panels.

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At Western States Metal Roofing, we’ve been manufacturing metal roofing and metal siding panels for over 20 years. Without a doubt, corrugated panels are our best sellers. You may be wondering if we think corrugated panels are so great, then why are we going to talk about their problems?

We want to keep you educated on the products you’re considering purchasing. It’s best to know the good and the bad so that when it comes time to choose your metal panels, you can make the best decision for your specific project. It’s not beneficial for us as a seller or you as the consumer to buy something that you’re not fully satisfied with.

In this article, we will discuss five of the biggest issues you will encounter with corrugated metal panels.

What Are The Disadvantages Of Corrugated Roofing?

1. Corrugated Metal Requires More Routine Maintenance
2. Corrugated Metal Is Less Weather-tight than standing seam
3. Corrugated Metal Is Not Suitable For Low Pitched Roofs
4. Corrugated Metal Requires You To Buy Extra Square Footage Due To Panel Sidelap
5. Corrugated Metal Looks Less Modern
   
   

Corrugated Panels Require More Routine Maintenance

While all metal roofing or siding should be inspected annually to prevent any problems from developing further, corrugated panels generally require more frequent inspections and maintenance.

The reason for more frequent corrugated panel inspections is so you can check the fasteners. Since the fasteners are exposed on corrugated panels, they may need to be tightened, or possibly even replaced if they are damaged, during inspection to avoid leaks.

The natural expansion and contraction of metal can cause the fasteners to become loose. Loosened fasteners leave space for water to penetrate that can potentially lead to leaks and damage that will need to be repaired.

An inspection should be done by a professional after any severe weather that you think may have caused damage. Checking on a roof right after a substantial storm, instead of waiting for your next routine maintenance, might save you from a larger problem.

Foam closures should also be checked during inspections to make sure they are still in good condition. Roofs and gutters should also be checked for leaf buildup, and leaf guards should be installed if you’re in an area with a large volume of leaves.

During inspections, also check the corrugated roof for cracked sealant. Sealant is a top reason for roof leaks as it has a short life span and usually isn’t replaced on time. The life expectancy of sealant should be listed on its container and replaced as suggested by the manufacturer.

Corrugated Metal Panels Are More Likely To Leak

Corrugated panels require thousands of fasteners to keep the roof in place. All of these penetrations in the roof leave a chance for moisture to get in. If the fasteners are not properly installed or become loose, the roof can be vulnerable to leaks. This is the biggest trade-off with a corrugated metal roofing panel when compared to a standing seam panel.

It's the most important part of the decision making process and we highly recommend that you read: Exposed Fastener Metal Panels v. Standing Seam Systems For Metal Roofs

Corrugated Metal Panels Are Not Suitable For Flat Roofs

• Corrugated panels should not be installed on a flat roof or even a very low sloped roof. We recommend a minimum of 3:12 pitch in order to use corrugated panels. The reason is due to the exposed fastening system of corrugated panels and the low panel height.

With a flat or very low sloped roof, rainwater tends to stay on the roof longer as it doesn’t have a steep pitch to help with runoff. This is not a good combination with the exposed fasteners as they are more susceptible to leaking. The longer water stays on a roof, the more likely a leak is to occur, potentially resulting in expensive roof repairs.

Corrugated Panels Require Panel Sidelap

Corrugated panels will incur a loss of square footage during installation due to the panel side lap, or the overlapping of two like panels.

The panels need to overlap two corrugations for roofing and one corrugation for siding. While this seems minor, it can add up depending on the size of the project.

For roofing, you will have to purchase 10% to 12% additional material for corrugated. For siding, you will need about 6% additional material. This increases the total cost of a job when using metal panels compared to other roofing and siding options.

If keeping the budget to a minimum is your primary concern we would recommend using R Panel. There is no sidelap loss on R Panel. 

What Is R-Panel Roofing? Definition, Alternatives, Cost, and Colors

Corrugated Metal Panels Have A Less Modern Appearance

The desired aesthetic of your project is subjective and based on personal preference. While the appearance of corrugated panels might not be a problem for every situation, there are certain projects that you might want to go with an alternative panel.

7/8” Corrugated Siding, Streaked Rust®

Corrugated panels have exposed fasteners, which is usually regarded as not being as modern or clean looking as a panel with concealed fasteners (such as standing seam).

Corrugated panels are generally used in industrial or agricultural structures. For a residential project where aesthetics are a top concern, corrugated panels are not usually the top choice.

Are you interested in learning more about Corrugated Metal Pipe? Contact us today to secure an expert consultation!

Standing Seam, Black Ore Matte®

If you would like a more modern looking metal roofing panel we suggest standing seam:

Corrugated Metal Roofing v. Standing Seam (Advantages & Disadvantages)

Should I Use Corrugated Metal Panels?

Corrugated panels are often used because they are budget-friendly and readily available, but they do not lack issues.

If you have a flat roof or are looking for the most attractive panel with the lowest maintenance, corrugated panels are not the right fit for you.

At Western States Metal Roofing, corrugated panels are our most popular panel. Despite their shortcomings, corrugated panels still provide many benefits of metal roofing that customers are looking for.