Metal Roof and Wall Panels Provide Industrial Aesthetic to Texas Ranch

Nearly 13,000 square feet of Petersen’s Galvalume Snap-Clad panels was used to clad the roof.

Nearly 13,000 square feet of Petersen’s Galvalume Snap-Clad panels was used to clad the roof.

As many architects can attest, designing a residence for oneself can present challenges. But architect Jack Carson rose to the occasion by creating a striking design for his new home, located on a ranch in the beautiful Texas Hill Country. Design for the 7,000-square-foot residence follows LEED principles and blends a unique palette of “industrial” materials with ultra-modern aesthetics.

“The house is truly on a ranch. We have cattle on the property,” says Carson, president of Carson Design Associates in Austin, Texas. “We wanted to keep the design somewhat in the ranch vernacular but with a contemporary look. The reliance on metal for the roof and cladding and an exposed structure helped create a ranch building feel. We like to think of it as an ‘industrial ranch’ aesthetic.”

The primary wall panel profile utilized was Petersen’s Precision Series panels, of which 2,400 square feet of the 16-inch Galvalume material was installed.

The primary wall panel profile utilized was Petersen’s Precision Series panels, of which 2,400 square feet of the 16-inch Galvalume material was installed.

Several of Petersen Aluminum’s PAC-CLAD profiles contributed to Carson’s success in delivering the desired look. Nearly 13,000 square feet of Petersen’s Galvalume Snap-Clad panels was used to clad the roof. The 16-inch roof panels were rollformed onsite because of extremely tight site conditions and because the only access to the site was via a dirt road that wasn’t wide enough to allow large trucks to deliver factory-formed panels. An additional 3,000 square feet of Snap-Clad panels also was installed vertically as siding around two garages and at specific locations on the house as accent panels.

The primary wall panel profile utilized was Petersen’s Precision Series panels, of which 2,400 square feet of the 16-inch Galvalume material was installed. All wall panels were manufactured at Petersen’s Tyler, Texas, plant.

The underside of the overhanging soffit is clad with Ipe wood that ends with an edge that Carson and Brown describe as “the wing” or “the blade.”

The underside of the overhanging soffit is clad with Ipe wood that ends with an edge that Carson and Brown describe as “the wing” or “the blade.”

The onsite fabrication of the roof panels and the installation of all roof and wall panels was performed by Dean Contracting Co., Kyle, Texas. “The greatest challenge was executing the architects dream for his home,” recalls Jesse Brown, vice president of Dean Contracting. “The design included a myriad of varying geometric shapes on many different planes and a blend of materials that required complex detailing. It was probably one of the top-five most challenging jobs that we have ever done.”

The Petersen profiles highlight the material palette, which also includes Texas limestone sourced directly from the property on which the home sits, Ipe wood, steel beams and a generous amount of glass. “We have great views into the valley with no neighbors,” Carson adds. “A large overhanging soffit covers a large portion of the deck and shades all of the glass.”

The underside of the overhanging soffit is clad with Ipe wood that ends with an edge that Carson and Brown describe as “the wing” or “the blade.” Fabricated with Alcoa Reynobond aluminum composite material (ACM), this transitional element smoothly links the standing-seam roof with the overhanging wood-clad soffit. Petersen functioned as distributor of the Reynobond ACM.

Fabricated with Alcoa Reynobond aluminum composite material (ACM), this transitional element smoothly links the standing-seam roof with the overhanging wood-clad soffit.

Fabricated with Alcoa Reynobond aluminum composite material (ACM), this transitional element smoothly links the standing-seam roof with the overhanging wood-clad soffit.

The decision to use Petersen for the roof and siding was arrived at rather easily. Carson notes: “I was familiar with PAC-CLAD and wanted to use it but also wanted to rely on the builder’s recommendations regarding materials and subcontractors. In our very first meeting with the roofer, Dean Contracting, they brought in samples of PAC-CLAD and recommended using it. That made the decision pretty easy.”

Carson is a big believer in metal as a roofing and cladding material. “We wanted to be as maintenance-free as possible. And sustainability was an important component as well,” Carson says. “We used LEED principles in our design. Metal is far greener than asphalt shingles and other alternatives. It’s just a great option for residential construction.”

The installation went smoothly, Carson adds, primarily because he relied on the expertise of Dean Contracting. “My approach is to listen to the experts. Jesse Brown and his crew worked out the complex detailing. They use metal all the time and are extremely capable. We collaborated as necessary but I basically left it in their hands.”

The Petersen profiles highlight the material palette, which also includes Texas limestone sourced directly from the property on which the home sits, Ipe wood, steel beams and a generous amount of glass.

The Petersen profiles highlight the material palette, which also includes Texas limestone sourced directly from the property on which the home sits, Ipe wood, steel beams and a generous amount of glass.

Brown was quick to give full credit to the crew that was led by Juan Rojas, sheet-metal superintendent. Rojas is a 24-year employee of Dean Contracting and Brown cites Rojas’ attention to function and precise detailing as a main reason why the job turned out so well.

The house—in spite of its size and location in the hot Texas climate and the large amount of glass—is energy efficient. Two inches of rigid insulation was installed under the metal roof and an additional 4 inches of sprayed insulation went under the roof deck. “The heavy insulation and the shade provided by the overhang makes it very energy efficient. The house stays a very constant temperature,” Carson says.

The entire property captures rainwater in 18,000-gallon collection tanks, which is yet another reason for using metal, Carson points out.

When asked about the challenge of designing for yourself, Carson thought it was easier than designing for a traditional client. “I was probably more demanding in ‘getting it right’, but once I knew I had the right design and materials, I didn’t have to convince myself that it was the best direction. There was no negotiation or comprising the design in any way,” Carson says. “The biggest problem any architect has in designing for themselves is in ‘editing out.’ We know all of the possibilities, and being able to prioritize and filter out the unnecessary options is often the hardest challenge.”

PHOTOS: Petersen Aluminum Corp.

DoD Is Retrofitting 577,500 Buildings with High-tech Roof Systems

The nation’s largest energy user, the Department of Defense (DoD), is learning how to transform some of its 577,500 buildings and structures into state-of-art energy-saving powerhouses, by retrofitting old buildings with new high-tech roofing systems. In partnership with the Metal Construction Association (MCA) and the Department of Energy’s Oak Ridge National Laboratory, the DoD is host to a demonstration project for reducing a building’s carbon footprint and lowering demand for energy and water. The demonstration project was part of the DoD’s Strategic Environmental Research and Development Program (ESTCP) at Goodfellow Air Force Base (GAFB) in San Angelo, Texas. The model will be replicated at potentially thousands of DoD buildings throughout the country.

“We are thrilled to see this technology come together. Both the MCA and DoD see a great benefit to the broader U.S. economy when new and retrofit buildings throughout the country adopt this high performance roofing design, and work toward net-zero energy buildings,” says Scott Kriner, Technical Director, Metal Construction Association.

The dynamic roofing system was installed at the Security Forces Building at GAFB and performs many functions, using a combination of technologies that heat and cool air and water, produce electricity, and collect rainwater. The metal roof retrofit system can be installed over an existing roof, saving installation costs and keeping old roofing material out of landfills. What makes this roofing system unique is that it brings together multiple functions in one holistically designed, integrated building envelope system that can be used on flat or sloped roof designs.

The technology used is a hybrid of metal roofing, insulation, hydronic solar thermal systems, engineered air pathways, and photovoltaic (PV) cells, all designed to work symbiotically. This high performance system includes a retrofitted metal roof installed over the existing roof, which creates a cavity between the existing and new roofs. Within that cavity insulation, solar thermal heating systems and cooling of air and water for the building can be installed. More specifically, the technologies incorporated into the metal roof system are:

    1) Cool metal roofing: high solar reflectance coatings on metal save up to 25% in summer cooling energy costs and helps mitigate the heat island effect in urban areas.

    2) Solar thermal water heating: sun is used to preheat water for use inside the building, reducing the use of fossil fuels or electricity for hot water heaters. The heated water can also be used for space heating using a heat exchanger.

    3) Rainwater harvesting: this subsystem harvests, manages and reuses rainwater for non-potable applications such as watering landscaping or flushing toilets.

    4) Solar electric (PV) panels: thin film solar panels laminated on the roof provide energy for the building and even allow electricity to be sold to the grid.

With the roofing system installation at GAFB, the Department of Defense and the Metal Construction Association are demonstrating how integrating energy efficiency and solar technologies with a retrofit metal roofing system can reduce energy and water consumption, mitigate the building’s environmental impact, and lower construction and operating costs.