Zinc: The Sustainable Choice among Architectural Metals  

Specifying zinc metal panels contributes to overall building design, longevity, life cycle benefits and sustainability.

Sponsored by Umicore Building Products USA Inc | Peter J. Arsenault, FAIA, NCARB, LEED-AP

This CE Center article is no longer eligible for receiving credits.

Sustainability Qualities of Zinc

According to the May 2008 issue of MetalMag, the trade journal for processed metals, "As the building industry migrates toward green practices, zinc will continue to play an increasingly important role in the development of truly sustainable buildings." This statement is readily backed up by a number of observable sustainable qualities of zinc products including a life expectancy of more than 100 years, a lower environmental foot print than competing materials, little or no maintenance over the life-time of the product and no replacement required over the life-time of building. More specifically, the following traits of these materials that readily contribute to green building design have been identified by the International Zinc Association and several manufacturers:

• Life Cycle Analysis: The long term service life implication of buildings has received more attention in recent years, particularly during the current process of developing the International Green Construction Code (IGCC). Among the provisions of the current Public Version 1.0, Chapter 5 of this emerging standard addresses Material Resource Conservation and Efficiency and calls for a Building Service Life Plan to be included in the construction documents for the project and provides detailed requirements for the plan. Of particular note is the identification of 100-year and 200-year service life elements. The long life expectancy of zinc will readily support this requirement.

Separate from requirements of codes and standards, many clients look for very positive Life Cycle Analysis (LCA) studies on building material and product choices as well. The International Zinc Institute has used LCA as a standardized scientific method for systematic analysis of all mass and energy flows as well as environmental impacts attributed to a product system, from raw materials acquisition to end-of-life management. The terms "cradle to grave," "cradle to cradle" and "total cost of ownership" describe this overall full life cycle concept of materials. Reviews of LCA studies are not only a matter of simple longevity, but also of the costs necessary in maintaining a material throughout its service life. To take roofs as an example, in a 2004 study conducted by Ducker International, owners and property managers reported performing little or no maintenance on their metal roofs (to be fair, the study included all types of metal roofs, not just zinc). A comparison of maintenance costs over the life of the roof for metal versus asphalt and single-ply membranes showed that owners of metal roofs spent approximately 3 percent of total installed costs on maintenance, versus 28 percent for asphalt and 10 percent for single-ply membranes. More specific studies comparing zinc roofing to other long lasting roofing materials have shown that, when including a credit for recycling of material at the end of its useful life, zinc has a noticeably smaller environmental footprint and a more favorable life cycle result than aluminum, copper, stainless steel, or cement tiles.

• Reducing embodied energy in materials: Zinc production is friendlier to the environment than other metals through its comparatively low embodied energy. Embodied energy includes the total amount of non-renewable energy needed to create one unit of a finished product, including raw material extraction, transport, manufacturing, assembly and installation, and in detailed calculations, to maintain it during its useful life and dispose of afterwards. Among the non-ferrous metals used in building, zinc has the lowest embodied energy. It is the least energy intensive to produce, requiring one fourth the energy of aluminum, and one third that of copper or stainless steel. Zinc is less energy intensive to extract than many other metals, and requires lower heat and therefore less energy to process. A complete embodied energy balance sheet must also take into account the energy value of labor to repair or remove old systems such as asphalt roofs, the energy cost of the replacement materials, the energy used in transportation of materials on each occasion, and impacts at landfills. Use of a longer lasting material such as zinc eliminates the cost and embodied energy of such removal or repairs of other roofing systems with shorter service lives. By contrast, at the end of the service life of zinc, an estimated 95 percent of the energy content embodied in a zinc product is conserved during recycling meaning that significantly less energy is used to produce zinc building products when recycled material is used instead of mining and processing new ore.

• Selecting materials with recycled content: Very few common building materials, including those considered to have low embodied energy, can match the recyclability of zinc material. Architectural-grade zinc must be very pure, and so it contains higher percentages of pure ore than industrial-grade zinc. However, once the pure architectural alloy has been created, it can be recovered and reprocessed for use in new architectural products. Some current zinc product manufacturers achieve very high levels of this recycled content in their architectural zinc, over 45 percent, almost all of which is post- consumer content. Specifying recycled content in zinc products is very realistic and achievable as a result.

Embodied energy in different types of architectural metals

Photo: VM Zinc USA

 

• Ability to recover and recycle at end of useful life: Removal and disposal of typical building materials can be a complex and costly job, and the resulting debris may have low or no value ending up in a landfill producing the associated costs for freight and disposal plus the long-term cost to the environment. However, of the millions of tons of discarded building materials taken to landfills every year, there is hardly a scrap of architectural zinc. This is because metallic zinc can be recycled indefinitely without loss of its chemical or physical properties. This theoretically infinite recyclability is, in fact, being approached in reality in the case of zinc used in buildings. The overall recycling rate for architectural zinc recovered from renovations and removal from old building is over 90 percent in some countries because of its high value. In Europe, buildings whose zinc parts outlasted them are numerous yet virtually no zinc on a building ever goes to a landfill. Recycling of zinc is a well-established industry because products can be recovered easily at the end of their life and there is an extensive network of buyers offering advantageous prices.

The ability to recycle and re-use zinc at the end of the service life of a building.

Photo: VM Zinc USA

 

• Reducing construction waste: The standardization of sizes of zinc products means that less cutting and scrap material may be produced during any given project. Nonetheless, any zinc construction wastes can easily be separated from other metals and sent to any local metal scrap dealer. In the United States, zinc is commonly reused by the galvanization industry or may be fabricated into other products. Even small amounts of scrap zinc generated on jobs are valuable and readily sold.

• Selecting low-emitting or no-emitting materials: Part of the beauty of zinc metal comes from its natural coloration which means that no additional paints, sprays, or other treatment is needed. As a result, manufacturers, fabricators, installers, and users will never need to apply any other coatings on the metal. Consequently, no Volatile Organic Compounds (VOCs) ever need to be introduced that might generate emissions which are contrary to healthy indoor environmental quality.

• Innovation in applications: Because of the versatility and wide range of possible building applications of zinc, it is possible to be very creative in its use to achieve sustainable building designs. Some of these innovations can take the form of advanced building envelope solutions such as rain screen designs, roofing variations, sun screens, etc. Zinc based batteries and fuel cells can be a contributing portion of an onsite renewable energy solution for buildings. Architects looking for advancing the state of green building design through innovation will find plenty of opportunity to pursue creative solutions when considering zinc for those solutions.

Architectural metals are used widely in commercial, institutional, and industrial buildings. In order to meet the variety of design conditions in these different building types, architects in the US have often turned to some rather energy intensive metal choices such as aluminum, copper, painted steel, and stainless steel. However, the use of zinc as an architectural metal of choice is gaining popularity in this country and catching up with its widespread and long term use in other parts of the world. Parts of Asia and Europe in particular have used zinc as a building envelope material for generations. Americans are recognizing not only the historical long term durability of zinc but the recent growth in its use in the US is based in part on the recognition of the green and sustainability attributes that it can contribute to a building design.

Zinc Overview

In reviewing any building material, it is always appropriate to start with a basic understanding of key characteristics of that material which are summarized below for zinc:

• Natural prevalence: Zinc is a very natural and significant mineral that is prevalent throughout the world. In fact, it is reported to be the 23rd most abundant element in the earth's crust found not only in rocks, soil, air and water, but also in all living organisms including plants, animals, and humans. As a human nutrient, it contributes to normal growth processes and it has been shown that a lack of zinc in human diets is a significant cause of childhood disease and mortality, particularly in underdeveloped countries. Zinc is used in fertilizers to enrich agricultural soils and increase yields yet it is this very ability to mix and link with other elements in soils that keeps it at safe levels for human exposure.

Photo: Gilbertson Photography

• Available supply: Zinc is mined worldwide predominantly from extraction processes that avoid strip mining meaning that less land is disturbed and any potential environmental damage is minimized. Various projections have been made about the worldwide supply of zinc, but current estimates go up to 750 years worth of supply at current extraction levels. When re-cycling and re-use of zinc is considered, the projections are even longer.

• Processing: There appear to be fewer zinc processing plants than other types of metal processing plants around the world however, these zinc processing plants are reputed to meet current and projected demand. The environmental air emissions produced from zinc processing at these plants are minimized due to the use of up to date equipment and emission abatement processes during smelting. But quite significantly, zinc requires less energy to process due to its relatively lower melting point of 786°F (419°C) compared to other metals like aluminum at 1120°F (660°C), copper at 1983°F (1084°C), and steel at 2372°F (1300°C).

• Durability: Since zinc is a non-ferrous metal, it is not subject to the rust and corrosion found in iron, steel, and other ferrous materials. According to the International Zinc Association's "Zinc for Life" program, "Zinc material requires little maintenance over its service life; its (natural) patina constantly renews itself as it weathers and ages and will ‘heal over' scratches and imperfections, requiring no touch-up or repainting. Because the metal is uncoated, there is no possibility of the fading, chipping or peeling that otherwise needs recurrent attention. A single zinc roof, with a lifespan of 80 to 100 years may well outlast the building it has been sheltering." It should be noted that wall panels using zinc, without the environmental rigors of roofing applications, may have service lives of 200 to 300 years, depending on the product used and local conditions.

• Coloration or patina: The key to the extraordinary durability of zinc roofs and facades, and its beauty over time, is the ability of zinc metal to develop a natural protective patina. Again according to the International Zinc Association, "Just as copper ages from orange to green, zinc over time develops its distinctive patina, going from shiny silver to matte gray (depending on the precise alloy, other colors and finishes are also possible). In contact with the water, oxygen and carbon dioxide molecules in the atmosphere, the surface forms a closely adhering protective layer of zinc carbonate, which is insoluble in rainwater and will hinder any further exchanges between oxygen and zinc, thereby protecting the zinc from further corrosion. Zinc continues to renew this protective layer throughout its life, although the heaviest formation is usually complete in about five years, and will self-repair any imperfections or scratches." It should be noted, too, that some manufacturers of zinc products provide a complete "color management" system that allows for a "pre-patination" to occur giving greater control over the color of the installed product initially and over time. In addition, the patina process means that architectural zinc panels can be perforated with any number of patterns without worry about rust and usually at a dramatic cost savings compared to treated steel and other mesh and expanded options on the market.

• Common construction uses: Zinc is commonly used as a stand-alone metal product or in combination with other metals for a variety of uses that you are probably already familiar with:

Zinc is mixed with copper to form brass
Zinc is the primary metal used to galvanize steel, causing a chemical reaction that protects the steel from rust and corrosion
Rolled and sheet zinc is fabricated into interior and exterior wall panel products for both decorative and functional purposes
Rolled zinc is fabricated into standing seam and other types of metal roofing products
Metal flashings and roof accessories are fabricated from zinc as an alternative to copper and other metals
Historical building ornaments such as metal finials, vanes, campaniles, dormers, etc. can all be fabricated out of zinc
Rainwater collection gutters and downspouts made from zinc are an alternative to other metals
Zinc is used in batteries and recently in fuel cells for alternative energy solutions

Zinc forms a natural protective patina that can be influenced by manufacturers to create different hues of color.

Photo: VM Zinc USA

• Standards: Products manufactured out of zinc are subject to strict standards that determine the quality and purity of the material since most of what we refer to as zinc metal is in fact an alloy containing well over 99 percent zinc mixed with trace amounts of copper, titanium, and aluminum. ASTM B6 - 09 "Standard Specification for Zinc" covers zinc metal made from ore or other material by a process of distillation or by electrolysis in five grades: LME grade (related to the London Metal Exchange standards), special high grade, high grade, intermediate grade, and prime western grade. Under this standard, the zinc metal is tested to conform to chemical composition requirements free of any surface corrosion and adhering foreign matter. The most common building related standard for products then manufactured out of zinc metal is ASTM B69-09 "Standard Specification for Rolled Zinc." This standard covers Type I coils or sheets cut from strip rolled zinc, and Type II zinc plates such as boiler and hull plates produced by any rolling method. This standard tests for chemical composition, tensile properties, and hardness. In Europe, zinc must meet similar stringent testing requirement under EN988 which also dictates the specific zinc material characteristics to be used in building products.

These characteristics and others of zinc have contributed to its widespread use around the world for centuries. In fact, the use of zinc as a building material can be traced back to the 1st Century ruins of Pompeii and even earlier. Zinc roofing in Europe has been used extensively since the 13th century as evidenced by the fact that approximately 85 percent of the current rooftops in Paris are made from zinc. With this long history of use, the knowledge base about zinc as a sustainable and durable building product are well documented and readily known.

In addition to the strong historical track record of zinc, architects should also be aware that there are some emerging trends and practices of companies that manufacture zinc building products that will make it easier to specify and design zinc into buildings in the US. First is the offering of material in 48-inch-wide products instead of only the previously available meter wide material. This coordination with American standard construction sizes will make it easier to design and install zinc wall and roofing products at new scales and with more economical installation. Second is the expanding range of color choices offered by some manufacturers. While maintaining the positive durability effects of the zinc patina, some products can be color managed through a pre-patina process meaning that the material will arrive onsite already showing some of its patination and coloring ahead of typical time frames. Third, is a global approach to the fabrication and service for a specific product. This means that a product can be specified in the US for a project in Europe, China, or the Middle East and have exactly the same make up and characteristics in any of those locations. Finally, zinc is being used innovatively to improve building performance such as rainscreen products that harness air flow in parts of the building envelope for enhanced heating, cooling, and ventilation. Coupling all of this with a growing awareness of an envelope that meets a strong and positive life cycle cost analysis, architects and designers are becoming increasingly savvy in making long term choices that allow for both contemporary and traditional aesthetics, even allowing a seamless flow from roofing to walls in some cases.

Third Street Lofts, in San Francisco, CA uses zinc for continuous roof and wall panels.

Photo: VM Zinc USA

Sustainability Qualities of Zinc

According to the May 2008 issue of MetalMag, the trade journal for processed metals, "As the building industry migrates toward green practices, zinc will continue to play an increasingly important role in the development of truly sustainable buildings." This statement is readily backed up by a number of observable sustainable qualities of zinc products including a life expectancy of more than 100 years, a lower environmental foot print than competing materials, little or no maintenance over the life-time of the product and no replacement required over the life-time of building. More specifically, the following traits of these materials that readily contribute to green building design have been identified by the International Zinc Association and several manufacturers:

• Life Cycle Analysis: The long term service life implication of buildings has received more attention in recent years, particularly during the current process of developing the International Green Construction Code (IGCC). Among the provisions of the current Public Version 1.0, Chapter 5 of this emerging standard addresses Material Resource Conservation and Efficiency and calls for a Building Service Life Plan to be included in the construction documents for the project and provides detailed requirements for the plan. Of particular note is the identification of 100-year and 200-year service life elements. The long life expectancy of zinc will readily support this requirement.

Separate from requirements of codes and standards, many clients look for very positive Life Cycle Analysis (LCA) studies on building material and product choices as well. The International Zinc Institute has used LCA as a standardized scientific method for systematic analysis of all mass and energy flows as well as environmental impacts attributed to a product system, from raw materials acquisition to end-of-life management. The terms "cradle to grave," "cradle to cradle" and "total cost of ownership" describe this overall full life cycle concept of materials. Reviews of LCA studies are not only a matter of simple longevity, but also of the costs necessary in maintaining a material throughout its service life. To take roofs as an example, in a 2004 study conducted by Ducker International, owners and property managers reported performing little or no maintenance on their metal roofs (to be fair, the study included all types of metal roofs, not just zinc). A comparison of maintenance costs over the life of the roof for metal versus asphalt and single-ply membranes showed that owners of metal roofs spent approximately 3 percent of total installed costs on maintenance, versus 28 percent for asphalt and 10 percent for single-ply membranes. More specific studies comparing zinc roofing to other long lasting roofing materials have shown that, when including a credit for recycling of material at the end of its useful life, zinc has a noticeably smaller environmental footprint and a more favorable life cycle result than aluminum, copper, stainless steel, or cement tiles.

• Reducing embodied energy in materials: Zinc production is friendlier to the environment than other metals through its comparatively low embodied energy. Embodied energy includes the total amount of non-renewable energy needed to create one unit of a finished product, including raw material extraction, transport, manufacturing, assembly and installation, and in detailed calculations, to maintain it during its useful life and dispose of afterwards. Among the non-ferrous metals used in building, zinc has the lowest embodied energy. It is the least energy intensive to produce, requiring one fourth the energy of aluminum, and one third that of copper or stainless steel. Zinc is less energy intensive to extract than many other metals, and requires lower heat and therefore less energy to process. A complete embodied energy balance sheet must also take into account the energy value of labor to repair or remove old systems such as asphalt roofs, the energy cost of the replacement materials, the energy used in transportation of materials on each occasion, and impacts at landfills. Use of a longer lasting material such as zinc eliminates the cost and embodied energy of such removal or repairs of other roofing systems with shorter service lives. By contrast, at the end of the service life of zinc, an estimated 95 percent of the energy content embodied in a zinc product is conserved during recycling meaning that significantly less energy is used to produce zinc building products when recycled material is used instead of mining and processing new ore.

• Selecting materials with recycled content: Very few common building materials, including those considered to have low embodied energy, can match the recyclability of zinc material. Architectural-grade zinc must be very pure, and so it contains higher percentages of pure ore than industrial-grade zinc. However, once the pure architectural alloy has been created, it can be recovered and reprocessed for use in new architectural products. Some current zinc product manufacturers achieve very high levels of this recycled content in their architectural zinc, over 45 percent, almost all of which is post- consumer content. Specifying recycled content in zinc products is very realistic and achievable as a result.

Embodied energy in different types of architectural metals

Photo: VM Zinc USA

 

• Ability to recover and recycle at end of useful life: Removal and disposal of typical building materials can be a complex and costly job, and the resulting debris may have low or no value ending up in a landfill producing the associated costs for freight and disposal plus the long-term cost to the environment. However, of the millions of tons of discarded building materials taken to landfills every year, there is hardly a scrap of architectural zinc. This is because metallic zinc can be recycled indefinitely without loss of its chemical or physical properties. This theoretically infinite recyclability is, in fact, being approached in reality in the case of zinc used in buildings. The overall recycling rate for architectural zinc recovered from renovations and removal from old building is over 90 percent in some countries because of its high value. In Europe, buildings whose zinc parts outlasted them are numerous yet virtually no zinc on a building ever goes to a landfill. Recycling of zinc is a well-established industry because products can be recovered easily at the end of their life and there is an extensive network of buyers offering advantageous prices.

The ability to recycle and re-use zinc at the end of the service life of a building.

Photo: VM Zinc USA

 

• Reducing construction waste: The standardization of sizes of zinc products means that less cutting and scrap material may be produced during any given project. Nonetheless, any zinc construction wastes can easily be separated from other metals and sent to any local metal scrap dealer. In the United States, zinc is commonly reused by the galvanization industry or may be fabricated into other products. Even small amounts of scrap zinc generated on jobs are valuable and readily sold.

• Selecting low-emitting or no-emitting materials: Part of the beauty of zinc metal comes from its natural coloration which means that no additional paints, sprays, or other treatment is needed. As a result, manufacturers, fabricators, installers, and users will never need to apply any other coatings on the metal. Consequently, no Volatile Organic Compounds (VOCs) ever need to be introduced that might generate emissions which are contrary to healthy indoor environmental quality.

• Innovation in applications: Because of the versatility and wide range of possible building applications of zinc, it is possible to be very creative in its use to achieve sustainable building designs. Some of these innovations can take the form of advanced building envelope solutions such as rain screen designs, roofing variations, sun screens, etc. Zinc based batteries and fuel cells can be a contributing portion of an onsite renewable energy solution for buildings. Architects looking for advancing the state of green building design through innovation will find plenty of opportunity to pursue creative solutions when considering zinc for those solutions.

Zinc Wall Panel Applications

Metal wall and façade panels are often selected to create a durable exterior skin that contributes to an overall high quality building envelope. Accordingly, wall panel manufacturers have developed innovative systems which use all the material qualities of zinc described above plus they have developed a range of systems supplied with preformed finishing accessories produced specifically for covering facades, for both new construction and renovation. Several general types of wall panels include:

• Flat wall panels: The traditional standing seam system allows long strips of profiled zinc panels to be assembled by forming single folds on the upstands. The sheets are laid on continuous sheathing and anchored using fixing clips. This system, which can be installed either horizontally or vertically, provides maximum water and wind resistance and is generally found to be an easy and cost effective installation. Further, it can be integrated with roofing systems for visual continuity, installed on curved surfaces, and applied to new or renovation projects. Smaller sized panels are also available primarily for flat facades that simplify installation but have more visible seams which may be desirable only in certain designs.

• Rain screen panels: The growing popularity of using ventilated spaces behind cladding to create a rain screen over a sheathing barrier has prompted a variety of zinc panels that are very appropriate for both new and renovation projects. Many rain screen panels of this type are interlocking and fabricated as metal pans giving them great structural rigidity over long vertical and horizontal distances. Further, they can be designed and specified to be fully pressure equalized assuring the best ongoing performance over the life of the building. The panels are typically connected by the use of an interlocking groove giving the elegant appearance of a recessed joint. They are fixed onto a framework of either wood or metal as appropriate to the design using metal clips which are concealed in the inside edge of the groove. Many have the advantage of requiring no sealants, gaskets or butyl tape in the panel joints meaning no dirty streaks will be created from them and maintenance is notably reduced or eliminated. Further, since the zinc metal panels are not laminated nor a composite, they will never delaminate.

Zinc wall panels installed as a rain screen with deep reveal joints.

Photo: Dri-Design and VM Zinc, USA

 

• Decorative shingles: In some peaked roof applications, the gable end wall is enhanced by the use of decorative zinc shingles. These pre-formed, pieces are typically designed for overlapping, easy installation that produce very good weatherproofing on vertical wall surfaces and can be integrated with a full range of flashings for an all metal envelope where desired.

• Innovative solutions: An emerging wall system in industrial buildings is the use of metal wall panels to act as a solar air collector to condition the ventilation air in the building. Known as a transpired solar pre-heater, zinc wall panels can be used to heat make-up air for industrial buildings and provide a simple, economical approach to meet air quality standards. When properly designed and coordinated into the building, ventilation air is actively heated by solar energy, heat loss through the wall is recaptured, and stratified heat at the ceiling is utilized at the working level. The transpired solar wall heater is usually installed on the south-facing wall of a building, where air at the surface of the wall absorbs heat from the sun. Fan units or passive openings located at regular intervals along the wall near the roof draw the heated air through tiny perforations in the metal wall cladding. Each fan has modulating outside air and return dampers, discharge air temperature sensors and controls, and a duct that distributes the solar heated air along the ceiling of the plant through numerous openings. When make-up air is no longer required and the fan system is shut down, the outside air dampers close automatically. During summer months, when heating from the wall is not required, outside air is brought directly into the distribution ducts through by-pass dampers.

Transpired solar collector used on an industrial building with perforated wall panels.

Photos: ATAS Corporation

 

Ventilation requirements for industrial facilities vary widely according to the type of processes taking place in the building. Air change rates of one half to four per hour are common. Heating these large volumes of air during cooler months can be expensive. Tests have shown that for this type of system, each square foot of transpired solar collector provides approximately 2 to 3 therms of energy annually. Further, in a typical industrial building with high ceilings, air within the space stratifies according to temperature such that all of the hot air can be up at the ceiling, leaving colder air at the lower levels where people are working. During cold weather, air distribution fans and ductwork from this system redirect the stratified heat trapped at the ceiling and carry the heat back down to the working level for the comfort of the employees. All of these benefits, based on free energy from the sun, translate to financial savings and an improved working environment.

Zinc Roofing Applications

The success of zinc roofing can be summed up in a few words: long-lasting, malleable, flexible, aesthetic and prestigious. Because zinc roofing is suitable for all roof pitches above 1:12 and for all types of shapes (straight, curved, folded, etc.), it offers a great deal of freedom of expression for roof design. Further, as with wall panels, product manufacturers provide a variety of choices and options to suit different conditions and design criteria:

• Rolled cap: This traditional longitudinal assembly technique involves timber battens and capping strips. The zinc sheets and long zinc strips are held in place by a zinc batten clip supporting the peripheral upstands. The capping strips are placed into position by overlapping, thus ensuring that the roof is watertight. This style has the key performance advantage of being adaptable to complex shapes and roof penetrations. From a design standpoint, it provides expression of strong, conspicuous contours, shadow effects and urban character. From a construction standpoint, installation is straightforward and easy with the ability for easy dismantling for repair, changes, or end of life deconstruction. This style is suitable for virtually all building types.

Traditional and contemporary zinc roofing applications

Photo: VM Zinc, USA

 

• Standing seam: The traditional standing seam system allows long strips of zinc metal to be assembled by forming double folds on the upstands. The sheets of zinc are laid on continuous decking and anchored using stainless steel fixing clips. Ideally suited to large roofing areas, this style of roofing will readily adapt to almost any design with very discreet joins. Since it provides maximum water and wind resistance, it is well suited to areas with harsh climates, strong winds, or heavy rains. This well known technology provides for a fairly easy and cost effective installation and it is possible to optimize metal consumption and minimize waste with the judicious layout of the seams.

• Decorative shingles: In steep roof situations (greater than 25 percent) zinc metal shingles can be used for a more decorative solution. As with shingle installations, the intent is to shed water, not repel it, so consideration should be given to the weather and climate conditions when considering this style.

• Coordination with other building elements: The zinc metal roofing will provide the outer weathering barrier of the roofing system, but obviously coordination with other building components is critically important. Trained and experienced installers are a must as with any roofing installation, but architects and designers should take care to understand the appropriate substrate, insulation, and framing support systems that are suitable for a given design. Product manufacturers have typically developed specific information on these points and even have entire product systems that are designed to work with particular insulation materials, provide a more structural support of their own, or be assembled in smaller panels to allow for greater flexibility. Certain products when placed in contact with zinc can have detrimental effects on the appearance and/or structural integrity of the zinc. There are no issues with zinc in combination with metals other than copper and mild steel. When zinc contacts copper in the presence of an electrolyte (such as water) a galvanic reaction would lead to corrosion of the zinc and subsequent failure of the roof or wall. Run off from a copper surface to a zinc surface must be avoided under all circumstances. Zinc in contact with mild steel is not desirable either, due to similar electron transfers between the metal resulting in zinc corrosion and deterioration.

In general, water should not be allowed to run from a higher potential metal to a metal with a lower one. Install metals in the following order (from top to bottom):

    • Aluminum
    • Zinc
    • Galvanized steel
    • Lead
    • Copper

Zinc can be installed adjacent to limestone; limestone buildings in Paris have numerous zinc protective flashing located between floors. The run off from limestone onto zinc material is acceptable. However, limestone dust and gypsum dust that are generated during cutting operations can react with zinc in the presence of water and form a superficial coating. The zinc surface must be cleaned of any limestone and gypsum dust. No dust should be in contact with unprotected zinc and good construction practices should be used to limit the amount of dust.

Examples of acceptable contact products for zinc include lead, aluminum (painted, anodized, or bare), galvanized steel, stainless steel and compatible woods including pine, spruce, scotch pine, and poplar. Examples of unacceptable contact products and run off for zinc include but is not limited to copper, steel (non galvanized), gypsum dust/ limestone dust, mortar, rosin paper, bituminous membranes, products with fire retardant and preservation treatments, acidic cleaners, and non-compatible woods including larch, oak, chestnut, red cedar, Douglas fir, white cedar, and all woods with a pH less than 5.

Installed correctly, a building that is clad with zinc wall or roofing panels will have the potential to be a long lasting, durable, attractive, and truly sustainable building over the course of its very long full service life.

University of North Carolina at Greensboro:
Building for a 100-year Life Span

As a public institution more than a century old, the University of North Carolina Greensboro has assumed its place among top tier universities in North Carolina. On the longevity of its buildings and their construction, Fred Patrick, Director of Facilities Design and Construction, is very discerning in the selection of materials. He states, "There is, by design, a consistency of colors and materials that contribute to the campus environment. We build our structures for the long term with an eye at a 100-year life. We are in the center of the brick capitol of the United States and that is not lost on our campus. Our exterior wall materials are typically constructed with brick and precast or limestone. Our roofs are built with zinc and slate. Both, with proper installation and monitoring, will meet our design life goals."

Each new construction project on the campus is reviewed for total cost of ownership. These costs include first costs, projected and actual maintenance costs, and warranty costs. The State of North Carolina requires that each project be evaluated with a formal lifecycle cost analysis program. Preferred roof construction at the university has gone through a learning process originating with flat roofs that have been problematic with maintenance issues and premature replacement costs. Studies have shown that flat roofs have a typical useful life of only about 17 years and the experience at UNCG is no different. Subsequently, flat roofs have been discarded for a sloped roof design in new construction and modernization. Recent examples of the University's sloped roofing preference can be found in the new Science Building completed in 2003 and, more recently, the Hall for Humanities& Research Administration completed in 2006. Both buildings feature double lock standing seam roofing formed from pre-weathered zinc.

It was during the 1997 architectural interview for the Science Building that Andy Zwiacher of Durham, NC-based O'Brien/Atkins Architects first learned of the University's priorities with regard to building materials and roofing in particular. The roof was viewed as a significant part of the design intent to keep within the context of the campus which was moving towards more sloped roof designs. The University also wanted to use materials that would stand the test of time although the selection of such materials is not always an easy decision. Many elements must come together including design, function, color, budgets, the balance of initial costs and long-term costs. "In the case of the University of North Carolina at Greensboro, those priorities came together to construct a building with a zinc roof that should last for a good long time" said Zwiacher. "We continue to specify zinc in the private sector on the right projects."

The Hall for Humanities & Research Administration was designed by Calloway Johnston Moore & West of Winston Salem, NC, and completed in April 2006. The firm's Andy Sykes was the project manager. He recalls UNCG's desire to be sure the building had a contemporary feel while still fitting into the context of the campus with its traditional character and pitched roof designs. Once again the life cycle costs were an overriding concern with roofing materials. "Zinc is a very natural material with a self-healing characteristic that protects it from scratches and mars. The color is more natural than other metals which look quite machined and typically do not share the same life span as zinc." The new building provides space for teaching, research, and administrative functions for five of the humanities departments of the College of Arts and Sciences. In addition, space is provided for externally funded research projects and the administration of research at UNCG.

Like many universities, the buildings are monitored for performance. While initial construction budgets may come from bonds or grants, many of the University's buildings are self liquidating, which means they must pay for themselves over time. Money is borrowed for construction costs and repaid just as in the private sector. According to Facilities Director Fred Patrick again, "Typically our new construction budgets are ample but our maintenance budgets are scarce. Utilizing better materials that will meet our long-term goals also saves money for us in the long run. The University is willing to pay a little more up front for quality materials that will meet our standards. It is my job to justify these costs to the Board of Trustees. Once they see how products like zinc actually save us money in the long run, we usually get the green light."

University of North Carolina at Greensboro zinc roofing blends in with the context of the campus and meets the life cycle goals of the University.

Photo: VM Zinc, USA

 

Peter J. Arsenault, FAIA, NCARB, LEED-AP is an architect and green building consultant based in New York State focused on sustainable design and practice solutions nationwide. He can be reached at www.linkedin.com/in/pjaarch

Umicore Building Products

Umicore Building Products is the world's leading producer of zinc construction products, which have been used successfully for more than 150 years throughout Europe and now for more than a decade in North America. Umicore's line of VM ZINC® panels for roofs and wall systems has been used on a wide range of projects including colleges and universities, museums, airports, libraries and an array of prestigious buildings across the country. www.vmzinc-us.com

LEARNING OBJECTIVES
  • Differentiate among basic qualities of zinc as a building material compared to other architectural metals.
  • Analyze and assess the multiple qualities of zinc that can contribute to green and sustainable building design.
  • Examine the different applications of exterior zinc wall panel systems including green building applications.
  • Explore the life cycle benefits of zinc roofing among common applications.