Metal cladding may not be the new kid on the block – the Statue of Liberty and the Chrysler Building are both beacons to the aesthetics and durability of the building material – but new composite-clad metals and innovative metal cladding systems are fueling a surge in demand worldwide.

“Metal cladding is on a growth trajectory globally,” reports Building Design + Construction. “This is reflected in rising demand for rain-screen cladding, which market research firm VMR values currently at over $10 billion worldwide and expects to see growth to over $16 billion by 2028. Adding to that is robust demand for—and faith in—architectural metal coatings, which are advancing from about $5 billion today to just under $6 billion by 2026, according to analyst Research and Markets.”

The growth can also be attributed to the growing popularity of rain-screen cladding and architectural metal coatings, which are able to harness the latest technology such as insulated metal panels (IMPs).

“Insulated metal panels (IMPs) are one of only a few types of building product that can provide an entire building enclosure in one prefabricated product,” explains a Metal Construction Association (MCA) white paper. “IMPs use a perfect barrier rain control approach for the enclosure element and usually use a drained approach for the joints. The sheet steel is a high-performance, durable water control layer: water simply will not leak through steel, and cracks and holes will not form over time.”

Understanding Metal Cladding: Its Role in Building Architecture

Metal cladding is a construction technique that involves applying a layer of metal to the exterior of a building's structure.

The primary purpose of metal cladding is to provide protection against weather elements and improve the building's aesthetics. Building Design + Construction says some of the more widely used metal cladding include:

• Insulated Metal Panels (IMPs)
• Metal Composite Materials (MCMs)
• Aluminum Composite Materials (ACMs)

Architects and developers often consider metal cladding as a compelling option due to its blend of cost-effectiveness, durability, and aesthetic appeal.

“Material selections during design and construction are almost always a compromise between aesthetics and the demands of cost, schedule, and durability,” John Myers, Preconstruction Executive, Gilbane Building Company, told Building Design + Construction. “Metal cladding offers components of each of these criteria, which makes it a good ‘compromise product’.”

By choosing metal cladding, project teams can achieve a balance between aesthetics and practicality, making it a versatile and widely used architectural solution.

Evolution of Metal Cladding: From Solid Plates to IMPs

Metal cladding has a rich history dating back to iconic structures like the Statue of Liberty (solid plate copper metal cladding) and the Chrysler Building (stainless steel spire metal cladding) in New York City.

While those iconic structures, and their metal cladding, have stood the test of time, advances over the years in manufacturing processes – spurred in part by research from the 1960s “space race” -- led to the development of thinner sheet metals and innovative metal cladding systems like IMPs.

“Recent advances in building science and metal cladding manufacture that increase the systems’ attraction, including the use of composite clad metals such as carbon steels bonded to more corrosion-resistant materials like copper and stainless steels, which result in lamellar composites with desirable properties not possible with a single material,” says Building Design + Construction.

The publication says that the manufacturing methods of these composite metals include:

• Hot Rolling
• Centrifugal casting
• Brazing
• Weld cladding.

IMPs have gained popularity due to their exceptional thermal performance. These panels consist of an insulating foam core sandwiched between two metal panels, providing superior R-values and excellent moisture resistance. They are lightweight, cost-effective, and sustainable, offering a long-lasting and durable enclosure solution with a high ROI.

Metal Cladding Trends and Innovations: Art + Science

Recent projects, such as the College of Health and Human Services at Southern Connecticut State University, showcase the artistic and scientific advantages of metal cladding.

“For this major new state-of-the-art center, the metal panels fit the design aesthetic of the campus,” Robert Skolozdra, partner with architecture, art, and advisory firm Svigals + Partners, told Building Design + Construction. “We also used them as the basis for our art integration element on the exterior, because it plays off of the university’s historical main gate made of ornamental metal.”

The use of aluminum in various forms allows for flexibility in curving, finishing, and laser cutting, enabling designers to create decorative metal panels at a reasonable cost.

Multi-material facades, combining metal cladding with brick veneer, glass, and other materials, offer diverse design options and aesthetic appeal.

Innovative coatings, such as built-up coatings with tactile bumps and versatile finishes, are revolutionizing metal cladding aesthetics. By layering these coatings, manufacturers achieve a visual impact like stone or terracotta but with lighter-weight and more economical materials.

Metal Panel Systems: Adaptive Reuse and Overcladding

Metal cladding is not limited to new construction; it can also reimagine existing buildings for new uses and increased value.

Over-cladding, a technique of hanging impactful metal skins over obsolete enclosures, is gaining popularity. It allows buildings to update their architectural image, improve energy performance, and provide continuous insulation, air, and water barriers without significant disruption to occupants.

“Hanging IMPs on new outer subframes or furring, according to the Metal Construction Association, the over-cladding approaches work well over varied substrates including CMU, cast concrete, and brick veneer, and provide an effective barrier and continuous insulation (CI) across entire enclosures,” reports Building Design + Construction. “In addition to increasing thermal performance, properly detailed over-cladding provides an air barrier and water barrier and improves fire and smoke containment to enhance building resilience.”

And a bonus: the over-cladding approach allows existing buildings to remain largely occupied and accessible during construction.

“Even better, over-cladding can be accomplished at modest costs and with fairly short design and construction schedules,” says Building Design + Construction.

Metal Panel Systems: The Future of Building Envelopes

The innovations in metal cladding, driven by projects like SpaceX's spacecraft and Tesla's Cybertruck, are paving the way for more cost-effective and advanced applications in the architectural world.

As technology and manufacturing processes continue to evolve, metal cladding, especially IMPs, will remain at the forefront of building envelope solutions, providing a harmonious blend of artistic expression and functional performance for modern architecture.

The 21st-century space race, with its cutting-edge materials and technologies, will undoubtedly influence the next generation of metal cladding innovations, making it an exciting area to watch in the world of building design and construction.