Complex custom architectural metalwork · Lesson 4 of 4

Complex custom architectural metalwork: defects, verification and case study

The defects custom metalwork shows and the causes each points to, how to diagnose oil canning, soldered and sealed joints, finish and compatibility faults, what is checked at which point, a constructed fascia case study, and hot-work cautions.

You will be able to: Diagnose a custom-metalwork defect from its pattern, choose corrective options in a sensible order, and document evidence a reviewer can accept.

11 min · 12 slides · 7 questions

All lessons in this module

Slide 1 of 12

Defect families and what each points to

Each defect points back to a cause a source names: waviness to stress (MCA), soldered seams weaker than the base sheet to cracking under movement and loads (IIBEC), open mitered corners to corners not sealed and soldered or welded watertight (UH), and color mismatch to alloy and finish choices (AAC, VA).

Match what you see to the cause the pattern points to, then confirm it with evidence.

Sources

Oil Canning in Metal Roof and Metal Wall Systems, technical bulletin (2013, Version 1) - Metal Construction Association (copy hosted by McElroy Metal)
Fully Soldered Metal Roofing: More Complicated Than You Think (N. Floyd and A. K. Patel, Simpson Gumpertz and Heger, Symposium on Building Envelope Technology, 2016) - IIBEC
Section 07 6200 Sheet Metal Flashing and Trim (master specification, UH Master 06.2020) - University of Houston Facilities Planning and Construction
Specifying Anodized Finishes on Aluminum, technical bulletin (initial release February 2013) - Aluminum Anodizers Council
Section 07 60 00 Flashing and Sheet Metal (national CAD standard specification, header date 10-01-23) - U.S. Department of Veterans Affairs, published on the Whole Building Design Guide

Videos for this lesson

What this video shows: Technique for soldering flat seams in copper at a maximum slope of 3:12, with preparation, tools and steps, narrated by the association's architectural applications specialist. This is another organization's method, not an AFS or UH requirement.

Video: How-To: Flat Seam Soldered Joint by Copper Development Association, on YouTube. Chosen from the video's published description.

What this video shows: Soldering sheet copper lap seams that run vertically or on a slope over 3:12: tacking and soldering. This is another organization's method, not an AFS or UH requirement.

Video: How-To: Vertical Soldering, Lap Seam (Part 1, Tacking and Soldering) by Copper Development Association, on YouTube. Chosen from the video's published description.

What this video shows: Types of stitches, such as a butterfly stitch, and how to stitch and inspect a soldered copper lap seam. This is another organization's method, not an AFS or UH requirement.

Video: How-To: Vertical Soldering, Lap Seam (Part 2, Stitching and Inspection) by Copper Development Association, on YouTube. Chosen from the video's published description.

Glossary

Dual pinning: Restraining a panel or run at more than one place so it cannot move; MCA says restraint like this can show as oil canning.
Tension leveling: A coil process that stretches the metal beyond its yield point so it lies flatter; MCA says it should be done after slitting and that ordering tension-leveled material reduces oil canning.
Installer warranty: A warranty signed by the installer covering materials and workmanship; UH's example asks for five years from Substantial Completion, one owner's requirement.
Nonconformance record: A written record of a defect with its evidence, the rule it breaks and the correction; it is how a reviewer can accept or reject the fix.
Pre-tinning: Coating the edges to be soldered with solder first; UH pre-tins to a width of 1-1/2 in and VA to at least 1-1/2 in on uncoated copper and stainless.