One-of-a-Kind Rustic Designs

by Marcy Marro | April 1, 2022 12:00 am

The architectural community has taken notice of weathering steel’s transition to a more mainstream design product. According to Sebastian Schmaling, AIA, LEED AP, principal at Johnsen Schmaling Architects[1] in Milwaukee, “It has been elevated from a niche product for industrial-chic applications to a much more mainstream material.”

With its unique design aesthetic, weathering steel can be found on all types of buildings and in all industries—residential, commercial, industrial. “It is being used not only in exterior applications but has become an accepted and fairly standard finish even in interior settings,” Schmaling says. “I think the material has established itself beyond any stylistic connotations and has proven itself to be more than just a passing fad.”

John Marx, AIA, chief artistic officer at Form4 Architecture[2] in San Francisco, says A588 corten steel is seen as a warmer façade material compared to bare metals. “It adds a rustic charm to urban projects such as industrial parks. We have also used it in lobbies, although corten can be more challenging to pair with other materials.”

A Unique Finish

To create the rusted metal look, metal panel manufacturer Bridger Steel[3], Belgrade, Mont., offers its own Truten A606 weathering steel finish, which acts like Corten but creates a metal roof rust that begins with a top layer coating made of copper, phosphorus and silicon, to form a textured oxide surface film on the panel. As the panels are exposed to different weather conditions, they start to rust into a unique, one-of-a-kind color. As Morgan Scott, marketing manager at Bridger Steel explains, weathering steel has been a popular product ever since its launch. “There’s been a steady and continuous increase of interest in this unique, one-of-a-kind finish. Since the weathering steel panels will rust as they’re exposed to different weather elements over time, they are truly a different product from anything else available on the market including traditional painted finishes.”

Weathering steel creates a timeless look that Scott says is unlikely to ever go out of style. “Home and building owners looking to create stunning rustic and modern-rustic styles are continuing to turn to this unique finish,” she says. “Not only will this finish be around for years to come because of the aesthetic it creates, but because metal is durable and strong enough to last for up to 70 years or longer. The chemical composition of weathering steel allows the panels to rust to a certain point without rusting all the way through so you can achieve a classic rusted look with the exceptional performance of steel.”

Scott notes that Bridger’s weathering steel finish can be used in many creative ways and is used on all types of applications from classic roofing and siding to unique accents and fencing. “It’s a popular choice to pair weathering steel with corrugated roofing panels or to pair it with modern looking standing seam siding panels. The beauty of weathering steel is that it can adapt to fit your style needs just by simply pairing it with the right panel profile to achieve your desired aesthetic.”

Versatile Applications

Traditionally, weathering steel was found more in the southwestern United States, and on ranch-style homes, or homes in the mountains. Today, weathering steel is typically incorporated into more than just homes looking to achieve a rustic look. “Weathering steel played an important part of the architectural syntax in the Southwest United States before it established itself as a viable building product in the rest of the country,” Schmaling explains. “Today, its popularity transcends particular regions and climates.”

“Although we’ve seen a lot of weathering steel used in the West and Northwest to achieve that true western style, people are incorporating this finish on projects and applications all over the country,” Scott says, “What’s truly amazing about this finish is that a home with weathering steel siding in a humid region compared to a dry region will have completely different rusting times and end results. It’s all about the design style you’re aiming for, which is constantly transforming across the country.”

Marx notes that they’ve been seeing unprecedented interest in corten steel in California. “It’s a modern-looking material that also has a rustic quality,” he says. “Further, corten steel has an earthy, natural look that integrates well with native California landscapes.”

This natural integration makes corten steel increasingly popular for planters and edging, as its earth tones complement the native xeriscapes so well. So much so, Marx says the firm includes corten steel in projects whenever possible. “Our firm takes a holistic view of projects, always looking for ways to integrate buildings and their adjacent grounds to activate courtyards as alluring social areas and even workspaces,” he says. “Corten is an ideal material for easing transitions from inside to outside. Its popularity should escalate as more municipalities’ planning departments familiarize themselves with the material and push back less on corten for aesthetic reasons.”

Lance Enyart, AIA, LEED AP, principal of Phoenix-based LEA Architects LLC[5], notes that his firm has been using corten steel for decades. “The material offers many benefits in that it requires no maintenance and has a beautiful natural patina that changes with time and weather. There are also cost benefits in that the material requires no long-term maintenance.”

Endless Possibilities

Versatile enough to serve as both roofing and wall cladding, Schmaling says he thinks architects like to use weathering steel as a building skin and for exposed structural components. “It’s partially due to the fact that a majority of commercial buildings have flat parapet roofs,” he says, “but perhaps more importantly, weathering steel is a truly durable, low-maintenance material, one that ages gracefully and is visually alive as its patina evolves over time.”

For example, LEA Architects has utilized weathering steel for both wall and roof applications, in a variety of panel profiles including standing seam, flush seam, decking and flat panel. They’ve used weathering steel in both public and private sector projects, on everything from municipal libraries, aviation buildings, public safety facilities to single-family residences. “When utilizing the material for roof applications it is important to consider a thicker gauge of metal especially on roofs with a lower pitch or in four season alpine climates that see a lot of snow,” adds Enyart.

Additionally, Marx notes, A588 corten steel panels work well as part of rainscreen systems. “Mounted about 1/4-inch out from the rainscreen’s waterproof barrier, corten steel helps protect breathable membranes from hail and other debris,” he says. “It provides functional and aesthetic benefits, particularly when compared to thinner metals such as copper or aluminum.”

This versatility of its applications, Schmaling adds, and its often-surprising architectural moments in a wide variety of buildings makes weathering steel such an interesting material. “It really spans the gamut like few materials do: great material performance and low maintenance, affordability and low life cycle costs, ease of installation, visual beauty and recyclability.”

“Aesthetically,” Marx says, “corten steel looks more upscale than galvanized at a slightly higher cost. Galvanized steel works where an industrial look is desired, and corten attractively combines industrial and rustic feels. We find that corten expands the creative possibilities, adding a rustic tone to the color palette.”

Benefits of weathering steel includes it being one of the most durable products on the market, Scott says, because it requires a heavier gauge steel to be used as a layer of the panel will rust. “It produces a truly one-of-a-kind look that will be completely different from anyone else who uses the finish on their home or building. Weathering steel can be used on new construction builds and end up looking like it’s been sitting there for 50-plus years as it weathers without having to worry about deterioration or rusting all the way through. One of the biggest benefits of weathering steel is its versatility. You can use this finish on roofing, siding, fencing, interiors and so much more. The possibilities are truly endless.

Source URL: https://www.metalarchitecture.com/articles/one-of-a-kind-rustic-designs/

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