When his architect proposed using zinc for the wall sheathing of the ultra-
modern Plaza Lofts Twenty-Two building in Hyattsville, Md., Chris Hanessian,
chief operating officer for developer University Town Cente LLC, needed some
convincing. Plaza Lofts Twenty-Two was the signature structure in University
Town Center’s massive, mixed-use community near the University of Maryland,
and Hanessian wasn’t in a position to take too much of a risk.
But after learning of zinc’s storied history as a roof and wall sheathing material in Europe and after visiting a few buildings in New Jersey that prominently feature zinc, Hanessian was sold.
“Plaza Lofts Twenty-Two is a unique building, and the discussion was what would be an appropriate skin for an ultra-modern building,” Hanessian said. “Zinc has been used extensively in Europe for hundreds of years. It lasts a long time, and it wasn’t much more expensive than brick and precast. And we liked the look of zinc. The building sits in the middle of the plaza-it’s the jewel of the Town Center-so we wanted it to make an architectural statement.”
A 22-unit upscale condominium building with a restaurant on the first floor, Plaza Lofts Twenty-Two has two curved façades that contribute to the building’s role as “an anchor and iconic image along this project’s primary retail corridor,” according to the project Web site.
Matt Lam, a senior designer with WDG Architecture, Washington, D.C., was the lead architect on Plaza Lofts Twenty-Two. “We knew we wanted to use metal cladding, and we knew we wanted something different,” Lam said. “The project’s design principal, Robert Keane, AIA, had used zinc on a project in Baltimore, and it fit perfectly with this design. We were attracted to the natural finish and self-healing capability of the material itself. W like the look, the gray finish of the zinc panel. And with the white and earthen surroundings of the building, it fit in well.”
Zinc’s physical attributes also meshed well with the building’s nonlinear design. “Because the building design is a curve, we’re working with an interlocking panel system,” Lam explained. “It also has that little bit of texture as well; it’s not perfectly straight. There’s a little oil canning to it, which also fit with the look we wanted.”
The initial reluctance of owners to specify zinc in building designs is understandable because the United States has lagged behind Europe in embracing the metal as a building material. A commonly quoted statistic states that zinc accounts for an estimated 80 percent of the roofs in Paris, but only a small fraction of the roofs here.
Even on occasions when zinc is proposed, many architects and owners search for reasons not to use it. Initial cost is a common objection as zinc is more expensive than other more commonly used materials. Unfamiliarity with zinc-whether it’s because the architect has never designed with it, the contractor has never installed it or the owner has never heard of it-is another.
Zinc is making inroads into the U.S. construction industry’s mindset, however. An increasing number of owners are taking a more discerning, objective view of their building’s purpose and concluding that zinc is exactly the material they should use to satisfy their most vital project goals.
The five primary benefits of using zinc for roofs and walls are:
- Longevity and life-cycle cost
- Aesthetics
- Low maintenance/durability
- Malleability
- Sustainability
On the Upswing
Zinc is one of the most malleable metals on the market, so architects may specify it for wall and roof design elements featuring dramatic bends and curves. Metals such as zinc and copper are often the best option for delivering on that vision.
Zinc is also low-maintenance, requiring only that debris and ponding water don’t accumulate on a roof. As Lam mentioned, it’s also “self healing,” meaning that scratches and other minor imperfections usually blend back into the matte finish over time.
A final reason that zinc is growing in popularity-and why it likely will continue to grab market share-is its “green” credentials. As sustainability increases as a goal and/or requirement in the U.S. construction industry, zinc and other metals may grow in prominence.
An article by Chantilly, Va.-based Sheet Metal and Air Conditioning Contractors’ National Association reports, “More than 30 percent of zinc used in all applications comes from recycling, and this percentage is expected to increase as demand grows. The amount of energy used to produce zinc from ore is the lowest of nonferrous metals. Energy consumption is even lower when zinc is produced from recycled material.”
Finding Qualified Installers
Hanessian said he had trouble finding a qualified contractor until he settled on Roofers Inc LLC of Baltimore. “It was something new for most of the local guys,” Hanessian said. “There were really only a couple of firms qualified, so it was a little tricky. It was a tighter market than we thought, and partly for that reason, the cost was a little higher than we expected.”
But this, too, is improving. As contractors realize the opportunities presented by zinc, more are familiarizing themselves with the material.
Most contractors who have installed zinc say it isn’t markedly different from installing other materials, but that the training required by zinc manufacturers, such as Umicore Building Products USA Inc., Raleigh, N.C., helps accelerate the process and ensures that minor challenges don’t lead to major problems.
From the installer’s perspective, the reasons an architect and owner choose zinc are less important than the fact that they have. They have no choice but to install the assigned material. Because Umicore requires anyone installing its roof or wall zinc products to undergo a two- to four-day training course, contractors have no alternative but to learn the best practices for getting the job done.
Contractors knowledgeable in zinc installation can add value to the process. Ben Pickens III, vice president of Pickens Roofing & Shee Metal in Anderson, S.C., said his company has advised designers about zinc’s properties as they relate to the design. This includes guiding designers on which wood products are best applied to zinc and avoiding situations where ponding water can compromise zinc’s durability and appearance.
Pickens believes the installation cost could drop as more contractors become familiar with the process of installing zinc and competition heats up. The challenge for owners and architects will be ensuring the installer is qualified, which is another reason the Umicore training program is such a critical part of the equation.
Despite zinc’s growing popularity, the decision to use it still requires uncommon foresight. Owners, in particular, must think long-term and big-picture. They must recognize the difference between value and cost and envision how a 100-year, low-maintenance product can benefit a building. While it may seem a leap of faith to use a product that’s somewhat uncommon here in the United States, zinc’s record of long term success in Europe should allay any fears an owner might have about using zinc.
Steve Collins is president of Cranston, R.I.-based Desana Partners Inc., a marketing and business consulting fi rm in the construction and building materials industry.
Plaza Lofts Twenty-Two at University Town Center, Hyattsville, Md.
Developer: University Town Center LLC
Architect: WDG Architecture, Washington, D.C.
Panel installer: RoofersInc LLC of Baltimore
Zinc walls: Umicore Building Products USA Inc., Raleigh, N.C.
