Metal Architecture Home


Metal makes industrial ranch design

Jack Carson, president at Carson Design Associates, designed his private residence in Texas with multiple materials to create an industrial ranch look.Jack Carson, president at Carson Design Associates, designed his private residence in Texas with multiple materials to create an industrial ranch look. It blends industrial materials and modern aesthetics. The material palette includes metal roof and wall panels, Ipe wood, steel beams, glass and limestone sourced directly from the property.

"We wanted to keep the design somewhat in the ranch vernacular but with a contemporary look," Carson says. "The reliance on metal for the roof and cladding and an exposed structure helped create a ranch building feel. We like to think of it as an industrial ranch aesthetic."

Several of Petersen Aluminum Corp.'s PAC-CLAD profiles were called for on the 7,000-square-foot residence, which was completed in 2015. Dean Contracting Co. installed 13,000 square feet of Petersen Aluminum Corp.'s 16-inch Galvalume Snap-Clad panels on the roof. Dean Contracting roll formed the metal roof panels on-site due to tight site conditions and the only access to the site was via a dirt road that wasn't wide enough to allow large trucks to deliver factory-formed panels.

The Snap-Clad panels were installed on walls as well. Approximately 3,000 square feet of them were installed vertically as siding around two garages, and as accent panels. Additionally, Dean Contracting installed 2,400 square feet of 16-inch Galvalume Precision Series panels on walls. All the wall panels were factory-made.

The underside of the overhanging soffit is clad with Ipe wood that ends with a metal edge. Carson and Brown describe this transitional element as a wing or blade. It smoothly links the standing seam roof with the overhanging wood-clad soffit. The edge was fabricated with Arconic Architectural Products' Reynobond metal composite material.

Jesse Brown, vice president at Dean Contracting, says, "The design included a myriad of varying geometric shapes on many different planes and a blend of materials that required complex detailing."

Carson says, "The biggest problem any architect has in designing for themselves is in editing out. We know all of the possibilities, and being able to prioritize and filter out the unnecessary options is often the hardest challenge."

Carson says the project was designed to require minimal maintenance, incorporated sustainability and follow LEED principles. Two inches of rigid insulation was installed under the metal roof and an additional 4 inches of sprayed insulation went under the roof deck. The property captures rainwater in 18,000-gallon collection tanks.

"A large overhanging soffit covers a large portion of the deck and shades all of the glass," Carson explains. "The heavy insulation and the shade provided by the overhang makes it very energy efficient. The house stays a very constant temperature."

Architect: Carson Design Associates, Austin, Texas,
Fabricator/installer: Dean Contracting Co., Kyle, Texas,
Metal composite material: Reynobond by Arconic Architectural Products, Eastman, Ga.,
Metal roof/wall panels: Petersen Aluminum Corp., Elk Grove Village, Ill.,