Folded plate roofs are most often used for industrial and commercial buildings, but they can also be found on mid-century modern homes. They’re typically chosen because of their high durability and weight-bearing capacity. If you’re a property owner interested in installing or replacing a folded plate roof on your building of choice, then you’ve come to the right place. In this article, we’re going to discuss everything you need to know about this type of roofing system.
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A folded plate roof is best described as an assembly of flat plates, or slabs, that are bent in different directions and joined at their longitudinal edges. The way the structural system is connected makes it capable of carrying loads without requiring the use of additional support beams.
These structures are typically built on-site of precast reinforced concrete, steel plates, or tempered glass. Various shapes include rectangles, pyramids, prisms, and non-rectangular shapes. Since folded plate architecture is less material-intensive than other types of roofing systems used for commercial applications, they’re also usually less expensive.
The folding plate structure originated in Germany in the s when it was used for an aircraft hangar at the Orly Airport in Paris, France. The roofing type became commonly used for immense factory buildings and coal bunkers throughout central Europe. It was introduced to North America during the s after World War II.
This roofing type is most often used for industrial and commercial applications. However, it can also be used for mid-century modern homes. We suggest contacting your local roofing experts if you’re interested in the folded plate roof design. They’ll be able to help you decide what would be best for your property.
Folded plate roof structures were introduced to North America in the s after the Second World War. They quickly became popular as a highly accepted and feasible form of construction. The style remains quite popular today, especially for commercial and industrial buildings. Folded roofs offer a variety of benefits, which we’ll discuss in greater detail in the next section.
Folded plate roof structures provide an assortment of advantages for property owners. They include:
Folded plates also have a few disadvantages that you should be aware of. They include:
The good news about this roofing style is that it’s often a cost-effective choice for a variety of commercial and industrial buildings. Why? It’s both faster and easier to assemble than other types of roofs, which helps reduce labor costs.
If you’re in need of an estimate for roofing installation or replacement, get in touch with your local roofing contractor. They’ll be happy to walk you through your cost options depending on the style and material you choose.
At Legacy Service, we’re dedicated to providing property owners with the building exterior they deserve. Get in touch if you’re interested in scheduling a consultation with a member of our team.
Folded plate roofs can be constructed from a variety of high-quality materials. Ones that are the most often used include steel plate, reinforced concrete, or tempered glass. In the sections below, we’ll discuss each material in detail to help you make a more informed decision.
When you’re installing or replacing a roof, it’s a good idea to consult with an expert to determine which style of roof and material will work best for you. We recommend getting in touch with your local roofing contractor to get started with your project. They’ll be able to walk you through the process.
Material 1: Steel Plate
Steel is one of the most commonly used materials for this roofing type due to its strength and durability. Steel folded plate roofs not only provide an interesting appearance but also offer the option of having large column-free areas. As for design, a standard module that’s open to prefabrication was created. Design charts have been prepared by experts, and they can be used for the preliminary design of steel frame folded plate roofs without having to use rigorous computer methods. Property owners interested in using steel can contact their local roofing company to get started on their project.
Material 2: Reinforced Concrete
Reinforced concrete is another one of the most popular materials used for folded plate roofs. Like steel, it’s known for both its strength and durability. The basic idea of creating a concrete folded plate roof was to achieve more constructive height and better rigidity while reducing the overall weight of the structure. It’s noteworthy to add that the strength of this type of construction is achieved through the proper design rather than the materials that form it. If you’re interested in concrete folded plate roofs for your property, get in touch with a local roofing contractor as soon as possible.
Material 3: Tempered Glass
Last but not least, tempered glass is the third material that’s most often used for folded plate roofs among property owners. You can use either glass alone or combined with other materials to make various roof, wall, and floor constructions. Whether you select glass or another type of material for your folded plate roof, you can rest assured that the structure will have an intrinsic rigidity and high load-bearing capacity. If you’re a property owner who would like to install tempered glass on your home or business, please do not hesitate to call your local roofing contractors.
Once you’ve decided that you’d like to install a folded plate roof on your property and you select the material, then it’s time to determine which type of structure would work best for your building. The five main structure types include butterfly-shaped folding plates, V-shaped plates, tapered folding plates, trough-shaped folding plates, and hyped folding plates.
Folding plate structures are assembled using flat plates, then they are bent in different directions, and finally joined along their longitudinal edges. Modern ones are typically precast steel plates or reinforced concrete. As a shell structure, they consist of a series of thin plates, also known as hipped plates. Folding plates cover large areas, while bent plates are used to cover smaller areas.
In the next section, we’ll discuss each type in more detail to help you decide. You can also get in touch with your local roofing company to receive a consultation with an expert.
Butterfly-shaped Folding Plates
Butterfly-shaped folding plates may not be as widely applied as other types, but they still have their uses. It’s important to keep in mind that they’re commonly used to cover petrol pump roofs and factory roofs as well as provisions for windows.
V-shaped Plate
Among the different types of folded plate structures, V-shaped tend to be the simplest. These types of plates are normally used for short spans since they don’t offer enough surface area for concrete, the bottom, and the top to resist compressive stresses.
Tapered Folded Plates
In many cases, tapered folding plates are mainly used for aesthetic purposes. It’s also important to remember that Z-shaped folding plates are only used for factory construction. The reason for this is that they provide a north-light roof.
Trough-shaped Folding Plates
Unlike V-shaped plates, trough-shaped folding plates will provide sufficient surface area for concrete at the top. They can also resist compressive stresses at the bottom. This type of plate can be used for a long time.
Hyped Folding Plates
Hyped folding plates are a structural type that’s mainly used for two types of projects. These projects include cooling towers in thermal power stations and also tent-shed roofs.
If you’d like to learn more about the different types of folding plates, schedule a consultation with your local roofing professionals.
Not only are folded plate roofs easy for architects to design, but they also offer plenty of design options for property owners. The best part is that they can make any building visually appealing while remaining highly functional.
If you’re wondering what shape would work best for your building, you should research and review the different shapes and overall forms that are available to you. In the next section, we discuss three of the most popular shapes including prismatic, pyramidal, and prismoidal.
If you’re seeking the opinion of an expert, we recommend getting in touch with your local roofing contractor.
Prismatic (Rectangular plates)
Folded plate structures consist of flat components, known as plates, that are connected along their longitudinal edges. Prismatic is one of the primary types of plates that property owners can select for their roofing structure. What differentiates them from other types is the fact that the plates are rectangular as opposed to another shape. In modern construction, the folded plate structures that are most widely used are made of precast reinforced concrete or cast-in-situ.
Pyramidal (Non-Rectangular plates)
Pyramidal is another one of the main shapes used for folded plate roofing structures. It’s best described as a type of non-rectangular plate. Property owners who’d like to see how pyramidal plates would look on their building should get in touch with their local roofing contractor. Many contractors offer consultations to give owners an idea of what’s best for them as well as a price estimate.
Prismoidal (Triangular or Trapezoidal plates)
The third folded plate shape that we’re going to discuss in this section is called prismoidal. This type is best described as triangular or trapezoidal plates. Depending on the type of appearance you’re going for, prismoidal may be an ideal choice. A roofing professional will be able to review your options to determine which type would be best for the preferences for your building. Folded plate construction is beneficial because it’s simpler to manufacture and requires less material than other types of roofs.
If you’re interested in folded plate roofs, then you probably have plenty of questions. In this section, we’ll answer some of the questions that our team is most frequently asked about this type of roofing structure. If you’re still interested in this roofing style, don’t hesitate to get in touch with your local roofers to schedule a consultation.
What is a folded plate roof?
Folded plate roofs are assemblies of flat plates that are joined together along their longitudinal edges. The way they are connected allows them to carry loads without needing additional support beams along the edges. These roofing systems are chosen by property owners for their durability and high weight-bearing capacity.
The first roofs originated in Germany during the s; they were constructed for massive factory buildings. They became popular in Russia and North America during the s. It was mainly used for the construction of warehouses back then, but it’s now the preferred solution for commercial buildings, large industrial structures, and even mid-century modern homes.
Why are folded plates economical?
Folded plates are economical over long spans that must be free of internal columns as well as other obstructions. These structures have a more intrinsic rigidity and higher load-bearing capacity than other types of roofing structures. They’re beneficial for property owners because they don’t require additional supporting beams along their mutual edges.
First introduced into the United States in the s, this roofing system quickly became popular for large industrial and commercial buildings. The technology allows the materials to be prefabricated and pre-stressed. Since they’re relatively easy to assemble, this can help shorten installation time and reduce overall costs.
Where are folded plates used?
Folded plates are the preferred roofing solution for large commercial and industrial buildings. They can also be used for modern mid-century homes. They originated in Germany during the s, where they were commonly used for coal bunkers and large factory buildings. After the Second World War, they were introduced into the United States, where they quickly became popular for a variety of large buildings.
If you’re interested in installing a folded plate roofing system, get in touch with your local roofing contractor. Many of them will be willing to schedule a consultation to review your options and determine the best solution for your property.
What is a folded structure?
A folded structure is a set of flat plates that are inclined in different directions and joined along their edges at the top. This type of structure is beneficial because it’s capable of carrying loads without requiring the use of additional support beams. It’s recognized for having many uses, including but not limited to visually appealing roofing of large spans, bunkers in silo structures, sheet piles, and box girders in bridges and overpasses.
The various types of folded plate structures include butterfly-shaped folding plates, v-shaped plates, tapered folded plates, trough-shaped folding plates, and hyped folding plates. Consulting with a professional can help property owners select the type that would work best for them.
What are the basic concepts of folded plates?
If you’re interested in installing a folded plate roof on your building, then you may be interested in the structure’s basic construction concepts. Let’s take a look:
Relatively speaking, folded plate structures are simple to install. The method we discussed was developed in China and is now used in other parts of the world.
If you’re interested in replacing or installing your own folded plate roof, then it’s time to get started on your own project. Get in touch with your local roofing contractors to schedule a consultation.
At Legacy Service, we provide installation and replacement services for roofing, siding, windows, doors, and gutters. If you live in southeastern Pennsylvania, New Jersey, or Delaware, please feel free to contact us so that we can help you enhance the exterior of your property. You reach us at 215-798-.
ASTM Standards – The American Society for Testing and Materials is an independent standards organization that regularly publishes testing and performance specifications for a wide variety of industrial products.
Backers – Backers provide the underside of painted metal used in metal roofs and walls with base color, some protection, and a substrate (basis) for adhesives. A backer is typically white or neutral color.
Bonderized – Bonderized refers to the thin layer of Zinc Phosphate on the surface of the sheet that is a weldable product and provides a surface to which paint will readily adhere. This is typically used in rainwater goods such as gutters and flashings for metal roofs.
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Camber -The curving or deviation of sheet metal from a straight, vertical plane. Also related to sweep, the curving or deviation of sheet metal from a straight, horizontal plane
Capillary Action – The movement of water through microscopic pores or channels within metal. As water molecules are ‘sticky’ they can flow through narrow spaces often against external forces such as gravity. Usually created when an exposed end of bundled painted steel is in proximity to water due to improper storage, leading to water travelling through the metal, resulting in wet stack corrosion.
Chalking – Chalking is the degradation of the resin system at the surface of the finish on a metal roof or wall, due predominantly to prolonged UV ray exposure. As the resin breaks down, resin particles along with embedded pigment particles lose adhesion and take on a white appearance.
Clear Coat – A clear coat is an optional layer for metal roofs and metal walls applied over the paint top coat designed to add perceived depth to the surface, enhance gloss, or provide an additional layer of protection for extreme environments such as coastal or industrial environments.
Concealed Fastener Roofing – See Standing Seam
Cool Colors – Cool colors refer to a coating for metal roofs which utilize infrared (IR) reflective pigments that have been altered chemically and physically to reflect IR wavelengths while still absorbing the same visible light. Reflecting infrared light reduces the heat buildup in structures, thus reducing building cooling costs.
Corrugated – Corrugated is a common type of metal roof or wall panel design, which incorporates ribs of equal or similar size and shape to create aesthetically pleasing shapes and shadow lines.
Cut-To-Length – Cut-to-length is a manufacturing process in which metal products, typically metal coil, are cut to the exact specifications of an end-user or manufacturer for use in metal roof and wall products.
Delamination – Delamination is the loss of paint film adhesion to the substrate or between the primer and the topcoat. It can be visually apparent in several forms including bubbling, peeling, checking, chipping, cracking, or complete loss of the top coat on a metal roof.
Directional Paint System – Due to the unique shape of the pigments in the paint, common to metallic paints, a directional paint system catches light in a specific way that can vary between batches and orientation. This guidance is given for certain colors to avoid mixing orientation or batches to provide a clean uniform look once installed on a metal roof or wall.
Dissimilar Metals – Refers to metals that are in different positions on the galvanic scale relative to one another. Two dissimilar metals in proximity to one another in a conducive environment can lead to galvanic corrosion, in which one metal corrodes preferentially (and sometimes rapidly) compared to the other metal. This is due to the ‘flow’ of current from one metal to another.
Edge Corrosion (field cutting induced) – Corrosion at the exposed, thin, unpainted end of a metal panel. Often created due to field cutting of panels by heat generating devise such as a grinding disk or sawzal (compared to a manufacturers shear or shearing action used on a jobsite to cut material) which leads to an inconsistent, exposed edge which can trap water and spread corrosion more rapidly.
Edge Wave (slitter or roll former induced) – The visible, unintentional waviness, or buckling at the edge of a metal strip due to the forces imparted on the panel during the production or forming process. Often due to improper production or quality control processes.
Electrolysis – Electrolytic Corrosion created by two or more dissimilar metals in contact with each other and an electrolyte containing small amounts of acid. A common example is moisture in a coastal environment. This leads to galvanic corrosion in which one metal will corrode preferentially to the other.
Embossing – Embossing is the process of creating a raised texture to the surface of the metal. Undertaken in a continuous process for metal applications such as metal walls.
Emissivity – Emissivity is the amount of heat a surface can dissipate away from itself. This is expressed as a percentage between 0-100%. Used in the calculation of the Solar Reflectance Index for metal roofs.
Exposed Fastener or Lap Seam Panels – Exposed Fastener or Lap Seam Panels are metal roof and wall panels which are lapped with one over the other, with the fastener then attached from the outside and driven directly through the metal.
Fading – Fading occurs to metal roof and metal wall products when UV rays and substances in the environment attack the pigments in the paint and cause their color to change. Color change is typically assessed based on its variance to the base state when new, represented by Delta E (dE or ΔE).
Film Thickness – Film thickness or dry film thickness (DFT) refers to the thickness of paint film on the strip surface, once the paint has cured. Typical dry film thicknesses for painted steel for metal roof and metal products range from 0.″ (0.5 mil) to 0.″ (1.5 mil).
Flexographic Roll Printing – Flexographic roll printing is the process Steelscape employs to impart its distinctive colors and designs, such as rustic and aged metallics onto metal for metal roof and wall products.
Galvalume® – See ZINCALUME®
Galvanic (bi-metal) Corrosion – The preferential corrosion of one metal over another, created when two dissimilar metals are in contact with one another in a conducive environment (presence of moisture with acid). Heightened by how dissimilar the metals are on the galvanic scale and how conducive the environment is (e.g. more prominent on the coast than in the desert).
Galvanizing – Galvanizing is the process of coating a thin layer of zinc to steel to improve corrosion resistance. Referred to by Steelscape as TruZinc. For most metal roof and metal wall products that use galvanizing this is applied before the paint layer.
Gauge – Gauge refers to the thickness of metal. A smaller gauge correlates to a thicker metal. For example, 22ga is thicker metal than 29ga. 22ga-29ga are also the most common gauges for metal roof and metal wall building applications. Sometimes spelled as gage.
Gloss and Sheen – Gloss and sheen are two terms used to describe how well a surface reflects visible light. Gloss is measured at a 60° angle from the surface, while sheen is measured at 85°.
Graffiti Resistance – Graffiti resistance, for Steelscape applications, refers to a painted metal wall surface in which aerosol or marker-based graffiti can be removed from the surface.
Inert Catchment – When acidic rainwater, created by certain environmental conditions, creates corrosion in areas downstream of the water catchment surface such as gutters and downpipes. Avoided by ensuring the correct material is selected relative to its environment.
Pressure Mottling – Uneven or irregular gloss visible on painted steel ( often in a splotchy or speckled pattern) due to variation in the pressure applied to the painted surface of the metal when it is stored in coil format. Typically a temporary condition that will dissipate with time.
LEED – Leadership in Energy and Environmental Design (LEED), is a green building rating system developed based on a pre-developed framework for healthy, efficient and environmentally sustainable structures.
Light Reflectance Value (LRV) – Light Reflectance Value measures the amount of visible or usable light that reflects from a surface. LRV is expressed as a percentage from 0 to 100; the higher the number the more visible light that is reflected. Used for both metal roofs and metal walls.
Mechanical Seam – Mechanical seam refers to metal roof products where the seams are mechanically attached together by ‘rolling over’ one seam with another by hand using special tools or with a mechanical seamer. This offers superior weather tightness and product performance in extreme environments.
Metallic Coating – Metallic coating refers to the process of applying additional metal elements, typically Zinc (galvanizing) or Aluminum and Zinc (ZINCALUME® or Galvalume®) to steel to improve corrosion performance of metal roofs and walls.
Mica – Mica is a specially formulated pigment that is added to paint for metal roofs and metal walls to create a sparkling or light-catching effect. This creates the effect of metal flakes in paint but with higher durability.
Oil Canning – Oil canning is a visual phenomenon seen as waviness or distortions in the flat surfaces of metal roofing and metal siding products. This effect is created by a range of different factors including stresses in the base material, improper fastener pressure, misaligned panels, and thermal expansion.
Pre-painted Metal – Pre-painted metal is the continuous process of coating steel rolls, called coils, with paint (also called coil coating). This type of metal is used in metal roofs and walls. The paint that is applied to the metal before it is formed into a finished product by a product manufacturer is called pre-painted metal.
Paint – Paint refers to the film applied to a surface to achieve a desired aesthetic and to protect the material underneath. Metal roof and wall paints typically consists of resins, solvents and pigments. Pigments add color, resins are the binder and add physical and chemical attributes, and solvents dissolve this combination into a liquid form.
Paint System – The paint system consists of a combination of the different painted layers, namely the pretreatment, primer and top coat to create a total finish solution. Paint systems can be modified to achieve different aesthetic or performance characteristics.
Polyester Paint – Polyester Paint is the most economical metal roof paint system and offers the lowest level of UV resistance when compared to SMP (Silicon Modified Polyester) and PVDF (Polyvinylidene fluoride) systems. Versatile and easy to form, their paint structure can be modified to suit a wide range of performance qualities and their flexibility means they can be offered in a variety of color and gloss options.
Pre-treatment – Pre-treatment refers to a coating process applied before painting in which the surface of the metal is cleaned to improve paint adhesion attributes to improve the longevity of painted metal roof and wall products.
PVDF (Polyvinylidene fluoride also known as Fluorocarbon or Kynar 500® and Hylar ®) – Polyvinylidene fluoride (PVDF) is the highest performing of the three common metal paint systems. It offers exceptional chemical, chalk, and fade resistance and can resist degradation when exposed to aggressive weather elements such as urban grime, air pollutants, salt, high temperatures and humidity. PVDF can be used on a wide range of preformed shapes, which is why they are often used for high-end architectural and high-profile commercial metal roof and wall projects.
Primers – Primers refers to a coating that prepares the substrate for painting by providing ‘bite’ for adhesion and directly supports topcoat color and flexibility. Primers also provide corrosion resistance for metal roof and wall products.
Reverse Impact Test – A reverse impact test is a stress test that is performed to determine if any paint adhesion is lost through a direct impact from the underside of the material. Like the T bend test, this simulates final forming into the finished metal roof and wall product.
Roll Forming – Roll forming is the process used to manufacture the majority of metal roof and wall products. A continuous production process where material is fed through a series of progressive rollers to form it into a finished state. Enables the end panels to be manufactured to desired end user’s length.
Self-Healing Properties – In metallic coatings such as ZINCALUME or galvalume, the galvanic action causes the zinc compounds to automatically build up at cut edges and scratches by an electrolytic reaction when water or moisture is present, slowing the rate of corrosion. This effect is sometimes referred to as “self-healing”. These properties are more pronounced on a factory cut edge with a shea, in which it is smooth and consistent as it essentially folds the Zincalume coating over the exposed raw edge of the base steel. Field cutting (provided its done in a shearing action) can have the same results as a factory cut edge.
Silicon Modified Polyester (SMP) – Silicon Modified Polyester is a paint system with a different resin structure to improve their UV resistance qualities compared to traditional polyester systems. SMPs offer a greater resistance to chalk and fade compared to traditional polyester systems and commonly used in residential metal roof applications.
Slitting – Slitting is a manufacturing process in which the width of a metal coil is trimmed to a desired size, or in which one metal coil is slit to form multiple narrower coils for use in metal roof and wall products.
Snap Seam or Snap Lock Roofing – Snap Seam or Snap Lock Roofing is a type of standing seam metal roof profile which typically have a nailing flange to affix the profile to the roof deck and the seams snap together to form the interlock.
Solar Reflectance (SR) – Solar Reflectance refers to the amount of solar radiation reflected off a metal roof or wall surface. This is expressed as a percentage between 0-100%.
Solar Reflectance Index (SRI) – Solar Reflectance Index is the most common index used to measure the reflectivity effectiveness of a color for a metal roof or wall. The consolidated value calculated from solar reflectance and emissivity with factors such as air flow considered. The higher the value the greater the reflectance. This is expressed as a range so that a standard black surface has an initial SRI of 0, where as a standard white surface has an initial SRI of 100.
Spangle – Spangle is a term to describe the distinctive finished appearance of unpainted ZINCALUME® steel as commonly used in metal roofs and walls.
Stamped Metal Tile, Shake, or Shingles – Stamped Metal Tile, Shake, or Shingles refers to the modular metal roof products manufactured using a stamping process to take on shapes of traditional roofing materials.
Standing Seam Roofing – Standing seam roofing is a common metal roof type for both residential and commercial applications. The seam, is the vertical rib which interlocks between each profile and is raised from the flat base pan of the panel. The fasteners that attach these panels to the structure underneath are covered in the installation process, which is why these profiles are also called concealed fastener roofing profiles. Standing seam reflects one continuous piece from ridge to eave and are available in a variety of widths from 12” up to 20” and beyond.
Striation – Striations refers to the small ridges formed in flat areas of metal surfaces used to reduce the visual impact of oil caning in metal roof and wall products.
Swarf – Swarf refers to the small metallic filings created when metal roofing or siding products are pierced or cut with friction saws, abrasive discs, or drills. If these tiny particles are left on a metal surface, they can corrode and cause rust stains.
T Bend Test – The T Bend Test simulates forming of metal into metal roof and wall products and assesses the flexibility of painted metal. During this test, a bend is formed in the test sample and inspected for any cracking.
Tension Leveling – Tension leveling is an in-line process on both Steelscape metallic coating lines and the Kalama Pickle Line, which induces tension into the strip in excess of the yield strength. Tension leveling results in a flatter product with improved properties for subsequent forming into metal roof and wall products.
Toll Forming – Toll forming is the process of coating or painting metal in which the base metal is provided or owned by the end user.
Top Coat – The top coat refers to the top painted layer of metal which provides metal roofs and wall with the visual color, offers protection from the outside elements, in addition to durability, and weatherability.
TruZinc® – TruZinc® is the terminology used to refer to Steelscape’s computer controlled galvanizing process for metal roof and wall products
Wet Stack Corrosion – The creation of corrosion or blistering to the surface of metal when stored in stacks and bundles. Due to trapped water between metal sheets, the capillary action of water through metal ends or other exposure to moisture due to the improper storage of the metal.
White Rust – The presence of a white, chalky substance on the surface of bare galvanized products. Typically occurs when new galvanized products are exposed to moisture or condensation before the zinc coating has stabilized.
Yield Strength – Yield strength represents the stress at which materials transition from elastic to plastic deformation. Once a material has been loaded past its yield point, it is permanently deformed making it unsuitable for use in metal roof and wall products.
ZINCALUME® (Galvalume®) – ZINCALUME® refers to a metallic coating consisting of 55% Aluminum and 44% Zinc to offer superior corrosion resistance. Coatings using the aluminum-zinc alloy offer a number of advantages to zinc alone. Aluminum is inert and provides a protective rather than sacrificial barrier compared to zinc. This combination is the common industry standard used for metal roof and wall products.
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