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Green Building Bible, Fourth Edition
Green Building Bible, fourth edition (both books)
These two books are the perfect starting place to help you get to grips with one of the most vitally important aspects of our society - our homes and living environment.

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  1.  
    As some of you may know, I've been looking into tin tabernacles and thinking of making my own. Link here: http://www.greenbuildingforum.co.uk/newforum/comments.php?DiscussionID=15752&page=1

    To avoid the problem of painting galvanised steel, I was thinking of using corten. I was also thinking of using it horizontally to span between the vertical timber members for the hempcrete. Only problem is whether it's possible to get it made. There's one source offering it for roofs, but they charge an astronomical price. If the machines are still available, it should be easier to corrugate it on demand. Though I've no idea whether any fabricators would do it, so I thought I'd ask here for any leads. Any ideas where to start?
  2.  
    I have always found MCS Roofing & Cladding (Leek, Staffs) very helpful.
    They made me some valley gutters to go between two agricultural building roofs. They have folding and chopping machines etc for sheet metal products.
    I know that they sell wriggly tin, so they might know where you can get some fabricated.
    •  
      CommentAuthorfostertom
    • CommentTimeJul 1st 2018
     
    Don't know where you are COP, but Cladco in Okehampton Devon sound like a regional equiv to MCS - recommended.

    Painting galv steel? You can get trad 3" x 3/4" 'corrugated iron' colour coated, as well as 0.7mm thk (vs standard 0.5mm).
  3.  
    Thanks both! @fostertom, Cladco responded this weekend to say they wouldn't fabricate wriggly corten, but didn't say why. Another fabricator has said that corten corrodes their rollers. Not sure why this would be, or whether there is an alternative method that doesn't rely on rollers. I'll post any follow up information I hear.
  4.  
    I've had a chat with the marketing director of a large corrugating company. He says he'd love to do corten, but they can only store it for a limited period of time before it starts to rust, and he can't get hold of small rolls of it to do small runs of corrugating.
    • CommentAuthorIan1961
    • CommentTimeJul 6th 2018
     
    what about using colour coated aluminium sheet? I'd have thought that would be considerably cheaper than corten and a lot easier to get.
  5.  
    That's an option, but I've used corten for various flashings and small areas of (flat) cladding and was interested to keep it the same. Painted galvanised steel is also an option. There is also some product where the paint is supposed to look like corten, but I'd prefer to go for the real thing if I could. I like things to look like what they are.
    •  
      CommentAuthorfostertom
    • CommentTimeJul 8th 2018
     
    Posted By: ComeOnPilgrimI've used corten for various flashings and small areas of (flat) cladding
    Really? That means you've managed to get it folded/fabricated in small quantities previously? How, where?
  6.  
    I've only been able to fabricate flat sheets so far. It works be possible to make wriggly sheets by hand, but it would be a huge amount of work.
  7.  
    Posted By: fostertom
    Posted By: ComeOnPilgrimI've used corten for various flashings and small areas of (flat) cladding
    Really? That means you've managed to get it folded/fabricated in small quantities previously? How, where?

    I also fabricate small areas of (flat) cladding in my garage/workshop. But then it depends upon your definition of 'small'
  8.  
    It seems impossible to get it in Europe, but Chinese suppliers seem to do it. I'm guessing that the company mentioned above imports it from China.
    •  
      CommentAuthorfostertom
    • CommentTimeJul 10th 2018
     
    I thought Corten was quite hardened, not as malleable as mild steel, hard to fold except on powerful machinery - perhaps why a supplier above said it would wear out his rollers.
  9.  
    I think you're right. I've asked for a test certificate from a corten supplier, so that might shed some light on the issue. On the positive side, I suppose this means that we might be able to get away with a thinner gauge of sheet, though I think the thinnest they do is 0.8mm. The old corrugated metal was 0.7mm I think.
    •  
      CommentAuthorfostertom
    • CommentTimeJul 10th 2018
     
    Standard corrugated iron is 0.5mm, the 'super' grade 0.7mm. Luvvvly stuff.
    • CommentAuthorCliff Pope
    • CommentTimeJul 12th 2018
     
    "To avoid the problem of painting galvanised steel,"

    Five years ago I built a new shed out of corrugated iron, and painted the fresh galvanising with the cheapest garage floor paint I could find online. It's lasting well, shows no tendency to flake, and is very resistant to abrasion.

    Recently I had to attend to the ridge cover (old plastic guttering, inverted) and the paint withstood sliding a ladder up the roof.
  10.  
    Hi Cliff, yes, if the 'tin tabernacles' can survive for 100+ years, then I suspect your shed should last a good amount of time!
  11.  
    As an update, the corten supplier is going to send a small sample to a fabricator to see if the machine can handle the material. I'll keep you posted.
  12.  
    I've found the following quote on this website: 'Sheets used for roofing were typically 18 SWG (1.2mm) thick and weighed around 1.2kgs per square foot. This compares with commonly available modern sheets which weigh around 0.7kgs per square foot.'

    See: http://www.buildingconservation.com/articles/corrugated-iron-architecture/corrugated-iron-architecture.htm

    So old sheets were thicker.
    • CommentAuthorbarney
    • CommentTimeJul 23rd 2018
     
    Older sheets may have been thicker, or thinner depending on cost, use etc

    Our old garden shed had sheets that were probably rolled locally and destined for use as formwork or similar for air raid shelters (Andersons ?) - they must have been about 5mm thick (perhaps about 6 or 8 Gauge)

    Our garage however, has sheets that were probably about 0.3mm thick - known by my old man as origami sheets (paper thin sheets of steel - as description he used for pretty well every modern car, as in "paper thin sheets of steel, folded into Toyotas" )

    I can recall a local engineering shop/welding shop that had a hand cranked rolls set, dumped in the yard - it could do flat strip into curves, corrugated sheets and even curved corrugated sheets - scrapped long ago I guess

    Regards

    Barney
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