Frequently Asked Questions

What is the average cost of a house per s.f.?
Varies due to many factors.  Compared to conventional building methods, material costs are about 5-10% higher.  Labor costs, however, are significantly lower for erecting the panel home, possibly 30-50% depending on geographic location and complexity of design.

Can I modify one of your plans?
Like any plan, modifications can be made.  Our in-house design team will do so on a time-available basis.  Or you may have an independent drawing done and submit to us for approval and quote.

Does Structall do custom homes?
You may send your floor plan and design to us.  Each plan is assessed individually, and our design team will contact you to discuss its viability.

Where can I find a contractor?
Please email us at residential@structall.com for information.

What are the payment requirements?
All residential projects are considered custom manufacturing, and subject to a 50% deposit with order, balance COD.

How much will it cost me to finish the home?
These costs vary greatly by geographic area, and the choice of interiors, subcontractors, materials, etc. 

How is electricity and plumbing supported in a Structall home?
Electricity:  We recommend the exterior wall and roof panels be “furred out” on the inside with 1.5” metal channels or 2x wood framing.  This allows electricians to surface mount equipment and wires using conventional parts and techniques.  We do not recommend putting chases (horizontal and vertical holes cored out of the foam at certain intervals) into the panels.  This weakens the panel and reduces its energy efficiency.
Plumbing:  We recommend “wet walls” be kept away from exterior walls if at all possible, otherwise you will have to “furr-out” the wall to accommodate the larger drain lines.  Supply lines can be run within the 1.5” space the metal furring channels create. 

Can any foundation support a Structall home?
Yes.

How are SIPs (Structurally Insulated Panels) connected to the foundation?
Panels are connected by a perimeter base channel fastened with concrete anchors.

What type of external finishes can I have on my home?
Any traditional finish including stucco and siding.

How is the inside of a SBS home finished?
Gypsum wall board is a code requirement on the interior of the home. Gypsum wall board, cabinetry, and trim are not included in a SBS home package.

How do SIPS stand up to high wind speeds?
Panels are inherently stronger than conventional framing. They are also extremely strong in racking and shearing, which are the primary issues with seismic and wind load calculations.

Where can I go to see a Structall house?
There are a number of locations available.  Please contact our office for a list of locations.

Can panels meet wind and seismic code requirements?
Yes they can. Panels are inherently stronger than conventional framing and are extremely strong in racking and shear, which are the primary issues with seismic and wind load calculations.

What makes metal panel construction resistant to damage from hurricane winds?
If you have been to or have seen pictures of an area damaged by a hurricane or even just high winds you will notice that a great deal of the damage consists of partially removed roof finishes and blown out eave soffits. The damaged roof finish starts the roof leaking causing additional damage to the interior finishes like drywall and woodwork. The damaged soffit lets the moisture in, but also allows the wind to enter the inside of the roof. At this point, the roof is in jeopardy of being torn apart piece by piece as the pressure of the wind acts on the many sheathing panels and framing members looking for a weak point.
With metal panel construction, none of this happens. The metal skin on the top side of the panel acts as an irremovable integral moisture and vapor barrier blocking any rain damage after the roof finishes are blown off. The metal skin on the underside of the panel as it passes over the wall to create the eave is water proof and virtually indestructible, the wind has nothing to grab hold of and it cannot enter the home to cause extensive damage.

What can I expect in terms of energy savings from a panel home as compared to a conventionally built home?
Depending on the overall design, amount of window area and life style of the home’s occupants one can expect a 30-50% decrease in energy use for heating and cooling a typical home built with panels.  This also translates into a 30-50% smaller air conditioning unit.

Are the metal panels “fire-proof”?
Our metal panels are fire-resistant, as nothing is “fire-proof”.  In a test to show “burn characteristics” our panels received very good scores in the “smoke developed” and “flame-spread” categories. In other words, our metal panels, when exposed to fire, produce almost no smoke and do not allow the fire to spread.   

What are some lesser known advantages to building a metal panel home?
One advantage is that the metal panel home owner, depending on the insurance company, may receive a discount on his insurance premium for building a wind and fire resistant home. Another advantage is that the home should receive a better bank appraisal due to the superior level of construction. Finally, metal panel home owners have described a comfortable evenness of temperature as one moves throughout the home. This is due to the lack of air leakage and drafts causing some rooms to be colder than others.

Why is a metal panel better than a wood panel?
There are many reasons. For instance, metal panels are the structure, insulation and moisture barrier in a single installed unit. Wood panels require an additional moisture barrier. Metal panels have a tremendous strength to weight ratio, this makes them light and easy to install without heavy equipment like cranes. A wood panel is about twice as heavy as a metal panel. Metal panels are essentially unaffected by insects and other pests. Unless you are purchasing a treated wood panel the wood in the panel is a food source for pests. Metal panels interlock without the need for an additional framing member at the joint. Wood panels require a lumber or plywood spline at each joint. Metal panels have extremely good fire resistance. Wood burns easily.  Also, since all components of Structall metal panels can be recycled, there is less waste on the construction site. Wood panels are not as easily recycled into an equally valuable product. Metal panels do not “off-gas”, in other words the components of the panel do not emit chemical gasses from their manufacturing process in to the building environment. Wood panels are made of plywood and may emit a number of chemical gasses including formaldehyde.

Are homes built faster using metal panels?
After the concrete slab is poured, the weather tight shell of a single story ranch style home of about 1500s.f. can be erected by an experienced crew of one lead carpenter and 4 laborers in about 5 days. This would be called the dried-in stage of construction with a water tight roof and all exterior windows and doors installed. The equivalent home built conventionally would take about two to three times longer.

Do the metal panels rust?
Our metal panels have sheet steel skins that are first high quality galvanized, then primed, and then painted with a polyester finish. It is unlikely through normal exposure to the weather the steel skins would rust through all these layers. Even field cut panel edges are not a problem due to so little exposed raw metal surface area.

What is the maximum supported load of the different SIP size walls? (roof span)
Our office staff can supply you with a span chart.  Dead and live load charts go up to 75 lbs. per square foot.

Can any type of external cladding work with SIPS?
Yes

What is the burn value of your panels?
In a test report dated February 22, 1995, the results showed a flame spread index = 5, and a smoke development index = 170.

What is the warranty for Structall panels?
There is a 10yr. limited warranty.

What is the R-value for Structall panels?
The R-value is R4 for every one inch of thickness. (i.e. 4 in wall = R16, 6in roof = R24)

How are Structall panels affected by pests such as termites and ants?
Unlike conventional wood construction, Structall steel panels are constructed from steel and foam; therefore, they do not offer any type of food source to pests such as termites.

How are SIPS sealed watertight?
Sealant is applied between the grooves in the joints of the panels.  When the panels are snapped together, the sealant fills the reservoir in the male edge of the panel and overflows to the outside of the panel, forming a water-tight seal both inside at the joint, and outside at the seam.

Can SIPS be used for internal walls?
Yes, SIPS can be used for internal walls however; it would not be possible to incorporate plumbing into the interior walls.  Compared to conventional methods, the cost would also be significantly greater.

How does financing work with purchasing the land, preparing the slab, buying the package, and then building everything?
Conventional methods of financing would be appropriate for building a SIP house.