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What is Corten?

COR-TEN® steel is the preferred choice of roll formed product end-users. Its unique look and naturally oxidizing finish make it especially desirable for many architectural projects.

Weathering steel is a group of steel alloys developed to obviate the need for painting, and form a stable rust-like appearance if exposed to the weather for several years.

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Rustic Roofing FAQ

What is COR-TEN®?
Corten Roofing vs. Bare Cold Rolled Roofing
What does it cost to deliver the rustic roofing?
How long will Corten® roofing last?
What can be done to increase the lifespan of Corten or Bare Cold Rolled Roofing?
Climates NOT to use Rusted Roofing
What gauge steel should I use?
Will the panel continue to rust?
Bare Cold Rolled Steel
Will the rust stain the surrounding areas?
Is there a warranty?
What do I have to do to get the roofing to rust?
Does it come pre-rusted?
What about color matching the screws?
Dissimilar Metals and Corten
Is there a special type of Underlayment for use with Corten?
Is trim and flashing available.
Can I buy COR-TEN®?
What is A606 Type 4?
Is square footage charged by the coverage of the panel or the actual width of the panel?
How do i install metal flat sheets?
What metal gauge do I need for flat sheets?
Do you recommend coil or flat sheets?
A588 or A606-4
Can Corten steel be welded?
Can we apply a clear coat to Corten products?
How much does rusted roofing cost?
How much does Corten® Roofing cost?
How much does bare cold rolled roofing cost?
How much does painted rusted roofing cost?

Corten Roofing vs. Bare Cold Rolled Roofing

Bare Cold rolled steel is used as a less expensive option to A606 Type 4 ( Commonly referred to as Corten ).
Bare Cold Rolled is widely manufactured for a variety of different purposes including metal roofing and costs less.
Both of these panels are completely different. However, they look similar in appearance.
After installation and exposure to normal weather the surface of the panel develops a gorgeous rustic finish and texture. CorTen contains copper, chromium, manganese, and nickel which makes this material more expensive. Cor-ten resists the corrosive effects of rain, snow, ice, fog, and other meteorological conditions by forming a coating of dark brown oxidation over the metal, which inhibits deeper penetration and negates the need for painting and costly rust-prevention maintenance over the years. Corten will last longer and would be more desirable in harsh climates.

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What does it cost to deliver the rustic roofing ?

It can be shipped anywhere in the country very inexpensively on one of our route trucks. The price depends on the job location, length and weight of panels. Just request a quote and we will quote the delivery price.

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How long will Corten® roofing last ?

There is no definitive answer to this question. It depends on the environment and the way in which it was installed. Many projects using bare cold rolled and corten products were installed in excess of forty years ago and there are no problems. It is likely that the panel will last at least two to three times as long as wood shingles. Corten will have a longer life-span than bare cold rolled steel. One of the most common problems is using a light gauge steel in a 24GA to 29GA range. Using a heavier gauge steel is the most important thing you can do to make your roof last. There is no warranty for either bare cold rolled or Corten, but there are a number of things that you can do to increase life span of the product.

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What can be done to increase the lifespan of Corten or Bare Cold Rolled Roofing?

Use a heavy gauge steel in a 20GA or 22GA.
Keep the roof free of debris and falling objects.
Have a minimum slope of 3 in 12.
Prevent moisture and debris entrapment. It is not a rustproof material. If water is allowed to accumulate in pockets, those areas will experience higher corrosion rates, so provision for drainage must be made.

Weathering steel is sensitive to climates with exposure to salt laden air. It is possible in these types of climates that the protective patina may not stabilize, but instead continue to corrode.

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Do NOT use rusted roofing in these climates:

Climates with exposure to salt.
Climates in which the material will be subject to excessive moisture.

Corten steel requires alternating wet and dry cycles to form a properly adhered protective layer. Areas that have salt laden air, high rainfall, humidity, or persistent fog are typically not the proper environment for Corten and even less so for Bare Steel.

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What gauge steel should I use?

Metal roofs in a galvanized, Galvalume®, or painted finish are normally 24GA to 29GA.
However, with Bare Cold Rolled or Corten products never use a gauge lighter than 22 GA.
The thicker gauge makes it more difficult for the material to rust through.

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Will the panel continue to rust?

A606-4 (aka Corten®)
Corten never completely stops rusting. The weathering process occurs after the panel is installed. It eventually decreases and from that point on the finish acts as a protective coating for the base metal.
This protective coating essentially stops the corrosion. Laboratory analysis of the rust film have shown that the alloying elements in the steel, particularly copper, chromium, and nickel produced insoluble compounds that clogged the pores at the rust/steel interface, thereby ending the regeneration.

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Bare Cold Rolled Steel

This panel will continue to rust.

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Will the rust stain the surrounding areas?

Yes, rust runoff will likely stain the surrounding areas.

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Is there a warranty?

There are no warranties for products made from Bare Cold Rolled or A606 Steel.
In addition upon placement of order it is required that you initial a brief statement that refers to " No Warranty "
Click for a copy of the document that will need to be initialed.

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What do I have to do to get the roofing to rust?

Nothing. This material will rust on its own if left exposed to the weather. Getting the material wet will increase the speed in which it rust.

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Does it come pre-rusted?

A606-4 and A588 steel arrives UNRUSTED and will rust with naturally exposure to the weather.

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What about color matching the screws?

Screws are furnished in a Stainless Steel/Painted Koko Brown

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Dissimilar Metals and Corten

In general do NOT use dissimilar metals with Corten.

Galvanized, Galvalume®, and zinc should NOT come into contact with Corten.

Stainless steel is compatible with Corten.

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Is there a special type of Underlayment for use with Corten?

It is recommended to use a high temperature underlayment. We do not sell underlayment. Contact an expert in underlayment for further details.

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Is trim and flashing available?

Yes, trim and flashing is available in a 22 Gauge in either bare cold rolled or A606 type 4 ( commonly referred to as CorTen ). Also 48" X 120" flat stock is available.
There are standard details and sketches on this page. If what you need is not listed just draw a sketch and E-mail or fax it and it probably can be made.

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What is COR-TEN®?

COR-TEN® is a trademarked name owned by U.S. Steel.

COR-TEN® steel is becoming more popular by roll formed product end-users. Its unique look and naturally oxidizing finish make it especially desirable for many architectural projects. Weathering steel, best-known under the trademark COR-TEN® steel, is a group of steel alloys which were developed to obviate the need for painting, and form a stable rust-like appearance if exposed to the weather for several years. Weathering steel has increased resistance to atmospheric corrosion when compared to other steels. COR-TEN® resists the corrosive effects of rain, snow, ice, fog, and other meteorological conditions by forming a coating of dark brown oxidation over the metal, which inhibits deeper penetration and negates the need for painting and costly rust-prevention maintenance over the years. In simple terms the steel is allowed to rust and that rust forms a protective coating that slows the rate of future corrosion.

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Can I buy COR-TEN®?

No, COR-TEN® is not available. What is available is steel in an A606-4 or an A588 finish. If somebody tells you that they are supplying you COR-TEN® they are almost certainly unaware of their own product. Simply ask them if their steel was purchased from U.S. Steel. If the answer is " No " or " I don't know " it's almost certainly NOT COR-TEN®. When someone needs COR-TEN® they are normally referring to A606 Type 4 or A588. If you want COR-TEN® this will be the best available option. Weathering steels, such as ASTM A588, A242, A606 and COR-TEN® exhibit superior corrosion resistance over regular carbon steel as a result of the development of a protective oxide film on the metals surface which slows down further corrosion. A606-4 steel is available in metal roofing/siding panels, standing seam panels, flat sheets, and coil form. If you are looking for a panel that will give you a rustic look the two best options are bare cold rolled finish and A606. A606 will cost more, but it will last longer.

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What is A606 Type 4?

The original Cor-Ten received the standard designation A 242 ("Cor-Ten A") from the ASTM International standards group. Newer ASTM grades are A 588 ("Cor-Ten B") and A 606 for thin sheet. All alloys are in common production and use.

It is also recommended that you read the recommendations and cautions which can be accessed by clicking on a profile from the home page.

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Is square footage charged by the coverage of the panel or the actual width of the panel?

  • 7/8" Corrugated
    The width of the panel is 37". On a roof there is 32" of coverage and on a wall there is 34 2/3" of coverage. Square footage is based upon 36".

  • 1/2" Corrugated
    The width of the panel is 26". There is 24" of coverage. Square footage is based upon 24".

  • R Panel & Western Rib
    The coverage is 36". Square footage is based upon 36"
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How do I install metal flat sheets?

Flat sheets (also referred to as flat stock) are construction materials usually purchased for design and build projects. Unlike a common pre-formed metal panel, there are no specific installation instructions. Installation of flat sheets will vary depending on your specific need. We recommend consulting with the designer or engineer of your project to determine the best installation method.

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What metal gauge do I need for flat sheets?

A metal’s gauge refers to its thickness, which greatly affects its resistance. Since flat sheets can be used in a variety of applications and are considered a design and build product, we recommend consulting with the designer or engineer of your project to determine the gauge required.

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Do you recommend coil or flat sheets?

Both, coil and flat sheets, can be used to roll form into panels. Since proper equipment is required to load/unload coils, for individuals looking to roll form panels in the field using a portable roll former or mobile roll forming machine, we recommend ordering flat sheets - since flat sheets can be fed into the machine manually. Always make sure to follow proper safety and lifting protocols when manually handling material.


A588 or A606-4

Both A588 and A606-4 are weathering steel specifications and have similar chemical compositions that meet the ASTM G101 of 6.0 or higher on the atmospheric corrosion-resistance index. The difference in our products is:

A588 is available in steel plate and starts at 3/16” thickness and increases up to 5” thickness. A588 is a high strength low alloy plate used for structural applications such as buildings and bridges.

A606-4 is used for thin sheets and has thicknesses up to 3/16”. We stock A606-4 in flat sheets, coil, and panels.


Can Corten steel be welded?

You can weld weathering steel using the same flux combinations so that the tensile strength of the deposited weld metal (welding rod or wire) is consistent with the tensile strength of the base metal (weathering steel). Typical tensile strength of based metal (weathering steel) is 68-78 KSI. We would advise only welding A606-4 or A588 together. Welding to other metals can lead to a dissimilar metal reaction with A606-4 or A588.


Can we apply a clear coat to Corten products?

If you choose to clear coat the material, do it after the A606-4 has a good rust/patina set into the steel. If you do it prior to a good rust/patina, then it is very likely your clear coat will take off the rust.

If you add a clear coat to the A606-4 material it will likely change the surface color due to the additives in your clear coat.

We do not have a specific recommendation on clear coatings. We recommend you check with your local paint supplier and get theirrecommendation as they are the coating experts.


How much does Rusted Roofing Cost?

Rusted roofing is a beautiful product and it is also inexpensive. The price point on this material is comparable to a standard Kynar® painted product. In some cases, it is quite a bit cheaper. When you are researching your options for rusted siding or roofing there are three different products.

The most important thing when purchasing rusted roofing is to purchase a heavy gauge. At a minimum purchase a thickness of 22 gauge. Another alternative is 20 gauge, but it will add 25 % to the cost. Anything lighter than 22 gauge is not appropriate for this type of product. In addition, anybody that tries to sell you a rusted steel in 24 gauge likely is not someone that you should buy this product from.

Corten roofing or wall panels will arrive unrusted and then rust with exposure to the weather. Cor-ten® resists the corrosive effects of rain, snow, ice, fog, and other meteorological conditions by forming a coating of dark brown rust over the metal, which inhibits deeper penetration and eliminates the need for painting and costly rust-prevention maintenance over the years. There are different alloys in Corten vs bare cold steel. Corten will last longer than bare steel and would be more desirable in harsh climates. If you purchase Corten® always ask for the mill certs as it does not visually look different than bare steel.

Bare Cold Rolled roofing is the least expensive option. Although you will still get a long lifespan it will be considerably less when compared to Corten This is a product that would be better for a fence or wall condition. It is used quite often on a roof, but when you look at the overall installed cost of your roof it is my opinion that the additional $ .50/Sq. Ft. savings is not worth the decreased lifespan. It will also arrive unrusted and then rust with exposure to the weather. There are different alloys in Corten vs bare cold steel and would be less desirable in harsh climates. There is NO WARRANTY for Corten or Bare Cold Rolled.

Painted Rusted Roofing is the most expensive of the options. However, it solves all of the problems that are associated with a real rusted roof. It arrives looking rusted, there are no rust stains, and there is a standard paint warranty. It will add about $ .75/Sq. Ft. when compared to Corten® or Kynar® products. This is a painted product that is designed to look like a rusted Corten roof. You really need to see these products up close to appreciate how realistic they look. Visit Painted Rusted Roofing for free samples and job pictures.


How much does Corten® roofing cost?

Corten roofing cost about the same amount of money as a Kynar® painted product. Here are some ballpark cost depending on the size of the job and panel type:
Exposed fastener panels: 7/8” Corrugated, PBR Panel, or Western Rib
Cost of Corten Corrugated, R Panel, Western Rib = $ 1.50 - $ 2.00/Sq. Ft.
Corten standing seam and wall panels will cost $ 2.50 - $ 3.00/Sq. Ft.


How much does bare cold rolled roofing cost?

Here are some ballpark cost depending on the size of the job and panel type:
Exposed fastener panels: 7/8” Corrugated, PBR Panel, or Western Rib
Cost of Corten Corrugated, R Panel, Western Rib = $ 1.20 - $ 1.50/Sq. Ft.
Bare cold rolled standing seam and wall panels will cost $ 2.00 - $ 2.50/Sq. Ft.


How much does Painted Rusted Roofing cost?

Here are some ballpark cost depending on the size of the job and panel type:
Exposed fastener panels: 7/8” Corrugated, PBR Panel, or Western Rib
Cost of Painted Rusted Roofing: Corrugated, R Panel, Western Rib = $ 2.40 - $ 2.75/Sq. Ft. Painted rusted standing seam and wall panels will cost $ 3.00 - $ 3.25/Sq. Ft.

Keep in mind that the rusted roofing cost that is shown above does not include trim, accessories, and freight. Generally, if you add an additional 25 % to 40 % to the prices above that will be a good guesstimate of these add-ons. Underlayment and installation cost for Corten is also not included. All roofs are different, and you should consult your installer for an installation cost. Please visit our website or call us in order to get an accurate cost for your project.


ABOUT WESTERN STATES METAL ROOFING

We are the leaders in products that look old and patina’ d. Our company is committed to your satisfaction. If you have a question concerning rusted roofing than we have experts on staff that work with this product daily. For over 20 years, we have serviced homeowners, metal roofers, general contractors, architects, engineers and design professionals with metal roofing products at prices direct from the manufacturer.
Western States Metal Roofing
(877) 787-5467
cortenroofing.com

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