Steel siding is popular for many reasons. It’s durable, and has a long lifespan, so it’s generally sold with long warranties, some even with lifetime warranties. It requires little maintenance, doesn’t mold, rot, warp, or swell, is scratch- and impact-resistant, and is noncombustible. In fact, steel siding is considered Class A fire-resistant. In addition, its coatings make it corrosion- and fade-resistant. It’s also environmentally friendly, as recycled steel is used in its manufacture, and is 100% recyclable. Although the initial cost of steel siding may be higher than other for materials, its comparative speed of installation and the lower skill level typically needed for installation can lower labor expenses to help offset some of the material costs. 

Finally, steel siding’s low maintenance and longer lifespan compared to other materials means reduced cost of upkeep and replacement over its lifespan. As Andrew Wilson, Vice President of Innovation at Central States Manufacturing pointed out, “There is no need to repaint it every five to six years like wood and it doesn’t become brittle like some other products.”

PRINTED Steel Applications

Recent technological advances in steel siding’s aesthetic options have greatly increased its appeal. It’s no longer considered just a functional but bland exterior cladding. Manufacturers have developed visually stunning creations that mimic natural materials, providing an array of choices for exterior steel siding and trim and even for interior decor. 


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Finish Options 

Steel siding has several types of finishes available, including embossing and HD printing to make it an attractive alternative to traditional cladding options like wood, vinyl, fiber cement, stone, brick, and stucco. 

Embossing

Although plain, flat steel siding use is still common, woodgrain, brick, stone, and other embossed patterns are available and produced using roll forming machines. 

HD Printing

Steel siding made a giant leap aesthetically in 2022 with the introduction of a technology developed by Steel Dynamics (SDI) called Tru-Steel HD®, distributed by United Steel Supply. After a two-and-a-half-year R&D process, collaborating with Graber Post Buildings to provide the best images of natural materials, SDI brought to market several high definition (HD) full-color, photorealistic woodgrain designs. They’re so realistic that someone might need to physically touch them to verify that they’re not actually wood. 

SDI achieved its amazing level of realism by applying cutting-edge 3D scanning and printing technology to the steel coil manufacturing process. The company had developed the concept several years before the technology had advanced to the level they needed. Up to that point, woodgrain printing was limited to the traditional rotogravure process, which repeated patterns every 28–32 inches. This repetition of the pattern over large wall surfaces made it noticeable and distracting. 

The new digital scanning and printing process, however, allowed SDI to create patterns that didn’t repeat for up to 32 feet. The technology also brought several other benefits. First, digital scanning allowed a resolution of 400 dpi, which is higher than typically used in print publishing. Second, digital scanning also allowed manipulation to remove flaws and defects in image of the natural wood, to lighten or darken features like knots, or even to move them for better placement. The final woodgrain designs were actually better than the natural ones. Third, the digital designs made it possible to achieve “end-to-end repeatability” in printing. In other works, the digital images never degrade over time, so every print run is identical, ensuring consistency of results. 

Tru-Steel HD® provides a durable finish with a propriety process that uses seven layers. 

1. Cold Rolled Steel Base 

2. Galvanized/Galvalume® Coating 

3. Pretreatment 

4. Primer Coat 

5. Top Coat 

6. High Definition Image 

7. Electron Beam Protective Clear Coat


(Right) Graber Post Buildings collaborated with Steel Dynamics developing printed steel by providing the best images of natural materials to produce amazingly authentic representations of wood, like the wood grain in these steel coils. Photo courtesy of Graber Post Buildings.

The board and batten siding on this home is wood-grain printed steel that’s nearly indisinguishable from the real thing. Photo courtesy of Graber Post Buildings

A closeup of Akzonobel’s CERAM-A-STAR® Expressions in Smokehouse. Photo courtesy of Bluegrass Metals and Lumber and  AkzoNobel

This beautiful home is clad with Akzonobel’s CERAM-A-STAR® Expressions in Smokehouse. Photo courtesy of Bluegrass Metals and Lumber and  AkzoNobel

This building in Mills Hall, Pennsylvania, is clad with Central States Manufacturing’s Hickory direct print on Board & Batten siding panel and has Burnished Slate Panel-LocPlus roofing panels. Photo courtesy of Central States Manufacturing

Lee Smith of Flatiron Steel in Greeley, Colorado, uses New Tech Machinery to roll form steel printed panels. Here he holds a stunningly realistic wood grain panel in front of a display of other printed wood samples. Photo courtesy of New Tech machinery

This Graber Post Buildings board-and-batten steel panel shows the incredible wood grain detail that the steel printing technology can produce. Photo courtesy of Graber Post Buildings

Graber Post Buildings collaborated with Steel Dynamics developing printed steel by providing the best images of natural materials to produce amazingly authentic representations of wood, like the wood grain in these steel coils. Photo courtesy of Graber Post Buildings.

Since SDI’s initial introduction of Tru-Steel HD®, the company has created more woodgrain designs, as well as stone, bark, camouflage, and other photorealistic patterns. The designs are so authentic looking that, in some cases, they might meet strict HoA requirements, allowing homeowners huge cost savings. 

Other siding companies are also producing printed steel. Jena Jackson, Vice President of Operations at Indiana Metal, inc. explained how their siding creates the illusion of embossing. She said, “All the woodgrain we fabricate is HD printed only. However, certain product lines — such as our rough sawn cedar —feature a textured print that gives the appearance of light embossing. This enhanced texture is especially popular in board and batten applications because the combination of the detailed print and added texture helps minimize oil canning, resulting in a more authentic look.”

Wilson of Central States Manufacturing said, “Direct print-to-steel technology, exemplified by our board and batten product, is revolutionizing the industry. It combines the timeless aesthetics of traditional materials with the unmatched durability and low maintenance of steel. This innovation not only enhances the visual appeal of buildings but also offers significant cost savings and environmental benefits.”

Profiles

Faux finish steel siding is available in a wide variety of popular profiles, including board and batten, traditional lap, shiplap, Dutch lap, shake, and log. This provides builders with many aesthetic options that weren’t on the market until recently. Their emergence is helping to drive a significantly increased demand in the construction industry and are quickly making their mark across the country. 

Rick Zand of New Tech Machinery said, “Portable rollformers like New Tech Machinery’s SSQ II MultiPro Roof and Wall Panel Machine can run board and batten panels on site, making the process even easier. With the growing popularity of bandominiums, mixed materials, and the benefits of metal in rural areas, board and batten siding used with wood, stone, and other designer coatings have ushered new styles into the metal siding market. A portable rollformer that produces custom panels on site facilitates the unique and personalized look that steel siding now offers.”

Bill Griffin of Metal Rollforming Systems pointed out how MRS works with customers to bring new designs to market while ensuring that they work well with existing products for efficiency, versatility, and economy. “Consideration is given to coil widths and gauges, and by designing around industry standards, we are able to provide a cost-effective solution to our customers without the need to add additional inventory, reducing costs, and increasing inventory turns. We spend additional time on finding rib profile designs that work with existing trim profiles. Many of our customers choose the more efficient route of rollforming trim profiles and by using the standard corner or J metal, we’re able to maintain those efficient means of trim production.”

Coatings

The three types of coating most commonly used on printed steel siding are PVDF, SMP, and clear protective topcoats.

PVDF (Polyvinylidene Fluoride) 

PVDF is the generic name of the resin used in paint. It’s commonly known by its trademarked brand names, Kynar 500®, a product of the Arkema company, and Hylar® 5000, which is manufactured by Solvay Solexis. 

PVDF has excellent UV resistance to prevent color fading and chalking and superior weather protection to resist corrosion but is more expensive than other coatings and is best for smooth rather than textured finishes. 

SMP (Silicone-Modified Polyester) 

SMP has strong scratch and impact resistance and relatively high fade resistance. It’s also available in textured finishes and is less expensive than PVDF. Amanda Paterline of AkzoNobel said, “A high- performing SMP print technology is AkzoNobel’s CERAM-A-STAR® Expressions. Expressions delivers excellent weatherability in a unique textured finish. The only SMP textured print system available in the market, CERAM-A-STAR® Expressions is applied over an innovative ink layer and AkzoNobel’s high-performance primer. The result is exceptional durability, superior resistance to moisture and UV exposure, and excellent flexibility and abrasion resistance. 

“AkzoNobel has recently introduced a standard palette of Expressions solid color and two-tone prints. By offering this, complexity is pulled out of creating authentic wood grain aesthetics and drives readily available materials for metal siding applications.

“CERAM-A-STAR® Expressions textured finish can be used to create innovative appearances and convincing imitations of natural materials, such as wood, slate, and stone. The high level of durability and unique aesthetic achieved with Expressions make it an ideal finish for metal board and batten and horizontal lap siding.”

Clear Protective Topcoats (Polyurethane, Acrylic, or Polyester-Based)

Clear topcoats enhance gloss, depth, or matte finishes in HD prints and add an extra protective layer against scratches and wear and improve stain and moisture resistance.

Conclusion

For decades, steel siding was dominated by plain, single-color panels, but in recent years with the introduction of groundbreaking technology and processes, they’re now available in breathtakingly beautiful designs that mimic nature so realistically that they’re virtually indistinguishable from the real thing. This opens up a whole new world of opportunities for builders and building owners. RB