Metal ceiling systems come in a variety of shapes and sizes, and can be used in both exterior and interior applications. From linear systems to wide panels, to curved and open cell, every manufacturer has a specific system for each of their metal panel ceiling options. Be sure to check with the manufacturer before beginning an installation.
According to Michael Coakley, co-president of C.J. Coakley Co. Inc., Falls Church, Va., an interior contractor, most metal ceiling systems get built similarly, but with different twists. For example, ceilings that have uplift requirements need ceiling framing components that can change. As he explains, most ceilings are hung from a 12-gauge wire, and if uplift is significant, then all thread may be required in lieu of wire. In locations where ceilings can be pressurized, such as train stations and laboratories, ceiling panels may need to be locked in place so they cannot be forced out. Additionally, he notes that security ceilings have to be made so that they are difficult for people to tamper with. "Each type of application requires a different level of care and price for the manufacturer," Coakley says. "And each type has a different amount of labor that will be required to get the ceilings in place."
One of the biggest challenges when doing metal ceiling installations is coordinating with other trades. Peter Jahn, senior project manager at Chicago-based ROCKFON LLC, says to achieve the desired look and performance, early coordination between the designers, ceiling panel manufacturers and installer contractors is key to a project's success.
To make sure everyone is on the same page, Robert Monn, engineer at Steel Ceilings Inc., Johnstown, Ohio, suggests having a meeting with all stakeholders early on in the project. This gives time for the subcontractors to review the contract with the general contractor and confirm the timing within the master schedule. "Coordinate with complimentary trades such as lighting and mechanical to ensure no installation clashes both in design and timing," he says.
Coakley agrees that time is generally the biggest issue with installing metal ceilings. "Typically they are one of the last things installed when the job is ready for the work to commence," he says. "Any slop in the schedule is already gone or they are behind when we are ready to do our work."
Once the timing and coordination of the trades has been figured out, it is important for the building to be sealed against moisture ingress and the weather before beginning the installation, Monn explains. This also reduces the amount of dirt accumulated on the metal mesh or panels and allows contractors to complete the work in the plenum, says Tom Bialk, LEED Green Associate, engineer at GKD USA, Cambridge, Md.
The slab of the floor above needs to be installed before beginning a metal ceiling system installation. The slab is where the ceiling grid will be installed, including suspension wires, rods, angles or compression struts, and anything that needs to be enclosed in the ceiling, such as ductwork, sprinkler pipes, electrical lines and plumbing work, needs to be in place before the installation can begin.
Most commonly, Jahn says the structural systems are cast-in-place concrete or concrete over metal decking with structural steel. "The metal suspension systems are typically attached to the structure using either hangar wires or brackets, and the metal panels are installed into the suspension grid," he says.
Once the ceiling grid is in place, the lights are wired and added, and the flexible duct branches, diffusers and return air devices are installed, explains Coakley. "With light fixtures smaller than the panel module, the contractor will typically cut a hole into the panel to fit the device and the electrician will mount the fixture to the tile and put it in the grid," he explains. "Similarly, tiles will be cut for sprinkler heads so they can be placed in the ceiling. Once all of these items are installed, tested and inspected, the ceiling is closed in with the field tiles."
Metal ceiling panels can be either field cut or factory formed. As Jahn explains, while factory forming the panels to precise measurements adds to the initial cost, it can save time and labor costs in the field. On the other hand, field cutting allows greater flexibility for on-site adjustments.
Since minor variations from what was drawn to what was built do happen, Coakley says ceilings should be field measured and verified. "The measurements cannot be taken until all the work that defines the perimeter of the ceiling and the work above the ceiling are installed," he explains.
"With respect to proper sizing, cutting and installation, careful consideration must be given to the perimeter conditions and the integration of the metal ceiling panels with light fixtures, air diffusers and other accessories," Jahn says. For factory-formed metal panels, accurate field dimensions, including notches for lights and columns, are essential, Bialk adds.
Additionally, Coakley notes that mechanical and electrical drawings are not always coordinated to make sure everything fits. "Many times the elevation of our ceilings have to be adjusted due to the fact that what is required above the ceiling will not necessarily fit into the space that was allotted for it."
If the contractor is going to be field-cutting the tiles, Jahn notes that a high-quality circular saw with metal-cutting blades can be a great tool to have. Other tools include laser alignment, laser measuring, tape measure, power guns for shots, aircraft snips, an aluminum saw, pliers and screwdrivers, Monn says. Clamps, screw guns, jig saws, whole saws and shot guns designed to drive fasteners into the slabs are also commonly used to install metal panels, according to Coakley.
Jahn explains that there are several standards that apply to metal suspension systems and metal ceiling panels, including ASTM C635, Standard Specification for the Manufacture, Performance, and Testing of Metal Suspension Systems for Acoustical Tile and Lay-in Panel Ceilings; ASTM C636, Standard Practice for Installation of Metal Ceiling Suspension Systems for Acoustical Tile and Lay-In Panels; ASTM E 84, Test Method for Surface Burning Characteristics of Building Materials; and ASTM E 580, Standard Practice for Application of Ceiling Suspension Systems for Acoustical Tile and Lay-In Panels in Areas Requiring Seismic Restraint.
The Ceilings and Interior Systems Construction Association (CISCA) covers the acoustical ceiling and wall systems industry. According to Coakley, the association recently completed a rewrite of its metal ceilings technical guidelines that is helpful in identifying the different types of panels on the market, and includes tips for best practices for installing metal ceilings.
"This segment of the market is growing and there are new arrivals on a yearly basis," Coakley says. "The best first step is to work with the manufacturer as to the details of their system. The next important step if you want to be involved in this niche, is to get involved in an association that supports this industry such as CISCA. Contractors from all over the country meet at conventions and seminars and exchange knowledge on a regular basis. If our team has a problem installing a ceiling system we have a network of colleagues from around the country that we consult with to get the solutions needed."