Why You Should Choose Manufacturing Products with Sheet Metal Profile from 0.45 mm and Up

When designing building components like facades, fences, and ceilings, material thickness matters. Architects and construction decision-makers should opt for sheet metal profiles from 0.45 mm and up in thickness, rather than ultra-thin 0.25–0.35 mm alternatives some competitors offer. Thicker metal panels provide significantly better strength, stability, noise dampening, and longevity. By contrast, sub-0.4 mm sheets may initially lower costs, but they carry serious risks of deformation, noise, or even structural failure over time. In this article, we’ll explore why using a sheet metal profile from 0.45 mm upward is the smart choice for durable, high-quality construction.

Recommended Thickness by Application

Different applications call for specific minimum metal thicknesses to ensure safety and performance:

1. Ceilings: ≥0.4 mm. For suspended or panel ceilings, using around 0.4–0.45 mm thick metal (often galvanized steel) prevents sagging and rattling. This thickness provides enough rigidity even in large panels, maintaining a flat appearance and reducing vibration. (Mehbud uses 0.4–0.45 mm+ steel for ceilings to guarantee stability.)
2. Fencing: 0.45–0.7 mm. Commercial fencing materials like metal fence panels should be at least 0.45 mm thick (with heavier-duty sections up to 0.7 mm). This ensures the fence can withstand impacts (e.g. a person leaning or minor collisions) and wind loads without bending. Thicker fencing profiles also have better noise dampening (no tinny rattles in the wind) and longer life. (Mehbud’s metal fences are made from 0.7 mm sheet metal for optimum strength and longevity.)
3. Facades: ≥0.7 mm (up to ~2.0 mm). Exterior cladding and facade panels experience high wind pressures and temperature fluctuations, so the metal thickness for facades should be no less than 0.7 mm. Many architectural panel systems even use 1.0–2.0 mm thick aluminum or steel for rigidity. Thicker facade panels resist oil-canning (waviness) and fatigue, ensuring the building envelope remains secure in storms. (Mehbud’s facade profiles use at least 0.7 mm steel, up to 2 mm for structural elements, to meet engineering best practices.)

Using these thickness guidelines aligns with industry best practices. For instance, one trapezoidal facade panel profile specifies a minimum thickness of 0.7 mm (and up to 1.2 mm) for proper performance (Panel overview – Euramax). In contrast, attempting to use very thin sheets (e.g. 0.25–0.35 mm) in these applications can lead to a host of problems, as we discuss below.

Sheet Metal Profile from 0.45 mm: Superior Strength and Stability

The primary reason to choose thicker sheet metal (0.45 mm and above) is strength. Structural rigidity increases dramatically with thickness. In fact, a modest increase in thickness yields a much stronger panel — according to the Metal Construction Association, a mere 10% increase in sheet thickness can boost impact resistance by up to 150% (Specifying Metal Thickness for Architectural Panels | ATAS International, Inc.). Thicker steel simply handles loads better.

1. Higher Load Capacity: A 0.5 mm thick steel panel can carry much more load than a 0.3 mm panel of the same design. Engineers note that a 29-gauge steel (≈0.36 mm) panel is not as strong as a 26-gauge (≈0.48 mm) panel (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?). The thinner 29-gauge material may suffice in mild conditions, but under stress it can deform. For example, if a roof in a snowy climate were built with ~0.35 mm sheets, the weight of accumulated snow could be too much – leading to leaks or even a roof collapse (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?). In contrast, a heavier 0.5–0.6 mm (approx 26–24 gauge) roof panel provides a safety margin to handle such loads without failure (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?).
2. Structural Integrity and Span: Thicker profiles ensure the structure holds its shape. Ceiling or roofing sheets of 0.45 mm+ remain sturdy across support spans, whereas a flimsy 0.25 mm sheet would noticeably flex or oil-can between joists. Builders find that with 0.4+ mm roofing, they can even use slightly wider beam spacing because the panel won’t sag under its own weight or moderate loads. The added stiffness of a thicker sheet metal profile keeps everything aligned and securely fastened over time.
3. Less Risk of Failure at Connections: Thin metals are prone to tearing or pull-out at fastener points. A common mode of failure with ultra-thin panels is the fasteners ripping through the sheet under stress. In one reported case, cladding panels (with material “relatively thin” for the application) detached from a building during high winds – the panels failed around the fixing holes (Metal cladding panels fail and fall to ground | CROSS) (Metal cladding panels fail and fall to ground | CROSS). The investigation found that insufficient thickness and poor edge distances led to the material literally giving way at the screw holes (Metal cladding panels fail and fall to ground | CROSS). Thicker material provides more tensile resistance around fasteners, reducing the chance of such catastrophic failures. It also allows for stronger connections (screws have more metal to bite into), enhancing overall structural integrity.

In short, thicker sheet metal profiles substantially improve structural strength. They can support heavier loads and resist deformation, which is critical for safety. You not only get a higher margin before any failure, but also a sturdier product that feels solid. This is why reputable manufacturers like Mehbud insist on using 0.45 mm and above for key products – it ensures the strength of the final structure is not compromised by a thin skin.

Reduced Noise and Vibration with Thicker Metal

Another major advantage of a thicker sheet metal profile is improved noise dampening and vibration control. Thin metal sheets tend to be noisy and prone to vibration issues:

1. Less “Tinny” Resonance: Anyone who’s been under a thin tin roof during rain knows the loud drumming sound it can create. Metal roofs or ceilings that are too thin will conduct and amplify sound easily, leading to disruptive noise from rain, hail, or wind. As one roofing expert puts it, “Metal roofs are noisy because they are thin and conduct sound well” (Silence is Golden – How to Expertly Soundproof Metal Roofing! – PRO Roofing – Tallahassee Florida Roofing Company). By choosing a thicker gauge metal, you add mass and stiffness, which inherently makes the panels quieter. The heavier panels don’t vibrate as readily, and they absorb more of the impact energy from raindrops or hail. This results in a quieter environment inside the building – an important factor for occupant comfort in homes, offices, and public buildings.
2. Vibration and Rattling: Thin sheets can flutter in the wind or vibrate from even minor impacts. This not only causes noise (rattling, buzzing sounds) but can also loosen fasteners over time. According to structural safety reports, “Thin sheets can vibrate, wind being one of the forcing mechanisms. [Metal] sheeting has very little inertia and almost no structural damping.” (Metal cladding panels fail and fall to ground | CROSS). In practical terms, a flimsy metal fence or facade panel on a windy day might start buzzing or clanging, whereas a thicker panel will remain steady. We’ve all heard loose metal panels that clatter when a strong gust comes – that’s often due to insufficient thickness or poor fastening. Thicker profiles greatly reduce this effect. They have more inherent damping and are less likely to get excited by wind gusts. As a result, you avoid those annoying noises and the structure feels more solid.
3. Better Fit and Finish: Thin material is not only louder by itself, but it’s also harder to install without some play or flex, which can cause pieces to rub or rattle. For example, a very thin ceiling tile might not seat firmly in its frame, leading to buzz under HVAC vibrations. By using a more robust 0.45 mm panel instead of 0.3 mm, the piece is stiffer and will mount more securely, eliminating those tiny movements that create noise. The overall assembly remains tight and quiet over time.

For architects designing libraries, schools, or homes – any space where acoustics matter – specifying a durable sheet metal thickness (at least 0.45–0.5 mm for panels) can help ensure the building is not plagued by unwanted noise. Proper underlayment and insulation matter, but starting with a sufficiently thick panel is a fundamental first step to achieving a quiet, high-quality result.

Longevity and Corrosion Resistance of Thicker Profiles

Choosing thicker metal profiles also translates to a longer lifespan and better resistance to wear and corrosion. While protective coatings (galvanization, paint systems, etc.) are crucial for preventing rust, the base metal thickness gives an additional buffer against deterioration:

1. Slower Corrosion Penetration: If the protective coating is breached (for instance, a scratch or cut edge), a thicker sheet can withstand more rust before structural integrity is lost. With a very thin 0.3 mm sheet, even a small amount of rust can eat through the material, creating holes or weakness quickly. In contrast, a 0.7 mm sheet under the same conditions has over twice the material thickness – it will take much longer for corrosion to compromise it. Essentially, thicker steel provides a larger sacrificial layer. This is especially important for fencing and facade elements exposed to weather 24/7. For example, a steel fence made of 0.5 mm galvanized steel will remain solid even if a bit of rusting occurs at the base or near fasteners, whereas a 0.25 mm fence might develop full perforations in those spots in a short time. Using at least 0.45–0.7 mm material for outdoor metalwork greatly extends the time before any rust becomes a structural problem.
2. Durability and Dent Resistance: Thicker metal is harder to dent or puncture, which preserves the protective coatings intact. A thin panel can be easily bent by hand or dented by something as minor as hail or a fallen branch. Those dents can crack the paint or coating, exposing raw steel to moisture. Thicker panels resist casual dents – for instance, a thicker 24-gauge metal roof (≈0.6 mm) often survives hailstorms with no visible damage (Metal Roof Mythbusting: What About Noise, Dents, & Heat?). By preventing damage, the coating stays intact and the metal doesn’t start rusting. In essence, thickness and longevity go hand in hand: thicker sheet metal stays looking new and rust-free for far longer under real-world use.
3. Extended Service Life: All the factors above (better corrosion resistance, less damage, more tolerance) mean that products made with sufficiently thick metal simply last longer. In fact, well-protected metal profiles of decent thickness can last decades. Some manufacturers note service lives of up to 60 years for steel profile fences, provided proper installation and maintenance (Metal fence profiles / Gloss (one-sided) 0.45mm/ RAL 8003 — Price 58 Kč | ROOFER). Even if “up to 60 years” is an optimistic scenario, it illustrates that a fence made of 0.45–0.7 mm galvanized steel can easily outlast thinner, cheaper alternatives which might start failing in 10–20 years. Thicker metal panels also often come with better warranties from suppliers, reflecting their confidence in the product’s longevity. No client wants to replace a facade or fencing prematurely due to material failure – by choosing a thicker gauge, you ensure the installation will have a long, trouble-free life.

In summary, investing in a thicker metal profile is investing in durability. You get a fence, roof, or facade that stands the test of time against rust and wear. This not only keeps the structure safe but also maintains its appearance and value for many years. It’s a clear win for long-term performance.

Weather Resilience and Real-World Performance Under Stress

Buildings must endure harsh weather and mechanical stresses over their lifespan – high winds, storms, thermal expansion, and impact forces. Here’s where thinner metal products often reveal their weaknesses, and why upgrading to thicker metal is crucial for reliability:

1. Wind and Storms: Under strong wind loads, thin panels can flex like sails. This oscillation not only causes noise as mentioned, but can lead to metal fatigue and connection failure. As a safety report explained, “wind can induce dynamic effects in thin members for which they and their fixings may not be designed” (Metal cladding panels fail and fall to ground | CROSS). Over time, that vibration can loosen screws or cause micro-cracks. There have been cases of cheap cladding literally flapping in storm winds and even blowing off. Thicker panels, on the other hand, are more rigid and tend to stay put. They also allow for more robust fastening systems. For critical facade cladding in high-wind regions, engineers will often specify 0.8 mm or 1.0 mm thick panels for extra safety. Using anything as thin as 0.3 mm on a building’s exterior in such conditions invites disaster. In short, a thicker sheet metal profile is far more likely to remain intact during extreme wind events, protecting both the building and bystanders below from flying debris.
2. Thermal Expansion and Structure: All metals expand and contract with temperature changes. On a hot day, a long metal panel will elongate slightly; when it cools at night, it contracts. Thicker metal profiles cope with this better. They are less prone to buckling or warping because they have more inherent stiffness to spread the stress. Very thin sheets, by contrast, may ripple or oil-can visibly when they expand if not properly relieved. Also, thin sheets heat up and cool down faster (due to lower mass), potentially undergoing more severe thermal cycling. A thicker panel has more thermal inertia and stays dimensionally stable, which helps maintain a facade’s flat, attractive look year-round. This is one reason facade systems commonly start at 0.7 mm – to avoid unsightly distortion over time and ensure the facade remains solidly anchored under all temperature conditions.
3. Impact and Mechanical Stress: Accidents happen – a ladder falls against the siding, hailstones pound the roof, or a person kicks a fence panel. Thicker metal offers greater impact resistance. As noted earlier, even a 10% thicker sheet can yield ~150% improvement in impact resistance (Specifying Metal Thickness for Architectural Panels | ATAS International, Inc.). For example, commercial fencing materials made from 0.5 mm steel will shrug off a small impact that would crease a 0.3 mm sheet. Similarly, a 0.8 mm facade panel might take a moderate hit without puncture, whereas a 0.4 mm panel could be punctured or dented badly. This resilience means fewer repairs after storms or accidents. In hail-prone areas, experts explicitly recommend using heavier gauges (lower gauge number) to prevent damage (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?). Thin-gauge roofs often end up with dings or even perforations from large hail, leading to water ingress. Upgrading to a thicker profile avoids such failures. Real-world performance under impact is a clear separator between cheap thin materials and robust ones – the latter keep their shape and protective function when nature throws challenges at them.
4. Installation and Maintenance Loads: During construction or maintenance, workers may need to step or walk on metal panels (for roofing especially). A profile from 0.45 mm up can typically support foot traffic on a roof with minimal denting if done carefully, but a thinner 0.3 mm roof sheet might bend or crack under a person’s weight. Even handling and transport can deform very thin sheets (they might buckle just from being carried improperly). By using sturdier panels, you reduce the chance of damage during installation and ensure the finished product isn’t compromised before it even goes into service.

Taken together, these points show that real-world conditions favor thicker sheet metal. What looks adequate in a static test can fail when nature exerts her forces repeatedly. Thicker profiles provide a margin of safety against winds, weather and wear-and-tear scenarios that thinner metal simply cannot match.

Quality Over Price: Long-Term Value of Thicker Metal (Mehbud’s Approach)

It’s understandable that cost is a factor when choosing materials – thinner metal is cheaper per square meter, which is why some suppliers push it. However, the long-term costs of using subpar thickness often far outweigh the short-term savings. As one industry source notes, “The cost of repairs down the line could be far greater than the initial savings from purchasing products with a higher gauge (thinner metal)” (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?). In other words, you might save a few dollars today by using a 0.3 mm sheet, but if it leaks, dents, or fails early, you’ll pay much more to fix or replace it later. When reputations, safety, and client satisfaction are on the line, cutting corners on material thickness is simply not worth the risk (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?).

Mehbud’s philosophy is to prioritize quality and durability. That’s why Mehbud refuses to go below 0.45 mm on any structural sheet metal profile. By adhering to the recommended thicknesses (0.4–0.45 mm+ for ceilings, 0.45–0.7 mm+ for fences, and 0.7–2.0 mm for facades), Mehbud ensures that every product will perform reliably over its lifespan. Clients may notice that some competitors offer slightly thinner panels to undercut on price – but with the information above, it’s clear that those savings come at the expense of strength and longevity. Mehbud chooses materials that meet engineering best practices and industry standards for durable sheet metal construction, rather than the bare minimum.

When you invest in a sheet metal profile from 0.45 mm and up, you are investing in peace of mind. Structures built with proper-gauge metal have fewer issues, generate fewer complaints, and maintain their structural and aesthetic integrity for years to come. The slight additional upfront cost is easily justified by avoiding premature failures or replacements. In the end, architects and builders have a responsibility to deliver quality – and selecting the correct metal thickness is a key part of that.

In conclusion, thicker sheet metal profiles offer superior strength, structural integrity, noise reduction, longevity, and weather resistance. They create robust roofs, facades, and fences that stand firm against loads and climates, whereas ultra-thin metals are prone to noise, damage, and failure. For any serious commercial or architectural project, choosing metal thickness starting from 0.45 mm and above is simply the best practice. It ensures that the final product not only looks good but also performs well for decades. Mehbud follows this approach in all its products, giving customers confidence that they’re getting lasting value.

For more information on our products and how we implement these optimal thickness standards, you can explore Mehbud’s offerings such as our steel facade profiles and metal fencing panels. You may also read our detailed blog post “Mehbud Fences from 0.7 mm Sheet Metal: Your Investment in the Future” which highlights the advantages of using adequately thick steel in fencing. By choosing quality materials and proven thickness specifications, you ensure that your project will stand the test of time, providing safety and satisfaction for years to come.

Comparison Table: Sheet Metal Thicknesses and Performance Characteristics

Recommended Thickness by Application (Industry Standards)

This concise table format effectively highlights why choosing sheet metal profiles from 0.45 mm and thicker ensures superior structural integrity, durability, and long-term cost savings compared to thinner alternatives. It can be placed directly within your blog article to give readers a clear, visual reference.

Sources

1. FBi Buildings – 29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference? (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?) (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?) (29-Gauge Steel vs. 26-Gauge Steel: What’s the Difference?)
2. Amazon (BELLA BAYS) – Product description for Aluminum Flashing (26 Gauge) (Amazon.com: Aluminum Roofing Flashing Roll 10in x 10ft – Standard Type Aluminum Sheet- Metal Flashing Roofing Roll- 26 Gauge (0.0157″/0.4mm) Thickness-Weather-Resistant : Everything Else)
3. Roofcrafters – Metal Roof Mythbusting: Noise, Dents & Heat (Metal Roof Mythbusting: What About Noise, Dents, & Heat?)
4. CROSS Safety Report – Metal cladding panels fail in wind (Metal cladding panels fail and fall to ground | CROSS)
5. PRO Roofing Blog – Silence is Golden: Soundproofing Metal Roofing (Silence is Golden – How to Expertly Soundproof Metal Roofing! – PRO Roofing – Tallahassee Florida Roofing Company)
6. Euramax Panel Specifications – Trapezoidal Profile Min Thickness (Panel overview – Euramax)
7. ATAS International – Specifying Metal Thickness (Did You Know Series) (Specifying Metal Thickness for Architectural Panels | ATAS International, Inc.)
8. ROOFER.cz – Metal Fence Profiles product page (Metal fence profiles / Gloss (one-sided) 0.45mm/ RAL 8003 — Price 58 Kč | ROOFER)
9. FBi Buildings – Steel panel cost vs. repairs (Blog)