Natural metals, folded and soldered by hand
Copper and Zinc Fabrication for Roofs, Bay Windows, Turrets and Gutters
Copper and zinc fabrication is slower, more careful work than painted steel, and it is some of the most rewarding work our Forney shop does. Architectural Metal Panels forms copper and zinc into standing seam, soldered flat-seam pans, bay window roofs, turrets, accent roofs, gutters and flashings for builders, architects and owners with their own installer.
Copper or Zinc: How Do the Two Metals Compare?
Both are natural metals that need no paint and weather to a protective surface. They differ in color, movement and the metals they can touch.
| Copper | Zinc | |
|---|---|---|
| Color when new | Bright, polished penny | Blue-gray, often sold pre-weathered |
| How it weathers | Darkens to brown; green patina takes many years and depends on climate | Settles into a soft, matte gray |
| Joining | Soldered seams or folded standing seams | Soldered seams or folded standing seams |
| Heat movement | Moderate | Higher than copper or steel, so expansion details matter |
| Runoff | Can streak stone and harm some metals downhill; see the rules below | Gentle on most materials below it |
| Typical uses | Bay roofs, turrets, accents, gutters, flashings | Standing seam roofs, wall accents, gutters, flashings |
In North Texas heat, copper usually turns brown well before any green shows. If the drawings call for a specific look, say so before fabrication so the expectation is set early.
What the Shop Makes in Copper and Zinc
Most natural-metal orders are small, detailed pieces rather than whole roofs. Each one is laid out from the drawings or a field template.
Standing seam roofs and panels
Copper or zinc panels folded with seams, for full roofs, porch roofs and accent roof planes over entries.
Soldered flat-seam pans
Small interlocking pans soldered at every seam, for low slopes, curves and bay window roofs that need a watertight skin.
Bay window roofs
Hip, shed and curved bay roofs measured to the window and built so the pans meet the wall flashing cleanly.
Turrets and cones
Tapered panels laid out to the cone’s radius and height, so the seams run true to the peak.
Gutters and downspouts
Half-round and box gutters, liners and downspouts in copper or zinc to match the roof.
Flashings and accents
Chimney and wall flashings, counter-flashing, valleys and trim pieces in the same metal as the roof.
Copper gutters are covered further on our gutter fabrication page, and built-in liners on the box gutters page.
Soldered Flat Seam or Standing Seam?
Choose soldered flat-seam pans when the surface is small, shallow in pitch or curved. Use standing seam for larger, steeper planes where long panels can run from eave to peak.
Flat-seam pans
Each pan has its edges folded so it hooks into the next one, and the joints are then soldered. The result is one continuous metal skin with no open seams. It handles low slopes and curved forms that a standing seam panel cannot follow, which is why it shows up on bay windows and barrel shapes.
Standing seam in copper or zinc
A raised seam lets each panel move on its clips, so it suits larger roof areas where heat movement adds up. Rib height and spacing follow the design. The painted-steel version of the same system is on our standing seam panels page.
Compatibility Rules for Natural Metals
Copper and zinc last for generations when they are kept away from the materials that attack them. These are widely followed practices; the metal maker’s guide has the final word.
- Watch the runoff. Dissolved copper in rainwater attacks zinc, aluminum and zinc-coated steel such as galvanized or Galvalume, so never put those metals downstream of copper. Copper gutters under a painted steel roof are fine; steel gutters under a copper roof are not.
- Match the fasteners. Copper is fastened with copper or stainless steel. Zinc is fastened with stainless steel or fasteners its maker approves.
- Separate dissimilar metals. Where copper or zinc must touch another metal, an isolating layer keeps them apart.
- Let zinc breathe. Zinc makers typically call for a vented or structured underlayment, because moisture trapped against the back of the sheet can corrode it.
- Mind the masonry and wood. Fresh mortar and some acidic woods can stain or etch zinc, so plan the details where they meet.
Questions about finishes and paint warranties on steel are answered on the warranties page.
How to Order Copper and Zinc Work
Natural-metal pieces are quoted per project, so the more detail you send, the tighter the number.
- Drawings or photos with dimensions. For a bay roof, give the window width, projection, wall height and pitch.
- The metal and its weight or thickness. Copper is usually specified in ounces per square foot. If the drawings name a weight, include it; if not, ask us.
- Profile choice. Flat seam, standing seam or a mix, plus any gutters and flashings that go with it.
- Templates for curves. Turrets, cones and curved bays need a radius, a height or a template taken on site.
- Finish expectations. Natural copper, or pre-weathered zinc if the design wants a gray surface from day one.
- Pickup or delivery. Finished pieces are packed for the trip; tell us how they should reach the job.
We confirm the ship date with the quote. For the full set of roof profiles, see roof panels; for one-off pieces in other metals, see custom sheet metal work.
Copper and Zinc Questions
Will new copper go green, and how soon, in a North Texas climate?
There is no fixed answer. In the hot, fairly dry North Texas climate, copper usually turns brown first and can stay brown for many years. A green patina depends on moisture and exposure.
Can copper gutters go on a house with a painted steel roof?
Yes. Rain coming off painted steel does no harm to copper. Trouble only starts when the order is flipped and copper sits uphill of other metals, as the compatibility rules on this page explain.
Is zinc soldered the same way as copper?
Both metals can be soldered, but zinc needs its own flux and a more careful heat because it softens at a lower temperature. Tell us which metal the seams are in when you order.
Can you build a copper roof for a bay window from photos?
Photos help, but the pans are cut to dimensions. Send the window width, projection, wall height and pitch, or a sketch, and we will draw the roof for approval first.
Do you make copper downspouts and conductor fittings?
We make copper downspouts and the gutters they serve. Tell us the size and shape you want, plus the number of outlets and the wall heights.
Why is copper quoted per project rather than per square foot?
Copper and zinc work is mostly small, shaped pieces with hand soldering, so the labor varies far more than on a flat roof. Pricing each job from its drawings keeps the number honest.
Request a Written Quote
Describe the panels, trim or sheet metal you need, or attach your takeoff. Expect to hear from Architectural Metal Panels by the next business day.
You can also text roof or wall photos to (972) 332-2809
Rather talk it through? Call (972) 332-2809. Insured in full.
Send Your Copper or Zinc Drawings
Email drawings, photos with dimensions or a template for a written quote on copper and zinc fabrication. Call the shop at (972) 332-2809 to talk through a curve or a turret first.