Corrugated Metal Panels: The Big Difference Between 7/8" and 3/4" Profile

At BarrierBoss, we produce an industry-leading 7/8" sheet that is 38 inches wide. Why are our panels slightly narrower than some competitor's panels, and how could that be an advantage?

We’ll explain by telling you a story. Recently, a customer shared their confusion with us resulting from an honest misunderstanding. They had been shopping around for sheet metal panels, and were under the impression that they were not getting a good deal on our 38-inch 7/8" panels. You see, another competitor had offered them 3/4" sheets that were 42 inches wide.

Savvy builders will immediately recognize the misunderstanding, but let's lay out the facts so the truth is crystal clear...

First, let's explain what the numbers mean.

Wave Profile

To compare corrugated sheet metal with a 7/8" profile to a 3/4" profile, it’s important to understand the material differences.

The wave profile in corrugated metal refers to the distinctive wavy appearance of the metal sheets. By bending the steel sheet into a series of alternating ridges and furrows, the material is significantly strengthened.

The 7/8" corrugated profile features deep and aggressive ridges that are seven-eights of an inch in height. This requires significantly more steel in its construction.

A 3/4" corrugated profile features a shallower wave three-quarters of an inch in height. This design uses less steel overall because the waves are not as pronounced.

A 1/2" corrugated profile can also be found. It has the shallowest ridges and is the lightest of the three mentioned here. These might lend well to more intricate sheet metal fence ideas. 

Taller and steeper corrugations add structural integrity to the sheet. They make it more resistant to bending or deformation under load. So if you want a strong sheet, go with a deeper groove.

In fact, research shows that panels with higher wave heights are stronger and can span longer distances. The 7/8" profile is preferred for its superior strength, aesthetic appeal (creating more pronounced shadow effects), and cost-effectiveness in terms of coverage and installation.

Panel Width

The width of the panel is how many inches (or centimetres) it is across. Builders care about width because it determines how many roofing, siding, or fencing panels will be needed. Ostensibly, purchasing fewer panels will be more economical.

Wider panels may be more cost-effective and quicker to install, but they can be more prone to oil canning (visible waviness or distortion in the panel) and may not perform as well in extreme weather conditions.

Yet, there is one more measurement of which we need to take note, and that's gauge.

Panel Gauge

Gauge is the thickness of a piece of metal. Without knowing the gauge of a panel of sheet metal, you are missing a huge piece of the puzzle.

Gauge is a standardized measurement used to determine the thickness of metal sheets. The number expresses an inverse relationship: higher gauge (bigger) numbers indicate thinner sheets, while lower numbers represent thicker ones. This measurement system is crucial for material selection, design, and product performance in sheet metal fabrication. The choice of gauge significantly impacts the durability, cost-effectiveness, and structural integrity of the final product.

Just looking at width tells you nothing about how much metal the panel contains. A wide panel might be very thin. It might have an almost-flat wave. It might end up being flimsy and prone to damage, incurring ongoing repair costs over time, while a narrow panel might have an aggressive wave and a heavy gauge.

In practice, smaller gauges (higher numbers) offer more flexibility, making them suitable for delicate sheet metal fence designs. Conversely, larger gauges (lower numbers) are the go-to choice for applications demanding durability and structural strength. Metal roofing typically uses gauges ranging from 22 to 29, with 24-gauge and 26-gauge being popular choices for residential applications.

Understanding gauge is essential when selecting materials that must withstand environmental stresses, wind loads, and general wear and tear. While the gauge system remains in use in some industries and by certain metal suppliers, it's worth noting that actual thickness measurements in inches or millimeters are becoming increasingly common.

Because gauge (panel thickness) and wave profile (ridge depth) are two major contributors to panel strength. These are the numbers you want to pay most heed to when constructing a roofing, siding, or fencing project. The panel width is of secondary importance.

The Implications

Ultimately, the difference between 38 or 42 inches is not very great. However, the difference between a 29-gauge and 26-gauge panel may be.

The choice comes down to understanding the trade-offs between perceived size and actual performance. The 42-inch width of a 3/4" profile may initially seem advantageous, but the flatter design undermines its structural capabilities and uses less steel.

A wide-surfaced sheet that is flatter and thinner, in essence, contains less metal, not more, and equates to less durability and strength.

A Robust Product for Serious Longevity

While the final width of a 38-inch metal sheet is narrower than its 42-inch counterpart, the increased use of material in the 7/8" 26-gauge panel ensures a more robust product. This is critical in applications where metal roofing sheets or sheet metal fence must withstand heavy wind loads, snow, or other environmental stresses.

Our 38-inch 7/8" profile prioritizes strength, durability, and material integrity, making it a superior corrugated metal paneling option for most structural and roofing needs.

Selecting the right type of fencing or roofing material depends on your specific needs and priorities. If you're building a privacy fence with corrugated metal for a commercial property or outdoor use, opt for lower (thicker) gauges and deeper profiles for maximum durability. By investing in high-quality materials like galvanized steel or steel sheets with a 7/8" profile, you'll enjoy a structure that is both functional and visually appealing.

For those seeking long-lasting, high-performance metal panel, the 7/8" is a clear winner. Superior strength and resistance to corrosion make them a standout option for a variety of applications, from fence installation to roofing and siding.

Let your metal fence ideas come to life with the durability and style of BarrierBoss premium materials that stand the test of time. Searching for sheet metal for sale? Enjoy the variety in our collection of panels for roofing, siding, and fencing.