Episode 42: Inside Metal Alliance, Inc. With Nick Fedele

Host Kathi Miller interviews Nick Fedele from Metal Alliance about their Bucks County Community College roofing project. Metal Alliance, a Philadelphia-area architectural sheet metal contractor specializing in historical restoration, successfully converted the college's aging slate roof to a McElroy 238T steel standing seam system.

Fedele discusses why they chose Galvalume steel over aluminum or zinc, addressing common misconceptions about steel's durability and warranties. The project involved complex dormers, concrete deck preparation, and custom stainless steel saddles. Other topics include Metal Alliance's 32-year history, exceptional employee retention, and collaborative approach with architects and engineers, exemplifying their expertise in high-end commercial roofing projects.

  • 27 min

Episode 42 Inside Metal Alliance, Inc. With Nick Fedele

The Building with Metal Podcast – Presented by McElroy Metal

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Notable Quotes

• "That's the stuff that we kind of get excited about" - Nick Fedele on tackling challenging projects that other contractors avoid, referring to complex historical restoration work.
• "Steel can't sag, and we had to make the roof sag again" - Fedele describing the unique challenge of maintaining historical accuracy when replacing structural elements during a copper re-roof project.
• "I will brag on our guys all day long and I'll put them up against anybody in the business. I think we have the best crew out there" - Fedele expressing pride in his team's expertise and craftsmanship.

What You'll Learn

• How to overcome client misconceptions about steel versus aluminum roofing products and their respective warranties
• The technical advantages of symmetrical T-panel systems for complex installations with dormers and obstacles
• Why Galvalume steel outperforms aluminum in expansion/contraction scenarios on longer panel runs
• Best practices for historical restoration work and the unique challenges of matching original craftsmanship
• Strategies for employee retention and developing apprentice programs in the metal roofing trade
• The importance of early contractor involvement in design phases for optimal project outcomes
• How to address water management issues when retrofitting existing concrete deck structures

Key Timestamps

[0:00-2:30] Introduction and guest background - Nick Fedele returns to discuss Metal Alliance's specialty in architectural sheet metal fabrication and historical restoration work in the Philadelphia/New Jersey market.

[2:30-5:15] Historical restoration challenges - Discussion of copper work, soldering techniques, and unique structural issues like maintaining deliberate roof sag for historical accuracy.

[5:15-8:00] Company history and transition - Metal Alliance's founding in 1993, Nick's acquisition in 2021, and continued partnership with original owner Rich Pacelli.

[8:00-12:30] Bucks County Community College project overview - Converting from failing slate to standing seam metal, initial client preferences for aluminum/zinc, and education process about steel benefits.

[12:30-16:45] Material selection rationale - Comparing warranties, addressing salt air misconceptions, and explaining Galvalume technology advantages over traditional galvanized products.

[16:45-21:00] Technical project details - Panel lengths, expansion considerations, dormer integration, and benefits of symmetrical 238T panel system.

[21:00-25:30] Installation challenges and solutions - Concrete deck preparation, insulation strategies, dormer pitch modifications, and custom stainless steel water management details.

[25:30-29:15] Employee retention and training programs - Exceptional tenure rates, apprentice development, and institutional knowledge preservation strategies.

[29:15-32:00] Project collaboration and early involvement - Working with architects, engineers, and McElroy Metal technical support for optimal design solutions.

[32:00-33:30] Project outcomes and wrap-up - Client satisfaction, weathertight inspection results, and future photography plans.

Mentioned Resources

• McElroy Metal 238T standing seam panel system
• McElroy Metal technical support team
• Galvalume substrate technology and warranty programs
• Metal Alliance historical restoration portfolio
• Connect with Nick Fedele on LinkedIn
• Connect with the host Kathi Miller on LinkedIn

When Bucks County Community College faced a failing slate roof system, they initially considered aluminum or zinc standing seam options, influenced by common industry misconceptions. However, their partnership with Metal Alliance and McElroy Metal revealed a superior solution that challenged conventional wisdom while delivering exceptional performance and value.

Metal Alliance, a Philadelphia-area architectural sheet metal contractor with over three decades of experience, specializes in the kind of complex projects that make other contractors hesitate. As Nick Fedele, the company's current owner, explains: "That's the stuff that we kind of get excited about" when describing their approach to challenging installations that others might avoid.

The college's original slate roof represented the kind of craftsmanship from decades past that's increasingly difficult and expensive to replicate. Rather than compromise the building's architectural integrity with basic asphalt shingles, the decision was made to transition to a high-performance metal roofing system that would maintain visual appeal while providing superior functionality and longevity.

Initially, the college's team gravitated toward aluminum or zinc options, influenced by widespread beliefs about steel's limitations. Fedele encountered the familiar refrain: concerns about corrosion, rust, and inferior warranties compared to aluminum products. This presented an opportunity for education rather than simple product sales.

The reality of modern Galvalume steel  technology tells a different story. The key distinction lies in understanding when salt air concerns are legitimate versus when they're based on outdated information. As Fedele notes, warranty exclusions typically apply only within 300 yards of breaking surf, making steel perfectly suitable for the vast majority of applications.

For the Bucks County project, the choice of McElroy's 238T system proved particularly advantageous. The building featured multiple dormers requiring complex water management, and the panel runs of 50-60 feet presented potential expansion challenges. Steel's lower coefficient of expansion compared to aluminum meant the panels could bend continuously over dormers without requiring problematic flashing transitions.

The symmetrical design of the T-panel system offered additional installation benefits that aluminum alternatives couldn't match. Workers could begin installation at any point and move in either direction, skip sections to accommodate mechanical equipment, and even remove individual panels for repairs without disrupting adjacent areas. This flexibility proved invaluable given the project's architectural complexities.

Installation challenges extended beyond panel selection to fundamental structural considerations. The existing concrete deck required a complete tear-off and rebuilding with proper insulation and moisture barriers. Original dormer pitches that directed water toward the building were corrected using tapered insulation to promote adequate drainage. Custom stainless steel saddles were fabricated to channel water away from critical transition areas.

These solutions emerged from what Fedele describes as institutional knowledge built over decades of specialized work. "When you've been doing this as an organization, and we have guys who've been here since day one, there are all these random little things that they pick up on," he explains. This expertise becomes particularly valuable when addressing problems that might not be obvious from architectural drawings but become apparent during actual installation.

Metal Alliance's approach to workforce development exemplifies best practices in an industry struggling with skilled labor shortages. The company boasts exceptional employee retention, with many team members dating back to the company's founding in 1993. Rather than simply maintaining the status quo, they've implemented what Fedele calls a "youth movement," pairing experienced craftsmen with apprentices to ensure knowledge transfer and business continuity.

The collaborative relationship between Metal Alliance, McElroy Metal's technical team, and project stakeholders demonstrates the value of early contractor involvement in design phases. Rather than simply executing predetermined specifications, this partnership approach allows practical installation expertise to inform design decisions, resulting in better outcomes for all parties.

Project success ultimately depends on this kind of teamwork, where each participant brings specialized knowledge to bear on complex challenges. As Fedele observes: "Our preference is to be involved as early as humanly possible. We have the benefit of being the installer and having seen a ton of this stuff, so we know what goes together well and what on paper kind of sounds great and looks great in a drawing, but when you actually get to trying to make that happen in real life, it just doesn't work that way."

The Bucks County Community College project stands as evidence that informed material selection, combined with skilled installation and collaborative planning, can transform challenging retrofits into long-term success stories. By moving beyond surface-level assumptions about material properties and embracing comprehensive technical solutions, educational institutions and other building owners can achieve superior performance while maintaining architectural integrity.

For Metal Alliance, projects like this represent more than successful installations; they're opportunities to advance industry knowledge and challenge conventional thinking. When Fedele states, "Steel can't sag, and we had to make the roof sag again" while describing a historical restoration challenge, he captures the creative problem-solving that defines excellence in specialized contracting.

The ultimate measure of success lies not just in immediate project completion but in long-term performance and client satisfaction. With proper material selection, expert installation, and ongoing collaborative relationships, metal roofing systems can serve educational institutions and other critical facilities for decades while requiring minimal maintenance and providing reliable weather protection.