Metal building systems provide Costco with cost and time savings

Metal building construction has come a long way since Costco Wholesale Corp. first tested using a system 32 years ago in California. So much so that the warehouse club giant uses metal building systems to construct 90% of its warehouse stores.

“The technology and the process for completing metal building projects have improved considerably,” said Ali Moayeri, senior VP of construction for Costco.

For example, he noted, metal building manufacturers can now achieve 60-ft. spans between rafters, which has enabled Costco to eliminate three bays, 200 joists and 33 columns.

“These changes result in a cost savings of about $150,000 per warehouse store and increase our flexibility for merchandising,” Moayeri said.

Speed of construction, durable and attractive exterior finishes, innovative coating processes, and the ability to achieve a lightweight, strong structure are other key benefits.

“We can enclose a metal building in 45 days,” Moayeri said. “Once the roof is on, the building is 100% watertight. The installation of electrical, plumbing, fire protection and lighting systems can proceed while the exterior details and features are being completed.”

Moayeri added that Costco has a very aggressive schedule.

“We can build a metal warehouse store—from foundation to opening—in 110 days,” he said. The typical schedule for a conventional construction process is 160 to 180 days.”

Russ Hazzard, AIA, president of MG2, an architecture firm that has designed more than 700 Costco warehouse stores across the U.S. and abroad, noted that metal building systems help architects to efficiently achieve the client’s practical goals while also meeting the aesthetic requirements of local jurisdictions.

“The prototype set we’ve developed for Costco serves as the basis for designing the warehouse stores,” he said. “How the parts of the metal buildings are put together is fairly consistent because the prototype is based on Costco’s merchandising and logistical requirements.”

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The wealth of finishes and products that metal building manufacturers offer is also a plus, Moayeri said.

“We have some amazingly attractive metal buildings,” he added. “They are modern, beautiful and simple yet architecturally handsome.”

The use of insulated, interlocking metal panels is one innovation that has proved to be a big success for Costco as the exterior side of the panels looks and feels like stucco and the color can be varied. The paint is baked on and it lasts 25 to 30 years — or longer.

“We use earth-tone colors—a beige or lighter gray—so the exterior finish won’t fade,” Moayeri said. “We have buildings that are over 30 years old and the color looks as good as Day One.”

The white finish on the interior side of the interlocking metal panels is also a plus. Originally, gray or bronze primer was used for Costco stores, said Ernie Brandi, VP of Span Construction, which has built more than 110 million square feet of space for Costco. But the company was challenged to have the steel come out of the plant in white.

“We worked through all the challenges and we now supply metal building components that are coated with white primer in the plant,” Brandi said.

In addition, a white vinyl facing on the walls and ceiling is used to cover the fiberglass batt insulation.

“All the joists and columns are white—or close to it,” explained Moayeri. “Eliminating the need to paint these on-site can save up to $100,000, which is how much a typical paint job for a Costco warehouse costs.”

Tony Bouquot is the general manager of the Metal Building Manufacturers Association (MBMA). He leads MBMA in its mission to provide research, leadership and education that increases the prominence and use of metal building systems.