How to Remodel With Corrugated Aluminum

Emrah Oruc

The industrial loft look is very popular. Exposed pipes, conduit and metal give a room the look and feel of an urban, warehouse-district living space. That design style can be duplicated in your home with simple materials like corrugated aluminum panels.

Corrugated aluminum panels bring urban loft design features into your home.

The panels can be used as wainscoting on walls or as an accent feature around a kitchen island or basement bar.

  1. Measure the total linear footage needed along the walls you want to cover. Panels overlap by one corrugation, so take that into account in your measurements. Wainscoting installs so the top is 34 to 36 inches in height measured from the floor. Select your corrugated panels accordingly.

  2. Use a stud finder to locate and mark the location of the studs along the wall. The panels will be secured to the wall with screws into studs.

  3. Cut the panels to size using a circular saw with a metal cutting blade. Wear your safety glasses when doing this. The tops of the panels should be between 34 and 36 inches from the floor once installed. File off burrs or sharp edges once you have cut the panel.

  4. Mark and cut openings for switches, electrical outlets and cable outlets. Drill a pilot hole with a metal bit large enough to fit a jigsaw blade through. Cut out the opening with a jigsaw and metal blade. File down burrs and sharp edges.

  5. Place the panel up to the wall and pre-drill holes through the panel where there are studs. Do this only at locations where the high spot of the panel contacts directly with the wall. If they do not line up with studs, trim the panel's width and re-position it so they do line up.

  6. Apply construction adhesive to the high points on the corrugated where they will contact the wall. Lay the panel against the wall and check that it is level by laying a bubble-level across the top of the panel. Screw the panel to the studs near the top and bottom edge for every stud. Depending on the the width and stiffness of the panels, a screw may be needed in the middle as well.

  7. Install each subsequent panel by overlapping with the previous panel by one corrugation. Install the last panel so the corrugation is touching the wall. Do not have the exposed vertical edge pointing away from the wall.

  8. Tip

    Wood or metal trim can be installed along the top of the panels to cover exposed edges.


    Never cover up an electrical socket. Always cut out a hole so the socket can be used and, if necessary, serviced.