Looking Ahead: 2022 Trends at a Glance

Upgrading Your Roof with Metal Panels

In a recent blog post, we reviewed key considerations to help a building owner decide whether to repair or replace a damaged roof. In this post, we’ll address some ways metal roofing systems are an advantage when upgrading your roof and restoring your building to “like-new”, weathertight condition.

MBCI Blog: Upgrading Your Roof with Metal Panels

Installing Metal Panels Over Existing Roofing

Some owners are concerned about replacing a roof because they dread the cost of removing the existing roof. This concern is valid in many low-slope roofing situations because the new roofing membrane might not be compatible with the existing one, and could cause premature deterioration. There are, however, metal panels specifically designed to be installed directly over existing roofing. And, many of these retrofit systems can be installed over existing roofs made of metal or other materials. Avoiding removal of the old roof obviously saves on cost. However, it also saves considerable time when installing the new roof. As an exposed-fastener metal roofing system, this retrofit application also requires fewer construction components, further streamlining the installation process.

Retrofit metal panels typically feature a membrane treatment that prevents rust or contaminants from the old building materials from transferring to the new panels. This is a versatile solution for both low- and steep-slope roofs (minimum slope: ½:12). It is also very durable and can feature approvals for use in extreme weather locations, including Florida. Metal panels are available in a variety of colors that enhance the overall design of a building. Often, this “replacement metal over existing roofing” approach is the most cost-effective, even compared to some repairs. Additionally, new roofing is more likely be eligible for a warranty, while repairs rarely, if ever, are.

Upgrading Your Roof with Insulated Metal Panels

Energy conservation is on the mind of many building owners and building code enforcement officals. Therefore, adding insulation when upgrading your roof is often required to adhere to building codes. In this case, applying zee-shaped sub-purlins over the existing roof system helps support a new layer of metal roofing. In between the sub-purlins, insulation can be added to meet or exceed current energy code requirements. This system also eliminates the need to remove the existing roofing while providing an added layer (or more) of insulation to improve the overall energy performance of the building. Insulated metal panels (IMPs) like MBCI’s can help keep buildings cooler in summer and warmer in winter—conserving energy year-round.

Sub-purlin systems can fit any existing metal panel, support new panels, and be made to accommodate many types of insulation between the old and new roofs. They can also  support or incorporate a variety of solar energy systems where desired. Roof panel options include variety of profile shapes, textures and colors to suit aesthetic preferences.

Altering the Roof Slope

In some cases, upgrading your roof means changing the roof slope (i.e., turning a low-slope roof into a steeper-sloped roof). In these cases, metal roofing systems can be the most economical choice. Steel framing (16-ga. to 12-ga.) installed over the existing roof frame creates a sloped plane that can support new metal roofing panels. Note that the existing physical shape of the roof, the existing structural system and other rooftop conditions are usually the biggest factors in the geometry and shape of the new roof. Nonetheless, the beauty of the system is that it can dramatically improve the appearance and drainage of a building’s roof, regardless of whether the substrate is steel, wood or concrete.

Lower-slope applications (1/2: to 2:12) are typically driven by economy and designed to efficiently discharge rainwater from the roof. Higher-slope applications (greater than 2:12) often serve to improve and update the look of an existing building. They achieve this by showcasing the metal roof while also improving its drainage and durability. Once the framing is installed, standing-seam metal panels can be installed over the top, creating a ventilated attic space. This allows space for additional insulation , thus improving the energy performance of the building.

Working with Building Professionals

Any of these options are applicable over an existing metal roofing system. They cab also convert other types of roofing systems to longer-lasting metal roofing, or replace an existing roofing system altogether. Of course, engaging the services of a design professional (architect, engineer, etc.) is always appropriate when considering your options. They can help properly assess existing building conditions and recommend the best overall metal roofing solution from metal panel manufacturers.

To learn more about upgrading your roof system with more durable, longer-lasting, better-draining and easier-to-maintain metal roofing systems, contact your local MBCI representative.

Should You Repair or Replace a Roof? How to Decide

Roofs on buildings of all types are prone to damage, wear, deterioration, or leaks. When this happens, it leaves the owner wondering whether to address the problem through repair or replace the entire roof. How to decide? There are a number of key considerations:

MBCI Blog: Repair or Replace Your Roof?

What is the existing roof type?

Different roofing materials require different construction methods, and range in suitability for various types of building conditions. Low-slope roofs commonly feature either asphalt/bituminous roofing, polymer-based membranes or metal roofing. Each of these roofing types has its own procedures, materials and costs associated with identifying and repairing a leak. Steeper-sloped roofs can feature asphalt shingles or metal roof panels. These have various life-span expectations (metal lasts much longer, for example) and different ways to identify issues. Understanding the existing roofing type is fundamental in deciding on the best course of action.

Is the roof under warranty?

Regardless of the roofing type, there may be a warranty in effect that requires any inspection and repair work to be performed by someone certified or approved by the roofing manufacturer. Otherwise, undertaking an independent repair may render the warranty null and void. Hence, before anyone does any work on the roof, contact the manufacturer and confirm the applicability (or not) of a warranty. At this time, you can also evaluate any other options or conditions for a repair. The advantage of a warranty is that there should be little, if any, cost to the owner to repair the roof as long as the work is done according to the warranty terms. Without a warranty in effect, it’s entirely up to the owner to decide whether to repair or replace the roof.

How old is the roofing?

If the current owner is the original owner of the building, the roof age should be easy to determine. But what if this is a pre-owned building? It is often beneficial to determine how old the roofing is so you can understand any potential service-life trade-off. This will play directly into the cost-efficiency of a repair versus a replacement. If the roof is near the end of its service life, then a repair might not make sense if a full replacement is imminent anyway. If the roof is fairly new, then the question of how long a repair may last is important. Will it need to be repeated again before the roof is ready for replacement, and if so, at what cost?

Where is the actual location of the damage?

Is it really the roofing that’s a problem? Could it be something related—such as edge flashing or seals around a roof penetration (i.e. a chimney, pipe, or rooftop equipment connection)? If the damage is in isolated areas, a simple repair or flashing replacement may be the easiest solution. If the condition is more widespread, however, then a replacement may be more logical to address the larger area(s) affected.

 Is this building in a high-risk area for more damage?

Buildings prone to high winds or other severe weather need a more durable roofing system than areas where the weather is less dramatic. If the building is in a high-risk area, it might be reasonable to avoid relying on repairs and instead go for a full replacement.

Are there other inherent issues?

Sometimes, the roof covering isn’t the root of the problem. For example, Low-slope roofs often experience “ponding,” where water can sit in a slightly depressed or settled section of the roof. This can lead to deterioration and leakage over time which is not the fault of the roofing, but of the structure or insulation beneath it.

Similarly, steeper-slope roofs may be designed with a geometry or penetrations that prevent proper drainage and cause issues due to water backups. Or, perhaps ice build-up in winter is causing problems with the insulation in the roof system. Identifying the proper issue that is causing the problem will allow for selecting the best solution.

Deciding to repair or replace

Answering the basic questions above will likely reveal which approach—repair or replace—is most appropriate. Small areas of damage in areas in low-risk locations may best be served by simple repairs. If there are many years of roof life remaining or a warranty is in effect, this is especially true. However, missing or faulty components, worn or brittle membranes, or rusting metal panels may all be indications to replace the roofing entirely. This is even more important if the roof is quite old, out of warranty, or in a high-risk area.

In our next post, we’ll look at how metal roof systems help solve a variety of problems within different budgets. In the meantime, contact your local MBCI representative to learn more about roofing warranties and roofing systems for buildings.

Are Metal Panels An Ideal Low-Slope Roofing Material?

Many large, commercial, low-rise buildings often don’t benefit from steeply-sloped roofs the way residences and small commercial buildings might. This is because a steep roof slope would add unwanted height and unnecessary construction cost. Buildings like warehouses, retail stores, etc. are more appropriately built with low-slope roofing, commonly known as “flat roofs”. The National Roofing Contractors Association (NRCA) defines low-slope roofs as those with “a slope at or less than 3:12″. Anything steeper qualifies as a “high-slope roof”. With this in mind, let’s look at some key points to consider when designing and constructing a low-slope roof.

MBCI Low-Slope Roofing

 Low-Slope Roofing Materials

When it comes to selecting low-slope roofing products, there are generally three fundamental choices:

  • Asphalt/ Bituminuous Products: The traditional commercial roofing norm for many years, the use of asphalt/bituminous products has dwindled as newer, more appealing options have emerged.
  • Flexible Membrane Roofing: This roofing material can be made from a variety of types of plastic/polymer-based materials (commonly known as EPDM, TPO, PVC, etc.). Rolls of the chosen membrane are laid out on the roof structure and secured in place either with mechanical fasteners (screws with large washers) or with a continuous layer of adhesive.
  • Metal Roofing: Sometimes overlooked, metal roofing is suitable for different roof slopes. Many metal roofs that use standing-seam systems are rated for use with a pitch as low as ½:12.

When considering which type of roofing material to use for a building project, there are a number of significant differences that illustrate why metal roofing is often the ideal choice.

Engineered For Superior Performance

Standing-seam metal roofing is made specifically for use on low-slope roofs as it meets a number of performance requirements:

  • Water resistance: Precipitation doesn’t penetrate through metal or through the standing seams where the metal panels join together. This is why they can tolerate such low slopes, allowing the water to drain away slowly and predictably without leakage.
  • Rigidity: The rigid nature of metal means that there is less opportunity for ponding (standing water). This is not always the case with asphalt/bituminous or membrane roofing systems.
  • Drainage: Metal roofs carry water to the building’s edge toward gutters and downspouts that carry it away from the building. Other roofing systems rely on drainage piped inside the building. This takes up space and has the potential to leak water inside the building and cause damage.
  • Wind Resistance: Standardized uplift testing shows that metal roofing performs as well or better in extreme weather than mechanically-fastened or fully-adhered membrane systems.
  • Durability: The most cited advantage of metal roofing is its long-term strength and durability. Engineered design and use of high-quality coatings ensures a longer lifespan—50 years or more. In contrast, other roofing types typically feature lifespan ratings of 20 or 30 years.
  • Puncture Resistance: Low-slope metal roofing is more puncture-resistant than asphalt/bituminous or membrane roofing. This makes it better able to tolerate foot traffic, hail and other puncture-inducing hazards.
  • Construction/ Installation Ease: Metal roofing panels are custom-made to suit specific building sizes and end uses. This customization typically means it takes less time to place and install metal roofing in the field. Further, metal panels can tolerate a wide range of temperatures and weather conditions and still install and perform as intended. Low-slope roofs are also safer to walk on with less risk of slips, falls and other hazards.

Cost-Effectiveness

Using metal roofing on low-slope roofing systems can be cost effective in a number of ways:

  • Fewer labor hours as a result of the ease of installation saves money during construction.
  • Competitive material costs, particularly if the metal roofing is part of a total metal building package from a single manufacturer.
  • Minimal maintenance requirements and aversion to rusting, mold growth and decay that save the building owner money over time.

This all adds up to a very favorable life-cycle cost.

The performance, cost-effectiveness and life-cycle benefits of metal roofing panels make them a viable option for low-slope roofing systems. Manufacturers like MBCI can help you select the right metal roofing products and provide information and resources to help ensure proper installation.

View examples of low-slope metal roofing projects and contact your local MBCI representative to start your project today.

Understanding LEED for Green Metal Buildings

Designing and constructing sustainable buildings has become a mainstream expectation of most building owners. Whether for reduced energy costs, higher returns on investment, or as an organizational philosophy, “green” building solutions are in demand. Perhaps the best known and most often cited program to achieve these goals is the US Green Building Council’s (USGBC’s) LEED® rating system. While some may think that green buildings are more complicated and costly to build, that is not actually the case. This is especially true when metal building materials are used. In fact, metal buildings are an ideal and economical way to pursue sustainability goals and LEED certification. How? We break it down as follows:

LEED

The LEED® Program

The LEED program has been in use since 1998 and is now used worldwide. It is a voluntary, point-based rating system that allows for independent review and certification at different levels. These levels include Certified (40-49 points), Silver (50-59 points), Gold (60-79 points), or Platinum (80 or more points). Since it allows for choices in which points are pursued, innovation and flexibility are entirely possible as long as specific performance criteria are met. It also encourages collaborative and integrative design, construction and operation of the building.

Points are organized into six basic categories, many of which can be addressed through metal building design and construction, as summarized below.

  • Location and Transportation: Metal buildings can be manufactured and delivered to virtually any location. That means they can support LEED criteria for being located near neighborhoods with diverse uses, available mass transit, bicycle trails, or other sustainable amenities. Metal building parking areas can also be designed to promote sustainable practices for green vehicles and reduced pavement. This all contributes toward obtaining LEED eligibility.
  • Sustainable Sites: Adding a building to any site will certainly impact the natural environment already there. Delivering portions of a pre-engineered metal building package in a sequence to arrive as needed means that the staging area on-site can be minimized—reducing site impacts. Additionally, using a “cool metal roof” has been shown to reduce “heat island” effects on the surrounding site and also qualify for LEED.
  • Water Efficiency: Any design that reduces or eliminates the need for irrigation of plantings and other outdoor water uses is preferred. Incorporating metal roofing with gutters and downspouts, as is commonly done on metal buildings, allows opportunities to capture rainwater for irrigation or other uses. It also helps control water run-off from the roof and assists with good storm water control.
  • Energy and Atmosphere: Metal buildings can truly shine in this category. Creating a well-insulated and air-sealed building enclosure is the most important and cost-effective step in creating an energy conserving building. A variety of insulation methods for metal building roof and wall systems are used to achieve this. Typically, metal building construction uses one or more layers of fiberglass insulation and liners combined with sealant and air barriers. Alternatively, insulated metal panels (IMPs) provide all of these layers in a single manufactured sandwich panel with impressive performance. Windows, skylights and translucent roof panels can provide natural daylight, allowing electric lighting to be dimmed or turned off. For buildings seeking to generate their own electricity,  standing-seam metal roofing provides an ideal opportunity for the simplified installation of solar photovoltaic (PV) systems. Metal roofs generally provide a sustainable service life in excess of 40 years. This means they can outlast the PV array, thus avoiding costly roof replacements during most PV array lifespans.
  • Materials and Resources: Life Cycle Assessments (LCAs) are recognized by LEED as the most effective means to holistically assess the impacts that materials and processes have on the environment and on people. Fortunately, the Metal Building Manufacturer’s Association (MBMA) has collaborated with the Athena Sustainable Materials Institute and UL Environment to develop an industry-wide life cycle assessment report. There is also an Athena Impact Estimator that can help with providing LEED documentation. Metal buildings support exceptional environmental performance through the significant use of recycled steel and the reduced need for energy intensive concrete due to lighter weight buildings.
  • Indoor Environmental Quality: Most people spend much more time indoors than outside, which impacts human health. Therefore, LEED promotes or requires using materials that don’t contain or emit harmful substances. It also promotes design options for natural daylight, exterior views and acoustical control to promote psychological and emotional well-being. Metal buildings are routinely designed to readily incorporate components that help achieve these indoor qualities.

In addition, some LEED points are available for demonstrating innovation and addressing priorities within a geographic region.

Considering the qualities listed above, metal buildings clearly provide a prime opportunity to pursue LEED certification at any level. To find out more about the LEED rating system, visit https://new.usgbc.org/leed. To find out more about successfully designing and constructing metal buildings pursuing LEED certification, contact your local MBCI representative.

Design and Performance Benefits of Insulated Metal Panels

In a prior post on insulated metal panels (IMPs) we reviewed some of the basic things everyone should know about this versatile and lightweight metal building component. In this posting, we will drill down a bit more on the benefits of incorporating IMPs into a new or retrofit construction project. Here are some of the top reasons they are so popularly used in both walls and roofs:

Insulated metal panels (IMPs) are a popular choice for walls and roofs for their energy conservation, durability, longevity and cost-savings.
Insulated metal panels (IMPs) are a popular choice for walls and roofs for their energy conservation, durability, longevity and cost-savings.

Energy Conserving, Space Saving Insulation

Foam plastic insulation is used between the metal skins of IMPs. Such insulation has been accepted for use by building codes for quite awhile provided it meets certain conditions. IMPs have been tested and shown to meet or exceed all code requirements for construction and for energy conservation too. Part of their appeal over other ways to insulate is that they can achieve high performance in a thinner wall or roof assembly than would be required with other types of insulation, such as fiberglass. IMPs are available in thicknesses that range from 2 to 6 inches and have corresponding R-values from R-14 to R-46 allowing design professionals to select the thickness that matches the energy performance level sought in a particular building. Other insulation types would require thicknesses of at least twice as much to approach the same R-values as IMPs. Further, the metal interior and exterior skins are the only finish material needed so the total panel thickness is very space efficient. Thinner IMPs in the walls and roofs can save space in the building or on the site all while achieving high energy performance.

Durability, Longevity, and Low Maintenance

The manufactured panels are rigid and quite strong. They have been tested for compression, tensile, and shear strength with impressive numbers that come about because of the combination of the rigid foam and steel properties. The surfaces are made from the same long-lasting galvanized and factory finished steel used in other metal wall and roof panels so their resistance to weather, abuse, and even harsh conditions has been proven, making them very easy to maintain. In locations where severe weather and storms are a concern, they can also be specified to meet requirements for heavy winds, hail, and similar concerns. Plus, since the skins of the IMPs are made of noncombustible steel, they provide an ignition barrier as part of an overall fire protection scheme for the building.

Cost Saving Construction

IMPs are an “all-in-one” product that takes the place of many other products and components used in traditional construction. Instead of requiring multiple trades and materials to be installed individually over some number of weeks, IMPs are installed by a metal building contractor and allow the walls and roof to be completely closed in with a single trade. The use of concealed fasteners in the side joint of the panels makes installation quick and easy. Unlike other construction systems, the inherent strength and resiliency of IMPs means that work doesn’t need to stop over weather concerns. All of this saves a considerable amount of labor costs and can also save a lot of time meaning buildings can be completed quicker and more economically. It could also mean that an owner is able to occupy and use the building sooner, thus reducing construction financing costs and allowing operations to begin more quickly.

Versatility for Use in Many Building Types

IMPs can be used in virtually any type of new construction and for many retrofit applications too. There is a range of modular panel sizes that can work successfully with different structural elements of the rest of the building. The finished profiles and colors can all be selected to match the design needs of the building with edges, corners, and trim details all based on simple, appealing aesthetics. There are even IMPs specially designed for cold storage or refrigerated space applications. These panels may be part of the building exterior or create an isolated space within a larger building. Either way, they are designed for the rigors of a high use installation.

With such a broad range of benefits and capabilities, you owe it to yourself to check them out for a building project that you may be involved in. The best place to start is by contacting your local MBCI representative, and by signing up for our newsletter to subscribe to our blog.

What You Need to Know About Insulated Metal Panels

Insulated metal panels (IMPs) are “lightweight, composite exterior wall and roof panels with metal skins and an insulating foam core” as defined by the Metal Construction Association (MCA). The outer skin serves as either metal wall siding or metal roofing using standard profiles, while the inner face serves as a metal interior finish or liner. The rigid insulation between the metal skins gives the panels their superior energy conservation properties and also provides a rigid core for extensive spanning capabilities across structural members.

With this basic make-up in mind, here are a few things you should know about using IMPs in a metal building project:

Building Types

Virtually any building being designed as a metal building should consider the use of IMPs. This includes all types of commercial, industrial, institutional, recreational and government buildings. More specifically, IMPs have been used very successfully on manufacturing facilities, schools, retail centers, offices, warehouses, power plants and many other building types.

Insulated Roofing and Walls Assemblies

IMPs serve as a complete wall or roof assembly. That means they can provide cladding, insulation, a water-resistant barrier, an air barrier, and finished surfaces all in one panelized product – essentially everything but the building structure upon which they are installed. These characteristics are true for conventional buildings as well as for specialty construction types such as the climate controlled processing, storage, or distribution of perishable food or other items. With panel thicknesses commonly available from 3 inches to 6 inches, walls and roofs can be designed to meet the specific thermal performance requirements of virtually any building need.

Aside from their thermal performance capabilities, IMPs have the versatility to achieve countless aesthetics for walls and roofs.
Aside from their thermal performance capabilities, IMPs have the versatility to achieve countless aesthetics for walls and roofs.

Architectural Design

IMPs are available in a wide variety of colors, widths, profiles and finishes, enabling virtually any aesthetic desired for walls and roofs. Further, architectural IMPs provide the freedom to address building-specific or unique circumstances with options such as custom shapes and widths, special custom colors and finishes, custom fabrication including, but not limited to bent corners, curved panels, and trimless ends. Architectural IMPs also offer options to integrate with windows, louvers, sunshades or other similar products to offer total building envelope solutions.

Panel Joints

Most IMPs are fabricated with the intention of working together as a complete system. That means attention has been paid to the design of the edges so the panels can interlock and be sealed to form a continuous joint that is water tight and air tight. In some cases panels may need to overlap, such as on long roof runs over 50 feet, but manufacturers have worked out those details to help assure the roof or wall performs as intended. Based on this, properly-installed IMP systems generally come with a very long warranty period.

Ease of Installation

The fact that IMPs are a single, finished, rigid panel, makes them quicker to install than other multi-product and multi-step assemblies. This translates to obvious labor savings and some material cost savings compared to other systems. Further, the simplified installation process has been shown to limit exposure to accidents, helping create a safer, more efficient work flow. It can also mean that construction time schedules are easier to meet or even beat.

To find out more about IMPs and ways to use their full characteristics and capabilities on a building you are working on, contact your local MBCI representative.

Why Upgrade a Roof to Metal Panels?

Have you considered using metal panels in building and roofing upgrades? Metal roofing panels from MBCI offer significant advantages over traditional roofing material, including the ability to be integrated with the existing structural system. For buildings that need to comply with strict code requirements, our huge selection of metal roofing can meet your needs.

Save Money with Metal Roofing

Using metal instead of asphalt shingles for roofing provides several cost-saving benefits, including:

  • 60-year lifespan: The strength and durability of metal is unparalleled compared to traditional asphalt shingles, and weathers the elements for a much longer period of time.
  • Sustainability: Our cool roof coatings are extremely energy-efficient, saving you cost associated with heating and cooling your building. With strict requirements in place for buildings today, reducing energy and maintenance costs is top-of-mind, and metal roofing is a simple solution that offers both. MBCI also works with LEED project documentation and has EPDs using LCA results for core panels.
  • Higher Quality Material: From insulated to standing seam and exposed fastening roof panels, our selection of panels are available in gauges ranging from 22 to 29, with a variety of finishes and coatings to ensure your metal roof stands the test of time.
  • Extensive Warranties: MBCI’s signature panels each come with their own unique warranty, with coverage for features including film integrity, chalk and fade, and more depending on the product.

It is important to note that when working with older buildings, there is a possibility of degradation of the subsurface as well as pre-existing structural issues such as overloading the structure.

MBCI's metal roofing panels are a durable and energy-efficient alternative to standard roofing products.
MBCI’s metal roofing panels are a durable and energy-efficient alternative to standard roofing products.

Panels & Systems for Every Application

  • Standing Seam Panels: Commonly used for a variety of commercial, residential, and recreational applications, these are some of the most durable and versatile systems available. We offer everything from mechanically field-seamed panels to curved and snap-together options. No matter what your building is used for, these systems withstand the elements and have fire and impact resistance ratings.
  • Lightweight Panels: MBCI’s product line features lightweight panels that can be used as framing and sheeting materials. For example, the BattenLok® HS is a high strength standing seam roof systems that can be installed directly over the purlins or bar joints. The type of metal paneling chosen for your roofing systems allows for additional customization by being able to choose your color with our extensive color chart. The experts at MBCI have years of experience matching the retrofit roof panels to the new roof membrane.
  • Exposed Fastening: With 9 different styles to choose from, MBCI’s vast selection of exposed fastener roof panels are sure to exceed your expectations. Cost-effective and easy to install, these panels are often used in commercial and agricultural buildings, and are designed for both vertical and horizontal installation.
  • Retrofit Systems: Selecting the correct roofing system is critical in the retrofitting process. MBCI’s NuRoof® retrofit system has the capability to “stick-frame” the current supporting structure. The new retrofit system allows for redistribution of loads while increasing the energy-efficiency of the building. If you prefer installing new panels over existing roofing, the Retro-R® Panel can enable you to skip the removal of the existing roof entirely. This is a great option for saving time and cost related to installation, and can keep your operation up and running with no downtime. The Retro-R® Panel’s Drip Stop membrane prevents rust from old roofs from interfering with new panels, providing a new look with a long life span. With availability in both 26 and 29 gauge Galvalume Plus® and 200 color options, the Retro-R® roofing system is a great option for retrofitting.

To find out more about which metal roofing panel is ideal for your new project or existing building, contact your local MBCI representative.

 

Benefits of Roofing Retrofits with Metal Roofing Systems

Many commercial buildings, and even some residential ones, have low slope or “flat” roofs that can be problematic to maintain. They typically rely on a membrane of some sort that in and of itself is waterproof, but every seam, penetration, flashing, and other detail is a potential leak if not installed and maintained properly. Further, the subsurface that the membrane sits on determines the actual slope to roof drains so if that is compromised, then standing water can sit on the roof and cause issues. Even the roof drains are a concern if they get clogged with debris or leaves and cause water to back up and stagnate on roofs.

Given the potential difficulties, and the frequency of replacement that is often needed for flat roofs (average of 20 years), it is no surprise that many facility managers or owners look to retrofit their buildings with sloped metal roofs wherever the size and geometry are conducive to it. In doing so they recognize the many benefits obtained which can include any or all of the following:

Reduced Maintenance with Metal Roofing

A complete metal roof system (e.g. metal framing, metal roofing, insulation, and ventilation) can be designed and installed to require minimal maintenance. That means not only fewer potential problems, but reduced operating costs over the course of many years.

Increased Roof Lifespan

Metal roofing is recognized by industry experts for having a very long lifespan even under challenging weather conditions. It is not uncommon for a metal roof system to last 60 or more years compared to a 20-year average for flat membrane roofs. If Galvalume® coated steel is used (i.e., zinc/aluminum coating licensed to roofing manufacturers), the roof lifespan can be expected to last the full service life of the building, according to studies done on standing seam roofs by the Zinc-Aluminum Coaters Association and the Metal Construction Association (MCA). Long-lasting roofing means there is only one installation to provide and pay for, not multiple ones over the life of the building.

Retrofit
Tum-A-Lum Lumber featuring Retro-R® Metal Panels

Improved Building Energy Efficiency

Retrofitting with new insulated metal roofing systems is an excellent solution to high energy consumption and associated costs in a building. Retrofit systems can be designed to work over existing flat roofs or even over older sloped metal roofs to upgrade a building to meet or exceed current energy code requirements. Such systems add insulation between the old and new roof reducing heat gain in summer and heat loss in winter. The metal roofing can also be finished to reflect the heat of the sun away, achieving  higher solar reflection index and reducing cooling costs.

Greater Sustainability

In addition to energy efficiency, metal roofing systems can be made from recycled steel and then be re-used or recycled at the end of its service life. This capability helps reduce the amount of material headed to landfills and can contribute to points in the LEED green building rating system, among others.

Improved Aesthetics

Sloped metal roofs can be used as a significant design feature on many low rise and mid rise buildings. The range of colors and textures provides architects and other design professionals a full palette of options.

Increased Property Value

Curb appeal and long term performance are common contributers when a property is being assessed for value. A retrofit metal roofing system can certainly help in this regard.

Overall, there are many reasons for choosing a retrofit system for an existing building. Whether to replace a leaking roof, correct the current geometry, meet new regulation or code requirements, improve the aesthetics, or increase the energy efficiency of a building, all of the benefits above can be realized. To learn more about MBCI retrofit metal roofing systems and how they might work on a building you are involved in, visit www.mbci.com/products/retrofit-products.

Reducing Peak Demand Costs with Cool Metal Roofs

Among the many benefits offered by cool roofs—including a decrease in urban heat island effect or increased roof system longevity—perhaps the most significant is a reduction in peak demand energy usage which directly affects building expenses.

Peak demand is the highest point in the day at which a building draws electrical consumption. A facility’s monthly utility rates are largely determined by the power usage level at this time, so anything that can be done to drive usage down will significantly reduce utility costs. As evidenced by their test values, cool roofs are an effective way to decrease air conditioning loads during peak demand times.

Cool roof values are expressed in terms of solar reflectance and thermal emissivity. The combination of these values is used to determine how hot a surface will become by its ability to reflect solar energy and radiate heat away from itself. Cool roofsare capable of reflecting solar heat away from a building by more than 70 percent. In fact, the U.S. Environmental Protection Agency estimates that ENERGY STAR® qualified roofing products can lower roof surface temperatures by up to 50°F.

According to Jeff Steuben, executive director, and Carolyn Richter, communications manager, Cool Roof Rating Council (CRRC), in a recent Florida Roofing article, “Building occupants can experience improved comfort as compared to a conventional dark roof, as the building’s interior is subject to less thermal flux and stays cooler during warm seasons,” and, “Reduced indoor temperatures lead to energy savings from reduced cooling energy loads.”

Along these lines, contractors can also access a CRRC-provided listing of cool roof rebates, codes and voluntary cool roof programs at: www.coolroofs.org/resources/rebates-and-codes.

Cool Roofing Longevity

In addition to energy efficiency, cool metal roofs are known for extended durability and longevity, with most products offering a 40-year finish warranty.

In fact, a well-noted extensive study, Natural Exposure Testing in California, conducted by the Oak Ridge National Laboratory, found that pre-painted metal roofing maintained higher levels of reflectance, over a three-year period, due to its ability to shed particulate matter, as compared to conventional roofing materials. Further, pre-painted metal roofing has been found to retain 95 percent of its initial solar reflectance over this same three-year period.
Increasing performance and energy savings, solar reflective pigments in cool metal roofs offer higher total solar reflectance and thermal emittance, even in darker colors. With cool roof technology, the ability for the roof to store heat and radiate that heat into the building after sundown is dramatically reduced.

Cool Roofs
Heitmann Residence featuring a Cool Metal Roof

Cool metal roofs are proven to deliver environmental and performance benefits, of which the most significant to building owners is their contribution to the bottom line. Although savings will vary based upon geography, materials and insulation, the U.S. Environmental Protection Agency estimates that reflective roofs can save up to 40 percent of a building’s cooling energy costs.

When utilizing the U.S. Department of Energy’s Cool Roof Peak Calculator, contractors will discover that the total value of energy savings offered by a cool roof averages more than $1,000 annually in most climate zones for a typical commercial building. Furthermore, this applies to both cool roofing installed over both existing roof insulation and new insulation.

Proven Strategy

As established by documented study and significant heat build-up reduction levels, cool roofs are a proven strategy for supporting longer lasting roofs, reducing both utility costs and decreasing a building’s environmental footprint as Steuben and Richter conclude, “cool roofs are one of the most effective ways to obtain energy savings and environmental rewards through building envelope design and re-roofing projects.”

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