Why Choose Retro-R® Panels?

If you are looking for a low-cost retrofit solution and want to cover your roof with a lightweight, through-fastened panel, MBCI’s Retro-R® Panel installed over your existing roof could be the answer. Retro-R® panels provide a host of advantages for the retrofit roof project, including allowing the existing roof to stay in place during installation, thereby eliminating business downtime; time and labor cost savings; minimizing the possibility for water entry into the building; and providing a safer working environment—all with energy-efficient, versatile options. Here’s a quick rundown of some specific benefits of Retro-R® panels.

MBCI's Retro-R® panel can be installed directly over an exiting R panel.
MBCI’s Retro-R® panel can be installed directly over an exiting R panel.

Cost and Time Savings

There are a number of potential cost saving scenarios afforded by choosing the Retro-R® panel solution. First and foremost, this panel entirely eliminates the roof or wall removal process as it is installed directly over an existing R panel. This allows the facility to remain open so there’s no interruption to business operations, minimizing the loss of revenue.

Also, by not having to remove the roof or wall, installers save time (which also equates to lower labor costs). Not only does installation of Retro-R® panels save time in the project schedule and maintaining operations, this exposed fastening system requires fewer installation accessories, thereby keeping costs down while still providing a new look and long product life.

Additionally, existing rooftop equipment, vents or light transmitting panels can all be accommodated by the Retro-R® system, again providing significant cost savings when compared to installing a new roof system.

Installers may also be able to reuse all the trim from the original building when utilizing Retro-R® panels for a retrofit. They may not have to remove certain roof elements, such as the rake, gutter or down spouts; in fact, they may not even have to disassemble them. On one recent Retro-R® retrofit project, for example, Texas-based Benny’s Transmission, installers only took the ridge vents up in order to lay the panels flush, and were able to reuse them once the roof was installed, adding up to large material and labor savings for the building owner.

With a seamless solution to their 41-year-old roof in mind, Benny's Transmission selected MBCI's Retro-R® panel to be installed over their existing roof.
With a seamless solution to their 41-year-old roof in mind, Benny’s Transmission selected MBCI’s Retro-R® panel to be installed over their existing roof.

Site Safety

Any time installation time and required manpower are reduced, jobsite risks are also reduced. Additionally, it is more likely an installer could fall through if the original roof is not in place. With Retro-R® panels, if tied off at the eave, that risk is minimized as well. Generally speaking, inspecting and evaluating the existing roof panel and structure to determine if they will support the new panels and any live loads on the roof during installation is a key safety guideline.

Long Lifespan and Rust Prevention

The Retro-R® panel has a Drip Stop membrane to prevent rust from the old roof or wall from transferring to the new panel, which helps contribute to a longer lifespan.

Coatings, Color Choices, and Energy Efficiency

With availability in both 26- and 29-gauge Galvalume Plus® and Signature 200 color options, MBCI’s Retro-R® roofing system is a great option for retrofitting projects. On the Benny’s Transmission project, for example, the color chosen was Galvalume Plus®, which comes with a 20-year Galvalume warranty through MBCI. Although there was no extra insulation added, the high reflectivity of the Galvalume roof increased the building’s energy efficiency.

All in all, Retro-R® panel systems can be a cost-saving, efficient, versatile solution for your next retrofit project.

To find out more about Retro-R® panelscontact your local MBCI representative or stop by MBCI’s booth #2245 at the International Roofing Expo 2019 in February to see this panel installed live. Can’t make it to IRE? Tune in to our Facebook page on Tuesday, February 12th to watch our demos live!

Five Retrofit Choices Using Metal Roofing Systems

Buildings usually need new or replacement roofing installed at some point during their service lives. New metal roofing is an ideal roofing retrofit option due to its longevity and durability, which can extend the life of the roofing and require fewer replacements over time. The aesthetic appearance of a new metal roof can also make a notable visual impact to upgrade the building itself.

When considering such a metal roof retrofit on an existing building, the first thing to realize is that there are a number of choices available. Here is a quick look at five of the most common ones that can be selected from and tailored to suit a particular building. Note that since all of them will add some structural loading to the roof, all the retrofit solutions should be reviewed by a professional structural engineer to be sure the existing building can accommodate the changes.

1. Double-Lok® Clip System

When an existing building has an existing PBR roof panel or similar, a Double-Lok® clip and panel system can be installed directly over the existing roof with minimal alterations. In this case, 2″ standoff clips are run from eave to ridge and fastened through the existing roofing panels down into the existing purlins. Then new standing seam metal roofing panels are installed along these clips so they are held 2″ above the purlins and 3/4″ above the major ribs of the existing panel roof. Because of these clearances, the cavity between the old and new roofs can either be vented or additional insulation can be added. Venting the cavity can be a good option when the existing roof slope is 3:12 or greater, as this allows for convective air flow during the summer and can help reduce the chance of ice damming in the winter. For any slopes of 1/2: 12 or greater, adding insulation can improve the overall thermal performance of the building. Generally, this system allows for considerable versatility, even if it takes more parts and labor than some other solutions.

2. Retrofit Roof Panels Over Existing

For cases where a standoff isn’t sought, new, non-structural metal roof panels with a specifically retrofit profile can be installed directly over existing roof panels on roof slopes of 1/2: 12 and greater. That means there is no need to tear out the old roof, since the new panels are through-fastened into the old ones and the purlins below, all in a pattern that avoids the original fasteners. Such retrofit panels are available in 29 and 26 gauge in full range of colors and come with a factory-applied vapor barrier on the underside. Even light-transmitting panels are available for this retrofit panel system.

Retrofit
5 most common choices for retrofit metal roofing systems

3. Notched Sub-Purlins

A variation on the metal-over-metal roofing approach is to use specifically designed z-purlins with notch-outs that are screwed down to the existing purlins. Unlike other systems that run retrofit support members from the eave to the ridge, the notched purlins run parallel to both (in line with existing purlins) with the notches spaced to clear the ribs or corrugations in the existing metal roofing. Profiles are available to match virtually any metal roof produced in the last 50 years. That means they can be installed over existing roofing and, in the process, provide enhanced structural capabilities because of the added sub-purlins.

4. Grid System

When an existing purlin spacing doesn’t meet current code requirements, then the use of crisscrossing hat sections in a grid pattern can provide the additional support needed. Such grid systems are designed to go directly over existing sloped roof systems but many require the use of specific metal roofing panels to work properly.

5. New Framed Roof System

In some cases, a full, steep-sloped roof (greater than 4:12) is sought to be installed over a low-slope roof (1/4:12 – 4:12). In this case, a full metal framing system is available that will create the desired roof slope and transfer the new roof weight to the existing roof deck above the existing roof structural members. As such, the coordination of the new system with the existing roofing, insulation and structure needs to be addressed by licensed engineers. Once designed and installed, an “attic space” will be created by the new retrofit roof system, which should include proper venting in accordance with applicable codes, allowing trapped moisture to escape. It is also recommended that such “attic space” be reviewed by other building, fire, or insurance-related officials for possible sprinkling or extension of existing fire walls to the bottom of the “new” roof system. Regardless, a minimum of 3″ vinyl-faced roll insulation between the retrofit panels and the retrofit purlins will help prevent condensation and roof noise in addition to improving energy efficiency.

To find out more about which retrofit options, or options, are best suited to a particular building that you are involved with, contact your local MBCI representative.

Installing Metal Roofing Over Asphalt Shingles

Can Metal Roofing Be Installed Over Shingles?

When an asphalt shingle roof wears out, one of the most long-lasting solutions is to retrofit the roof with metal panels, and not remove the asphalt shingles.  While it’s a change of appearance, the metal roofing panels will provide a greater durability and longer service life.

UCI
UCI Retrofit Corporate Office installed 7.2 roof panels over the existing asphalt shingle roof

Installing Metal Roof Panels Over Asphalt Shingles

There are a number of considerations when installing metal panels over an existing asphalt shingle roof.  First, the building codes allow metal over shingles if there is only one layer of asphalt shingles.  A third roof is not allowed, so there must only be one shingle roof in place.

If you’re considering installing metal roofing over asphalt shingles, contact us today to learn more about MBCI’s panel systems.

Choosing the Correct Retrofit Metal Roofing System

Fastener choice is important for wind resistance.  As is the pull-out resistance of the deck. The panel thickness (e.g., 24 gauge), panel width, height of the standing seam, spacing between clips, and clip strength all help determine the overall wind resistance of a metal panel recover installation.  Wind design loads are specific to geographic location and height of the building; work with the metal panel manufacturer to determine the design specifications.  Importantly, use fasteners that are long enough to penetrate through the asphalt shingles and the deck by at least ½” to ensure proper strength.UCI_2

 

Because metal panels run from eave to ridge, the flatness of the existing roof can affect the appearance—the waviness—of the metal panels.  Three tab shingles are quite flat versus laminated dimensional shingles.  Consider installing a base sheet or a #30 underlayment over the shingles before installing the re-cover metal panels.  The uneven surface of the asphalt shingles can be telegraphed to the metal panels, leading to an uneven or wavy surface of the new metal panels.  And, like oil canning, it’s not a performance issue, but homeowners don’t want an unsightly roof.  Spending a few dollars on a heavy base sheet/underlayment is cheap insurance to ensure an aesthetically pleasing roof, and that means a satisfied homeowner who is willing to pay for the new roof!

Benefits of Installing Metal Roofing Over Shingles

There’s a sustainable advantage to installing metal over existing asphalt shingles.  Not removing the asphalt shingles not only saves money but also reduces the amount of waste sent to a landfill.  Roofing tear-off is one of the largest contributors to landfill waste in the U.S. And, while there’s a lot of discussion about the reuse of asphalt shingles (i.e., downcycling) in asphalt roads and bike paths, the reality is that much of the shingle tear-off is not actually reused.  For example, the Colorado Department of Public Health and Environment no longer considers asphalt shingle waste to be a recyclable material.  Not because it’s not recyclable, but because there is no significant market for its use.  These ideas will influence some homeowners, so use them when selling the idea of recovering with metal.

Installing metal panels over existing asphalt shingles is a smart choice.  Design it right, and the new metal roof could last the life of the house.

Contact us today to learn more about how our panels can be installed over asphalt shingles.

Reroofing and the Building Code

Reroofing is and always will be the predominant project type in the roofing industry.  Roughly 70-90% of all roofing projects (depending on the year) are performed on existing buildings.  Understanding the reroofing requirements in the building code is critical to proper design and construction.  And fortunately, the reroofing requirements are not all that complicated.International Building Code

The 2015 International Building Code, Section 1511, Reroofing provides the building code requirements when reroofing.  Reroofing projects are divided into two types: recovering and replacement (which includes full removal of the existing roof).

Metal panel reroofing projects must meet the same fire, wind, and impact requirements for roof systems for new construction; however, they do not need to meet the minimum slope requirements (¼:12 for standing seam; ½:12 for lapped, nonsoldered and sealed seams; 3:12 for lapped, nonsoldered, non-sealed seams) if there is positive drainage.  Also, reroofing projects do not need to meet the secondary drainage requirements (i.e., installation of emergency overflow systems is not required).

The requirements for metal panel and metal shingle roof coverings are in Section 1507.4, Metal roof panels and Section 1507.5, Metal roof shingles of the 2015 IBC.  These apply for new construction and reroofing, and include information about decks, deck slope, materials, attachment, underlayment and high wind, ice barriers, and flashing.  The 2012 IBC has the same requirements; the 2015 IBC added new language about deck slope and attachment requirements for metal roof panels.  Nothing was changed for metal roof shingles.

In general, recovering is only allowed if there is one existing roof in place, except if a recover metal panel roof system transmits loads directly to the structural system (bypassing the existing roof system).  This provides a great advantage for metal panel roofs!  The existing roofs do not need to be removed, but new supports need to be attached through the existing roof (typically a metal panel roof) directly into existing purlins.

If metal panels or metal shingles are installed over a wood shake roof, creating a combustible concealed space, a layer of gypsum, mineral fiber, glass fiber, or other approved material is required to be installed between the wood roof and the recover metal roof system.

Good roofing practice is codified in the reroofing section of the IBC; contractors who design and install a recover or replacement metal roof are legally required to follow locally adopted code requirements.  And, of course, all metal roofs must be installed according to the manufacturer’s approved instructions.

When It Comes to Roofing Expertise, It Doesn’t Hurt to Diversify

As is often the case when it comes to your investments, it’s always a good idea to diversify. This also applies to the investment of your construction expertise as a roofing contractor. Even with the mild uptick in new construction activity of late, contractors are smart to explore the additional revenue stream that can come from roof renovations and retrofits.

Example of Retrofit Metal Panel, NuRoofMost metal roof retrofit work entails adding slope to an existing flat- or low-sloped roof.  According to a 2013 article in Metal Construction News, about 25 percent of U.S. commercial, institutional and public buildings are 55 years old or older and consist of flat-roof stock that has reached the end of its service life. Two years later, that percentage is surely higher.

To transition from a flat roof to a sloped roof is a good move, because it will result in lower energy and maintenance costs for years to come.  It is also environmentally smart, because metal is one of the most recycled materials used in construction, and metal roofing is 100 percent recyclable at the end of its service life. A metal roofing system provides for additional insulation, as well as the installation of solar panels that reduce reliance on electricity. And in most circumstances, a new metal roof can be installed without having to remove the existing flat roof. A metal retrofit may carry a higher initial cost, but when total life-cycle cost is considered, a metal retrofit will end up being the lowest cost alternative.

A large number of buildings with flat membrane or built-up roofs require a framing system to produce an adequate slope. But this particular type of retrofit can be challenging. In general, the retrofit market is more specialized and much more technical than what roofing contractors are likely used to in the existing metal building market. At the same time, the retrofit market can be very profitable and is worth getting up to speed on.

Whether you’re doing a small retrofit project or a complete renovation, MBCI can assist you with developing a preliminary budget, estimating, engineering, as well as providing a complete set of shop drawings for your retrofit project.

Stay tuned for future posts where we’ll provide some guidelines on how to successfully navigate the design process of retrofitting a flat or inadequately sloped built-up or membrane roof.  Adding this diversity to your portfolio of roofing skills will likely net a high return on investment.

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