Metal Roof Replacement Texas

Isolated leaks and local damage on an otherwise sound roof are repair work. Replacement becomes the better route when several of these apply:

• corrosion has eaten through the panels or the laps across large areas, not just at the edges;
• fastener leaks are everywhere and keep returning after repair;
• the insulation below is wet, sagging or falling away from the panels;
• purlins or supports have corroded and need repair or replacement themselves;
• hail or wind damage is spread across the roof rather than limited to a few panels;
• the roof is too damaged, too heavy or too irregular to take a retrofit framing system above it.

Age alone is not a reason to replace a roof. A 30-year-old roof in good order can often be restored; a 10-year-old roof that was badly detailed may not be worth saving. The decision comes from the condition we find.

R-panel and PBR roofing

R-panel and PBR are exposed-fastener panels with 36 inches of coverage and trapezoidal ribs at 12 inches on center. PBR adds a purlin bearing leg at the side lap for a stronger overlap. They are economical, quick to install and common on metal buildings, workshops and agricultural buildings. Their weak point is the screws and laps, so fastener type, washer quality, lap sealing and closures matter.

Standing seam roofing

Standing seam panels are fixed with concealed clips, and the seams are snapped or mechanically folded together above the water line. The clips let the panels expand and contract with temperature, which matters on long Texas roof runs. With no exposed fasteners through the weather surface, standing seam suits buildings that want a longer-lasting roof with less maintenance and roofs at lower slopes.

Insulated metal roof panels

Insulated metal panels combine an outer metal skin, a foam insulation core and an inner metal face in one factory-made panel. They suit cold storage, food buildings and any roof where insulation and a clean interior finish are wanted in one layer. See insulated metal panels.

Gauge, coating and color

Panels come in different steel thicknesses (26, 24 and 22 gauge are common) and with a metallic coating such as Galvalume underneath a paint system. Silicone-modified polyester and PVDF paint systems are the usual choices. Lighter and reflective colors keep a Texas roof cooler; the panel manufacturers publish reflectance and emittance values for each color.

With the roof open, the insulation can be replaced or upgraded properly. On metal buildings this is usually faced fiberglass blanket draped over the purlins, or a liner system that holds a thicker layer. Thermal blocks at the purlins reduce heat loss through the supports.

The facing or liner acts as the vapor retarder. Its seams and edges need to be sealed so warm, humid inside air does not reach the cold underside of the roof sheets and condense. If the old roof dripped on cold mornings, the new design should solve the cause, not just replace the insulation.

The roof comes off in sections, and each section is closed in before the next is opened. The size of each area depends on the weather forecast, panel lengths and what is underneath. We plan:

• which areas are worked first, so production lines, stock and offices are protected;
• temporary protection for anything sensitive below an open section;
• crane or lift positions, delivery times and storage for new panels;
• removal and recycling of old metal;
• a weather-tight finish at the end of every working day.