Category Archives: Retrofit

MCA’s New Metal Roof Installation Manual: An Essential Tool for Anyone Working with Metal Roofs

Using the Right Methods, Materials and Tools is Essential to Installing Your Metal Roof Properly
Using the Right Methods, Materials and Tools is Essential to Installing Your Metal Roof Properly

By: John Ryan, Metal Construction Association

Using the right tools is key to getting any job done correctly. Contractors and installers who work with metal roofs know how important it is to have the right seamer or a quality screw gun. And architects and specifiers know how important it is to have a good architectural scale and the most current reference manuals.

MCA Metal Roof Installation Manual
MCA Metal Roof Installation Manual

If you work with metal roofing, MCA has another essential tool for your toolkit: the new Metal Roof Installation Manual. Now available at MetalConstruction.com in the Technical Resources section, this new manual offers 20 chapters of best practices, tips and training for installing metal roofs. The manual covers a full range of useful information about installing metal roofs, including:

  • Introductory information about roofing materials
  • Panel types, attributes and profiles
  • Roof deck substrates
  • Safety
  • Sealants and Fasteners
  • Maintenance
  • Re-Roofing

Download your copy of the MCA Metal Roof Installation Manual today, and keep the document handy as a reference as you come across questions with your metal roof project. It’ll soon become an essential tool in your toolbox.

And the best part about this tool? It’s free!

Visit MCA at the International Roofing Expo in Las Vegas

MCA Exhibits at IREWe’re excited to be heading to Las Vegas next week for the International Roofing Expo (IRE). If you’re at the show, we hope you’ll stop by and visit us in booth #2341. We’ll be at the Mandalay Bay Convention Center in Las Vegas from Wednesday, February 26 through Friday, February 28. We’d enjoy meeting you, and look forward to answering any questions you might have about metal roofing.

Many MCA members will also be exhibiting at IRE next week, as well. Stop by their booths to see the exciting products and services that they offer.

Exhibitor Name                             Member Category                               Booth Number
ABC Supply Co., Inc.                    Distributor                                            1423
Arkema, Inc.                                  Manufacturer                                       562
ATAS International, Inc.                Manufacturer                                       2242
BASF Corporation                        Insulation Mfr                                       925
Drexel Metals                               Distributor                                             2437
Englert, Inc.                                   Manufacturer                                       1037
Fabral                                            Manufacturer                                       2135
Firestone Building Products        Manufacturer                                       1813
GSSI Sealants, Inc.                       Accessories                                         2154
MBCI                                             Manufacturer                                       2121
McElroy Metal                              Manufacturer                                       2349
Metal Construction News            Publication                                          2336
Metal Roofing Magazine              Publication                                          2141
Metal Sales Manufacturing         Manufacturer                                       2127
Metalforming, Inc.                        Equipment Mfr                                     1436
Petersen Aluminum Corp.           Manufacturer                                       842
RHEINZINK America, Inc.            Distributor                                            1722
Roof Hugger                                Accessories                                          742
SFS intec, Inc.                              Accessories                                          1727
Sheffield Metals International    Distributor                                             2259
TAMKO Building Products, Inc.  Manufacturer                                        525
Triangle Fastener Corporation   Accessories                                         2131

We hope to see you in Las Vegas!

In Atlanta, Grab a Moment of Zinc

Holy Innocents Episcopal Church, Atlanta, GA

By: Jane Martinsons, Metal Construction Association

While in Atlanta attending METALCON on Oct 1–3, you may want to check out the recently renovated and expanded Holy Innocents’ Episcopal Church. The sanctuary’s new roof features flat lock zinc panels by Umicore Building Products USA., Inc.,  to help bridge the existing building’s mid-century architecture and  its modern chapel features.

06-2013 Holy Innocents 04d WEBAccording to project architect Bob Balke of TVS Design, Atlanta, zinc was selected to replace an existing asphalt shingle roof because of its longevity and clean, authentic appearance. As one of the few metals to naturally develop a protective patina, zinc also

• promotes a lengthy structural lifespan through its ability to withstand harsh elements

• “self-heals” imperfections, which keeps the metal looking better longer

• is recyclable at the end of its useful life.

06-2013 Holy Innocents 17d WEBWhile there, be sure to note the complex roof slopes and valleys, and gutters at the prow of the roof. (Zinc gutters formed by using masked stainless steel clips conceal the gutter system.) Other notable features include the sanctuary’s exposed steel structure, structural red oak wood in the decking and ceiling, an aluminum veneer curtain wall system, and a continuous ribbon vaulted skylight.

Once inspired, it’s time to head back to the show to network with colleagues and learn more about the latest in metal. See you there!

“Cool” Roof Retrofit Earns Praise for Energy Efficiency

By: John Ryan, Metal Construction Association

Sometimes the word “cool” can be a bit overused–but not in the case of this recent metal roof retrofit project with the U.S. Air Force’s Goodfellow Air Force Base in Texas. This roof is cool–both literally and figuratively.

In 2010, a team of leading metal construction companies and the Metal Construction Association (MCA) were awarded a $1 million Environmental Security Technologies Certification Program (ESTCP) grant to develop a retrofit metal roof system with integrated renewable energy technologies, including an integrated assembly of six different roofing system components.

View the video above or read MCA’s case study to learn more about the project’s energy-efficient technologies, which include photovoltaics to generate electricity, solar-thermal technologies for domestic hot water and space heating, and rainwater capture for irrigation.after photo WEB

The Department of Energy’s Oakridge National Laboratory will soon be analyzing a full year’s worth of data on heat transfer, energy output from the photovoltaic panels and water usage from the building. MCA expects that the results will be positive, and the Air Force reports that preliminary numbers how a 44-percent reduction in energy consumption.

Stay tuned for the full report and results in the coming months from this “cool” project.

Shipping Containers Find New Life in Metal Construction

Monterrey Technical University - Student Center
Student Center, Monterrey Technical University, Juarez, Mexico

By: John Ryan, Metal Construction Association

Fortune Magazine recently featured a story about Starbucks’ use of shipping containers in the design of their new drive-through coffee shops. According to Fortune, a good portion of the 900 or so drive-through locations that Starbucks plans to build in the next five years will be made using retrofitted metal shipping containers.

The use and repurposing of metal shipping containers in construction is a growing trend, even though they are not always less expensive than other manufacturing methods.  And re-using a metal shipping container that would otherwise be destined for the scrap heap can make a statement about sustainability, especially when used with other “green” building efficiencies.

MCA’s 2012 Chairman’s Award Winner in the Education-Colleges & Universities category is a creative example of how shipping containers can be used in construction. The project, a student center for Monterrey Technical University in Juarez, Mexico, was designed by Ruben Escobar, a graduate of MTU and principle at the architecture firm Grupo ARKHOS.

Monterrey Technical University 1 WEBThe student center uses 14 metal shipping containers to make a 7,000 sq. ft. space for students to  interact socially. With exposed metal making up 80% of the new building’s structure, Escobar integrated a metal skin composed of Reynobond composite aluminum panels around the building’s entrance. The 4-mm panels from Alcoa Architectural Products proved to be a perfect complement to the shipping containers, and also were chosen for their durability.Monterrey Technical University 2 WEB

Not only is the new building constructed primarily of recycled materials, but it also is designed to keep cooling costs low. An outdoor paint scheme that uses automotive paint mixed with ceramic nanospheres helps repel the desert sun’s rays, and  a series of aluminum and glass garage doors open up to provide natural ventilation about 8 months out of the year.

It is estimated that there are more than 17 million shipping containers in the world today. Because the United States imports far more than it exports, there is a surplus of empty shipping containers in this country. Metal shipping container-inspired architecture is just one way to give new life and purpose to these resources.

Kriner to Present at Energy Efficient Roofing Conference on April 8

Energy Roofing Conference LogoAttending the Energy Efficient Roofing Conference in Charlotte, NC, next week? Don’t miss Scott Kriner’s presentation on the integrated energy efficient metal roof retrofit system at Goodfellow Air Force Base, San Angelo, TX.

“This Department of Defense (DOD) demonstration project is a result of the $1 million Environmental Security Technology Certification Program grant, which was awarded to a team of industry professionals representing metal roofing, retrofitting, solar technologies, insulation, and the Metal Construction Association  (MCA),” said Kriner, MCA technical director. Results of the installation are expected later this year.

Kriner will be presenting on Monday, April 8, from 3:50–4:10 pm. At 4:30 pm he will serve as a panelist in a Q&A session.

Metal Construction Blogs Provide Valuable Perspective

By Cathy Szmurlo, Metal Construction Association

Several members of the Metal Construction Association, which consists of manufacturers and suppliers of metal roof and wall components, have jumped on the blogging band wagon. By adding their input on products, projects, industry issues and current events to the blogosphere, these companies are providing a valuable resource to architects and building owners. We hope you’ll check out these members’ blogs for additional insights, and add them to your reading list:

  • Alpolic Mitsubishi Plastics Composites America – Descriptions of company case studies, news and projects as well as views on compelling metal architecture, design and sustainability projects.
  • American Iron and Steel Institute – Institute news and viewpoints on national and international issues affecting the steel industry.
  • Classic Metal Roofing Systems – Issues and benefits regarding metal roofing for residential building projects.
  • Copper Development Association – News and views regarding the use of copper in specific industry categories, including building construction.
  • Drexel Metals — Photos and videos along with viewpoints on company metal roofing products and projects.
  • Englert  – Metal roof and wall panel project commentary and insight on industry issues.
  • Kingspan – News and winning entries for Generation Kingspan™ Student Architectural Competition – a competition for students of architecture.
  • MBCI – Insights on metal roofing and wall issues such as the green movement, LEED, solar roofing and PV.
  • Metal Construction News – Industry news and views from publication staff.
  • Metalforming USA – Company and industry news from architectural machinery manufacturer.
  • Metalmag – Metal construction industry viewpoints from online magazine.
  • Miller Clapperton – Company, project and business opinion from this MCM fabricator.
  • Petersen Aluminum – Descriptive project articles and photos on a variety of company metal roofing projects.
  • Rigid Global Buildings – Company news and events from this metal building, roof and wall panel manufacturer.

DOD + Metal Retrofit = Energy Efficiency

The United States Department of Defense (DOD) is a leader in energy efficiency for good reason—it is mandated to reduce energy use on its properties by 30% by 2015 and by another 37.5% by 2020. Three years ago, a team of leading metal construction companies and the Metal Construction Association (MCA) were awarded a $1 million grant to develop a retrofit metal roof system for a DOD building with integrated renewable energy technologies. Today, Goodfellow Air Force Base in San Angelo, TX, boasts a retrofit metal roofing system that integrates a host of solar energy-saving technologies and the ability to capture rainwater for irrigation purposes. View the case study of the project for more complete information.Goodfellow AFB

The Department of Energy’s Oak Ridge National Laboratory (ORNL) is monitoring the building’s temperature and heat information. According to Scott Kriner, MCA technical director, both the DOD and the project team “are confident that this integrated retrofit roof system will perform as predicted and allow for the technology to be transferred throughout the DOD, to other federal agencies, and into the commercial-building sector.”

ORNL should be completing a year-long study of the building’s energy data in 2013 to quantify the impact of the metal roof retrofit project. Stay tuned–we will post more information to this site as it becomes available.

Take the Long View with Metal Roof Retrofit

By Mark James, RetroSpec, LLC.

St. Louis, MO steel roof systemsIf anyone understands long-term life cycles, it’s a cemetery owner. I know one in St. Louis, MO, who owns two large, old mausoleums that stand side by side. One mausoleum has steel and copper roof systems that have remained relatively maintenance- and repair-free—and beautiful—for as long as 80 years. The other mausoleum has a flat-roof addition, built in 1986, which has a conventional roofing system that has been plagued by leaks for decades.

After determining the life-cycle costing and return on investment on the two roofs, it’s not surprising that the owner decided to retrofit the flat-roof addition with a metal roof. He anticipates far fewer worries with a metal roof, given its ability to shed rainwater and its 40- to 60-year service life.Retrofitting 40 year old roof with steel and copper

In addition to its longevity and durability, metal retrofit also offers long-term cost-savings in the form of appreciable value of the building, better insurance rates, and energy-efficiency. Adding insulation to a metal retrofit can provide R30 thermal resistance—one reason why you increasingly see them on military and municipal buildings, including schools. Many building owners choose to add renewable solar energy technologies to these roofs, such as photovoltaics or solar hot-water systems, which can reap huge tax benefits.

For designers and architects, metal retrofits add generous curb appeal to buildings. Architectural metal roofs are meant to be seen, and a stunning sloped metal retrofit is seen far and wide—and well into the future.

Mark James is president of RetroSpec, LLC, Dallas, TX. He can be reached at mark@retrospecllc.com.

School Construction Trending Towards Metal

By: John Ryan, Metal Construction Association

My daughter just started kindergarten this fall, and picking her up from school each day often reminds me of my days in grammar school. The brick-walled schools that I attended years ago are still in use today (they seemed so much bigger back then), and still providing students with a great environment in which to learn.

But just as I am reminded that every year I am getting older, there are reminders that the country’s thousands of school buildings are aging, too. Many are being replaced with new, state-of-the-art schools, and many more are being retrofitted to make them current with the latest education, technology and energy standards.

Retrofitted High School
William Allen High School, Allentown, PA

And with more frequency than in the past, those familiar brick walls are being upgraded and replaced with new, energy-efficient metal walls and roofs. Take, for instance, the Metal Construction Association’s newest case study on the William Allen High School in Allentown, PA. The school—originally constructed with brick masonry—had outgrown its existing space, so they built a new addition on an adjacent lot. The exterior of the new building is a combination of brick and metal panels, with the majority of wall surfaces being insulated metal panels (IMPs).

The metal complements the brick aesthetically—a trend that we are seeing more and more of—and it helped the new building attain LEED gold certification. Not only are the IMPs energy-efficient, but the added benefit of quick installation (IMPs allowed the building to be enclosed with insulation and the finished panel in one shot) made them an ideal choice for this project.

Check out our case study library for additional examples of how schools—new and old—are making use of metal walls and roofs.