6 Smart Ways to Upgrade an Aging Butler Building
If your Butler building is more than 25 years old, chances are it's functioning very well, but there are likely some updates that could be made. Whether it's rising energy bills, persistent roof leaks, or outdated finishes, aging metal buildings can cost you more than you think.
The good news? You don’t need to start from scratch. Butler buildings were designed with long-term service in mind. With the right upgrades, you can breathe new life into an older structure and bring it up to modern standards—for far less than the cost of new construction.
From precision-engineered roof replacements to thermal insulation systems and daylighting, here are 7 ways to upgrade your Butler building and protect your investment for the next 20+ years.
1. Reroof with the Industry-Leading MR-24® Roof System
The roof is the first—and most important—line of defense in any metal building. Over time, older roofs can develop leaks, corrosion, and structural weaknesses, especially if they use exposed fasteners or lack flexibility for thermal expansion.
The MR-24® roof system is Butler’s flagship standing seam roof and one of the most trusted solutions in commercial roofing—installed on over 3 billion square feet globally.
Why MR-24® is a superior reroofing solution:
- 360° Pittsburgh Double-Lock Seam: Field-formed using a portable seaming machine, this seam is the tightest in the industry, sealing out water and wind—even in extreme conditions.
- Floating Roof Design: Custom clips allow up to 2.5" of thermal expansion and contraction, preventing stress that leads to leaks or fatigue over time.
- Factory-punched components: Roof panels and structural members are precision-punched to ensure perfect alignment and faster, error-free installation.
The retrofit process:
Butler’s slope build-up or metal-over-metal systems allow you to install an MR-24® roof over your existing one—virtually eliminating tear-off costs, business disruption, and landfill waste. Structural sub-framing can be added to increase pitch or remove problem areas like internal gutters.
Bottom line: This is an incredibly reliable way to turn an aging roof into a high-performance, low-maintenance asset + a 25-year weathertightness warranty to back it up.
2. Boost Energy Efficiency with the ThermaLiner™ Insulation System
Older metal buildings often underperform when it comes to insulation. That’s not surprising—energy codes have advanced dramatically over the last two decades. The ThermaLiner™ system is Butler’s advanced insulation upgrade that meets or exceeds modern code requirements and drastically cuts energy waste.
Key performance features:
- R-values up to 41: Uncompressed blanket insulation with a steel interior liner delivers tested, in-place performance, not just theoretical ratings.
- Vapor barrier protection: The continuous liner helps prevent condensation and protects the insulation from internal moisture and damage.
- Durable, cleanable finish: Available in painted or Galvalume® finishes, the interior surface looks great and resists abuse in warehouse or industrial environments.
Installation process:
- The steel liner panel is installed first, providing temporary enclosure and a safe work surface.
- Blanket insulation is layered above the liner, up to 13" thick.
- The roof system (such as MR-24® or Butlerib® II) is installed on top.
Because the liner panel spans across framing members, it acts as a diaphragm—reducing the need for bracing and speeding up construction.
Why it matters: Buildings with ThermaLiner can cut HVAC loads significantly and often qualify for utility rebates or LEED® points.
3. Upgrade Wall Performance with Butlerib® II or EX Wall Systems
Wall panels are among the most visible components of a building—and some of the most neglected during maintenance cycles. If your wall panels are faded, damaged, or inefficient, it’s time for a change.
Two great upgrade options:
- 1½" deep corrugations for superior strength
- Available in 26 or 24 gauge steel
- Factory-punched for faster installation and perfect fit with other Butler systems
- 25-year Butler-Cote™ finish warranty
- Features a metal stanchion system that increases insulation depth without compression
- Exceeds the thermal performance of a 2.5” insulated metal panel (IMP) using standard blanket insulation
- Tested U-factor: 0.047 (R-21+ equivalent)
- Easier to transport and install than IMPs
Upgrade benefits:
- Meets new ASHRAE 90.1 or IECC energy codes
- Cuts heating and cooling costs year-round
- Gives your building a fresh, modern appearance
4. Add Daylighting Systems
Many older buildings rely entirely on artificial lighting, leading to higher energy bills and poor interior visibility. Daylighting translucent roof panels can solve both issues—naturally and efficiently.
Why it’s worth it:
- Reduces lighting energy use by up to 50%
- Admits diffused natural light, reducing glare and shadows
- Seamlessly integrates with MR-24® and Butlerib® II roof systems
How it works:
Daylighting units are installed in the roof as translucent panels that align with the metal panel profile. These panels are UV-stabilized and available in various light transmission ratings.
Result: Better visibility, enhanced productivity, and lower electricity costs—with no sacrifice in weather resistance.
5. Cool Roof Finish Upgrades with Butler-Cote™
Many buildings built before 2005 used standard polyester coatings that chalk and fade with time. Butler Manufacturing's Butler-Cote is a level above - a premium 70% PVDF fluoropolymer finish with high solar reflectance.
(Solar Reflectance Index (SRI) is a measure of how well a roofing material reflects solar radiation and emits absorbed heat)
Available in “cool roof” colors with SRI ≥ 29:
- Cool Solar White (SRI 87)
- Cool Shell Gray (SRI 63)
- Cool Marsh Green (SRI 33)
…and more
These coatings are:
- Fade and chalk resistant (25-year warranty)
- Energy Star® rated
- Qualify for LEED® Heat Island Effect credit
Cool roof finishes reflect sunlight instead of absorbing it, reducing indoor temps and cooling costs—especially critical for warehouse or manufacturing facilities.
6. Reseal Roof Penetrations with Butler’s Engineered Roof Curbs
Up to 80% of leaks in older metal roofs come from improperly flashed penetrations like HVAC curbs, skylights, vents, and hatches. Butler's patented Internal Flange (IF) Roof Curb System solves this permanently.
Why it works:
- Concealed fasteners inside the curb flange eliminate exposed screw heads that corrode over time
- Curb base floats with the roof system, allowing for movement during thermal cycling
- Pre-engineered for MR-24® and Butlerib® systems
No more field-engineered curbs or emergency patch jobs—just a clean, sealed, long-lasting solution designed to integrate into your roof system.
Ready to Upgrade?
Your Butler building was built to last. But even the strongest systems need a performance boost over time. With the right upgrades, you can reduce costs, improve comfort, and extend your building’s useful life—often without interrupting your operations.
At ButlerMFGParts.com, we stock authentic Butler parts, roof systems, wall panels, insulation, fasteners, and other Butler accessories. Whether you’re upgrading one component or doing a full building modernization, we’re here to help you get it done right.