10 Signs It’s Time to Retrofit Your Metal Building Roof
Your metal building roof is your first line of defense against the elements—and while metal roofs are known for their durability, they’re not immune to time, wear, and weather. Eventually, every roof reaches a point where patching it again just isn’t enough. That’s where a retrofit comes in.
A retrofit roof allows you to install a new, high-performance metal roof system right over your existing one—without costly tear-offs or extended downtime. If you’re not sure whether it’s time to make that move, here are 10 clear warning signs to watch for—and what a Butler retrofit can do to solve them.
1. Chronic Leaks Are Impacting Operations
If water is infiltrating your building during heavy rains, it’s a red flag. Leaks can stem from degraded sealants, aging fasteners, panel rust, or poorly aligned seams. Over time, even small leaks can damage insulation, rot interior finishes, or create safety hazards. Butler retrofit systems like the MR-24® standing seam roof eliminate exposed fasteners and use a 360° Pittsburgh double-lock seam—proven to stay watertight through decades of rain, wind, and thermal movement.
Did you know? The MR-24's seam is the same double-lock method used to seal soda cans. It’s tested to handle extreme pressure and has over 2 billion square feet installed worldwide.
2. Ponding Water or Sagging Roof Areas
Flat or low-slope roofs may begin to sag over time, creating areas where water collects. Standing water accelerates corrosion, promotes microbial growth, and adds extra weight. Butler’s slope build-up retrofit solution solves this by engineering a new roof pitch directly over your existing system. It increases drainage, reduces long-term water damage risk, and enhances the building’s appearance.
3. Roof Repairs Are Frequent and Costly
A roof that’s constantly being patched is more than just a nuisance—it’s a money pit. Emergency repairs can add up quickly, especially if they require interior cleanup or downtime. Rather than continue paying for short-term fixes, many building owners save money long-term by investing in a retrofit system that includes a new warranty, upgraded materials, and extended life.
Fact: Butler retrofit roofs are known to last 40+ years with minimal maintenance, significantly lowering lifecycle costs compared to repeated patchwork.
4. Heating and Cooling Bills Are Too High
Older metal roofs often lack modern insulation. Gaps, compressed batting, or missing vapor barriers can lead to significant energy loss. Retrofitting offers an opportunity to drastically improve energy efficiency. Butler’s ThermaLiner and TBS insulation systems allow you to add blanket or rigid board insulation—achieving tested R-values as high as R-38.7.
Surprising stat: Uninsulated or poorly insulated roofs can account for up to 25% of total energy loss in a commercial building.
5. Your Roof Panels Show Visible Rust, Fading, or Deterioration
Metal fatigue, rust spots, fading paint, and cracked sealants are all signs that your roof is nearing the end of its service life. Retrofitting allows you to upgrade to roof panels finished with Butler-Cote™—a premium 70% Kynar 500® or Hylar 5000® resin coating that resists chalking and fading for 25+ years.
Bonus: These finishes also meet ENERGY STAR® cool roof standards, potentially qualifying your building for LEED® points.
6. Roof Fasteners Are Backing Out or Missing
Thermal expansion and contraction can cause screws to loosen, especially in exposed-fastener systems. Once fasteners back out, water infiltration becomes a real risk. Butler’s retrofit systems use hidden fasteners, floating clips, and return-leg designs to secure panels while allowing the system to move naturally with temperature shifts.
Butler Scrubolt™ fasteners are also available, offering up to twice the pull-out strength of standard self-drillers.
7. You Can’t Afford to Shut Down for Roof Work
Tearing off an old roof means exposing your interior to the weather, dust, and delays. Retrofitting allows crews to install the new system directly over your current roof—with no tear-off required. This keeps your building operational, reduces the risk of downtime, and speeds up the project timeline.
Real-world benefit: Many Butler retrofit projects are completed without halting factory, warehouse, or retail operations.
8. The Building Looks Dated or Unattractive
A retrofit can dramatically modernize your building’s exterior. Butler building systems offer clean architectural lines, standing-seam profiles, and steep-slope upgrades. Combined with new color options and high-gloss finishes, a retrofit doesn’t just protect your roof—it transforms your building’s curb appeal.
9. Previous Expansions Created Transition Issues
Has your building grown over the years? If you’ve added on to your structure but kept the original roof, chances are you have awkward transitions and vulnerable seams. Butler retrofit systems allow you to unify your roof into one integrated, weathertight system—eliminating transition leaks and creating a continuous thermal envelope.
10. Your Roof Is Over 20 Years Old
Even well-installed metal roofs have a service life. Once your roof hits the 20- to 30-year mark, issues like sealant failure, rust, and thermal bridging become more common. A proactive retrofit can give your building a fresh 25+ years of performance, with warranty-backed protection and higher energy efficiency.
Fast Fact: Butler’s retrofit MR-24® roof systems often outlive original roof systems and carry warranties up to 25 years for weathertightness.
Bonus: A Retrofit Is a Sustainable Choice
Instead of tearing off and landfilling your old roof, a retrofit lets you build on top—reducing waste and conserving materials. Butler roofs are made from recyclable steel, support solar installations, and qualify for LEED® credits through reflective coatings, energy efficiency, and material reuse.
Time To Retrofit?
If any of these signs apply to your building, it may be time to start planning a retrofit. At Butler MFG Parts, we supply genuine Butler Manufacturing roof components, retrofit kits, fasteners, insulation, and accessories. We're also Kansas City's Butler Builder, so we're experts in construction of Butler products.
Let us help you modernize your roof with proven systems trusted on over 2 billion square feet worldwide. Ready to protect your building for the next 25+ years? Let’s talk.