The Top 5 Mistakes in Metal Building Re-Roofing Projects
Avoid These Common Pitfalls to Get the Best Roof for the Long Haul
Re-roofing a metal building might sound simple: just pull off the old panels and put on new ones, right? Not quite. Metal building re-roofing is a major investment—and getting it wrong can lead to leaks, wasted money, energy loss, or worse. At Butler MFG Parts, we’ve seen what works, what fails, and how to avoid costly errors.
Here are the top 5 mistakes to avoid when re-roofing a metal building—and what you should do instead to ensure long-term performance.
1. Not Accounting for Thermal Movement
Why it matters:
Metal expands and contracts with temperature changes. A 100-foot steel roof panel can move nearly 1 inch with a 100°F swing. In parts of the country with hot summers and freezing winters, this expansion can stress panels, pull out fasteners, and cause leaks.
The mistake:
Many re-roof projects use panels and fasteners that lock the system in place, preventing natural movement. Over time, this leads to warped panels, torn fasteners, and leaks—especially around roof curbs and penetrations.
The solution:
Choose a system like Butler’s MR-24® standing seam roof, which uses floating clips and factory-punched panels to allow up to 2.5 inches of expansion without damage. It’s the only system with a 360° Pittsburgh double-lock seam, the same type of seal used in soft drink cans.
2. Using the Wrong Fasteners or Panel System
Why it matters:
Not all roof fasteners are created equal. A standard self-drilling screw might work short-term, but it can back out over time, especially with wind or roof traffic.
The mistake:
Cutting corners by using generic fasteners or trying to patch a standing seam system with through-fastened panels like R-panels or corrugated sheets. These mismatched systems don’t hold up together and almost always lead to failures at the seams or panel edges.
The solution:
Butler’s proprietary fasteners—like the Scrubolt™, which has twice the pull-out strength of standard fasteners, and the Lock-Rivet™, which doesn’t loosen over time—are specifically engineered for long-term performance. When re-roofing, match panel systems and fasteners to the building’s design and climate.
3. Misaligned Panels and Weak Splices
Why it matters:
Roof performance depends on tight, accurate panel alignment. Misaligned seams and unsupported splices are common in rushed re-roofing jobs and lead to uneven seams, ponding water, or leaks—especially under foot traffic or heavy rain.
The mistake:
Many roofing contractors cut and punch panels on-site, leading to human error. Even small misalignments can throw off the entire roof’s water-tightness and make it hard to seal trim or accessories.
The solution:
Use factory-punched panels and structurals that align perfectly every time. Butler’s MR-24® and Butlerib® II systems are punched and cut at the factory for fast, accurate installation. Splices are designed to fall directly over structural members, not “in midair” like many systems, ensuring full support and better weather resistance.
4. Skipping Insulation and Vapor Upgrades
Why it matters:
Roof replacements are the perfect time to boost energy efficiency—but many building owners miss the opportunity. Poor insulation leads to higher heating and cooling bills and moisture issues like condensation or mold.
The mistake:
Installing a new roof over outdated or compressed insulation—or worse, no insulation upgrade at all.
The solution:
Consider systems like the ThermaLiner™ insulation system, which can deliver R-values up to 38.7 and provide a clean, durable interior finish. Or go with the TBS™ above-the-purlin system, which installs faster and avoids punching the vapor barrier, preserving energy efficiency and air quality.
5. Overlooking the Benefits of Slope Build-Up Retrofit Systems
Why it matters:
Flat or low-slope roofs are more prone to ponding water, leaks, and structural wear. Simply re-covering these roofs without improving drainage is a missed opportunity.
The mistake:
Choosing a metal-over-metal re-roof or single-ply overlay without improving slope, which doesn’t solve long-term water management issues.
The solution:
Install a slope build-up retrofit system, like Butler’s fully engineered slope framing solution. These systems add proper pitch (up to 30°), improve drainage, and allow for new insulation—without tearing off the old roof. It’s a greener, cleaner way to boost performance, extend roof life, and even enhance building aesthetics.
Common Mistake | Why It Fails | What to Do Instead |
Ignoring thermal movement | Panels warp or tear due to seasonal expansion and contraction | Use floating systems like MR-24® that allow for up to 2.5" of thermal movement |
Using mismatched fasteners or panel systems | Leads to leaks, loosening over time, or incompatible performance | Specify full-system Butler parts like Scrubolt™ or Lock-Rivet™ for matched strength and fit |
Poor panel alignment or splice placement | Causes leaks, seam stress, and failure under roof traffic | Choose factory-punched panels and ensure all splices are over structural support |
Skipping insulation/vapor upgrades | Missed energy savings, risk of condensation or mold | Add ThermaLiner™ or TBS™ systems to meet or exceed code-compliant R-values |
Replacing without fixing slope/drainage | Water ponds, leaks continue, roof wears out again | Use a slope build-up retrofit system to improve drainage and increase energy performance |
Bonus Tip: Don’t Cut Corners—Choose a Full-System Approach
Butler’s re-roof systems are engineered to work together—roof panels, fasteners, trims, curbs, insulation, and even fall protection (Sky-Web®). Choosing parts from multiple suppliers might save money upfront, but it often leads to headaches down the road. A full-system approach means better warranties, faster installation, and long-term peace of mind.
Wrapping Up
Metal roof replacements are not just about putting on new panels—they’re about doing it right so your building stays protected, efficient, and leak-free for decades. Avoid these 5 costly mistakes, and you’ll get a roof that’s not only durable, but also smart, sustainable, and cost-effective. Have any questions? Need any parts for your Butler roof replacement? Reach out!