By The Coffee Shops™.  

Understanding common retrofit approaches and the risks they can create. 

Building owners looking to extend the life of an existing metal roof are often presented with several retrofit options. Not all approaches provide the structural performance needed to withstand wind uplift, snow drift loads and other demands placed on a modern roofing system. Roof Hugger emphasizes that proper installation and structural design play a critical role in long-term roof performance. 

One common mistake is the use of hat sections installed over existing metal roof ribs. Because only one screw may connect directly to the existing purlin while another fastens into thin metal panels, the system can lack sufficient pull-out strength. Long attachment screws may also be exposed to movement that can contribute to fastener fatigue over time. 

Another frequently seen concern is the use of wood purlins over existing roof ribs. In addition to similar attachment concerns, pressure-treated wood can be corrosive when it comes into contact with metal roofing components. Increased fastener requirements can also add labor and material costs. 

Stand-off clip systems can also present an issue. These systems may face challenges when building codes require tighter purlin spacing in roof corners and edge zones. In those situations, additional structural support may be needed to address higher wind-load requirements. 

Coatings and thermoplastic polyolefin (TPO) systems must also be carefully considered. Coatings do not address updated code requirements for wind or snow loads, while TPO systems require careful attachment design and do not add structural strength to an existing roof. In addition, TPO systems have a shorter service life than metal roofing systems, reducing their long-term value. 

Ultimately, retrofit decisions should be evaluated not only on initial cost but also on structural integrity, code compliance and long-term performance. 

Learn more about metal retrofit roofing approaches and the structural considerations involved.

By The Coffee Shops™. 

How to determine which option is right for the job, and what each option has to offer.  

When contractors meet with building owners to discuss an aging metal roof, the conversation often comes down to two possibilities: recover the roof with a thermoplastic polyolefin (TPO) system or retrofit it with a new metal roof. In an episode of Roofing Road Trips®, Heidi Ellsworth sat down with Roof Hugger founding partner, Dale Nelson, to discuss the strengths, limitations and long-term implications of each approach. 

Dale unpacked why TPO holds appeal for many building owners. “One of the big positives of TPO is that it's less expensive,” he said. He went on to explain that TPO can be a practical option for low-slope roofs and buildings with numerous penetrations, various rooftop equipment or complex design needs. He also noted that these systems can incorporate insulation and provide a reflective surface that contributes to energy efficiency. 

Still, Dale believes that contractors should help owners understand that cost is only one part of the equation. “TPO is going to last you 18 to 25 years,” he said, while adding that metal roofing systems can deliver significantly longer service lives. “Metal is simply going to outlast any other roofing material out there, so it's an investment no question.” 

The discussion also touched on sustainability and future flexibility. Dale contrasted the average 70% recycled content of steel roofing with that of TPO which is around 4½%.  He highlights the ability to add photovoltaic systems to standing-seam metal roofs years later in a building's life cycle. “It's a solar-ready roof,” he noted. 

For contractors, the key takeaway is understanding a building owner's goals before recommending a system. Budget, expected ownership timeline, roof configuration and future building value can all influence the decision. 

Ultimately, Dale encouraged contractors and owners to look beyond initial installation costs and consider potential TPO overloading, code compliance, long-term performance, maintenance requirements and lifecycle value when evaluating roofing options. 

Listen to the entire podcast or Watch the video to learn more about TPO and metal retrofit roofing options. 

By Emma Peterson. 

How Roof Hugger introduced retrofit roofing as an alternative to metal tear offs and coatings. 

Founded 35 years ago, Roof Hugger has made a name for themselves fabricating metal retrofit solutions. To learn more about the story of how this innovative company came to be, Heidi J. Ellsworth sat down with Roof Hugger president Dale Nelson for an episode of Roofing Road Trips®. 

The story of Roof Hugger begins in 1991 with Dale and his partner Red McConnohie. Dale recalled:  

Red had this idea that we could make some kind of bracket that, when installed, would allow you to put a new metal roof over the old one. So, we came up with the concept of this Z shape with little notches in it that matched the configuration of the old roof. And it allowed us to put new metal panels right on top of the old one.  

Once the concept was proven (which Dale and Red did by testing it on one of Red’s own properties), they brought in Terry Wolfe to help them make sure they were engineering everything in the best way possible. Dale shared, “We were fortunate early on to have very good engineering guidance from Terry. He was incredibly helpful in getting us to understand metal panel design, which we had to understand fully so that we could design our retrofit assembly accordingly.” 

This may appear to be a lot of work and fuss for one product, but the Z clamp that the Roof Hugger team created was more than just another product, it was a revolutionary innovation. Dale explained, “Traditionally, there were two ways to repair or replace an old metal roof – tearing it off or coating it. And both methods have their downsides. Tear offs are often very wasteful and time consuming while coatings struggled to address deep structural problems. What we did with Roof Hugger was create a third option – retrofitting. There wasn’t really a retrofit industry before us.” 

Listen to the podcast or Watch the recording to learn more about how Roof Hugger’s metal retrofit solutions work. 

Ten companies have been committed to METALCON and the industry from the beginning.

When the industry gathers in Orlando for METALCON this fall, the Legacy 10 will be honored for exhibiting at every show, dating back to 1991.

With that kind of long-term commitment comes worthy recognition. The Legacy 10 will be honored in a variety of ways leading up to and at the show, scheduled for October 7-9 at Orange County Convention Center.

AkzoNobel, ATAS International, Atlas Bolt & Screw, AZZ Precoat Metals, Englert, Metal Construction News, McElroy Metal, Metal Rollforming Systems, PPG and Roof Hugger make up the Legacy 10. To learn more about the Legacy 10 visit www.metalcon.com/legacy10.

“These companies have supported METALCON from the very beginning and, in many ways, helped build the event into what it is today,” says Judy Geller, VP trade shows, METALCON. “Their continued commitment reflects not only the value of face-to-face business, but also their investment in advancing the metal construction industry.

“There is an abundance of marketing options for the manufacturers and suppliers in our industry. So, the long-term consistent commitment to METALCON by these industry leaders makes METALCON and our industry stronger.”

“We were an early member of the Metal Construction Association, a half-owner of the tradeshow,” says Dale Nelson, president of Roof Hugger. “Tom Black set up an educational program for attendees and we were quick to volunteer to show folks it was possible to retrofit an existing metal roof.”

Roof Hugger has annually been a participant in live demonstrations at METALCON, including solar panels being installed on metal roofing.

“For a company like ATAS International, exhibiting at METALCON is important because it places us at the center of the metal construction industry’s most influential gathering,” says Lee Ann Slattery, FCSI, CDT®, CCPR, LEED AP BD+C, sales support manager at ATAS. “METALCON is recognized as the largest international event dedicated exclusively to metal construction and design, bringing together architects, contractors, distributors, fabricators, manufacturers and building owners from around the world.”

Trade shows attract decision makers and METALCON specifically welcomes these architects, specifiers, roofers and builders.

“For Atlas Bolt & Screw, METALCON has always been more than a tradeshow,” says Don Bratcher, vice president of sales for OEM, Atlas Building Products. “It’s a critical touchpoint with the people and the industries we serve. As a longtime exhibitor, we find METALCON a unique opportunity to connect face-to-face with contractors, fabricators, manufacturers and industry partners who rely on fastening solutions every day.”

METALCON attendees cover the full metal construction ecosystem: contractors, designers, fabricators, manufacturers, suppliers and professionals, the entire gamut of customers for exhibitors.

“It allows us to put the Englert brand directly in front of a highly targeted, qualified audience of architects, contractors and metal construction professionals,” says Jonathan Giacchi, B2B marketing manager, Englert. “METALCON provides a captive audience of decision makers who are actively evaluating products and solutions, making it one of the most efficient channels to build brand awareness, reinforce market positioning and influence specification and purchasing decisions.”

Trade shows provide suppliers and customers with an opportunity to shake hands and open up about business challenges.

“Our focus is on knowing what our customers need and delivering solutions as timely as possible,” says Bill Griffin, president and co-owner of Metal Rollforming Systems. “It’s important for MRS to exhibit at METALCON so we can have face-to-face conversations, allowing us to really get a deeper understanding of what our customer’s challenges and priorities are. These connections allow us to stay ahead of market trends and provide solutions for the evolving priorities of the industry.”

Exhibitors recognize the opportunity to provide hands-on product education at METALCON.

“We have a booth at METALCON because the mix of potential customers is different than other roofing trade shows,” says Charlie Smith, national recover manager at McElroy Metals. “The attendees are specifically in the metal roofing business in one way or another. Other shows include contractors who do low-slope single-ply or steep slope shingles. I like that METALCON is focused on metal roofing.”

In addition to cultivating new business, METALCON exhibitors show up to support the industry, providing attendees with the greatest selection of products and services under one roof.

“PPG and METALCON have partnered for 35 years and we are honored to be among the Legacy 10 companies that have been part of the show’s story from the beginning,” says Steve Rutkowski, senior manager-coil & appliance, PPG Industrial Coatings. “Our ongoing support and lead sponsorship of the Design District, reflect our commitment to collaboration, industry leadership and the community of manufacturers, architects and designers. We are grateful for the opportunity to showcase our products for building products and architectural products that push design and performance forward. As METALCON marks 35 years, PPG is proud to celebrate a legacy of partnership that has helped advance innovation, strengthen the industry and support people who continue to shape metal construction.”

Ten companies have been committed to METALCON and the industry from the beginning. Ten companies that have never missed a show: The Legacy 10. Their commitment has helped transform the metal construction industry over the past 35 years. They have played a significant role in advancing the performance, durability, efficiency and design possibilities of metal construction products while driving broader adoption across commercial, industrial, institutional and residential markets.

To explore each Legacy 10 company, view historical photos and learn more about their lasting impact on METALCON and the metal construction industry, visit www.metalcon.com/Legacy10.

By Jenny Yu.  

Contractors can help building owners maximize roofing investments through engineered retrofit solutions. 

Warmer weather signals the start of peak construction season, bringing a wave of reroofing and maintenance projects for contractors across the country. While many building owners focus on immediate roofing needs, contractors have an opportunity to guide conversations toward solutions that deliver long-term value rather than short-term fixes. 

One option gaining attention is metal roof retrofit systems that allow building owners to upgrade aging roofs without the cost and disruption associated with a full tear-off. Roof Hugger's engineered retrofit system is designed specifically for this purpose, providing a structurally correct attachment surface for a new metal roof over an existing metal roof. 

For contractors, retrofit projects can offer significant advantages. Because the existing roof remains in place, building operations can often continue with minimal disruption. This helps reduce downtime for facility owners while eliminating many of the logistical challenges associated with tear-off projects. 

The benefits extend well beyond installation efficiency. Roof Hugger retrofit systems are designed to support long-term building performance by extending roof service life, improving structural performance and creating opportunities for enhanced energy efficiency. Contractors can also help owners incorporate additional insulation into the retrofit assembly, supporting efforts to keep buildings cooler during summer months and warmer during colder weather. 

As energy costs remain a concern for many commercial property owners, retrofit systems can become an important part of broader building improvement strategies. Roof Hugger systems can also support solar integration, allowing owners to prepare their facilities for future renewable energy investments while maximizing the value of their roofing project. 

Sustainability is another factor driving interest in retrofit solutions. By avoiding a complete tear-off, contractors can help reduce the amount of roofing material sent to landfills while providing a cost-effective upgrade path for aging facilities. 

Perhaps most importantly, contractors can position retrofit roofing as a long-term investment. A properly engineered retrofit metal roofing system can provide service life exceeding 60 years, helping owners focus on lifecycle value rather than repeated repair and replacement cycles. 

As construction season ramps up, contractors who bring long-term solutions to the table can help building owners improve performance, increase energy efficiency and protect their facilities for decades to come. 

Learn more about how you can take advantage of Roof Hugger roofing solutions!

By Jenny Yu.  

Roof Hugger reflects on 35 years of engineering and industry partnerships while reaffirming its commitment to advancing sustainable, contractor-focused solutions. 

For 35 years, Roof Hugger has helped shape the metal-over-metal retrofit market, building a reputation for engineering expertise, rigorous testing, and long-term performance. As the company celebrates its 35th anniversary, Roof Hugger is reflecting on the partnerships and innovations that have fueled its growth while reaffirming its commitment to advancing retrofit solutions for the future. 

Founded in 1991, Roof Hugger has specialized in sub-purlin retrofit framing systems that allow new metal roofs to be installed over existing metal roofing systems. The approach helps building owners avoid costly tear-offs while improving energy efficiency, structural performance, and sustainability. Over the decades, the company’s systems have been used on projects across a wide range of commercial, industrial, and institutional buildings. 

Company leaders say the milestone is less about looking backward and more about recognizing the relationships that have made the company successful. “As Roof Hugger takes on its 35th year this feels like the perfect moment to reflect on how far we’ve come — and to thank the many partners who helped us get here,” the company shared in its anniversary message. 

Roof Hugger didn’t get here alone; in its early years, it was contractors who embraced their sub-purlins for their strength and ease of installation.  Later, the metal building manufacturers noticed their testing, consistency with their standards and dedication to providing a performance-tested, reasonably priced and dependable result for retrofitting their buildings.  “To our customers, contractors, engineers and industry leaders: your trust in our metal-over-metal retrofit systems is the foundation of our success,” the company stated. “Every project, every installation and every conversation has shaped who we are today.” 

Going forward, Roof Hugger will continue to center innovation in their mission, emphasizing its focus on engineering systems that help contractors differentiate themselves while meeting growing demands for resilient, energy efficient and high-performing long life roofing assemblies. “As we move through our 35th year, our commitment remains stronger than ever — to innovate, to test and to engineer retrofit solutions to meet today’s rigorous code standards to set our customers apart from their competitors,” the company wrote. “From rigorous real-world testing to continuous improvements in performance and design, we’re dedicated to delivering systems built to last and built to lead,” the company added. 

As the retrofit roofing market continues to expand and evolve, the legacy of Roof Hugger’s 35-year milestone underscores the role experience, innovation and industry partnerships play in helping contractors and building owners extend the life of existing structures. 

Learn more about Roof Hugger’s retrofit roofing solutions and 35-year celebrations!

By Jesse Sanchez. 

Metal-over-metal retrofit systems help address aging roofs while meeting modern structural and code requirements.  

Across the United States, a large portion of installed metal roofs are growing closer to the end of their service lives. Data compiled from the Metal Building Manufacturers Association (MBMA) shows that billions of square feet of metal roofs were installed between the 1970s and late 1990s, meaning many are now between 25-50 years old. For manufacturers such as Roof Hugger, this aging building stock represents a significant opportunity for offering metal-over-metal retrofit systems that extend roof performance without requiring a complete tear-off. 

The scale of this market is substantial. Estimates indicate there were roughly 24.3 billion square feet of metal roofing constructed during those decades, along with approximately 1.9 billion square feet of metal roofing used on U.S. military facilities. As these systems age, building owners increasingly face decisions about whether to repair, recover or replace existing roofs.  

One factor influencing those decisions is modern building code compliance. Many older metal buildings were designed with purlin spacing of five feet or more, a configuration that may not meet current wind load and snow drift design requirements. Retrofit framing systems can help address this issue by reducing attachment spacing so new metal panels meet contemporary code expectations for edge zones, corner zones and field-of-roof conditions.  

Contractors evaluating retrofit projects typically begin by assessing the condition of the existing structure. This process may include examining purlins for corrosion, determining whether penetrations such as skylights are still required and evaluating insulation or sound concerns inside the building. Walking the roof and speaking with the building owner about current performance problems also helps determine whether repair or a full recover is the best approach.  

Several structural panel options are available for recover systems. Trapezoidal panels are generally the most economical and work well on simpler roof geometries with minimal penetrations. Vertical ribbed asymmetrical panels are often used on more complex roof layouts with hips or valleys. Symmetrical standing seam panels typically offer the highest wind uplift resistance and improved watertightness, though they require additional material and installation complexity.  

A metal roof that has reached the end of its service life is no longer a crisis point for a building, it’s simply the next chapter waiting to be written. With a properly engineered retrofit system, that tired old roof becomes the foundation for a modern, code‑compliant metal roof designed to perform for 50 years or more. The transformation doesn’t just protect the structure; it breathes new life into the entire building, turning what once felt like an aging liability into a renewed, long‑term asset. And in an era when new construction costs continue to climb at a staggering pace, revitalizing an existing building can be one of the smartest and most valuable investments an owner can make. 

Learn more about how metal-over-metal roof retrofits help extend the life of aging metal roofs while meeting modern wind, snow and building code requirements!

By Jesse Sanchez. 

Engineered metal-over-metal retrofit improved wind performance efficiency and long-term durability for a high-traffic waterfront facility. 

In 2011, Metal-Fab Manufacturing and Roof Hugger delivered a complex metal-over-metal retrofit for the Port of Baltimore Cruise Terminal, completing a much-needed public infrastructure upgrade. The 65,000-square-foot facility serves cruise passengers traveling with Royal Caribbean, Celebrity and Carnival Cruise Lines and required a roofing solution aligned with coastal exposure demands. 

The Maryland Port Authority selected an engineered approach that both preserved the existing structure while also increasing performance. Metal-Fab supplied the complete retrofit framing and roofing package, installed by Xpert Xteriors, using a system tailored for speed, precision and structural reliability. 

Jamie Fick described the decision path clearly, sharing, “There was only one way to retrofit the existing metal building and that was to use factory-notched sub-purlins supplied by Roof Hugger, Inc.” The sub-framing system allowed installers to work directly over the original roof while maintaining alignment and load continuity. 

Beyond constructability, the sub-purlins delivered structural advantages. The ease and speediness of installation, combined with components that increase the load carrying capacity of the existing building’s roof purlins, offset added system weight. That balance proved essential for completing the retrofit without operational disruption. 

Above the framing, they installed jobsite roll-formed 22-gauge Met-Fab III standing seam panels with a bare Galvalume finish. The heavier gauge addressed elevated wind requirements while the 16-inch structural profile and mechanically locked ribs supported long panel runs up to 120 feet. 

Thermal performance was improved through the decision to install fiberglass insulation placed between the original ribbed panels and the new roof assembly. Roof Hugger also engineered a specialized hat-over-zee system at edges and corners, enabling clip placement between existing purlins spaced five feet on center. 

Careful staging and coordinated system selection allowed the installation to proceed smoothly, delivering durability, efficiency and resilience for a critical transportation asset. 

Learn more about engineered metal retrofit systems supporting complex facilities through Roof Hugger and Met-Fab!

By Jenny Yu.  

Contractors will gain practical insights from leading experts while connecting with top manufacturers and suppliers. 

The Florida Roofing and Sheet Metal Contractors Association (FRSA) is hosting its 104th Convention & Expo from June 10-12, 2026, at the Gaylord Palms Resort & Convention Center in in Kissimmee, Florida. With a strong lineup of sponsors and an educational program packed with timely topics, this year’s event is set to provide contractors with practical insights and valuable networking opportunities. 

A wide range of industry leaders are lending their support for the event, underscoring its importance across the roofing and metal construction sectors. Platinum sponsors include Eagle Roofing Products, ABC Supply and TAMKO®; while gold sponsors CertainTeed LLC, Polyglass and SOPREMA further highlight the depth of industry participation. Additional support from emerald sponsor Adams & Reese LLP; sapphire sponsors BITEC, Drexel Metals, MetalForming LLC and Sika Corporation; silver sponsor SRS Building Products; bronze sponsors Duro-Last®, IB Roof Systems™, PAC-CLAD Petersen and Roof Hugger; and affiliate sponsor, Roofing Contractors Association of South Florida (RCASF), reinforce the event’s focus on innovation, performance and contractor success. 

Educational sessions 

Education remains the cornerstone of the convention, with sessions designed to address today’s most pressing challenges in the industry while providing attendees with opportunities to earn CE credits. Legal and compliance topics are a hot topic with multiple sessions led by Trent Cotney, RoofersCoffeeShop® Influencer and partner at Adams & Reese LLP, including: 

• “Building an OSHA Inspection SOP” - Wednesday, June 10, 8:00 a.m. 
• “Roofing Legal, Labor and Policy Trends” - Wednesday, June 10, 12:30 p.m. and Friday, June 12, 7:00 a.m. 
• “Artificial Intelligence in Roofing” - Thursday, June 11, 7:00 a.m. 
• “ICE Raids and I-9 Audit Defense” - Thursday, June 11, 8:15 a.m. and Friday, June 12, 8:15 a.m. 

These sessions will provide contractors with actionable guidance on navigating regulations, mitigating risk and adapting to emerging technologies.  

Business operations are also a key focus. John Kenney, Influencer of The Coffee Shops™ and CEO of Cotney Consulting Group, will lead “Estimating for Small Business” on Wednesday, June 10, at 9:15 a.m. and Thursday, June 11, at 7:00 a.m., offering practical strategies to improve accuracy and profitability for contractors of all sizes. Meanwhile, Chad Westbrook, founder of Service Alignment, will present “Documenting a Roofing Project” on Thursday, June 11, at 9:30 a.m. and Friday, June 12, at 7:00 a.m., helping attendees strengthen processes that support accountability, communication and long-term project success. 

Additional sessions cover critical issues including Florida Building Code updates, metal roofing best practices and safety topics such as heat illness prevention. The “SkillsUSA: Build a Workforce Pipeline” session on Thursday, June 11, at 9:30 a.m., will also highlight strategies for developing the next generation of roofers, a growing priority for contractors facing ongoing workforce shortages. Together, these seminars provide well-rounded education opportunities tailored to both roofing and sheet metal professionals.  

Register to reserve your spot and take full advantage of everything the 104th FRSA Convention & Expo has to offer!

By Heidi J. Ellsworth. 

Advancing retrofit solutions through engineering, collaboration and industry partnership. 

In today’s evolving construction landscape, the role of building enclosure professionals has never been more critical. From ensuring long-term performance to meeting increasingly complex energy and structural requirements, consultants are at the forefront of delivering smarter, more resilient buildings. That is why partnerships between manufacturers and organizations like the International Institute of Building Enclosure Consultants (IIBEC) are so important to the future of the industry. 

For companies like Roof Hugger, this commitment goes beyond participation. It is about actively supporting the consultants, engineers and professionals who are specifying and guiding building enclosure solutions every day. They have built a reputation of delivering proven, engineered retrofit systems designed specifically for metal buildings. These solutions are not just about covering an existing roof. They are about enhancing the entire building system. By eliminating the need for a costly tear-off, their retrofit approach helps extend the life of existing structures while improving structural integrity, increasing energy efficiency and delivering long-term value. 

This aligns directly with the priorities of IIBEC members who are tasked with evaluating total building performance. Consultants are increasingly looking for solutions that address multiple challenges at once, including sustainability, cost control and durability. Roof Hugger’s engineered systems provide a practical path forward, offering tested and reliable options that meet these demands while minimizing disruption to building occupants. 

What stands out is Roof Hugger’s willingness to support projects at every stage. Whether a consultant is in the early phases of evaluating options or preparing specifications for a complex retrofit, their team offers expertise that ranges from individual Hugger components to complete engineered systems. This collaborative approach reflects a deep understanding of how building enclosure consultants work and what they need to deliver successful outcomes. 

Equally important is the company’s focus on tailoring solutions to each project. No two buildings are exactly alike, and retrofit systems must account for varying structural conditions, climates and performance goals. By providing preliminary evaluations and customized engineering support, Roof Hugger helps ensure that each system is designed with precision and purpose. 

Their message to the industry is straightforward and resonates strongly with the IIBEC community. At Roof Hugger, they are committed to providing proven, engineered retrofit solutions that extend the life of metal buildings while improving performance and efficiency without the need for tear-off. They welcome the opportunity to support projects at any stage, offering guidance, technical insight and responsive service to meet the specific needs of each client. 

As the demand for retrofit solutions continues to grow, partnerships between manufacturers and organizations like IIBEC will play an increasingly important role. By aligning innovation with education and professional standards, companies like Roof Hugger are helping to shape a more sustainable and resilient future for the built environment. 

For more information, visit the Roof Hugger directory on RoofersCoffeeShop® and MetalCoffeeShop®.