Proving strength in metal roof retrofits

By Jesse Sanchez. 

How retrofit testing is redefining metal roof performance and why documented, real-world structural testing is essential. 

Metal building owners are asking a more direct question than they did a decade ago. The issue is no longer simply whether a roof can be replaced, but whether the existing structure can handle added weight, comply with current codes and support future rooftop systems such as solar. That concern is pushing the industry to focus on structural retrofits that are tested, measured and documented. On this episode of MetalCast™, Dale Nelson and D.J. Highnote of Roof Hugger explained how testing changed the way retrofit performance is evaluated. They emphasized that if a system claims to strengthen a building, it must prove it. 

Dale said the company’s approach began with a hard lesson in the field. “It was structurally not correct, but that's all we knew to do at the time,” he said, describing early overlay methods. That realization led to the creation of a notched Z component designed to create a direct structural connection into the building frame. Still, observation was not enough. Crews noticed stiffer roofs after installation. “After you put the roof hugger on, it didn't spring anymore,” Dale said. But building owners and engineers needed more than feel. They needed data. 

To provide it, the company constructed a 50-foot multi-span test bed to simulate real building conditions. “We did over 30 tests of various gauges, profiles, heights of parts,” Dale said. D.J. emphasized why that mattered. “If you can imagine taking on this project of building a 50-foot long test bed, which is going to be a multi-span Perlin, which is what a metal building is really going to be,” he said. The goal was to mirror actual building behavior, not idealized lab conditions. 

The result is documented capacity increases supported by sealed engineering calculations that engineers can review and verify. As D.J. put it, “Not every test goes the way you think it's going to,” a reminder that real performance is uncovered through repeated testing, not assumptions. In today’s market, structural strengthening cannot rely on reputation or field impressions alone. It must be tested, calculated and clearly proven. 

Listen to the podcast or Watch the interview to learn more about how retrofit testing is redefining metal roof performance and why documented, real-world structural testing is essential.