Metal Roofing: A Platform for Renewable Energy Systems

S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • NO V E M B E R 2 0 1 0 K R I N E R A N D J A M E S • 8 3
METAL ROOFING:
A PLATFORM FOR RENEWABLE ENERGY SYSTEMS
SCOTT KRINER
METAL CONSTRUCTION ASSOCIATION
4700 Lake Ave., Glenview, IL 60025
Phone: 847-375-4718 • Fax: 847-375-6488 • E-mail: skriner1@verizon.net
MARK JAMES
ROOF HUGGER, INC.
Tampa, FL
COAUTHOR:
ROB HADDOCK
THE METAL ROOF ADVISORY GROUP
8 4 • K R I N E R A N D J A M E S S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • NO V E M B E R 2 0 1 0
ABSTRACT
The Department of Energy states that more energy is lost through existing building
envelopes than is generated by their heating systems. Solar heat gain and internal loads
from equipment and occupants can easily add 50% to the annual heating capacity. Solar
heat gain and air infiltration through roofs contribute as much as 24-30% to cooling loads.
This paper introduces metal roofing as the platform to address deficiencies in existing
roofs as well as new construction. It will describe how to integrate proven energy savings
technologies into a “sandwiched” plenum between the old and new roofs. Various types of
radiant air barriers and above-sheathing ventilation (ASV) for natural convective cooling
ventilation will be explained. Other new-generation, energy-saving technologies, such as
phase change materials (PCM) for extreme thermal resistance, renewable solar thermal
heating and cooling (water), and solar heat recovery (air) for space and process heating, as
well as roof-mounted photovoltaic systems, will be illustrated. All of these materials can be
installed separately or collectively to create a fully integrated encapsulated thermal-composite
roof assembly over an existing roof that is aesthetically and architecturally pleasing.
The paper will also introduce previous and current research being conducted at Oak
Ridge National Laboratories (ORNL) that relates the benefits to building owners and design
professionals. This research substantiates the systems’ performance insofar as energy consumption
and potential savings through third-party independent case studies. The presentation
will conclude with an overview of the various incentives that are applicable to these
reroofing technologies, including funding, grants, and federal tax credits/deductions afforded
to building owners through the American Recovery and Reinvestment Act (ARRA).
SPEAKERS
SCOTT KRINER — METAL CONSTRUCTION ASSOCIATION
Scott Kriner, MCA’s technical director, is the president and founder of Green Metal
Consulting Inc. A LEED® AP, he began his career in the metal construction industry in 1981
with Bethlehem Steel. His company is a member of the U.S. Green Building Council,
California Association of Building Energy Consultants, and the Residential Energy Services
Network (RESNET). Kriner has served as an officer/director of the National Coil Coating
Association, Cool Roof Ratings Council, Metal Roofing Alliance, Metal Construction
Association, Zinc and Aluminum Coaters Association, NamZAC, and he was founding chairman
of the Cool Metal Roofing Coalition. He is a U.S. patent holder and has published over
25 technical papers in the last 29 years.
MARK JAMES — ROOF HUGGER, INC.
Mark James has been an active contributor to the growth of the retrofit concept in the
metal construction marketplace since 1986. He has been instrumental in the successful
preparation and completion of over 20 million sq ft of retrofit projects. His over 35-year construction
industry experience includes the design, sales, fabrication, and construction of
conventional and preengineered buildings and architectural metal roof systems. He is a recognized
and accomplished technical seminar speaker/presenter for building owners, contractors,
and design professionals seeking knowledge to properly retrofit existing buildings.
He is now vice president of sales and marketing for Roof Hugger, Inc., of Tampa, Florida.
S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • NO V E M B E R 2 0 1 0 K R I N E R A N D J A M E S • 8 5
ABSTRACT
Buildings are responsible for 39% of all
energy consumption, 72% of all electricity
consumption, and 55% of natural gas use
in the United States.1 The Department of
Energy states that more energy is lost
through existing building envelopes than is
generated by building heating systems.
Approximately 15% of residential2 and commercial
building heating loads are from the
direct loss of heat through the roof,3 up to
24-30% when combined with air infiltration.
4 For cooling, the heat transfer from
residential building exteriors to the interior
accounts for 15% of cooling loads.5
Furthermore, the Heat Island Group of the
Lawrence Berkeley National Laboratory has
stated that cooling costs attributed to solar
heat gains on roofs can reach $175 million
annually.6
One of the most significant opportunities
to increase energy efficiency lies within
the commercial roof sector where over 50
billion sq ft of flat roof surface is currently
available for retrofit.7 An annual energy savings
would exceed $2 billon if the insulation
levels in these commercial roofs were
upgraded from their current condition to
the levels required by the Commercial
Building Tax Deduction provisions in the
American Recovery and Reinvestment Act of
2009, which references a building that
meets ASHRAE 90.1-2001.
In addition to addressing both energy
efficiency and renewable energy, the roofing
market provides a significant multiplier
effect for achieving national energy goals.
For every new roof installed on a new building,
approximately three additional roofs
are installed on existing buildings to replace
older, less efficient roof systems.8 As a
result, the footprint of the reroofing industry
greatly exceeds the footprint of new construction
starts by a factor of four, accounting
for more than 16 billion sq ft of commercial
and residential reroof installations
annually.
Metal roofing is an excellent platform to
address deficiencies in roofs on existing
buildings and in new construction.
Retrofitting an existing roof with a metal
roof allows for the integration of energy savings
technologies into a “sandwiched”
plenum between the old and new roofs.
These technologies include various types of
radiant air barriers and above-sheathing
ventilation (ASV) for natural convective
cooling ventilation. Other new-generation,
energy-saving products and technologies
can be integrated into the metal retrofitted
roof, such as phase-change materials (PCM)
for extreme thermal resistance, and renewable
solar thermal heating and cooling
(water) and solar heat recovery (air) for
space and process heating. Owing to its
established durability, metal is the ideal
platform for roof-mounted photovoltaic systems.
All of these energy-saving materials
can be installed separately or collectively to
create a fully integrated, encapsulated,
thermal-composite roof assembly over an
existing roof that is aesthetically pleasing
and functional.
EXECUTIVE SUMMARY
The term “retrofit” has many connotations
when used in the current green construction
market for building energy
improvements. Retrofitting is often focused
on changes to lighting systems, HVAC
equipment, and fenestration systems. While
there are a multitude of building envelope
retrofit methods and concepts employed to
achieve energy savings, many do not provide
significant savings in either the short
term or long term. However, retrofit reroofing
with metal provides substantial and
continual energy savings with long-term
service life. In addition to improving the
thermal performance of a roof system, this
type of metal roof application also provides
an opportunity to employ rooftop renewable
energy technologies.
The Department of Energy (DOE) estimates
that 25% of our nation’s buildings
have poorly insulated and maintained
roofs,9 making them immediate candidates
for high-performance retrofit metal reroof
applications. Furthermore, the DOE’s
Building Technologies Program (BTP) identified
residential and commercial buildings as
the largest energy-consuming sectors,
accounting for about 40% of the total U.S.
annual energy use.10
METAL ROOFING RETROFIT
APPLICATIONS
Metal-over-metal retrofit roofing systems
have been installed on over 50 million
sq ft of buildings since 1992, including 1.85
million on military and federal facilities
nationwide. The most common metal roofing
retrofit applications involve the installation
of metal roofs over existing low-slope
conventional roofs or over existing steepslope
roofs. Both of these can improve a
building’s appearance and reduce maintenance.
The metal retrofit system can introduce
greater slope to a building that previously
had a low-sloped roof.
A licensed design professional from the
state in which the structure is located
should fully engineer the metal roofing
retrofit system for the structural analysis,
design of the new structural framing system,
wind uplift, and snow loads. From the
design phase through completion of installation,
several steps must be taken to
ensure the integrity of the system and the
project. The existing roof needs to be thoroughly
inspected for degradation such as
water deterioration or rust. The roof structure
must also be analyzed to ensure that it
can support the added weight of 2 to 5
pounds per sq ft in addition to any resultant
increase in snow loads due to roof geometry
and /or increase in insulation levels for the
retrofit system. The actual weight depends
on the complexity and gauge of the steel
support framing system required to meet
specified building codes.
A full engineering analysis is required to
determine the appropriate framing and
anchorage system, and it is imperative that
the new retrofit system be properly
anchored to the existing roof’s structural
system. Improper attachment can result in
the new system’s being torn from the building
in severe wind uplift. It has been documented
in wind uplift tests that proper
attachment is the main factor in maintaining
system integrity. Since the installation
involves through fastening of the steel framing
into the existing roof structural support
system, a temporary waterproofing plan is
required to protect the areas where the
existing roof is penetrated. These areas are
METAL ROOFING:
A PLATFORM FOR RENEWABLE ENERGY SYSTEMS
eventually enclosed and protected by the
full retrofit system.
In the engineering phase, the designers
can evaluate other opportunities to improve
energy efficiency of the new retrofit metal
roof system. An air space is created between
the existing roof and the new metal roof, in
which a more balanced ventilation system is
possible and additional insulation can be
added. In addition, the installation of a new
metal roof allows for integration of a number
of rooftop renewable solar energy technologies.
EXISTING LOW SLOPE ROOF
APPLICATIONS
The two common types of retrofit applications
on existing flat-roofed structures
are low-slope and steep-slope metal roofs.
During installation of either of these types
of retrofit systems, the building interior is
not exposed to outside elements or contamination
from construction.
Low-slope installations are usually utilitarian
and economically driven. Typically, a
low-slope metal roof retrofit system does not
add curb appeal but is designed to improve
discharge of rainwater. In contrast, steepslope
metal roof retrofits improve the aesthetics
of the building. They use a variety of
framing methods that can turn a low-slope
roof into a new roof sloped with a pitch up
to 8:12.
Metal roof retrofit systems can solve
problems that may result from existing lowslope
roof geometry,
such as poor drainage,
snow drifting, or the
addition of a new building
adjacent to the existing
structure.
BENEFITS OF METAL
ROOF RETROFITS
Metal roof retrofit
systems provide design
professionals and building
owners with solutions
for improving energy
performance and for
correcting problematic
roofs. In a retrofit application,
an air space is
created between the
existing roof and the new
metal roof. The air space
provides an opportunity
to place additional insulation
and/or enhance
natural ventilation. Both
help to reduce the heat gain and heat loss
from the roof, thereby reducing energy
demand and substantially reducing dependence
on fossil fuel.
Retrofit metal reroofing creates benefits
for building owners in many ways. According
to a Ducker Worldwide study,11 a metal roof
can reduce the maintenance of a flat roof by
as much as 40-50% compared to other conventional
low-slope roofing materials. This
helps to lower the overall life-cycle cost of the
roofing system, in addition to the energy saving
benefits mentioned previously.
A retrofit system uses many components,
including light-gauge steel framing
members, fasteners, insulation, metal roof
materials, and renewable solar energy technologies.
The growing interest in retrofitting
existing buildings creates an increase in the
job market in areas of components manufacturing,
design, and construction. The
metal roof retrofit systems are engineered to
comply with all governing national and local
building codes.
THE SOLUTION IS RIGHT OVER OUR
HEADS
Designers and building owners often
overlook an obvious solution when needing
to improve an existing building’s energy efficiency.
A metal roof retrofit system is a well
established technology that is available
throughout the United States. The system is
economical and long-lasting and provides
building owners with immediate and continuing
returns on their investment. This technology
has been used for several decades by
all types of governmental bodies and commercial
building owners. When retrofitting a
building for energy efficiency, metal roofing
should be considered as the platform upon
which to achieve greater energy savings and
sustainability. Retrofit reroofing systems are
installed on existing buildings with both
low-slope and steep-slope roofs, as shown in
Figures 1 through 4.
ENERGY SAVINGS AND
ENVIRONMENTAL BENEFITS
Retrofit metal reroofing has several
environmental benefits. In most cases, the
light-gauge steel framing system can be
installed over the existing roof and secured
into the structural system of the roof. This
typically eliminates the need to tear off the
original roof, eliminating the solid waste
stream to a landfill and improving the cost
of landfill management. The International
Building Code provides for a standing seam
metal roof to be installed over an existing
roof without tear-off since the metal roof is
attached directly to the structural support
system of the building.12
According to the Construction Materials
Recycling Association, 11 million tons of
asphalt shingles are dumped into U.S. landfills
annually.13 With a metal roof retrofit
system, much of this tear-off material can
remain in place. The metal roofing material
provides more than double the service life of
Figure 1 – New steep-slope metal roof over existing low-slope roof.
8 6 • K R I N E R A N D J A M E S S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • NO V E M B E R 2 0 1 0
asphalt-based products, reducing the frequency
of roof replacement and materials
being taken to the landfill.
Metal roof retrofit systems provide many
options that can include the addition of
insulation to upgrade the building to current
energy code standards, convective ventilation
for cooling the roof assembly, and using
Energy Star®-labeled “cool” metal roofing
that reflects and emits a high percentage of
solar energy. In addition, integrated renewable
solar water heating, solar space heating,
and solar electricity can easily be employed
in the reroof assembly. Each of these systems
is well known in the retrofit construction
marketplace, with years of history that
prove their sustainable value by their ability
to pay for themselves. Metal roofing is a good
platform for these technologies due to the
long-lasting, high-performance roof material
that is currently assessed with a 41.6-year
service life.14 That durability allows for the
roof platform to outlast the solar technology
being integrated into the roof.
The use of
metal roofing
in retrofitting
applications
allows a building
owner to use a material that is high in
recycled content and fully recyclable at the
end of its useful life. According to the Steel
Recycling Center, steel’s recycled content is
at least 28%.15 The recycled content of steel
manufactured using the electric arc furnace
is as high as 45%.16 In the case of aluminum,
the recycled content is even higher.
For both steel and aluminum roofs, the
material can be completely recycled through
existing waste segregation and reclamation
systems in the nation. For a USGBC
Leadership in Energy and Environment
Design (LEED®) Existing Building-registered
building project, the use of material with
high recycled content and complete recyclability
can qualify for points in the Material
and Resource category.
The scrap that is generated during
installation can be segregated into a 100%
recyclable stream, which can qualify for
LEED® points in waste management credit.
HIGH-PERFORMANCE, INTEGRATED
RETROFIT REROOFING SYSTEMS
The accompanying illustrations explain
the basic fundamentals of integrated, energy-
efficient, and renewable-energy roof systems
depicting a retrofit application over an
existing steep-sloped metal roof. When the
metal roofing requires replacement, it is
generally caused by the local environment
or in cases where the roof has reached its
full service life. Metal roofs of yesteryear
employed less advanced coatings and
design practices than are used and practiced
today. According to the Metal Building
Manufacturer Association (MBMA), some 18
S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • NO V E M B E R 2 0 1 0 K R I N E R A N D J A M E S • 8 7
Figure 4 – New metal steep-slope roof after retrofit.
Figure 2 – New metal roof
over existing steep-slope
metal roof.
Figure 3 – Existing lowslope
roof before retrofit.
billion sq ft of preengineered metal buildings
were erected between 1970 and 1990,
resulting in roofs that are from 20 to 40
years of age.17 Many of them are prime candidates
for retrofit applications that use
high-performance integrated systems, such
as above-sheathing ventilation, solar heat
recovery, and solar water and space heating.
Above-Sheathing Ventilation
The air space created between the existing
roof and the new metal retrofit roof can
allow for natural convective cooling to take
place in warm climates. This phenomenon
is referred to as above-sheathing ventilation
(ASV). The air flow in this plenum, as shown
in Diagram 1, can dissipate heat through
the ridge vent and has been proven to
reduce the heat transmission
through the new
cool metal and existing
roof assemblies by as
much as 45%.18 This air
space can also act as an
insulator to reduce heat
loss from the roof assembly
in colder climates.
Solar Heat Recovery
Similar to ASV, a
solar heat recovery system
captures the ventilated
air above the old
roof assembly, but rather
than allowing it to flow
out the ridge vent, it
redirects it to the building’s
existing ductwork
and/or other convective
construction materials
that retain heat, as
shown in Diagram 2.
Solar thermal heating
technologies can be
applied for space heating
to lower energy consumption
in the winter
months. In summer
months, the air is vented
out through damperable
roof ventilators located
at the high point of the
roof, or it is used to
assist in heating water.
Solar Water and Space
Heating
Solar water heating
technologies can be integrated
directly into a
metal roof application as
shown in Diagram 3. The
surface of the metal roof
is heated by solar energy,
and the heat is transferred
to a fluid for heat
exchange in domestic
water heating, radiant
space heating, and process heating and
cooling systems. This renewable source of
heating can significantly lower energy
demand in the building. These systems are
highly efficient and can provide returns on
investment in as few as five years. These
technologies can be integrated with ASV
and solar thermal heat recovery in the same
retrofit roof assembly.
8 8 • K R I N E R A N D J A M E S S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • NO V E M B E R 2 0 1 0
Diagram 1
Diagram 2
Photovoltaic Solar Electricity
With a durable retrofit metal roof acting
as the platform for retrofit reroofing, the
addition of renewable photovoltaic solar
electricity installed atop the new metal roof
is very feasible. The two common photovoltaic
systems include thin-film laminated
photovoltaic and mono- or polycrystalline
modules, as shown in Figures 5 and 6. The
thin-film laminated PV is adhered to the flat
pan region of metal panels, between the
standing seams. The crystalline PV modules
are mounted to the new metal roof’s standing
ribs/seams. In both cases, no penetrations
of the roof are made in the installation
process. When installed with an ASV system,
the efficiency of these PV systems is
improved because of the cooling of the roof
assembly.
Rainwater Harvesting
Rainwater harvesting
systems reduce the
consumption of fresh water and
can help major urban areas with
stormwater drainage problems
and related costs. These types of
integrated rooftop systems meet
the requirements of almost any
structure for delivering nonpotable
water and have a 95% collection
efficiency.19 They meet
building requirements for
stormwater drainage and surface
water runoff. There are numerous
nonpotable uses such as landscape
irrigation, equipment
/vehicle washing, exterior building
maintenance, fire protection,
and toilet flushing. Water efficiency
is another area in the LEED®
program where a metal roof can
qualify for points if it is integrated
with rainwater harvesting systems.
ECONOMIC IMPACT
Roofs in North America offer
tremendous opportunity to
achieve long-term energy independence
while reducing environmental impact and
sustaining a strong economy. Metal roofing,
whether for new construction or retrofit
reroofing, is an excellent “platform” for the
deployment of high performance insulation
systems, renewable solar photovoltaic PV
and thermal systems, and other integrated
roof assemblies as explained in this paper.
According to U.S. Census data, the existing
rooftops of the United States alone offer
over 200 billon sq ft of potential surface
area for the installation of these high performance
technologies. Assuming only 25%
Diagram 3
Figure 5 – Thin-film adhered photovoltaics.
Figure 6 – Mono- or polycrystalline.
S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • NO V E M B E R 2 0 1 0 K R I N E R A N D J A M E S • 8 9
of this area is suitable for unobstructed and
continuous operation, the photovoltaic PV
systems alone could generate over 50,000
megawatts, or the equivalent of ten Grand
Coulee Dams.20
Furthermore and possibly more realistic,
the DOE states that the average commercial
building size is approximately
15,000 sq ft and the average residence is
2,300 sq ft. Applying those figures and the
relative market share of the metal roofing at
10%21 in each of these two building segments,
we can project that 37,000 commercial
buildings and 730,000 homes could
potentially see their cooling/heating energy
loads reduced by at least 45%, thereby saving
10-12 Gigawatts of energy (kWh PV-T)
annually.
A recent McGraw-Hill report projected
the retrofitting of existing buildings to grow
between 20-30% by the end of 2014, and in
the process, create as many as 50,000
jobs.22 It is estimated that 7,500 of these
new jobs will be in the metal construction
industry, which experienced a net loss of
30,000 jobs during the recent economic
slowdown.
SUMMARY
Over the past 25 years, thousands of
buildings have been retrofitted with metal
roofing on schools, federal/military installations,
and state and municipal facilities,
as well as commercial buildings. Each of
them is currently enjoying the benefits and
cost savings of this reroofing concept. If the
other previously mentioned energy-saving
retrofit techniques would be employed with
a retrofit metal reroof application, the
result would be a building that has come
closer to achieving net-zero energy status.
ENDNOTES
1. United States Green Building
Council (USGBC).
2. J. Huang and J. Hanford, et al.,
Residential Heating and Cooling
Loads Component Analysis, Lawrence
Berkeley National Laboratory
Building Technologies Department:
LBNL-44636, 1999.
3. J. Huang and E. Franconi et al.,
Commercial Heating and Cooling
Loads Component Analysis, Lawrence
Berkeley National Laboratory
Building Technologies Department:
LBNL-37208, 1999.
4. Department of Energy, Oak Ridge
National Laboratory research conducted
from 2002-2010.
5. Ibid.2.
6. S. Konopacki, H. Akbari, et al.,
Cooling Energy Savings Potential of
Light-Colored Roofs for Residential
and Commercial Buildings in 11 U.S.
Metropolitan Areas, Lawrence
Berkeley National Laboratory: LBNL-
39433, 1997.
7. Center for Environmental Innovation
in Roofing (2009), Economic
Growth, Energy Independence &
America’s Rooftops.
8. National Roofing Contractors Association,
2006-07 NRCA Annual
Market Survey, 2008.
9. Energy Information Administration
Report (2006).
10. Ibid.4.
11. Ducker Worldwide Metal Roofing
Report, 2006-2007.
12. International Building Code (IBC)
Section 1510.3.
13. Construction Materials Recycling
Association, Environmental Issues
Associated With Asphalt Shingle
Recycling Report, 2007.
14. Ibid.11.
15. Steel Recycling Institute, Steel Takes
LEED with Recycling Content, 2009.
16. Ibid.15.
17. Kwon Kim, MBMA Statistics Report
on Metal Building Shipments 1970
Through 1990, 2008.
18. W. Miller et al., (2007), Natural
Convection Heat Transfer in Roofs
With Above-Sheathing Ventilation,
2007.
19. Englert, Inc., Rainwater Harvesting
Data Sheets, 2009.
20. Ibid.7.
21. Ibid.8.
22. McGraw-Hill Smart Market Report,
Green Retrofit and Renovation Market
Opportunities, 2009.
9 0 • K R I N E R A N D J A M E S S Y M P O S I U M O N B U I L D I N G E N V E L O P E T E C H N O L O G Y • NO V E M B E R 2 0 1 0