How long does a metal building re-roof take on a 30,000-square-foot facility in Houston?
Plan on three to five working weeks for a 30,000-square-foot repanel, weather permitting. Crews work in sections of roughly 4,000 to 6,000 square feet so no open area is left overnight. Standing seam retrofits over the existing deck usually run faster because there is no tear-off phase and no daily dry-in.
Can we keep operating inside the building while the roof is replaced?
Yes, in nearly every case. A retrofit over the existing panel keeps the old roof in place as a working ceiling, so production, storage, and tenants continue uninterrupted. On full repanels we sequence over unoccupied bays first and coordinate any area that sits directly under open framing, typically one day per section.
What does a metal building re-roof cost in Houston?
Commercial metal building re-roof projects with Achilles start at $20,000. The final number moves with square footage, panel profile and gauge, insulation scope, purlin repairs, and how much curb and penetration flashing has to be rebuilt. A $150 assessment produces the measured scope, and GreenSky financing is available for approved projects.
Can new panel go over the old roof instead of tearing it off?
Often yes. Metal-over-metal retrofits use sub-purlins or notched bearing plates to carry new panel above the existing one, and the code path for recover assemblies is set out in the International Building Code chapter on roof assemblies. The limits are structural capacity for the added load and whether existing panel is dry and sound enough to remain.
Why do my roof screws keep backing out after being retightened?
Because the hole, not the screw, has failed. Thermal cycling in Houston’s 40°F-to-160°F annual surface swing enlarges the panel hole until the washer no longer seals. Oversize replacement fasteners buy a season or two. A 20,000-square-foot R-panel roof can carry 15,000 to 25,000 exposed fasteners, which is why systemic backout signals a re-roof.
Water drips inside when it isn’t raining. Is that still a roof leak?
That pattern is condensation. With summer dew points in the low 70s, humid interior air contacting cold panel underside produces liquid water without any breach. The fix is an intact vapor retarder, thermal blocks at the purlin, and insulation that is not compressed. Leak detection separates the two causes before anything gets replaced.
Which panel profile and gauge hold up best on Houston metal buildings?
For long-term performance we favor 24-gauge standing seam, because concealed clips let panel move with temperature instead of grinding against a fixed screw. Through-fastened R-panel remains the value option and performs well when gauge is upgraded and laps are sealed properly. Slope, span, and budget drive the choice more than brand.
Do rusted purlins get replaced during the re-roof?
Where section loss is measurable, yes. Purlins usually corrode along the top flange under leaking laps and around curbs, not across the whole roof, so replacement is typically limited to specific runs. We photograph and mark every affected member during the assessment so purlin work appears in the written scope rather than as a change order mid-project.
Will a metal building re-roof actually lower our summer electricity bill?
Two things drive the savings: a reflective surface that stops absorbing heat, and continuous insulation that stops conducting it. Either alone helps; together they cut peak cooling load meaningfully in a zone 2A climate. The EPA summarizes measured reductions in roof surface temperature and building cooling demand from reflective roofing.
How is hail damage assessed on a metal roof for an insurance claim?
Metal dents rather than fractures, so adjusters look at coating breach, seam and clip deformation, and functional damage instead of granule loss. We document strike density per test square with dated photos and elevation notes. Our hail damage reports are built for carrier review, including panel gauge and finish system.
What permits and inspections apply to a Houston metal building re-roof?
Commercial re-roof work inside Houston requires a permit, with inspections tied to the adopted building code provisions for roof assemblies, recover limits, and rooftop structures. We pull the permit, coordinate inspection timing against the panel sequence, and hold the file until closeout, so the paperwork is not left for your facility staff to chase.
What warranty comes with the work, and what keeps it valid?
Achilles backs its workmanship with a 5-year warranty, separate from the manufacturer’s panel and finish coverage. Keeping it intact means documented annual inspection, clear gutters and drains, and rooftop trade work that does not cut or overload panel. A maintenance plan handles the inspection record for you.