Case Study: Replacing a Historical, Lightning-Damaged Metal Roof in Georgetown, Texas 

Discover how Texas Traditions Roofing restored a lightning-damaged historical metal roof in Georgetown, TX, while preserving its original 1890s look.

A metal roofing project in Georgetown, Texas, presented unique challenges for one of our customers, Texas Traditions Roofing. The project featured soldered roofing installed in the 1890s and had been registered with the city as a historical landmark, which meant any changes to the roof would need to be approved by the city. After lightning struck the residential building, it needed redone to restore its appearance while also retaining that historical look.  

In this case study, we’ll look at how Texas Traditions Roofing completed this project, and how they utilized Sheffield Metals products to get the job done.  

Key Project Aspects: 

Location: Georgetown, Texas 

Customer profile: Residential 

Challenges: Historical significance, lightning damage, complex design 

Contractor: Texas Traditions Roofing 

Metal Supplier: Sheffield Metals   

What Were the Core Challenges for this Project? 

Drone view of a historical metal roof in Georgetown, Texas

Historical Restrictions  

One of the most unique and challenging parts of this project was the building’s historical aspects. Built in the 1800s, it was over a century old and carried importance for the community. Because of that historical significance, the contractor could not change fundamental aspects – such as the slope – of the roof in any way without consent from the city.  

Any additions or changes to the design would need to be approved by the city before any work was done. It was clear that this wouldn’t be a standard process and would likely require back and forth with the city to iron out the details and ensure all parties were satisfied. 

Lightning Damage  

Lightning damage created the need for a renovation of the roof. Once the contractor started to examine the damage, they found many issues, including leaking, rotten decking, and fascia that needed replacement.  


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Roof Complexity 

The red Georgetown roof featured over twenty different roof planes, with challenging penetrations between roof vents, the chimney, and the skylight. The original roof was made of sheet metal and soldered, which meant that the metal panels were bonded together with filler metal flowing into the joints. 

The roof wasn’t that large, but its complex nature meant that the project would be cut-up and require detailed work to be completed.  

Access to the roof was limited due to its narrowness and the surrounding trees, so installers needed to take extra time to maneuver the roof and avoid tripping while also handling panels correctly.  

How They Succeeded 

Closer view of a historical Georgetown metal roof with TPO

2.0” Mechanical Standing Seam System  

“Down here in Texas, a metal roof can really benefit someone because it’s going to last longer than a shingle roof. Most of your typical shingles have a lifetime warranty but they age a lot quicker. With a prefinished metal roof, you’ve got a 40-year finish warranty up there. The metal is actually going to be more durable to withstand the hail that we typically experience down here in Austin.” 

-Michael Pickel, Texas Traditions Roofing 

The low slope of the roof, which ranged from ¼:12 to 2:12, and variety of transition points created the need for a mechanical standing seam system which would offer the best defense against leaks.  

Texas Traditions Roofing opted with a 24-gauge, Galvalume® mechanical lock system for this project. Installers used continuous inseam sealant to secure the roof and Sharkskin underlayment was installed as a base. The decking underneath the roof was replaced, along with a majority of the gutter due to rotting. Insulation was added underneath the roof to give it more slope.  

The contractor also used a portable rollformer to form panels for the project onsite, which enabled better efficiency during the project and kept installation on track.  

A mechanical seam system is one of the more durable metal roofing systems on the market, which would mean the historical building would be protected for many years to come.  


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TPO  

Thermoplastic polyolefin (TPO) was installed in low-slope areas of the roof that needed extra assistance for shedding water. TPO is a single-ply reflective roofing membrane made of different types of rubber. It’s often installed to add protection for the roof and prevent weathering damage from wind, sunlight, and water.  

For this project, the TPO’s main function was to deal with the collecting water in the extremely low-sloped sections of the roof. TPO was also used as an internal gutter throughout the project.  

Roofing Details 

The roof had a lot of leaks and rotted decking. We had to replace some fascia and things like that so it was a slow, cut-up project. Not your biggest roof, but very cut-up and very detailed.” 

-Michael Pickel, Texas Traditions Roofing 

The cut-up nature of the roof demanded attention to detail and an experienced team to complete the job and ensure the system was effective. The team did their best to lay panels so that penetrations wouldn’t fall on a seam.  

Standard details were used for hips, ridges, and valleys. Custom details were utilized for the fascia. The portable rollformer onsite allowed the crew to customize panel lengths when needed so they could eliminate waste. Using a rollformer for this project was especially helpful, as the roof was complex and required a lot of customization.


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Stretched Timeline  

“We had to make sure that we weren’t changing the integrity of the roof in any way. So if they had a sloped area, we had to make sure we kept that the same way. If we had to add a new downspout, we had to get that approved. We had to make sure that if we were doing TPO and things like that, if we were doing new products, we had to make sure that the city was 100 percent okay with it.” 

-Michael Pickel, Texas Traditions Roofing 

This project also required patience and effective communication in order to meet the historical requirements of the roof and gain approvals from the city for any changes to the design. Texas Traditions Roofing went back and forth with the historical community for eight months to ensure that the work was approved and the city had given their okay.  

Once approvals were met, actual installation was completed in around a month and a half.  

Results 

Aerial view of a mechanical seam metal roof in Georgetown, Texas

After approvals were met and solutions were found for the low-sloped areas and damage caused by the lightning strike, the project plans were followed through and completed effectively. 

The 2.0” mechanical seam system provided modernized functionality for the roof, improving its durability and longevity while also retaining all the aspects of its historical significance.  

Key Takeaways  

A 2.0” mechanical standing seam system met the needs of the low-sloped roof and provided increased durability.  

TPO additions created extra defense against leaks and ensured ponding water would be shed from the roof more effectively.  

Careful installation and knowledgeable installers met the high skill level for this roof, as small sections needed to be handled with care and precision.  

Patience and effective communication made room for approvals to be discussed and met smoothly.  

The historical Georgetown project reiterated the need for careful considerations during the planning phase of a metal roofing project, a reliable metal roofing supplier with quality products, and an experienced team with confidence about taking on a project of this complexity.  

Texas Traditions Roofing mentioned that Sheffield’s trusted support from the Technical Department helped this project succeed.  

Need Help with Your Next Metal Roofing Project? 

Every metal roofing project has its unique challenges that need to be overcome. As a contractor, it can be difficult to try to tackle all of these issues on your own. 

At Sheffield Metals, we provide more than just metal coils, sheets, and accessories to our customers. We also offer comprehensive support through our Commercial, Architectural, and Technical (CAT) team, who can offer assistance throughout your whole project, from start to finish.  

Whether you need help with your project’s design, putting a submittal together, getting a weathertight warranty, or information on technical aspects of installation, our team can help. Reach out today to start collaborating.  


Contact Sheffield Metals today!