Why Your Metal Roof “Failed” — Common Install Errors + Expectation Mistakes

If you’ve ever wondered why a metal roof failed, or why a detail just won’t seal, this is for you. We’re tackling the most frustrating and costly installation mistakes that keep coming up, and how to finally put them to rest.

In this Q&A Mondays episode, metal roofing expert Thad Barnette sits down with Jason Ayres and David Stubbs from the Sheffield Metals Technical Department to break down real-world metal roof installation mistakes they still see across the country on both residential and commercial projects.

We cover:

►Fastener and accessory issues, including ultra-low profile (ULP) fasteners vs. tested pancake head fasteners for wind uplift

►How to avoid fasteners telegraphing through standing seam panels with the right clip selection and panel design

►The “expectations gap” with homeowners, GCs, and building owners (there’s no such thing as a perfect metal roof)

►Why clear communication and early mockups are crucial to avoid rework and callbacks

►Correct Z-closure installation on vertical details (sidewalls, rakes) and why “bottom-up” thinking can cause reverse laps

►What goes wrong at complex metal roof details: miters, hips to ridge, sidewalls to headwalls

►Why modified Z’s are rarely a good long-term solution for panel attachment and snow load resistance

►How poor design decisions (panel selection, slopes, window placement, water concentration) can doom a roof before install even starts

►If you’re a contractor, installer, architect, or building owner considering metal roofing, this episode will help you spot issues before they become leaks, callbacks, or expensive tear-offs.