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Commercial Projects

Gerard stone coated metal roofing is an ideal roofing material & thanks to its beauty, low maintenance and excellent durability. Not only will a Gerard stone-coated metal roofing system protect a commercial building from all of the elements, but it will look beautiful for life too! Commercial building owners know that visually attractive buildings attract the best tenants.

With a Gerard roof, commercial building owners can put an end to re-roofing projects every 10-15 years. Your Gerard metal roof will also help to minimize costly maintenance and repair expenses. Plus, being one of the most energy-efficient roofs available, imagine how much money can be saved in energy costs.

Our stone coated metal roofing is commonly used on commercial; churches; multi-family; housing communities; governments; schools; and hotels.

A Gerard Roof is the answer to all of your roof-related challenges associated with commercial buildings.

Commercial roofing projects range from simple mom and pop businesses to massive developments needing complex roofing systems, such as malls, gyms, schools, big box stores and stadiums. Before construction, architects and developers must decide what specific roofing materials, such as stone coated metal roofing for example, are suitable for the roof design.

What factors do the architects, engineers, and builders consider when selecting a roof? Depending on the size of the commercial roofing project, these elements are of prime concern: sustainability, durability, longevity and finally, style and color. Since a roof is one or the most expensive components of any building, determining the primary cost issues to achieve those desired results is of the utmost importance. The roof is the most vital part of the building envelope, and therefore, the most critical investment. Two well respected architectural firms, Brian Khoury Engineering Structures and HISinc. Design & Build, have confirmed that using Gerard's lightweight tiles against traditional roofing tiles saves enough money on both structural materials and labor to offset the cost of the roof itself.

It's no overstatement to say that we now enjoy a wider range of roofing materials and roofing system than at any other time in history. Generally, there are two types of roof systems or categories of roofing. The flat roof, also called the low slope, and the sloped roof are the two most prevalent. What constitutes a low slope roof? Generally, a roof is determined to be low slope if the pitch is less than 18 degrees. In order to guarantee that the roofing system will last and remain dry and durable, the roofing materials must include several key components such as flashing, copings and drains for proper removal of water and moisture. Sometimes, cover boards are installed to offer additional puncture and moisture protection.

High quality work also demands that insulation material be included to guard against changes in temperature, while the introduction of an underlayment can also be a significant temperature barrier. Most low slope roof membranes have three principal components:

  • Weatherproofing layer or layers — it keeps water from entering a roof assembly.
  • Reinforcement — this adds strength, puncture resistance and dimensional stability to a membrane.
  • Surfacing — This component protects the weatherproofing and reinforcement from sunlight and inclement weather. It can also provide fire resistance, increase solar reflectivity and improve traffic and hail resistance.

Once the roof is installed, it should be maintained in accordance with recommended procedures to insure that it remains beautiful and viable.

Conversely, a steep slope roof is first and foremost, more than 18 degrees in pitch. They are designed and installed using a wide variety of materials, including asphalt shingles, clay and concrete tile, wood shakes and wood shingles, slate and metal roof systems for steep-slope applications.

Steep slope roofs typically consist of three primary parts:

  • Roof deck — A roof deck is the structural substrate and normally is a wood-based material such as plywood or strand board (Oriented strand board (OSB), also known as flakeboard, sterling board and aspenite in British English, is a type of engineered lumber similar to particle board, formed by adding adhesives and then compressing layers of wood strands (flakes) in specific orientations).
  • Underlayment — Offers temporary protection until a roof covering is installed and delivers a secondary weatherproofing barrier. The underlayment is usually referred to as “felt” or “paper.”
  • Roof covering — The roof covering is the external material that sheds water.

In commercial work, low-slope roofs (with a pitch between 2/12 and 4/12) are most common. Roofs with a pitch of less than 2/12 are considered flat, even though they technically have some slope. The minimum allowable slope for drainage is ¼" per foot.

Steeper sloped roofs are generally more aesthetically pleasing and tend to last longer, as the water runs off immediately and ice damming is avoided. However, they also cost more because of the additional materials required to build them, and are impractically tall for larger buildings. In commercial properties, it’s not uncommon for steep-slope roofs to be paired with a flat roof on another part of the building. This design element allows more of the roof to be seen from the ground then is the case with a flat or low slope roof. 
Roof material selection is highly dependent on roof slope. For instance, single-ply or torch-down roofs are not appropriate for high-slope applications. On the other hand, visually appealing roofing products such as shingles or tiles do not work well on low-slope roofs.

Roof pitch, however, is not the only factor in roofing system selection. More often, the overall weight of the roof plays a deciding factor. Vegetated and ballasted roofs, for instance, can put a significant load on various structural elements. Similarly, roof underlayment and insulation can eliminate some roofing materials from consideration. Hot-applied or torch-down roofing is definitely not compatible with rigid foam insulation. Given the extreme durability and lightweight nature of Gerard stone-coated metal roofing material, the benefits of choosing a stone-coated metal roofing system will create engineering and build savings in new building construction costs, and those savings will offset the additional cost of your premium metal roofing material.

For conventional and steep-slope commercial roofing, asphalt and stone, or modified membrane are the most common choices. They have been used for roofing for hundreds of years, and are the most regularly used roofing material in North America. Asphalt shingles are likely the most affordable roofing option for moderate and steep sloped roofs, running between 50 cents to $1.50 per square foot, but come with many drawbacks when compared to stone coated metal roofing. They weigh at least 250 pounds per 100 square feet, on the light end for roofing materials, but according to some industry experts, the main drawback to asphalt shingles is related to the service life. Asphalt roofing shingles are available in grades with an expected life of 20-50 years depending — on the price. But issues with durability and material failure often occur earlier than expected in some conditions. Asphalt shingles can be used on low-slope roofs with a pitch between 2/12 and 4/12, but they require special underlayments and installation techniques to handle ice damming and other water issues.

The Gerard advantage includes the best protection against all climate conditions. Because stone-coated metal roofing systems enable buildings to be much lighter than those with alternative roofing systems, their entire structures are stronger, allowing them to withstand a range of testing conditions: from earthquakes and fires to tornados and beyond.

An overwhelming majority of commercial and institutional buildings have flat roofs, and for more than 100 years, that constituted using a multi-ply Built-Up Roofing (BUR) system. Sometimes called a “mop-on” or “tar-and gravel” system, it uses a combination of roofing felt, tar and gravel. The felt is installed in three-foot rolls, and the layers adhered together with hot asphalt, bitumen, or coal tar. A final gravel surface is broadcast over the final layer of asphalt for UV protection, worker safety, and to reduce fire danger. BUR systems are still preferred by many building owners and operators as a proven and viable method.

If you’ve ever seen a hot mopped roof installation you’ll be thankful you’re not the one doing it. This is definitely a “professional only” roofing category. Hot mop roofing is a very dirty and somewhat dangerous job, it’s essentially putting molten asphalt tar over a roof. This hot mop roofing application is seen almost entirely in commercial buildings. However, it is occasionally applied on porch roofs on homes or other flat roofing area’s. Also referred to as hot-mopped asphalt roofing, hot tar roofing, tar roofs, multi-ply tar roofing — or most commonly, SMELLY.

It requires high heat/fire to put down and offers no resistance to catastrophic fires or fire insurance discount. In contrast, Gerard stone coated metal roofing carries a Class A fire rating and also prevents fire from spreading internally within the building. Gerard quality materials combined with the unique interlocking tile technology and solid  installation methods, completely seals and protects the wooden under-deck against outside fires. Flying embers cannot breach the tightly interlocking and overlapping metal tiles, while  "dead air" space between the tile and wooden roof deck offers superior insulation even against actual wood fires burning on top of the Gerard roof.

The average lifespan of a hot-mopped roof is around 20 years, but many last as little as 15 years depending upon proper maintenance and conditions. Conversely, stoned coated steel roofing requires virtually no maintenance and looks its best for up to 50 years — guaranteed! The durability means increased cost savings; one of the main reasons architects can feel confident recommending Gerard stone coated steel roofing to their clients. Gerard also is LEED Certified and is a member of the U.S. Green Building Council. LEED-certified buildings are resource efficient. They use less water and energy and reduce greenhouse gas emissions. As an added bonus, they save money!

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