# Tuesday, June 03, 2014
Roof scuppers are used to drain rain water from flat roofs which are prevalent mostly on commercial and government buildings. Flat roofs can also found on contemporary residential buildings. A low wall typically runs around the perimeter of the flat roof and holes are cut through these low walls where the roof and wall intersect. A drain pipe or roof scupper extends through the opening that allows rain water to run through to ground below. Some roof scuppers utilize an ornamental design such as the copper lion head or gargoyle roof scupper designs below which greatly enhance any building and dress up the drab style of ordinary plain drain pipes or scuppers.

lion head roof scupper rain spout
Roof Scupper - Lion Head Rain Spout

roof scupper lion head rain spout

lion head rain spout roof scupper
Rutland craftsmen painstakingly form, hammer by hand, TIG weld and polish these architectural copper roof scupper and rain spout designs to enhance any type of building architecture that utilizes water spouts or scuppers to drain rain water. You may view additional water spouts and scupper designs at this link Roof Scuppers - Water Spouts.
gargoyle roof scupper rain spout

fish rain spout scupper
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# Tuesday, April 01, 2014

Custom Copper Roof Finial (about 4' tall with flat roof base)

Rutland craftsmen can create custom roof finials from your design, specifications or request. Architectual roof finials can be constructed to almost any size and are typically crafted either from pure copper or aluminum. Aluminum finials can be left unfinished or painted in Rutland's professional in-house paint shop. Decorative copper finials are usually left unfinished to weather naturally to a beautiful verdigris copper patina. All roof finial seams can be TIG welded and then polished for best strength and appearance. Different finial roof bases can optionally be ordered, such as flat, gable, hip, pyramid, ridge, etc.


Roof Finial - Custom Copper Work (with gable roof base)

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# Wednesday, August 31, 2011
TIG Welding


TIG Welding Diagram


TIG Welding Copper Sculpture


Soldered, Caulked or Riveted Leader Head Examples




 
TIG Welded Leader Heads with Ground, Polished Seams

Rutland

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# Friday, August 05, 2011
Rutland creates a wide assortment of custom architectural metal finials. Their newest custom metal finial design featured here has an octagonal base topped with a double ribbed bell shape, then a spear shaped finial cone with a finial ball near base of cone. This custom metal finial was crafted from pure heavyweight copper. The metal finial sections were TIG welded together, then any seams were ground and polished for a flawless, fine crafted appearance. TIG welding makes metal finials stronger, more durable and longer lasting in addition to giving them their fine, elegant appearance. 

copper finial - custom metal roof finial shown in copper            metal finial - custom metal roof finial shown
Copper Finial Design - Custom Metal Roof Finial

While the custom metal finial project highlighted here specified a copper finial, a representation of a paint-able aluminum finial with same design is also shown above. Rutland artisans work with many architectural metals including copper, aluminum, galvanized steel, stainless steel, galvalume and zinc. Copper and aluminum are the two most chosen and workable metals for finial fabrication. Copper finials are most always left unfinished while aluminum metal finial can be supplied in (unfinished) mill finish aluminum or else custom painted in any color to the client's specifications. Architectural metal finials are frequently used as the perfect crowning touch or focal point at the top of a roof or roof peaks and tops of cupolas, domes, turrets and gazebos. Metal finials are also used as decorative finials in gardens, on top of outdoor walls, on parapets, on fence posts and at building entrances. Metal finials can be scaled to almost any size and often may be sized quite large, to better be seen from distances or from the ground and provide greater presence and architectural interest. Additional architectural metal and copper finials may be viewed at the Rutland Finials webpage. 
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# Sunday, July 31, 2011
To break up the monotony of large expanses of roof, especially non variegated roofing and oftentimes long unbroken rooflines, consider adding a roof top finial. Roof finials provide focal points of interest and accentuate your home or commercial building's roof and architecture. Finials and larger roof structures such as cupolas, domes, dormers and chimneys help to visually break up large expanses of roofing or long unbroken roof lines and make them much more attractive and interesting. Below are pictures first of plain monochromatic roofing and then pictures of more variegated roofing with roof finials and other roof structures.

metal roof line shown metal rooflines shown with expansive metal roofing
Monochromatic - Non Variegated Roofing

copper finials - roof top finials shown being installed copper finials - roof finials shown installed on top of building
Copper Finials on Top of Roof


roof finials - copper dormers and chimneys shown on large residence roof finials - shown installed on top of high steep roof
Roof Finials - Roof Dormers and Chimneys

Roof finials are available in many shapes, sizes and materials. Finials can be simple, streamlined designs, contemporary designs, classic designs or very ornate and intricate designs. Finials can range from under a foot in height to 4 foot, 5 foot or even taller. Most roof finials are constructed from metal with copper and aluminum being the most popular finial materials. Aluminum finials are light in weight, lower cost and are available either in unfinished mill aluminum or can be custom painted to match or color coordinate with any building's trim or roofing. Copper finials are typically left unfinished and really dress up any architecture with copper's beautiful, elegant, timeless appearance. While copper does cost a bit more than aluminum and other materials, copper is also the most durable and longest lasting building material and requires no maintenance or painting. Therefore copper has proven to be a very cost effective material for finials, cupolas, dormers, vents, domes and other roof structures or accessories.
copper finial design shown  copper finial design with copper finial ball shown
Copper Finials - Roof Top Finials
    
roof finial design with copper finial ball shown  roof finial design with aluminum finial material shown copper finial design with ornate copper finial balls shown
Roof Finial Copper - Aluminum Finial - Copper Finial

Rutland has over 50 roof finial designs available in a wide variety of sizes including both copper finials and aluminum roof top finials. Rutland also fabricates custom styles and sizes of roof finials according to customer specifications and drawings, including finials with weathervanes. In addition to roof finials, Rutland manufactures a wide assortment of styles and sizes of roof cupolas, roof vent dormers, roof domes, custom chimney caps and chimney pots. Rutland has extensive expertise in custom architectural metal and copper work and utilizes their in house CAD design, machine shop, TIG welding and professional paint shop facilities.

copper dome roof with copper finial design shown copper roof dome with copper finial design shown
Copper Roof Domes with Copper Finials
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# Tuesday, July 19, 2011
The stunning copper roofing turret featured in today's architectural blog article is fashioned from custom diamond shaped copper roof tiles and is topped with a spear shaped copper finial turret roof cap. This lovely turret copper roofing graces and enhances this beautiful new home undergoing final stages of construction. Additional custom copper work includes copper flashing, half round copper gutters, round copper downspouts and copper leader heads adorned with copper lion head castings. Radius round copper gutter encircling the base of the copper turret roof is planned.

 architectural copper accents featured on this multi-story home residence feauring a copper roofing turret and finial roof cap
Beautiful Palatial Home with Custom Architectural Copper Work

copper roof turret with custom copper roof tile and copper finial roof cap
Copper Roofing on Turret with Custom Copper Roof Tiles

copper turret roof with custom diamond shaped copper roof tile and a copper finial roof cap - closeup picture
Close-up of Copper Roof Turret with Copper Finial Roof Cap

copper gutter system featured with half round copper gutters, round copper downspouts and custom copper leader head with lion head design
Round Copper Gutters and Downspouts - Copper Leader Head

This custom metal and copper work is being installed by Shelby Roofing & Sheet Metal Inc. from Brampton, Ontario who services the greater Toronto metropolitan area. Shelby is a full service residential and commercial roofing, siding and custom metal contractor. They reroof old style tar & gravel or install latest environmentally friendly TPO flat roofing and sloped roof materials include asphalt, cedar, slate and metal. Shelby works with all metals from painted steel to pure copper and zinc. Their custom metal working and copper work includes standing seam panels, wall siding, dormers, fascia, soffit, flashing, gutters (eavestrough), downspouts (downpipe), chimney caps and bay roofs. All photos above are courtesy Shawn Power at Shelby Roofing (www.shelbyroofing.ca)

Rutland welcomes and appreciates pictures from all of our clients including builders, contractors, architects, designers, renovators or remodelers of new construction or renovations, whether completed installations or work in progress which feature one or more of Rutland's many roofing accessories, gutter supplies, custom metal fabrication, architectural copper work and our custom copper home decor accents, copper kitchen accessories and garden sculpture products to feature in one of our blogs. Rutland customers with architectural pictures from either residential or commercial projects please send them to us via e-mail with narrative describing your project and pictures.

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# Tuesday, July 12, 2011
There are many rain gutter styles, rain gutter types or guttering profiles and shapes available.  Many of the earliest rain gutters in the U.S. before the late 19th century were made of wood and were cut or carved into a variety of shapes from simple boxy channels to those having more ornamental carved facades. When metal roll forming machines were introduced in the early 1900's, metal gutters began to take hold of and eventually dominate the rain gutter marketplace. Most of those early metal rain gutters were being constructed into a pleasing half round shape, which still have that traditional, classical and distinctive look today. The early gutter forming machines were large, heavy and expensive so most metal rain gutters were made in factories until about the 1970's when light weight portable gutter machines were introduced and becoming popular. These light weight gutter machines could be carted around on trailers to work sites and produce the needed rain gutter on the spot. A portable gutter machine is typically set up to produce only one style of gutter and in usually only one size and sometimes two. Rain gutter styles were becoming standardized to just a few of the most popular rain gutter profiles offered by the gutter machine manufacturers. The ability to drain away a large volume of rain water led to standardization and predominance of different variations of a channel or boxy looking rain gutter.

rain gutter profiles or some of the standard SMACNA rain gutter styles pictured
Standard Rain Gutter Profiles - Styles (courtesy SMACNA)


Box gutters like in Style A above, have the largest volume for the shape and amount of gutter material used were were finding favor in large commercial, public and industrial applications by minimizing cost and maximizing water carrying capacity. Other variations of the plain industrial looking box gutter were becoming popular for residential rain gutter installation. Of these different boxy variations the Style K gutter with it's somewhat more sculpted facade became most popular and ubiquitous across American residential housing and for light commercial buildings. Consequently most of the portable gutter machine manufacturers standardized on this particular profile. This wide availability of K gutters, also known as Ogee gutters among gutter installers, also made that style of gutter the most marketed, price competitive and therefore commonly selected rain gutter choice, especially in the most universally available plain white color choice.

k style rain gutter profiles pictured in various K gutter sizes
K Style Gutters Shown in Varying Rain Gutter Sizes


box gutter profiles pictured in SMACNA rain gutter style Abox gutter beveled profile pictured in SMACNA rain gutter style D or E
Box Gutters - Style A Box & Style D-E Beveled Box Gutter


Half Round Gutters Shown in Varying Round Gutter Sizes

   quarter round gutter profiles pictured shown in copper gutter materialcustom gutter profile as a variation of quarter round gutter style pictured and shown with copper gutter material
Quarter Round Gutter Profile & Custom Quarter Round Gutter

Above are some of the rain gutter types which Rutland produces in sizes ranging from 4 inches wide to 12 inches in width. Most gutter installers portable gutter machines typically produce gutters in a 5" or 6" width and sometimes 7". Those gutter machines also only form one rain gutter profile, K style, half round or box for example. Instead of owning many different gutter machines, guttering contractors can also order different rain gutter styles and/or larger sizes from a large rain gutter manufacturer and supplier like Rutland Gutter Supply at a competitive price to accommodate their customers needs or preferences. Custom rain gutter roll forming machines can also be specified and purchased from roll forming machine manufacturers which can produce different rain gutter profiles. These less common rain gutter styles may be more decorative, flashy, unique and trendy although less competitive and sometimes more costly. Frequently they start to resemble some of the more ornately carved wood gutters or integral gutters with sculpted fascia, some may have appearance similar to colonial, cove or crown molding.

rain gutter profiles in less common or unique rain gutter styles pictured
Rain Gutter Styles - Custom Rain Guttering Profiles

   wood gutter profiles or wooden rain gutter styles styles pictured
Wood Rain Gutter Profiles (available from blueoxmill.com)

integral rain gutter installation diagram pictured
Integral Gutters - Built-in Gutter System (courtesy SMACNA)
integral rain gutter installation diagram pictured with copper flashing, copper gutter inserts or integral copper gutter liners
Integral Copper Gutter System (courtesy copper.org)

Integral gutters can be made from many different materials including wood, metal and concrete but often have a robust metal gutter insert or lining with soldered seams to insure a water tight gutter system as any leaks can prove very damaging and costly. These metal gutter inserts or linings can also be more easily and cost effectively replaced at the end of their useful life and also do not require as much vigilant monitoring and maintenance as do porous materials or materials which can crack or split possibly leading to leaks and water damage. For this reason, metal linings are sometimes used with wood gutters as well. Metal linings inside integral and wood gutters are not readily visible from the ground. The shape or profile of integral gutters, wood gutters and gutter lining inserts resemble metal gutter profiles including box styles and half round gutter profiles.

Unfinished rain gutter materials such as copper, zinc, stainless steel and galvalume will also greatly affect and enhance the appearance of all styles of gutters as can a judicious choice of vibrant gutter colors on aluminum and galvanized steel gutters. Decorative gutter hangers or gutter brackets, visually pleasing smooth round or square downspouts, decorative downspout brackets and elegant leader heads will also enhance the appearance of any rain gutter system. Rutland also offers embossed gutters in different available patterns and radiused half round gutter end caps to further increase the attractiveness of rain gutter systems. Radius or curved metal gutters in a variety of materials and including box or half round profiles and k style are a Rutland specialty as metal can readily be formed to follow irregular or rounded building and roof contours.

     embossed gutter style pictured with copper gutter radius endcap
Embossed Rain Gutter and Radius Round vs. Flat Gutter Endcap

 
aluminum gutters installed in k-style profile and half round profile copper gutters installed pictured
Aluminum K Gutter Style & Copper Half Round Gutter Profiles

 rain gutter profiles installed in k-style gutter profile and with radius copper gutter sections pictured
K Style Rain Gutter Profile with Radius Gutter Sections

 rain gutter profiles installed in half round gutter style and with both straight and radius copper gutter sections pictured
Round Gutter Style with Straight and Radius Gutter Sections

rain gutter profiles installed in box gutter style and with straight and radius aluminum gutter sections pictured
Box Gutter Profile with Straight and Radius Gutter Sections
7/12/2011 10:26 AM Eastern Daylight Time  #    Disclaimer  |   |  Trackback
# Sunday, June 19, 2011
A perfect way to dress up a home or building with a chimney is with a copper chimney cap custom crafted to accentuate your home's architecture. There are endless designs of custom chimney caps possible and they can be fully functional and protective while also providing additional architectural interest to your building. A good chimney cap design will definitely make a statement and enhance your home while also keeping out rain, promoting proper draft or air flow for your fireplace or stove and screening to keep out birds and animals and serving as a spark arrestor. Below are a few examples of custom copper chimney caps which have these qualities.

copper chimney cap with domed chimney top, bottom vents and spark arrestor copper screening pictured   copper chimney cap with copper dome top, bottom louvered venting and animal - spark arrestor copper mesh screen pictured
Copper Chimney Cap - Domed Top - Bottom Vents and Screening

copper chimney caps with covered pyramidal chimney top, bottom venting and spark arrestor mesh copper screening or woven lattice work pictured here   copper chimney cap with copper dome chimney top, bottom vents and spark arrestor - animal copper screen pictured
Copper Chimney Caps - Covered Chimney Top and Screen Openings

Rutland can custom build copper chimney caps or chimney pots in any size and in any shape or design. Choose from one of Rutland's many unique chimney cap or chimney pot designs or provide your own design and Rutland will custom fabricate your chimney cap to your exact specifications and drawing. Rutland uses heavyweight copper with TIG welded polished seams for enhanced durability, strength and a polished superb appearance. Rutland can also craft your custom chimney cap in thick gauge aluminum, either mill finish or custom painted and in stainless steel if you prefer. See more of Rutland's Copper Chimney Caps designs and you may also view some of Rutland's many standard design architectural Chimney Cap CAD Drawings.

6/19/2011 4:01 PM Eastern Daylight Time  #    Disclaimer  |   |  Trackback
# Wednesday, June 08, 2011
Buildings, including residential, commercial, public, and industrial consume about one third of all energy use and about two thirds of all the electricity generated. Demand for electricity in the U.S. is increasing three times faster than new power plants and lines are being built to accommodate this rapidly increasing demand. Heating and cooling costs dominate most building's energy usage. A building's roof can have the greatest impact on the energy consumption by a building so any technological advances and improvements in roofing energy efficiency and performance will greatly affect both energy usage and consequent cost savings. Energy efficiency, durability, performance, sustainability, recyclability and life cycle costs are the focus of green building. Architects, builders and consumers have been changing the way they select building materials and designing buildings. They are increasingly shifting their focus to green building materials and energy performance with so called cool roofs becoming a key focus. Cooling costs significantly affect a building's energy consumption in most parts of the country and cooling is the predominant cost in the southern states. Cool roofs can save up to 40% in cooling energy as reported by several studies including Lawrence Berkeley Laboratory Heat Island Group. Cool roofs essentially are roofs which reflect much of the sun's radiation away from a building, employ above sheathing ventilation (ASV) cooling under the roof, readily emit any heat which they do absorb back away from the building and cool quickly at night. The less solar radiation and heat entering a building's interior space through the building's roof, the lower the building's cooling costs and energy use will be.

 cool roof heat gain - heat flux diagram
Net Heat Flux Through Roof (courtesy coolmetalroofing.org)

Cool roofs or reflective roofs can be comprised of a variety of materials including asphalt or fiberglass shingles, clay or concrete tile, EDPM rubber or PVC roofing membrane and variety of metals as long as they can reflect away much of the sun's radiation and readily release any heat they absorb into the atmosphere. White and the more lightly colored roofing materials are the most reflective but different material composition as well as special designed and engineered coatings or paints used on them can also greatly affect reflectivity and emissivity. Some of these new coatings or paints, especially those applied to newer more advanced metal roofing, incorporate special pigments designed to provide higher reflectance of solar infrared and ultraviolet radiation. Infrared and ultraviolet radiation can contribute even more to absorbed heat energy from the sun than visible light so any type of roofing material incorporating these special reflective coatings may outperform conventional light colored materials without them. Even darker colored roofing which incorporates these special IR and UV reflective coatings will outperform older non treated darker colored roofing saving as much as 25% in cooling costs.

cool metal tile roofing shown having solar reflective coating cool roof and green roof energy saving properties cool metal tile roofing shown having cool roof and green roof properties
Reflective Cool Metal Roofing Tile (courtesy coolmetalroofing.org)

Even with the advent of newer reflective coatings, white and light colored roofing still is the best performing cool roof providing the most energy and cost savings. C
onsumers, builders and architects however still like the aesthetics in having varied colors and materials and many still favor darker roofing hues. Ultra violet (UV) represents about 3% of the total solar energy striking the earth’s surface. Visible solar energy amounts to 40% while infrared (IR) energy accounts for the largest percentage 57% of the solar energy spectrum and is felt as heat. Thus roof materials which can be coated with newer UV and IR reflective coatings, even the darker shades of roof color, can now be much more energy efficient than in the past. Darker shades of roofing still won't reflect near as much of the visible solar radiation as lightly colored and white roofing. Though with engineered reflective coatings they will now block a high percentage of the UV and IR radiation which actually constitute more of the solar energy radiation and heat gain than visible solar energy. In addition to solar reflectivity, heat emissivity of roofing materials must also be considered as a large factor affecting building energy usage and possible contribution towards heat island effects. Any solar radiation which is not reflected by the roofing surface is then absorbed, converted or transferred to heat energy and some of this heat can conduct and radiate down into the interior building space affecting cooling costs. If the roof material has good emissivity much of this heat can re-radiate back to the sky in the form of IR energy especially cooling off during the night and there will consequently be less heat build up. Any concentrated heat build up, especially in tight grouped urban areas leads to heat island effects where temperatures in the air above these heat islands can be up to 12 degrees hotter than normal, leading to higher air conditioning costs, higher use of energy and higher levels of ozone and smog.

   thermal image of Atlanta at night time showing warming heat island effects
Atlanta at Night Thermal  (Blue=cool, green=lukewarm, red=warm, white=hot)

In addition to emphasizing high solar reflectance and emissivity properties, roofs can additionally be kept cooler, limiting or preventing heat gain or heat flux down into a building' interior space below, by promoting convection cooling underneath the roof material using above sheathing ventilation (ASV). Heat emanating from the underside of the roofing can be removed using convective air flow (balanced ventilation) moving from soffit vents or eaves up to and out a ventilating roof ridge cap. Testing at Oak Ridge National Laboratory showed that by employing the natural convection of heated air below the roof covering, temperatures in an attic space are reduced. Air enters at the eave, is heated by the roof, and because hot air rises, it is naturally drawn up and vents to the outside. This natural convection controls heat gain and reduces the temperature in the
attic below.
The Oak Ridge National Laboratory study found that dark-colored metal-shingle roofs using above-sheathing ventilation had similar heat energy flows compared to their lighter cooler colored counterparts. About 30 percent of measured reduction in heat gain was contributed by ASV. When a cool reflective roof surface was used with ASV, an additional 15 percent reduction in heat gain was achieved for 45% total. The improved summer performance of cooler roofs coupled with the reduced heat losses during the winter show cool roofs can both reduce energy usage in summer months while negating any supposed heating penalty in cooler months or northern heating dominated climates.
* (see http://www.metalconstruction.org/pubs/pdf/ORNL-TM-2006-9.pdf)

A convective air space below the roofing material can be easily set up by using a batten, cross batten or metal purlin framework on top of roof sheathing or a roof deck, on which sturdy roofing panels can be attached. Less sturdy roofing material can employ a 1 1/2" metal roof deck or else just a purlin spaced layer of OSB below the existing roof sheathing. Even darker roof materials such as weathered bare copper which does not have a great solar reflectance index (SRI), can provide good to outstanding energy efficiency results with the use of either an underneath or above sheathing ventilation approach. Additionally winter or cold weather heating performance is improved with the use of below or above sheathing ventilation as that convection air space between the roof material and lower roof deck or sheathing further acts as an insulative layer and helps to prevent heat loss and condensation. Ventilated cooled roofs work great and are energy efficient in any climate. They tend to last much longer too with less heat degradation. 

roof deck batten - cross batten construction framework shown on top of which cool roofing will be installed
Batten - Cross Batten Above Sheathing Ventilation (ASV)

roof structure cut out showing an energy saving cooling ventilated convection space positioned below the roof sheathing of a copper standing seam roof installation
ORNL Copper Roof Ventilation Test (images courtesy CDA at copper.org)
roof heat gain chart comparing different kinds of roofing including asphalt and cool metal roofing to a ventilated copper roof

* These test results reflect using a 1½” fluted metal roof deck, ¾” OSB (plywood would work just as well), underlayment and red rosin paper underneath a standing seam copper roof. The use of a fluted metal roof deck is optional; similar results can be obtained by using other designs that provide an air space below the deck. The test roof had a 4/12 slope and faces south. The ventilated copper roof system was compared with a control roof of typical black asphalt, a typical non-ventilated copper roof assembly and two very good examples of above-the-sheathing, ventilated stone-coated steel roofs using special Cool Roof reflective coating colors. The graph above shows the ceiling heat flux crossing the attic floors of the respective attic assemblies. The light gray stone-coated cool metal roof (SR246E90) dropped the ceiling heat flux by roughly 29% of that measured for the asphalt shingle roof (SR093E89). The copper roof with the fluted metal deck further dropped peak ceiling heat flux an additional 23% of that for the coated steel shingle roof, bringing the total reduction for the copper roofing system to 50% of the asphalt control. Peak heat flux dropped an additional 1.5 Btu per hour per square foot for the copper roof as compared with the stone-coated metal roof. These results show clearly that a vented copper roof assembly will greatly reduce heat gain resulting in lower energy costs for the structure. Further, it dispels the notion that copper roofing must have high reflectance and emissivity in order to be effective in saving energy. * See Copper Roofs Are Cool

Cool roofs with their large energy saving and cost saving benefits can be realized by employing light colored roofing materials with very good solar reflective properties or roof materials using special engineered reflective coatings or most any type of roofing utilizing balanced and well functioning
below or above sheathing ventilation (ASV). White or lightly colored highly solar reflective roofs employing ASV still provide the greatest energy and cost savings. It must also be stated that using higher R-values for ceiling insulation or better insulation below the roof in structures without attics will also control or limit heat gain into a building interior and consequently also lessens the heat gain differential using less reflective roofing materials or darker roof colors. Adding a radiant barrier and insulation board underneath your lower roof deck and convection space can further prevent the intrusion of heat gain from roofing into attic and living space. Additional attic vents, gable vents, dormer vents and roof vents will also reduce heat gain from roofing. More sloped roofs also perform much better and have less heat gain than flat or low sloped roofs and should be considered for any new construction. Some buildings with flat or low slope (<2:12) low-rise roofs may also be candidates for retrofitting them with a lightweight sloped roofing structure framework when re-roofing them especially with lighter weight roofing such as metal roofing. That framework could simultaneously also provide a convective roof cooling space underneath the new roofing. Resulting lower energy costs, less maintenance and no roof replacement for 50 years or longer could provide a good return on that investment. The bottom line is that when evaluating roofing energy efficiency, heating and cooling costs, looking only or primarily at roofing material properties such as SRI, reflectivity and emissivity is not sufficient to see the whole picture. You have to look at what effect the entire roofing system and structure has on heat gain, cooling load, heat loss and energy usage of the building and it's systems. The performance of the whole system must be examined in totality when the end goals are reducing energy costs and going still further, in achieving the most eco-friendly green buildings. In a subsequent blog article, the green building aspects of roofing will be discussed in more detail. Then again there are specialized roof systems such as KME's Tecu Solar System copper roofs below which are expressly designed as efficient solar heat collectors for heating a building's interior space, it's hot water and even swimming pool. Where do such technically advanced roofs fit into energy efficient roofing guidelines, requirements, ratings and green design certification?

 copper roof integrated solar heating collection system shown in patinated green copper finish
Copper Solar System Roofs (photos courtesy KME.com - Italy)
copper roofing solar heating collector system for heating building and hot water system - shown in new raw copper finish
6/8/2011 8:55 AM Eastern Daylight Time  #    Disclaimer  |   |  Trackback
# Monday, May 16, 2011
Rutland supplies a complete array of metal roll formers or roll forming machines including single panel and double panel roll formers, decoilers (metal roll uncoilers), slitters (metal slitting machines) and embossers (metal embossing machines). Roll forming is a continuous forming or shaping process in which a long sheet of metal or metal coil roll is fed through a series of metal rollers, each only incrementally performing the forming until the metal reaches it's final shape or cross-section profile when it passes the last rollers. When metal needs to be formed into an exact profile in either large quantities or in long lengths, roll former machines accomplish this task in an ideal fashion. Roll formed metal has an advantage over metal extrusions of similar shape with roll formed sections typically being much stronger and lighter with the cold metal having been work hardened. Metal passed through and shaped in roll forming machinery can also be pre-finished or painted saving an additional fabrication step and labor. Finishing labor is greatly reduced with the high volume capability of roll forming. Roll formed metal is used for many architectural or construction purposes including metal roof panels, metal roofing tile, metal wall panels or siding, metal purlins or wall studs, metal door frames, metal shutters, metal floors or decking, guardrails and many other applications.

roll former machines - metal roll forming machinery pictured
Roll Former - Metal Roll Forming Machine

A decoiler, also known as an uncoiler, is a spindle type uncoiling machine which feeds the metal coils used in roll forming operation at an exact rate to the roll former. These metal coils can be rather large and very heavy and the large decoilers are often provided with hydraulic operation. Metal coils come in many assorted widths and lengths and also in a variety of metals including aluminum, copper, galvanized steel, galvalume, stainless steel and zinc. The metals may be in a raw state or unfinished, especially in the case for your green materials like copper, zinc and stainless steel and sometimes even galvalume which are more resistant to corrosion. Metals which are more subject to corrosive effects such as aluminum, galvanized steel and galvalume may be pre-finished or painted before passing through the roll former without the finish being damaged. The precisely shaped metal exiting the roll former machines is usually cut to pre-determined lengths by the machine. The pre-cut metal panels can then be transported to the job site and installed.

decoiler - uncoiler for uncoiling metal coil rolls for metal roll forming operations
Decoiler - Metal Roll Uncoiler

An embosser or metal embossing machine can emboss or impress one of many attractive patterns into the metal and used as is or fed into roll forming machines, providing additional architectural interest to wall panels, roof panels or flooring decks. The embossed patterns can also add strength or rigidity to the metal material. Usually a decoiler is situated at both the feeding and receiving ends of the embosser machine for volume operation.

embosser machines - metal embossing machine pictured
Embosser - Metal Embossing Machine


Metal Embossing Samples

A slitter or metal slitting machine cuts sheets or rolls of metal coil into exact widths when the metal material needs to be trimmed to size before being fed into roll forming machines. Decoiler machines positioned before and after the slitter can both feed and receive the metal material when long lengths are cut to size.

slitter machine for metal coil roll slitting pictured
Slitter - Metal Slitting machine

Roof panel, wall panel and floor deck profiles or shapes which are formed into the metal material by the roll formers provide added strength, rigidity and architectural interest. The metal panels formed can be shaped to interlock with each other and an attractive roof tile look can also created by metal roll former machines. 

roof tile - roll form roofing tile profile picturedroof panel - roll form roofing panel profile pictured
Roofing Tile Sample Profile - Roof Panel Sample Profile


See more on the different types of roll forming machinery, samples of various wall and roof panel profiles and samples of metal embossing patterns including pictures, videos, detailed information and specifications available at Rutland's Roll Formers website.
5/16/2011 11:10 AM Eastern Daylight Time  #    Disclaimer  |   |  Trackback
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