Installation begins with complete tear-off to the roof deck. The deck is inspected for rot, fastener pull-through, and structural deflection. Damaged sheathing is replaced with CDX plywood or OSB rated for the fastener schedule.
A high-temperature synthetic underlayment is installed over the deck with 6-inch overlaps and fastened per the manufacturer's specification. The underlayment provides a secondary water barrier and protects the deck during the panel installation sequence.
Panel Layout and Fastening
Standing-seam copper panels run from ridge to eave in continuous lengths when the slope allows. Panels are formed on-site or pre-formed to the roof's dimensional requirements. Concealed clips are fastened to the deck at 12-inch intervals along the panel seam, and the panel edge locks into the clip without penetrating the copper surface.
Seams are either mechanically seamed with a hand seamer or soldered. Soldered seams provide a watertight joint that resists capillary action and wind-driven rain. Mechanical seams are faster to install and allow for thermal expansion without solder cracking.
Flashing and Trim
Copper flashing is fabricated for valleys, ridges, chimneys, and wall transitions. Valley flashing is soldered at the seams and extends 12 inches under the panel on each side. Ridge caps are formed from the same copper coil as the panels and soldered or mechanically seamed to the ridge line.
Eave and rake trim is formed from copper coil and fastened to the fascia with stainless-steel fasteners. Copper and stainless steel do not react galvanically. Aluminum, galvanized steel, and zinc fasteners are not used in contact with copper. They corrode when moisture bridges the dissimilar metals.
Gutter Integration
Copper gutter systems are specified to match the roof material. Half-round or K-style gutters are fabricated from 16-ounce or 20-ounce copper and soldered at the seams. Downspouts are copper, and the gutter hangers are copper or stainless steel.
The gutter system is installed after the roof panels are in place, and the eave trim is integrated with the gutter back to prevent water from running behind the gutter.