This 200 Square Metal Roof was Replaced in One Month with No Business Interruption 

The deteriorating metal roof was replaced using a structural sub-purlin system that allowed for 6 inches of compressed R-19 Insulation.

The deteriorating metal roof was replaced using a structural sub-purlin system that allowed for 6 inches of compressed R-19 Insulation.

Global Archery’s company headquarters is located in an older 1980s vintage metal building in Ashley, Indiana. The existing roof had several penetrations for equipment that had long since been abandoned. John Jackson, Global Archery’s owner, stated that it was a battle to keep his inventory safe and dry, so something had to be done.

Fortunately, a nearby contractor in Goshen, Indiana had some excellent solutions available that would stop any further problems from the deteriorating metal roof. Tim Short of Zehr Construction, Inc. recommended that they utilize a Roof Hugger, LLC structural sub-purlin system. The factory-notched Roof Hugger system would be installed directly over the existing oddball 20.5” on center vertical rib standing seam metal roof with stand-off clips. In addition, the existing roof system’s structural supports were bar joist, so, Zehr needed a supplier that had the flexibility and versatility to suit the unique demands of this project.

The deteriorating metal roof being replaced using a structural sub-purlin system

Since Roof Hugger can accommodate any rib spacing and height, the 20.5 inches was not a stumbling block, and neither were the existing stand-off clips. Roof Hugger supplied over four-thousand lineal feet of their Model-T sub-purlin that has a field bend-out bracket that fastens to the existing roof ribs. This bracket prevents roll in the sub-purlin during thermal expansion and contraction. The 4.5-inch height of the Model-T allowed for 6-inches of unfaced fiberglass insulation to easily be installed between the old roof and underside of the new metal roof.

The existing building was 120 feet wide x 168 feet long, requiring a new metal roof with panel runs of 60 feet from eave to the ridge. A 24-gauge bare Galvalume™ MBCI Double-Lok® roof was selected and shipped to the jobsite full-length. A total of 20,160 square feet of Double-Lok was installed by Superior Rigging, a metal roofing sub-contractor located in Lagrange, Indiana.

Metal Roof constructed with a structral sub-purlin systemWith the assistance of Global Archery’s drone, aerial photographs were taken during the installation allowing him to keep tabs on the progress. The work was started in late August and completed October 1st – an impressive timeline considering that they were able to complete the 20+ thousand square foot re-roof in little more than a month. Thanks to the commitment of Zehr, Roof Hugger and Superior Rigging, the job was completed without any interruption of operations for Global Archery.

Visit these websites for more information: Global Archery, Inc. at, Roof Hugger, LLC, at, MBCI at and Zehr Construction at

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