How to Build a Copper Roof

Copper turns from a bright bronze color to a warm green with weathering.

Copper is a durable material that has been used for hundreds of years in architecture. It is warm and adds to the character of the building. Some copper roofs have been in place for centuries, and it is extremely resistant to the elements.



The economic advantage of copper roofing is long term, as it is a low-maintenance material, in addition to its longevity and requires no painting or finishing. Through natural weathering, the bronze color of copper gradually leads to, what is described by Copper.org as an "elegant green patina finish."

Things You'll Need

• 16 oz. or 20 oz. cold rolled copper sheets
• Copper shingles - depending on style of roof
• 30 lb. roofing felt
• 4 lb. (at least) building paper
• Flashing
• Copper nails and washers
• Plywood underlayment (if necessary for replacing bad wood).
• Power pan former
• Power seamer
• Brake
• Dumpster for cleanup
• Gutter former and gutter accessories

Instructions

Underlayment

1. Clean the underlayment surface of any debris or projecting nails or screws. Any rotten wood should be replaced with the same width plywood. If replacing the roof, all previous roofs should be already ripped off and disposed of.

2. Flash around all protrusions in the roof such as chimneys and pipes along edges. Install new ventilation pipes or systems.

3. Cover the entire surface of the roof with felt, 30 pounds or heavier. The roof felt is typically secured with construction staples using an swing staple-hammer. This underlayment acts as a cushion for the copper or other roofing, as well as a temporary protection for the exposed roof.

4. Lay a sheet of building paper over the felt. The reason for this is that the metal roof conducts heat, and the felt will melt and bond to the metal, inhibiting movement and flexibility that eventually can cause tears, which can lead to leaks. The building paper acts as an intermediate surface that will not bond to the copper.

5. Create uniform pans or sheets of copper with a power pan former. These should be nailed to the underlayment with copper nails.

   Power pan formers take flat or coiled copper sheets and create uniform pans of any length. Power seamers are used to create seams that connect adjacent sections of the metal roof. Other specialized equipment for this project include a seam former, a power curving machine, a brake, a portable brake and gutter-forming machines. Additionally, standard tools such as hammers, swing-guns (for staples) and other standard roofing tools are necessary.

6. Create gutters from a power gutter-former and install.

7. Clean up every day. Don't leave debris around, not even nails, at the end of the day and make sure that not even a small piece of debris is present by the end of the project. This will impress the customer as much as the new roof and earn you a good reputation.

Tips & Warnings

• A copper roof adds dignity and warmth to a building or home. Choose copper roofing to set a house apart from others in the neighborhood.

• "It is far better to have a contractor install the roof rather than risk improperly installing your investment," according to Copper Roofing.net

• Installing a new roof of any type usually requires some construction background. Copper roofing requires specialized equipment and training. Permits are necessary for most types of roofing or new construction.

References

• Copper.org: Roofing Systems
• Copperroofing.net: Copper Roofing

Resources

• Specialty Copper Roofing
• Old World Distribtors, Inc.