![\"The](\"\/wp-content\/uploads\/2015\/09\/Screen-Shot-2015-09-15-at-12.43.19-PM.png\")
<\/a>The roof of the Callaghan
residence in Ponte Vedra
Beach, Fla., features 12,000 square feet of Petersen Aluminum\u2019s Snap-Clad in Slate Gray.<\/p><\/div>\u201cWith the larger lot, we thought we could do something unique to the neighborhood,\u201d Callaghan says. \u201cWhen we first met with the architect, there were a few keys we wanted to stress. First, we didn\u2019t want a boxy-looking house. We also wanted shingle-style siding and a metal roof. We like the look of the metal roof, we like the durability, and we thought it would be a good way of complementing the shingles on the house.\u201d<\/p>\n
At every phase of the project, the team of construction professionals ensured the project was executed with precision, down to the last detail of the metal roof.<\/p>\n
THE DESIGN<\/h4>\n
The house was designed by Jaycox Architects & Associates<\/a>, Jacksonville, Fla. According to William R. Jaycox, principal, the plan made the backyard pool the home\u2019s focal point. \u201cThey wanted to do a casual, shingle-style beach house that wasn\u2019t like everyone else\u2019s house,\u201d Jaycox notes. \u201cWe designed the house so it was mostly single-story and spread it out around the pool, which made for an interesting roof design. It\u2019s all in small modules.\u201d<\/p>\n The L-shaped home features a master-bedroom suite on one side while the other side contains the living room, dining room, kitchen, family room and guest bedroom. \u201cThis one also has a four-car garage under the main roof, and, because the house wraps continuously around the pool, you get a fun little foyer in the front with a little cupola up above, you get the dormers for the bedrooms in the attic, and the master suite is a little pod unto itself,\u201d Jaycox adds. \u201cThe back has a pool pavilion separate from the house. When you put all of those elements together, you get a very interesting structure, and the metal roof was perfect because it accentuates the lines.\u201d<\/p>\n The roof system specified included 12,000 square feet of aluminum panels in the cool-color Slate Gray. \u201cThis house is only a few blocks from the ocean, and in those cases we typically use aluminum,\u201d Jaycox says. \u201cWe\u2019ve had great success with that system. It\u2019s absolutely bombproof from a corrosion standpoint with stainless fasteners, heavy-gauge aluminum and the Kynar finish.\u201d Thorne Metal Systems installed a high-temperature, self-adhered underlayment beneath the metal roof, as specified.<\/p><\/div><\/p>\n When applied by a certified installer, the system can qualify for a 20-year Oceanfront Finish Warranty from the manufacturer. In addition, the roof meets all Florida\u2019s tough building-code requirements. The system, consisting of 0.040-gauge aluminum, 16-inch-wide panels with fastening clips spaced at 24-inches on-center, carries a Miami-Dade NOA with a -110 PSF uplift. (The UL 90 uplift is -52.5 PSF.)<\/p>\n The roofing contractor on the project was Thorne Metal Systems of Middleburg, Fla. Owner Bill Thorne has been installing metal roofs since 1989. He formed his own company 13 years ago, and it has become the go-to metal roof installer for Jaycox Architects Thorne has a lot of experience installing this particular aluminum roof system. \u201cThe system is a very easy system to install,\u201d he says. \u201cIt\u2019s very user- friendly. The panels have male and female joints that snap together and are held in place with stainless-steel clips.\u201d<\/p>\n PHOTOS:<\/strong> Petersen Aluminum Corp. The structure was designed to wrap around the pool, which is the home\u2019s focal point.<\/p><\/div>Challenges on the Ponte Vedra Beach project included the roof\u2019s size and complexity. \u201cThis was a large project, and the roof is very cut up,\u201d Thorne recalls. \u201cIt has many different angles and an extreme pitch.\u201d<\/p>\n According to Thorne, the key was attention to detail. \u201cWe specialize in tough projects,\u201d he adds. \u201cWe make sure the hips line up, the ridges line up, the panels line up from side to side. It takes extreme focus from everyone at the company, from the top down.\u201d<\/p>\n Thorne credits Earl Drummond for maintaining quality control on the job site, and his own son, Cody Thorne, for managing the office and scheduling personnel. \u201cThe two of them work together to make sure everything runs smoothly,\u201d Thorne says.<\/p>\n The process of ensuring all the panels line up correctly begins long before the company is on the site. \u201cYou need to address all of the issues in the layout,\u201d Thorne asserts. \u201cIt\u2019s all in the preparation. You also have to take into consideration the penetrations coming through the roof and make sure the penetration is in the middle of a panel and not on a rib.\u201d<\/p>\n The company\u2019s attention to detail extends to safety. \u201cSafety is a big, big concern for us,\u201d Thorne adds. \u201cWe are always pushing safety, and we never use subcontractors. I tell my guys, \u2018You\u2019re being paid by the hour. Do it safe and do it right. If it takes longer than we planned, don\u2019t worry about it. That\u2019s my problem.\u2019\u201d<\/p>\n On this project, the company used full-body harnesses and self-retracting lifelines on the roof at all times. \u201cWe make sure everyone has the proper personal-protective equipment,\u201d Thorne says. \u201cWe also make sure everyone has sunblock to prevent skin cancer. It\u2019s something you just have to do. And you have to remember to hydrate, hydrate, hydrate on the roof. It can get very hot.\u201d The house is only a few blocks from the ocean, which prompted the architect to specify heavy-gauge aluminum, stainless fasteners and a Kynar finish.<\/p><\/div><\/p>\n Thorne Metal Systems installed a high-temperature, self-adhered underlayment beneath the metal roof, as specified. \u201cThe architect did a great job and paid a lot of attention to waterproofing, which was a big concern,\u201d Thorne notes. \u201cIt wasn\u2019t even leaking before we put the metal roof on.\u201d<\/p>\n Scheduling the work of the various trades can be difficult, but Thorne credits C.F. Knight with excellent management on the job site. \u201cThere was a lot of coordination necessary on behalf of the general contractor,\u201d Thorne recalls. \u201cWe had to pre-flash for the painters so they wouldn\u2019t overspray our panels. There was a lot of coordination handled by the superintendent on the site. Everything went very smoothly. It was a team effort.\u201d<\/p>\n PHOTOS:<\/strong> Petersen Aluminum Nowhere was the team effort more obvious than with the many architectural details for the metal roof. The architect, manufacturer and roofing contractor all reviewed the drawings to make sure they were on the same page.<\/p>\n The roof features multiple dormers; the windows supply light to the upstairs bedrooms.<\/p><\/div>\u201cWe\u2019ve worked on those details on many, many projects, and we\u2019ve really refined them,\u201d Jaycox says. \u201cWe coordinated with the manufacturer on the size that they wanted, and then we worked with the contractor to ensure he followed the drawings and built it the way we drew it.\u201d<\/p>\n Thorne often provides feedback on details and makes suggestions. \u201cWe use the manufacturer\u2019s recommendations and elaborate from there,\u201d he says. \u201cWe go above and beyond to ensure the system will perform well. We don\u2019t want to be afraid to answer our phones when it\u2019s raining out.\u201d<\/p>\n The construction phase took just over a year to complete, and Jaycox and Thorne look back on the project with pride. \u201cWe do high-end residential for a living; each one of them is different but that one was an interesting little amalgamation of roofs\u2014like a little village\u2014 and it turned out great,\u201d Jaycox says. \u201cI was very happy with the result.\u201d \u201cThe homeowners were awesome to work with on this project,\u201d Thorne remembers. \u201cThey were open to our suggestions and asked for our input. They thanked us and even had a catered meal for everyone on the job site near the end of construction. That doesn\u2019t happen very often.\u201d<\/p>\n The bottom line is a very satisfied customer. \u201cWe couldn\u2019t be more pleased,\u201d Callaghan adds. \u201cA metal roof costs more but it lasts longer. It\u2019s also a safer roof in high winds, and hopefully we won\u2019t have a hurricane but you never know, so we felt the roof was a good investment. In fact, we also purchased a summer home in New Hampshire and we\u2019re getting quotes to put a metal roof on it.\u201d The cupola is one of many detailed touches in the roof.<\/p><\/div><\/p>\n PHOTOS:<\/strong> Petersen Aluminum <\/p>\n Roofing Contractor: Thorne Metal Systems, Middleburg, Fla., (904) 284-4353 Aluminum Panels: Snap-Clad from Petersen Aluminum Corp.<\/a> When Charles Callaghan purchased the two vacant lots next to his home in Ponte Vedra Beach, Fla., he thought they would form the perfect location…<\/p>\n","protected":false},"author":93,"featured_media":3158,"comment_status":"open","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":false,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":"","jetpack_publicize_message":"A Metal Roof Crowns a Residential New-construction Project","jetpack_publicize_feature_enabled":true,"jetpack_social_post_already_shared":true,"jetpack_social_options":{"image_generator_settings":{"template":"highway","enabled":false}}},"categories":[42],"tags":[166,3892,3306,3886,3889,3891,650,348,3893,407,1880,3885,3884,3887,3888,3890],"jetpack_publicize_connections":[],"yoast_head":"\n<\/a>THE INSTALLATION<\/h4>\n
\n& Associates and the general contractor on the project, C.F. Knight Inc.<\/a>, Jacksonville.<\/p>\n
\n
\nThorne Metal Systems usually fabricates the panels on the job site. \u201cWe have the machines, and we can just order the material in coil form from the manufacturer and we roll it right there on the job,\u201d Thorne notes. \u201cIt cuts down on freight and cuts down on damage to material. We can fabricate panels to whatever length we want. We often have panels 110- or 115-feet long, and you can\u2019t even ship material like that.\u201d<\/p>\n<\/a><\/a>
\n<\/p>\nDETAILS, DETAILS<\/h4>\n
<\/a><\/a>TEAM<\/h3>\n
\nArchitect: Jaycox Architects & Associates<\/a>, Jacksonville, Fla.
\nGeneral Contractor: C.F. Knight Inc.<\/a>, Jacksonville<\/p>\nROOF MATERIALS<\/h3>\n
\nUnderlayment: Mid-States Asphalt<\/a><\/p>\n","protected":false},"excerpt":{"rendered":"