53 year old Bulter metal building

[threeputt]

57 year old Bulter metal building

I have a metal building I use for storage and sometimes working. The building was built in 1961 and has held up good but the roof is rusting pretty bad. I need to put a metal roof over the one on now or tear off the metal and install new one. It only leaks where the skylights are installed but the other part is showing lots of surface rust. The skylights are made of fiberglass and it looks like small holes are beginning to show up. I put cool seal on part of the roof in 1995 but it is now showing surface rust. Not sure how long before it comes all the way through, could be many years from now. I could go up and start sanding and painting it but I think that might take me forever. The building is 70x50. I do not need to spend a fortune on it as I am now retired. I had a so called painter quote me a price of $8000.00 to paint it a few years ago but no way I would trust his work.There is a business right across the road from me that makes the metal and they do sell to the public. I thought about buying the sheets and just installing it on top of the metal on their now but make sure it would not touch. Any thoughts on how I can repair this old building without breaking the bank. Tom

 

[countryroad82]

Me personally, I would ditch the skylights first, then Cool Seal over top of everything else. That old metal is tough stuff, as long as the flanges aren't crushed by careless steps it lasts and lasts. The skylights are your problem, when I had my building built I had the included skylights put on the sides rather the roof because they are always a problem down the road. Where you may run into an issue is most new-style metal roofing material does not match up to the old stuff so you may have to scrounge around to find some old material or rig up a way to use the new. The good news is you already said you're retired so you have the time to figure this stuff out lol

 

[RPH]

Butler is still around. Contact them and ask questions. There on the southern east coast. Was at there plant but been to too many plants over the years.

 

[Red05GT]

We have a 20 x 30 Butler building that was built in the 50's. It was sound but pretty
unattractive as far as buildings go. We found a deal on Styrofoam beadboard and cut it
to fit inside the webs of the panels. We then screwed 1/2 inch plywood over the webs,
felt papered and then put grand rib metal over that. We did the same on the inside
of the walls and used liner panel to finish off the inside. We did this 5 or 6 years ago,
and it eliminated the problem of condensation inside the building. The exterior of the
sidewalls we just screwed the siding over the existing flat surface. Looks like a new
pole structure from a distance.

 

[threeputt]

Redo5gt, how much did that cost you back then? My wife does not want me up on the roof but I think I can handle it. I am almost 67 and when I last used the Cool Seal on the front part I was in my mid 40's. We have always had condensation in that building .I remember when I was working there years ago it would rain on me in the morning if you know what I mean. I just loved to get hit with water in my face on a 30 degree morning Thanks for all the tips from everyone. This old building has stood the test of time except those skylights. I just do not want things I store in it to ruin from water damage. I think I can handle the skylights replace. If you read about man falling through building it would probably be me Also like someone mentioned this building is ugly. Like the colors that was used on cars in the 60's. It looks sort of pink and faded something

 

[Red05GT]

threeputt, I got the Styrofoam dirt cheap at the time so that is going to be a major part
of your cost for this project. Figure $ 50. a square for the beadboard, $50. a sq. for osb
or plywood, $ 10. sq. for felt, $ 60. a sq. for Grand Rib metal, probably another $ 20-30
a square for miscellaneous trims and fasteners, about $ 200. per square for materials.
That's about what the painter quoted you, but of course this doesn't cover any labor.
But the paint job is not going to fix your condensation problem. What part of the country
are you in?

 

[threeputt]

Thanks, I live in central Alabama

 

[kbs2244]

First, crawling around on a roof is young mans work.
What you are talking about isn’t rocket science, but it does require some balance and reflexes.
Just accept the fact that those days are gone.
Hire some young guys and get them some good platforms to work from.
(It is a hard lesson to learn. But I now know that just because I know how to do something doesn’t mean I can do it.)

Second see if you can match the rib pattern with new stuff.
I would expect so. There isn’t much need to change them.
Then look for some newer material for the skylights
Plastics are one of the ever improving things out there.
UV and abrasion resistance has improved tremendously in the last 50 years.

Replace any panels with pin holes and then paint the whole thing for extra protection and looks.

 

[Bib Overalls]

My friend Barry is going to have a section of old, rusted roof covered with silver covered bed liner. Apparently it is warranted for almost forever in this application.

 

[Orange65]

Be careful on the roof. A friend of mine had a brother that fell thru one of those degraded fiberglass roof panels and died. Replace those panels- IMO, with new metal panels. Even if they are not leaking I would remove them.

If the roof panels are galvalume and the rust is just surface rust, I would look into rust treatments like POR15 or something that either converts the rust or encapsulates it. I would then top coat it with a good paint or possibly the coating mentioned above.

Where in central Alabama? I have a house in Clanton.

 

[M17715]

I would just cover the roof with new metal siding/roofing. Just screw it right into the old roofing. It should last for another 50 years.

 

[Bib Overalls]

I live on Lake Martin.

Great area. Used to visit occasionally when I was stationed at Ft Benning. Great place to kick back and take it easy.

 

[threeputt]

I just got around to logging back here and seen the posts. I noticed where one person said to leave this up to a young person. Most around here are strung out on something and no way I want one to go on top of my building. I can still do what most any young person can do as I am in good health and I do work out. The person that poured the concrete in this building in 1961 was 83 at the time. He could out work any young man around. His son did concrete work until he was in his 80's. I have a first cousin who just turned 81 who runs a D7 everyday and can outwork any young person around. I can still manage to do most anything and I have been on this roof many times so I know where and where not to walk. Also the only way it will get repaired correct is I do it. I can also use a safety rope to get this done. I appreciate the tips but to say just because my age tells me I might be older and to leave it to young people is not going to happen. I like the idea of ditching the skylights then Cool Seal over top of everything else. I plan on doing when the fall gets here. To hot now unless I do it at 5 am lol. Thanks for the tips and remember what I said about age. Its only a number. I saw a man yesterday that was telling me he could no longer do what he once could. I asked how old are you and he said he was 51. I got him 16 years. I plan on being careful but I do plan on doing the job myself. Thanks for the tips though. Orange 65 I drove through Clanton two weeks ago. The Peaches are ready and look great. Take care to all and if you read about an old fool falling off a roof in central it is probably me but I will have a rope tied to me. Tom

 

[truckman5000]

Seems like you up for the task.
The age thing i do get it. If your up for it do it.
I think what others mean is, what is your time worth/getting hurt doing the job?
Personally i have an area at my home that needs to be side walled. Yes i can do it. Its a very tricky area and id have to buy 500$ in staging. The foreigners (no offence) will strip and side for less than 80 a square. So in this matter i"ll pay to have it done.
I do understand why you want to do it, to get done correctly. Maybe oversee someone..
Good luck

 

[kbs2244]

I am the guy that said "It is young mans work."

I understand your concern about "young drug users."
And I also know those my age that can out work "youngsters."
But my feet now belong on the ground, not 30 feet above it.
You are not talking something where years of learning technique can out class young muscle and reflexes.
Your job is classical “bull work.”

Talk to the local H S team coaches.
They know the kids that are clean and can take direction.
And those that can use a few summer dollars.
If you can explain, in detail, exactly what you need done, any kid that can run a HS football play can do what you need.

And you may end up with a multi-generational friend.
And they can be handy to have sometimes.
(Don't be surprised if the coach shows up at your place to check on his guys.
Many of them take the “life lessons” part of their job seriously.)

 

[fnieto]

Took me three full days (with help) to skin the roof on my 40'X80'. I'm sure you could replace the old with new safely. I opted out of sky-light panels as the ploy carbonate would only last about ten years in Arizona. I believe your unto the task but you really need some help and perhaps a reach fork.
If you start at the last panel placed (old) and work back words you would still have a safe place to stand while working.
Are you sure a good coat of elastomeric roof coating would work? That stuff is what most our roofs in Arizona are coated with and it hold up well. The surface needs to be fairly clean and can be sprayed on if thinned a bit.
Good luck

 

[southalabama]

I'm in south alabama

Butler must have been the big dogs back in the day. A lot of the older metal buildings are butlers. Dad has a business in a 40 yr old building. We are having the same issues. We've put sealant to the point it's time for a new roof. Dad doesn't want to spend the money. I guess you get in 70s you don't think long term. The skylights are brittle and need to go. I'm afraid we gonna fall thru.

 

[fnieto]

Its refreshing to know these roofs last 40+ years (probably longer in AZ) as I'm 51 years old and just did this. It won't be my problem when the time comes. LOL
kbs2244 has good advice, but the two guy on my roof don't weigh more than 160 lbs. The ribs will crinkle if a big boy steps on a ridge.
BTW many older folks refer to steel building as "Butler building" because Butler was the leader back in the day. I have a Muieller and have been very pleased so far.

 

[readhead]

I'm in the metal building business. There are two common ways to take care of this.
First, remove the rake trim and start replacing sheets in reverse order. If you are using a formed ridge you should do both sides as you go. I would not replace the lite panels.
Second, install a furring product over the existing roof and install new sheets and trim. The second way provides an opportunity to install insulation between the sheets.
If you put some kind of coating on the roof all you have is an old failing roof with a coating on it.
A metal component company should be able to work up a quote for all the material.

 

[6768rogues]

I am 62 and still able to do almost anything. However, there are things I no longer do such as replace the roof on my house. I realize that a fall that I could have withstood years ago might be fatal now and that if I get hurt it will take longer to heal if ever.

 

[threeputt]

Just accept the fact that those days are gone.

No, those days are not gone. Age is only a number. This metal roof is still in great shape other than light surface rust. I have already replaced one skylight panel. My questions is will this newer style panel last ? It is white in color and really makes the inside of building bright. Looks like a light is on in the area that was replaced and I mean bright. It was a cloudy day also.

Yes I did this myself with the help of a person my age. He weighs probably 130 and I weigh 165 so we are both in good shape and not overweight. We are also very careful doing this. These new skylights do seem flimsy so my next question before I replace any more is will these things is will they hold up like the original ones made of fiberglass ?

The one we removed you could stick your hand through . The new panel that we did replace fit like a glove to this old roof.

 

[fnieto]

Not sure how to answer your question on durability of the replacement sky light. If you bought a polycarbonate material it should last a while. It also depends on the region you live in. Here in AZ, Plastic and alike don't fair well.
Finally, age is a number, but healing takes longer after 45 or so. I'm 51 and still firefight and build/fix on my own stuff, but nothing is getting easier (phyically).
good luck.

 

[threeputt]

We have completed two skylights so far and you just cannot believe how bright this old building is.
We have four more to go and I think I will just remove the skylights on those and install metal. When the doors are open three of those skylights are blocked anyway.
I am also not sure how hot this building would get if we installed all six skylights. I am well pleased with the two we installed No leaks so far but we took our time and was very careful.
My cousin who is my age (67) helped me with this. I will say I am not as young as I once was but I am still able to get on that roof. This building has a dropped down front section so we were not as high as the next four but still high enough so again safety is number one rule.
I have to keep telling my cousin to slow down and lets not get hurt. I will try and get a picture of what the inside looks like since the skylight install. It looks like the lights are on all the time. Tom

 

[930dreamer]

Let's see some pictures of the roof in question.

 

[CNGsaves]

Kudos to you sir for improving the old Butler building !! When done properly, those "skylights" make a real difference in getting natural light in building (ie free light).

As for age, Jack LaLanne at age 70 or 80 could work circles around millions of guys half his age !!
http://en.wikipedia.org/wiki/Jack_LaLanne

 

[Charles (in GA)]

One of my neighbors has skylights. They are about black from dirt and tree sap from the pines. That convinced me right there to not do them in my place. I did put in two sidewall skylights in the south wall. Turned out to be a waste as I ended up putting a pallet rack in front of them, but the light helps finding stuff on the pallet rack. Of course I have doors on the east end that are skinned in translucent fiberglass, 56 ft wide by 14 ft tall, and a 14Hx12W garage door in the west end with five panels (10 ft of height) of tempered glass. In addition I used man doors with glass in the top half of them.

If the weather is good, I just open the place up.

Charles

 

[readhead]

Good job. The absolute best option for a metal building. Here in cold country we tend to put them high on the side walls so they don't get covered with snow.

 

[threeputt]

I had to slow my cousin down several times and keep reminding him of safety. Other than that things went good. When he starts doing something he is one to go at it 200%. I kept telling him we both are retired and I am in no hurry so if he didn't slow down I would just call off the project. I finally made him understand.

It will also be a little more spooky doing the other four as they are higher up. The building design is the front area is lower so it did seem better when doing the front two.

As I mentioned I don't think I will go with the skylights on the other four. It would make the shop warmer in the winter but I don't work when it real cold anyway. When the doors are raised three of the skylights are blocked anyway so regular metal is what I will go with.

 

[threeputt]

Update on skylights. They are holding up great but if I had to do it over I would have replaced the old ones with metal. These skylights I bought are just not as heavy duty as the old ones but they will stay .

 

[johnyg]

threeputt...i really admire your work ethic....old school..and i feel the same way. i am only 58 but am starting to realize i am not the man i used to be. if i can come to grips that what i do might take twice as long as it used to but is done right and nobody got hurt i think i can live with that. getting olds a *****..just do it gracefully!!!!!

 

[brownbagg]

i bougtht some metal last week, it was $2.12 a lineral foot

 

[rburke65]

I started to read this and then realized its 3 years old....bummer.

 

[kbs2244]

The problems, and the fixes, don't change all that much over time.

 

[TorqueWrench]

I have similar problems with my older 60x120 steel building built in the 60's. Surface rust and pin holes. Has anyone ever used the roof hugger system?

What about the Ames research coatings?

 

[threeputt]

Part of my leaking roof is repaired with Cool Seal. I did it all myself and took my time as all can see from when this post was first started Only one leak left that I can see but no big deal on that.

Now my problem which I thought I had took care is still hanging around. Water is dripping behind the gutters and making the old building rust.

I cannot see anything that would make this happen. The edge of roof is extending at least one inch out into gutters but when it was raining yesterday I could see it plain that all down the side of building it drips behind the gutters.

I first thought that by mending the holes left by person who removed the old gutters with Cofair QR325 Quick-Roof Waterproof Repair from amazon would have stopped this annoying problem but not to be.

Any ideas ? on what to try next. I

 

[SALIV8]

Ialso had a problem with water behind my gutter on my house. Have no idea if this is the same issue as yours, but after banging my head on the wall I finally figured out the water was traveling over the top of gutter supports, then wicking its way down the face of the gutter and since the gutter was slightly angled towards the house, the water followed this path underneath the bottom of the gutter, and then finally hit the area where the gutter was touching the house. Then it was dripping down the back porch siding.

Not sure I'm being clear, but what I'm trying to say is be sure the water is not going over the outside of the gutter, and then following the gutter's exterior to be brought right back to the barn.

If that's not it, make sure you have proper drip edging and overhang of the roof.

Good luck either way and great job in handling the leaks yourself!

 

[kbs2244]

Make sure the downspouts are clear.
And big enough.
That is a lot of roof and it need oversized, or even doubled, downspouts for the amount of water it will collect.

Drive down an ally behind a shopping center and look at how they do it.

 

[Capt Chrysler]

Nice save.

Capt. Chrysler

 

[threeputt]

I have let my 57 year old building run down but in the process of getting it back to 1961 standards Hard work but love bringing back that 1961 look .

 

[Farmall450]

Thanks for the update Tom, and good to see you back on here!