Stone-Coated Steel Roofing: A Guide

Metal roofs are tough. They can last forever (more than 50 years in some cases).But not everyone likes the metal roof aesthetic, which is generally either industrial or very minimalist and modern. Some people want a more traditional look.

If you're one of those people, stone coated steel roofing may be for you. 

Stone-coated steel combine the toughness of metal roofs with the traditional beauty of shingle, clay tile, slate, or even wood shingle roofs.

In this article, we'll uncover the compelling advantages of stone-coated steel roofing. We'll talk about what it is, how it's made, pros and cons, what kind of designs and finishes are available, it's best uses, and how its installed.

By the end, you'll have a grasp on whether this increasingly popular roofing option is right for you.

Table of Contents

• Introduction: What is Stone Coated Steel Roofing?
• The Pros and Cons of Stone Coated Steel Roofing: Is it Right for Your Commercial Building?
• The Installation Process: How Stone Coated Steel Roofing is Installed on Commercial Buildings
• Designs, Colors, and Finishes: How to Choose the Perfect Stone Coated Steel Roof for Your Building

Introduction: What is Stone Coated Steel Roofing?

Stone-coated steel roofing is an innovative roofing solution that blends the resilience of a steel core with the aesthetic appeal of stone. Its design features a structural grade steel base, coated for protection against corrosion, overlaid with a layer of acrylic polymer adhesive and crushed, natural stone granules. This composition mimics the appearance of traditional materials like clay, wood, or slate, while offering significant durability against severe weather, fire, and rust.

This unique blend of materials offers the best of both worlds, combining the strength and longevity of steel with the natural beauty of stone.

The Genesis of Stone-Coated Steel Roofing 

Stone-coated metal roofing has its roots in WWII-era Great Britain, when the government needed a coating that could protect corrugated steel roofs from the wet climate.

Leap to the current times, and stone-coated metal roofing has become popular for its ability to achieve both the aesthetics of traditional stone roofs and the strength and durability of steel. 

The Aesthetics of Stone-Coated Steel Roofing 

One of the crowning glories of stone-coated metal roofing is its aesthetic flexibility. It can masterfully mimic a plethora of traditional stone and even asphalt shingle roof styles, making it a visually appealing choice. 

• • Slate: This roofing can be crafted to resemble slate, lending an air of classic elegance and sophistication.

  • Clay tiles: For those seeking a Mediterranean or Spanish vibe, stone-coated metal can mirror the look of clay tiles.

  • Shake: Emulating wooden shakes, stone-coated metal creates a timeless, all-American look.

  To achieve the desired aesthetic, an acrylic film is used to adhere a layer of stone chips to the metal panels. These stone chips are natural, eco-friendly, and resistant to corrosion, enhancing both the beauty and durability of the roof. 

The Making of Stone-Coated Steel Roofing 

The creation of stone-coated metal roofing is a meticulous process involving 5 essential steps: 

Steel Preparation: It all begins with high-grade steel sheets. These sheets are typically galvanized (coated with zinc) or a mix of zinc, aluminum, and silicon-coated steel (known as Galvalume) to guard against corrosion. 

Base Coat: The steel sheets are then treated with an acrylic primer that allows the stone to stick to the surface. 

Stone Coating: Next, a layer of natural stone granules is applied, embedded in the basecoat. The stones, chosen for their durability and non-porous nature, can be colored to achieve the desired final appearance. 

Overglaze: An acrylic overglaze is applied over the stone granules, protecting against weather, enhancing color and UV resistance, and imparting a slight gloss to the sheet. 

Cutting and Forming: Once the coated sheets are dry and the layers have bonded, they are cut and formed into individual roofing panels. These panels can imitate various traditional styles, such as shingle, shake, or tile shapes, rivaling asphalt shingles, and metal roofs in versatility. 

The panels are typically around 3 feet by 1.5 feet in size, but manufacturers can offer different dimensions to fit a specific project. The design and size of the panel ensure that, once installed, the roof will closely mimic real stone or even asphalt shingles.

It's not just about the practicalities; stone coated steel roofing brings the beauty of traditional stone roofing and the strength of modern materials together, providing your building with a unique blend of old and new.

The Pros and Cons of Stone Coated Steel Roofing: Is it Right for Your Commercial Building?

When is Stone Coated Steel a Good Option? 

Stone coated steel roofing can be great option if:

• Longevity Is Important: If you're looking for a 'fit and forget' solution, this type of roofing offers impressive longevity - we're talking 50 years or more.

• Aesthetics Are Paramount: Not only is it practical, but it's also aesthetically appealing. Stone coated steel roofing is available in a variety of styles, colors, and finishes, so it can fit virtually any architectural design. 

• Energy Efficiency Is Important: If you’re passionate about minimizing your carbon footprint, you’ll be pleased to know that this type of roofing is energy-efficient. In fact, Stone coated steel roofing can reduce energy costs by up to 20%.

Specific building types that may benefit from stone coated steel include:

Upscale Establishments and Resorts 

The aesthetics of stone coated steel roofing cater perfectly to upscale designs. It can be a stylish and practical addition to high-end condominiums and resorts, adding beauty and class while offering long-lasting durability. 

Historic Buildings and Churches 

Historic buildings and churches often come with unique architectural designs. With the variety of styles, colors, and finishes available with stone coated steel roofing, matching the original aesthetic is easier than you might think. 

Institutional Buildings and Other Establishments 

For institutional projects like schools or government buildings, the longevity and energy efficiency that stone coated steel roofing provides are incredibly beneficial. 

Remember, when it comes to choosing the right roofing for your building, you need to consider both the aesthetic and functional aspects. Stone coated steel roofing offers the best of both worlds. It's not just about how it looks, but also how it performs and lasts.

When Might Stone Coated Steel Not Be the Best Option? 

On the flip side, there are circumstances where stone-coated steel might not be the best fit for your commercial property. 

• Tight Budget: If you're on a tight budget, the initial cost of stone coated steel roofing might be a deterrent. It's more expensive upfront than traditional roofing materials.

• Flat Roof: Stone coated metal roofing is not recommended for roofs with a pitch of less than 3:12. From an aesthetic perspective, this choice also simply wouldn't make sense, as the beauty of the stone wouldn't be visible from the ground. 

• DIY Project: The installation of stone coated steel roofing requires skilled professionals, so it may not be the best choice if you're looking for a quick, DIY project.

• Weight Limits: While it's lighter than traditional tiles, it's still heavier than some roofing materials, so you'll need to ensure your building can support the weight. 

Buildings for which stone-coated metal isn't a great fit include:

• Warehouses and Industrial Buildings: These structures typically have flat roofs, and as we stated above, stone coated steel isn't recommended for roofs with a pitch less than 3:12.  Additionally, the aesthetic appeal of stone coated steel is usually not a factor for these utilitarian structures.

• Office Buildings with Flat Roofs: As we've mentioned, buildings with flat roofs are not a good fit for stone-coated metal.

Remember, choosing the right roofing material involves considering multiple factors such as your budget, your building’s location, its architectural style, and your long-term plans. Take the time to weigh your options and consult with a roofing professional to make the best decision for your commercial property.

The Installation Process: How Stone Coated Steel Roofing is Installed on Commercial Buildings

Let's roll up our sleeves and dive into the installation process of stone coated steel roofing. This is not your everyday DIY project and requires specialized knowledge and skills. Therefore, it's always recommended to hire a professional roofing company. 

Step 1: Pre-Installation Assessment 

Before the actual installation, the roofing company will perform an assessment to determine the specific needs of your commercial building. This includes checking the roof's structure, identifying potential problem areas, and estimating the amount of material required. 

Step 2: Preparing the Roof Deck 

Once the assessment is complete, the next step is to prepare the roof deck. This involves cleaning the roof surface and installing an underlayment which acts as a secondary barrier against water penetration. 

Step 3: Applying the Panels 

The stone coated steel panels are then applied over the underlayment. These panels are usually secured using special clips and screws to ensure maximum stability and longevity. 

Step 4: Installing the Flashings 

Flashings are installed next, to provide extra protection to the vulnerable areas of the roof. This includes the edges, valleys, and any roof penetrations like vents and chimneys. 

Step 5: Final Inspection 

Once all panels and flashings are in place, a final inspection is conducted. This is to ensure that everything is correctly installed and securely fastened. 

Boom! Just like that, your commercial building has a brand-new, durable, and stylish stone coated steel roof. But remember, it's essential to have a regular maintenance plan in place to ensure the metal roof top's longevity. Regular inspections can prevent minor issues from turning into major problems.

A typical installation of stone-coated steel roofing may involve one of two methods: laying down a series of battens on the roof deck or attaching the roofing material directly to the deck itself.

Batten System Installation

A batten installation method involves the creation of a grid-like structure across the roof deck before the stone-coated steel roofing panels are installed. This is achieved by placing wooden or metal battens, typically in a 2'x2' formation, across the existing roof structure. The roofing panels are then fastened onto this batten grid, leading to the creation of a continuous 1-½” airspace beneath them.

A crucial advantage of this batten installation method lies in the enhanced ventilation and air circulation it facilitates. The battens create an airspace that allows for the movement of hot air out of the roof structure and the inflow of cooler air, leading to a significant decrease in the roof's overall temperature.

This cooling effect can have a profound impact on energy consumption, especially during the peak of summer when reliance on air conditioning systems is high. By keeping the roof—and consequently, the building—cooler, the batten installation method can contribute to substantial energy savings.

Direct-Deck Roof System Installation

In the direct installation method, the stone-coated steel roofing material is attached directly to the roof deck, skipping the batten system. This process generally reduces the labor and material costs associated with the installation.

A direct stone-coated steel roof installation is typically recommended only for areas with lower wind activity, as it doesn't offer the same wind resistance provided by a batten installation.

Designs, Colors, and Finishes: How to Choose the Perfect Stone Coated Steel Roof for Your Building

When it comes to stone coated steel roofing, one size certainly does not fit all. That's the beauty of it - with a range of designs, colors, and finishes, you're bound to find one that seamlessly matches your building's aesthetic. But where to begin?Let's break down your options. 

Exploring the Design Possibilities 

The world of stone coated steel roofing is more diverse than you might think. From tile profiles that conjure images of sun-soaked villas, to shingle styles that offer a modern edge, there's a design out there that matches the aesthetic of your commercial building—while providing all the benefits of this durable roofing material. Let's delve into the range of designs available: 

• Mediterranean Barrel Tile: Perfectly capturing the romantic appeal of old-world Italian architecture, this design is all about rounded, barrel-like tiles. It's a classic look that never goes out of style.

• Shake Style: This design mimics the aesthetic of wooden shingles, but with the increased durability and strength of stone coated steel. It's a great way to achieve a rustic, natural look without the maintenance headaches associated with real wood.

• Shingle Style: If you're after a clean, modern look, the shingle style may be just what you're looking for. Its smooth, flat surface and straight edges create a streamlined aesthetic that's perfect for contemporary commercial buildings.

• Tile Style: For those wanting an elegant, high-end look, the tile style is a great choice. These tiles are typically larger and more detailed, providing a luxurious appeal.

• Slate Style: Slate style offers the charming, layered look of traditional slate roofing but with far greater durability and lifespan. It's an excellent option for those who appreciate a touch of historical charm.

So, whatever your building's architectural style—be it modern, rustic, or something in between—there's a stone coated steel roofing design that can enhance its aesthetic appeal. But remember, choosing the right design is just as important as choosing the right material. After all, a roof isn't necessarily just about protection—it's also about making your building beautiful. 

Tip: Keep in mind the overall design of your building when choosing a roofing style. The roof should complement, not clash with, the architectural style of your structure.

Want something a bit more rustic? Shake profiles offer a natural, rugged look without compromising on durability. 

Colors 

Color is the next consideration. With stone coated steel roofing, you're not restricted to traditional grays and blacks. In fact, the color palette is as wide as your imagination. 

Think earth tones like terracotta, moss green, or sandy beige for a natural, organic look. Prefer something more striking? Bold hues like blue, red, and even purple can make a statement. 

Finishes 

Finally, let's talk finishes. A stone coated steel roof can be glossy or matte, smooth or textured. It all comes down to what suits your building's overall look. 

Glossy finishes reflect more light and can help your building stand out, while matte finishes offer a more subdued, sophisticated vibe. Textured finishes, on the other hand, can add depth and character to your roof. 

The Upshot

In conclusion, stone coated steel roofing offers a robust, flexible, and stylish solution for your commercial building needs. With a rich history dating back to World War II and an array of designs, colors, and finishes to choose from, this roofing style can complement any architectural style while providing long-lasting protection against the elements. 

As a property manager or commercial building owner, the choice is ultimately in your hands. If your roofing choice is purely functional, stone-coated metal should probably not be on your list, but if both aesthetics and functionality are important, it may be just the thing.

Now that you've learned all about stone-coated steel, set up a call with GIDEON. In a free, 30 minute call, our nationally-recognized roofing experts can provide you with customized guidance.