Flat-Lock Copper Case Study

Flat roofs are the most difficult roofs to maintain long-term watertightness. When installing a flat roof there are many options available to you but not all are created equal.  There’s no better option than the flat-lock copper roof. The system starts with #30 felt underlayment. Then a rosin building paper is installed. It prevents the felt underlayment from melting and sticking to the metal during the soldering. This promotes expansion and contraction over the life of the roof. Once all the seams are soldered, this roof will be watertight even if it were completely flooded. Due to the relatively high cost of installing a copper flat-lock roof, it’s often utilized on smaller areas. It’s a great solution for walk-out porches, bay windows, and dead valleys. HKC Roofing has the skilled technicians to install your flat-lock project.

Watch a Video by HKC Roofing Related to Flat-Lock Copper

Curved Copper Bay Window Case Study

Middletown, Ohio –

The Problem
The original curved bay was Tin and stayed in place for over 60 years. This was primarily due to it being coated with asphalt . It leaked and caused wood damage and interior damage to the old plaster ceiling. When installing these types of tricky roofs it’s best to use material that will last a very long time. We oftentimes recommend copper or lead-coated copper if a pewter color is desired.

The Solution
HKC hand-made this curved metal roof starting with nothing more than flat copper sheets. Each panel was bent to include two standing ribs. Our skilled technicians shrank the metal until it conformed to the curvature of the roof. Once all the panels were fitted, we rolled the seams two times to create a roof that is locked together. This traditional metal roofing technique is referred to as “Double-Lock” standing seam. You can still find this style of metal roofing in service on many homes built at the beginning of the 20th century.

Copper Pipes Case Study

Ft. Mitchell, KY –

The Problem
These failing pipe boots are one of our most commonly serviced items on steep sloped roofs. They have a serviceable life of 6-8 years depending on their location on the roof. Even the most cost-effective roof is designed to last for 20-25 years. It doesn’t make much sense to install a pipe boot that will have to be replaced twice throughout the life of the roof system.

The Solution
These copper pipes were hand-made, locked, and soldered on the backside. Afterwards they were soldered to a copper base for complete watertightness. These can be expected to last over 75 years. Another good material to use is lead. HKC cares about these types of details. We think it’s worth a little extra time to ensure the roof and all it’s details last for the intended timeframe.