Michael Hovar, Senior Architect and South Texas Regional Manager for Building Sciences at Raba Kistner, discusses the evolution of metal roofing and building envelope design. The conversation covers re-roofing drivers, thermal movement challenges, solar integration solutions, and emerging technologies in metal cladding.
Hovar emphasizes the critical importance of proper detailing at transitions and seams, sharing insights on continuous panel systems and BIM modeling techniques.
The discussion explores how rain screen technology enables unlimited design possibilities while maintaining performance standards, and concludes with predictions about AI's transformative impact on architecture and construction sequencing in the coming years.
Notable Quotes
Michael Hovar: "The part of the building that has the greatest exposure to the elements, the greatest ultraviolet exposure... folks like myself are probably in a good profession because we're gonna see new roofs placed on buildings every 20 to 25 years."
Michael Hovar: "When you look at a roof and it's leaking... your shirt doesn't rip in the middle of your chest, it rips where the pocket is tied to it, or it rips at a sleeve, it rips where there's a seam."
Michael Hovar: "I would have to say that 95% of the problems that we see are related to sequencing of construction... installing one roofing system before it should be installed."
What You'll Learn
- Key factors driving the need for re-roofing in commercial buildings and the typical replacement cycle
- How thermal movement affects metal roofing performance and strategies to accommodate expansion and contraction
- Modern attachment solutions for solar installations that avoid roof penetrations
- The role of rain screen technology in expanding design possibilities for metal cladding
- Advanced BIM and 3D modeling techniques for complex roof and wall transitions
- Common failure points in metal roofing systems and how proper sequencing prevents leaks
- Future applications of AI in architecture and construction project management
Key Timestamps
- [0:00] - Introduction and guest welcome
- [2:30] - Michael Hovar's background and role at Robert Kistner
- [4:15] - Discussion on what drives re-roofing projects
- [7:45] - Solar integration challenges and penetration-free solutions
- [11:20] - Recent innovations in metal roofing and siding materials
- [16:35] - Thermal movement accommodation and oil canning considerations
- [22:10] - Challenges integrating metal roofs with other building systems
- [28:45] - BIM and SketchUp modeling for complex transitions
- [34:20] - Project examples featuring continuous panel systems
- [40:15] - Future of AI and technology in architecture and construction
- [46:30] - Closing remarks and contact information
Mentioned Resources
- Raba Kistner
- S-5! - Clamps and accessories for metal roofing, snow guards, and solar mounting systems
- LinkedIn Profile - Connect with Michael Hovar
Episode Deep Dive
The world of metal roofing is evolving at a faster pace than ever before. New technologies, environmental concerns, and the growing demands of modern buildings are pushing the industry in exciting directions. I recently had a fascinating conversation with Michael Hovar, who works as a Senior Architect and South Texas Regional Manager for Building Sciences at Robert Kistner. His insights into the future of metal roofing opened my eyes to what's coming next in this field.
What's Driving People to Replace Their Roofs?
If you want to understand the roofing business, you need to know why building owners decide to invest in new roof systems. Hovar puts it pretty simply: "The part of the building that has the greatest exposure to the elements, the greatest ultraviolet exposure... folks like myself are probably in a good profession because we're gonna see new roofs placed on buildings every 20 to 25 years." It's just the natural cycle of things, and it gets even more complicated when you consider how many different building systems come together on a modern roof.
Solar panels have shaken things up. These days, people don't just think of roofs as something to keep the rain out – they see them as prime real estate for solar installations. But here's the problem: you want to keep your building dry, and traditionally, mounting solar panels meant putting holes in your roof. Hovar calls these "conflicting desires," and they've pushed manufacturers to get really creative with their solutions.
Solar Without the Holes
One of the biggest breakthroughs lately has been systems that allow you to mount solar panels, walkways, and other equipment without drilling holes through your roof. Hovar explains that "there's been the development of many technologies recently, not only for metal roofs but also for low slope roofing, where the systems become part of the roof system." These clamping systems are game-changers because they solve the age-old problem of keeping water out while still allowing you to use your roof for other purposes.
What's particularly interesting is how roofing companies have partnered with specialty manufacturers to make this happen. Take McElroy Metal's partnership with S5 – they've created comprehensive systems that handle all kinds of mounting needs without compromising the roof's primary job of keeping everyone dry underneath.
Rain Screens: Opening Up Design Possibilities
If you ask me, the most exciting thing happening in metal cladding right now is rain screen technology. This approach separates the pretty part of your building from the functional part, giving architects incredible freedom to play with colors, textures, and shapes. When Hovar talks about this, you can hear the excitement in his voice: when "the rain screen itself and the underlying layers of weather proofing and air and thermal resistance are done right, it allows an architect almost unlimited possibilities in putting color, texture, shape onto a building facade."
The printing technology has gotten so good that metal panels can look like just about anything – wood grain, stone textures, you name it. But the goal isn't to fool anyone into thinking it's something else. As Hovar puts it, the idea is to "take those aspects of the wood, the color and the texture, and use it in the composition." You get the look you want with all the benefits that come with metal – durability, low maintenance, and long-term performance.
The Biggest Challenge: When Metal Moves
Despite all these amazing advances, there's still one problem that keeps Hovar up at night: thermal movement. He doesn't mince words about this: "The biggest issue that we see in all of our work is the effects of thermal movement." Metal expands and contracts with temperature changes – it's just physics – but too many installations don't account for this properly, leading to failures and ongoing headaches.
The answer lies in continuous panel systems that don't have exposed fasteners or end laps everywhere. These systems are designed to adapt to temperature changes instead of fighting against them. Hovar has seen clients completely change their minds about metal roofing once they switch to these systems. Folks who "suddenly love them because they're no longer leaking, and they're a beautiful, low-maintenance surface" after years of dealing with problems from older installations.
Where Things Actually Go Wrong
Here's something that might surprise you: roof failures rarely happen in the middle of a big flat area. Hovar uses a great analogy to explain this: "When you look at a roof and it's leaking... your shirt doesn't rip in the middle of your chest, it rips where the pocket is tied to it, or it rips at a sleeve, it rips where there's a seam." Problems arise where different systems intersect and connect.
Modern buildings often mix different materials and textures, creating numerous seam conditions that require special attention. Hovar estimates that his team spends "10% of our time doing the overall roof design and 90% of it focusing in on the details" where different systems come together. These transition areas are where you really need to know what you're doing.
Better Tools for Complex Problems
The tools we use to design and explain complex roofing solutions have come a long way. Building Information Modeling (BIM) has completely changed how teams can see potential problems before they become real problems. But Hovar points out that while BIM is great for coordination and figuring out quantities, it's "not always the best tool for actually drawing our three-dimensional drawings."
For detailed work, many professionals prefer tools like SketchUp, which lets them model complex transitions and show contractors exactly how to install things step by step. These 3D models don't just show what the finished product should look like – they show how to get there.
The shift from traditional drafting to digital modeling represents a fundamental change in how we think about and communicate complex building systems. Hovar reflects on this evolution, noting how the profession has moved from "drawing with rapidographs and pencils with straight edges and triangles to where we're at today, not even having a single drawing board in the office."
Seeing It Work in Real Life
When these technologies come together on actual projects, the results can be pretty impressive. Continuous panel systems have been successfully used on runs up to 285 feet long, creating installations that perform beautifully and look great too. Hovar describes watching these installations as "like a ballet when you're watching the crews pick the panel up off the roll former that's elevated and ejecting it onto the roof."
These systems work particularly well for renovating existing buildings. Warehouses, gyms, and other large buildings that have been struggling with thermal movement problems can be transformed into high-performing, attractive facilities while staying operational during the work.
Getting the Order Right
One of the most essential things Hovar has learned from investigating building failures is how much construction sequencing matters. He estimates that "95% of the problems that we see are related to sequencing of construction" – doing things in the wrong order or not coordinating properly between different trades.
Usually, it's not that contractors don't know what they're doing. The problem is often schedule pressure that pushes them to move ahead before everything is prepared correctly. Better planning and coordination tools could prevent most of these sequencing errors from happening in the first place.
What AI Might Change
Looking ahead, artificial intelligence is poised to transform how architects and contractors work. Hovar believes that "AI is going to change everything we do" in architecture, though he thinks the changes will happen gradually rather than all at once.
Early applications will likely focus on helping architects evaluate different options more efficiently – aspects such as building orientation, material choices, and code compliance. More advanced uses could include AI that helps prevent those construction sequencing errors that cause so many problems.
Eventually, AI combined with advanced BIM could enable real-time collaboration in virtual environments. Hovar imagines a future where "you and I can stand there and we can talk about our roof design and maybe see it develop on the screen in front of us."
Solving Other Problems Too
The industry keeps developing new technologies to address persistent challenges. Sound-deadening materials built into metal panels help with noise concerns, while moisture control systems using polyester fleece laminates provide extra protection against condensation. These innovations show that the industry cares about both performance and comfort.
Color retention and corrosion resistance have also improved significantly, which is especially important for buildings near the ocean where salt air can be brutal. These advances help ensure that buildings look good throughout their entire service life.
Where We're Heading
The future of metal roofing is really about bringing together several trends: smarter design tools, better integration with other building systems, enhanced performance, and improved installation processes. The evolution from simple weather protection to sophisticated building systems reflects how construction in general is moving toward more intelligent, integrated solutions.
Success in this changing landscape means understanding not just individual components but how they work together in complex building systems. The professionals who excel will be those who can navigate the intersection of technology, performance, and design while maintaining a clear focus on the primary goal: keeping buildings dry and functional.
As we look toward this future, the wisdom from experienced professionals like Hovar gives us valuable guidance: focus on transitions and details, accommodate thermal movement, embrace new technologies while respecting fundamental principles, and never forget how critical proper construction sequencing is. These insights, combined with emerging technologies and design approaches, will shape the next generation of metal roofing solutions and continue to push forward the state of the art in building envelope performance.
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