Metal Roofing Systems for Airport Terminals: Managing 24/7 Operations While Maximizing Weather Resilience

Airport terminals present one of the most demanding environments for roofing systems, where safety, operational continuity, and weather performance converge at a massive scale. When construction and facility teams evaluate replacement options, they need systems that perform flawlessly while accommodating stringent security protocols, continuous passenger flow, and the financial impact of downtime.

Metal roofing systems meet these challenges through exceptional longevity, installation flexibility, and superior weather performance that conventional materials simply cannot match.

The Financial Case for Metal Roofing at Aviation Facilities

Airport terminals represent enormous long-term capital investments, where roofing decisions influence operational budgets for decades. Traditional low-slope roofing systems typically require replacement every 12 to 15 years, redirecting funds away from critical airfield, security, or passenger improvements.

For example, a 200,000-square-foot terminal facing repeated reroofing cycles accumulates millions in costs over its lifespan. In contrast, research from the Metal Construction Association shows that properly installed Galvalume®-coated standing seam systems can exceed 60 years of service life.

This longevity fundamentally changes the financial equation. A terminal built in 1980 with a conventional roof could be on its fourth or fifth replacement by 2025, while a metal roof from the same era would likely still be in service—delivering major lifecycle savings.

Energy Efficiency and Thermal Control

Airports operate nearly around the clock, with terminals requiring extensive heating, cooling, and ventilation to maintain passenger comfort. According to the U.S. Department of Energy, HVAC systems account for roughly 35 percent of total building energy use.

Metal roofing with cool roof pigment technology can reduce cooling loads by up to 20 percent, particularly valuable for terminals operating in warm climates or coastal regions.

In addition, above-sheathing ventilation systems, when feasible, maintain an air space that limits heat transfer—keeping attic temperatures within roughly five degrees of outdoor conditions, compared to 40-degree differentials common in conventional assemblies.

Real-World Example: Southwest Airlines Hangar, Orlando

Southwest Airlines' 70,000-square-foot hangar in Orlando illustrates these benefits in practice. After sustaining damage from multiple tropical storms and Hurricane Charley, the facility received a metal-over-metal recover system that has since withstood numerous storm seasons.

This approach allowed hangar operations to continue uninterrupted throughout construction, avoiding costly aircraft relocations and scheduling disruptions that would have impacted operations far more than the roof replacement itself.

Weather Performance and Safety Advantages

Airports operate in open, unprotected locations where wind, hail, and lightning exposure are amplified. Metal roofing offers the robust performance such environments demand.

• Fire Safety: Metal's non-combustible properties provide critical protection where fuel systems and electrical infrastructure demand Class A fire ratings.
• Hail Resistance: Class 4 impact-rated metal panels withstand strikes that would puncture conventional membranes, minimizing weather-related closures and service disruptions.
• Wind Uplift: Mechanically seamed standing seam systems use concealed clips engineered to exceed code requirements, distributing uplift forces evenly across the structure.
• Lightning Protection: Metal roofing naturally conducts electrical energy to ground, creating a Faraday cage effect that protects sensitive electronics, radar, and communication systems from surges.

Maintaining Operations During Roof Replacement

Airports cannot pause operations for construction. Passenger activity, TSA security protocols, and revenue streams all depend on uninterrupted service. Traditional tear-off replacement exposes interiors to weather, debris, and noise—conditions incompatible with active terminals.

Metal roofing's recover installation method—such as McElroy's 238T system—allows new panels to be installed directly over existing roofs. This maintains terminal operations below while preventing debris contamination, minimizing fall hazards, and reducing interior exposure.

Because crews work entirely from the exterior, recover installations can also simplify security logistics. The result is faster installation, reduced security overhead, and minimal disruption to passengers and staff.

Environmental conditions also remain stable: recover methods generate minimal dust, avoid disturbing insulation, and control noise levels—allowing nearby gates or retail spaces to stay open during construction.

Planning and Design Considerations

Strategic planning ensures that terminal roofing projects deliver both immediate operational continuity and long-term value.

• Facility Assessment: Document existing conditions, verify structural adequacy for metal loads, and identify opportunities for recover installation.
• Construction Phasing: Coordinate timing with runway schedules, TSA operations, and passenger traffic to sequence installations in manageable sections while maintaining weather-tight protection.
• Contractor Qualification: Require demonstrated experience on active airport projects, security clearance capabilities, manufacturer certifications, and proven safety performance.
• Solar Integration: Consider solar-readiness during the design phase. Metal roofs provide optimal support, orientation, and durability for future photovoltaic systems.

Material selection also matters. Galvalume substrates deliver exceptional corrosion resistance, while fluoropolymer coatings like Kynar 500® resist color fading and chemical attack through decades of exposure. These coatings help terminals—often the first architectural impression of a community—retain a clean, professional appearance long after installation.

Quality Assurance and Long-Term Value

Achieving the expected performance from a metal roofing system requires factory-certified installers, technical support, and comprehensive warranty coverage. Partnering with manufacturers that offer trained contractor networks and detailed oversight during installation ensures system integrity and long-term reliability.

Conclusion

Airport terminals choosing metal roofing gain solutions engineered for the demands of 24/7 operations—balancing safety, durability, and efficiency. The combination of exceptional lifespan, weather resilience, low operational disruption, and energy savings makes metal roofing the optimal long-term choice for aviation infrastructure.

By investing in systems that deliver measurable operational and financial advantages, airport authorities ensure sustainable, resilient, and reliable performance that supports millions of travelers for decades to come.