The first step in installing a copper roof is selecting the right grade and thickness of copper sheets. Copper roofing typically comes in 16, 20, and 24-ounce sheets, with the weight determining the durability and flexibility of the material. Choosing the right gauge is crucial, as lighter sheets offer easier manipulation for intricate designs, while heavier sheets provide enhanced durability for extreme weather conditions.
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Once the appropriate copper is selected, the material undergoes a tempering process to balance malleability and strength. Copper can be purchased in a soft, semi-hard, or hard state, with semi-hard being the preferred choice for most roofing applications due to its ability to be shaped without excessive brittleness. Before installation, sheets are measured, cut, and treated with a protective coating (if desired) to slow the patina process or maintain the original luster.
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Precision cutting is performed using sheet metal shears or hydraulic press brakes, ensuring smooth edges that will fit seamlessly together. Additionally, The Metal Roofers carefully inspect every sheet to eliminate imperfections that could impact the roof’s longevity. Once all materials are prepared, we move on to the essential step of forming and shaping the panels for installation

Unlike other metal roofs that rely on prefabricated panels, copper roofing often requires custom fabrication to fit the unique dimensions of a structure. Using press brakes and rolling machines, copper sheets are shaped into standing seam panels, interlocking shingles, or batten seam profiles depending on the chosen style.
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Each panel is meticulously formed with raised seams or interlocking edges to ensure a watertight seal. Standing seam panels, one of the most durable options, feature mechanically crimped vertical seams that prevent water infiltration and enhance structural integrity. Traditional shingle-style copper roofing requires hand-forming techniques using a mallet and metal brake to shape the copper into layered sections that overlap seamlessly.

During this step, expansion and contraction allowances are also factored in. Copper is highly reactive to temperature changes, expanding in heat and contracting in cold. To accommodate this movement, we incorporate expansion cleats and slip seams, allowing for thermal movement without warping or buckling. This attention to detail ensures the roof remains structurally sound for decades.

The insurance company will approve the work required as long as it’s covered under the policy, and issue a repair estimate as well as the funds needed to cover the repairs.

Once the substrate is prepared, the copper panels are carefully positioned and secured using concealed stainless steel or copper fasteners. Unlike traditional exposed fasteners used in other metal roofing systems, copper roofs utilize cleat-based fasteners that allow for secure attachment without puncturing the surface of the panels.
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For standing seam copper roofing, we employ mechanical seaming techniques, where panels are crimped together using specialized seaming tools that create a permanent, watertight connection. This process requires precision to ensure uniformity across the entire roof surface. For shingle-style installations, individual pieces are interlocked and fastened using custom clips that allow for expansion and contraction.
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During installation, all panels are carefully aligned to create a visually seamless finish. This process requires skilled craftsmanship, as copper must be handled delicately to avoid scratches or dents that could affect its appearance. Once the panels are secured, we proceed to the detailing phase, ensuring every seam, valley, and penetration is properly sealed.

Proper flashing and trim work are essential to preventing leaks and ensuring the longevity of a copper roof. At The Metal Roofers, we fabricate custom copper flashing for chimneys, valleys, ridges, and eaves to provide full waterproofing protection.
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Copper flashing is formed using hand-soldering techniques to create seamless, watertight joints. Unlike sealants that can degrade over time, soldering provides a permanent bond that enhances durability. Each flashing piece is tailored to fit precisely into place, ensuring no gaps or weak points.
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In addition to flashing, decorative elements such as ornate ridge caps, finials, and custom gutter systems can be incorporated to enhance the visual appeal of the roof. These finishing touches not only provide aesthetic charm but also contribute to the overall structural integrity of the system.