Architectural Home Transformed with Calibre

The 285m² house was designed to complement the breathtaking natural surrounds, utilising natural cedar and schist as a feature of the exterior cladding, adding texture and warmth.  Taking inspiration from a neighbouring property, flat concrete roof tiles were chosen, with its appearance mimicking a slate roof.

Approximately 10 years after the roof was installed, the first issues arose. It started with the pointing coming out of the gable and bargeboard details, allowing birds to creep under the roof and nest in the roof cavity.  At extra cost, repairs were made to the roof to try and fix these issues.  Then the roof started leaking under wind driven rain.  In certain conditions, the roof window overlooking the kitchen would leak and leaks also appeared around a few other unique flashings.  More repairs - and added cost - were undertaken until it became obvious that repairs were not going to solve the root cause: The tiles were no longer providing protection against water ingress. So, the decision was made to reroof the property.

Warren says of the decision “It’s regretful - I never thought I’d have to replace a roof in my lifetime. I also own a property in Devonport and its roof is 90 years old and it’s still ok.  But that’s an old metal roof, and to have a roof that I’ve done in May ‘98 and replacing it already is a bit of a contrast”.  The search was on to find a roofing solution that not only fit the aesthetic of the home, but also provided long-term performance so he wouldn’t need to reroof again in his lifetime. 

Gerard’s new roof profile, Calibre, caught Warren’s eye, with its horizontal panelling best complementing the style of the existing cladding.  The lightweight steel panel system features Concealed Fastening (CF) technology, made up of an interlocking design which adds strength to the roof, while hiding fasteners from view providing clean lines without interruption.  The staggered installation, CF design, and concealed weather channels culminate in a stylish and high performing roof.

Warren was delighted with a solution that came in a wide variety of colours, backed by a well-known manufacturer.  “Gerard products are known for their paint durability, and I was satisfied that Gerard have long established place in the roofing industry in New Zealand.” Warren explains.  Aside from aesthetics, the durability and performance of the paint was critical due to the house being on a rainwater tank.  The degradation of the concrete tiles led to many issues, Warren explains “The roof always looked wet, it had a large amount of moss. In the off season when the moss dried up on the lower edge of the tiles, it would fill the spouting with sludge. Then the birds would come and eat the moss, it caused all sorts of problems.” Apart from clogging the spouting, those problems included the family contracting campylobacter from a dead bird in the roof system, which laid the family out for weeks.  With Calibre, being on a rainwater tank is no issue, as testing on Gerard’s roof coatings has proven the coatings to be aligned with Australian and New Zealand standards for rainwater collection (AS/NZS 4020).

And switching from a concrete roof to a metal panel roof had extra benefits.  The lightweight construction meant Warren could sleep easy at night with around 7 times less weight above the family’s heads while still maintaining the longevity and durability needed for the roof.  The panel design results in a high strength-to-weight ratio, creating a robust matrix that is able to withstand challenging winds and heavy impacts.

Warren wanted to be very hands-on throughout the reroof process and with his background in engineering and a thorough understanding of construction, it was important for him to work with a team and a manufacturer he could trust.  And Gerard fit the bill. 

With his decision made, Warren contracted the Gerard Roofing Centre (GRC) to complete the reroof on his home, using the new Calibre profile in the colour Ebony. The old concrete roof had a few more unpleasant surprises in store though.  When the GRC team started removing tiles from the roof, it quickly became apparent that the structure underneath wasn’t in a suitable condition to leave in place.  The heavy weight of the concrete tiles had caused the trusses to sag and become uneven, requiring new trusses to be erected before the new roof could go on.  Once the new trusses were in place, the Calibre installation began.  Warren worked closely with Scott Caskey, GRC Manager, who was onsite to work with Warren throughout the reroof process. 

The difference between the old roof and the new roof is stark.  Calibre’s clean, sharp lines lend an illusion of a modern slate-type roof, while the UV-stable paint gives the roof a sleek aesthetic.  Despite the challenges in reroofing his home, Warren is thrilled with the results, “Gerard rose to all the challenges with this roof.  They overcame them after consultation with me, working through solutions and options.  We got a great result, and the finished product speaks for itself.”