Building a Foundation for Lasting Solutions

Carlisle LogoFor more than 45 years, Carlisle SynTec has manufactured quality roof systems – systems that can turn a failing metal roof into a durable, long-lasting rooftop. Carlisle’s single-ply solutions extend the life of metal roofs without the need for costly tear-offs and replacements.

Improving a Bleak  Rooftop View

Metal roofs are not a lost cause. Thanks to Carlisle’s proven metal retrofit systems, there is a long-term, cost-effective solution that meets the needs of most buildings. The process builds upon the existing metal roof, filling the flutes and covering the metal deck with premium Carlisle insulation and then either mechanically fastening or adhering a Carlisle single-ply membrane to the top

Revealing the Less-than-lustrous Side of Metal

Satisfaction with a metal roof can be short lived. The once-alluring benefits of low installation cost and fire resistance can dull in comparison to the necessary upkeep. In just a few years, fastener back-out and rust can lead to leaks that require costly maintenance.

Coatings and spray-on foams are one possible solution; however, coatings will need to be reapplied every three to five years while poorly applied spray-on foams can result in unnecessary and excessive pounding water.

Starting over may seem like the surest means to restore water tightness, but beware, as replacing the metal roof comes with added risks. Installation of a new metal roof can disrupt operations and expose the interior of the building to the possibility of roof leaks.


  • Preserves the existing metal roof to prevent further deterioration
  • Creates a stable system by reducing expansion and contraction
  • Provides a quieter roof system for occupants
  • Improves R-value and saves energy
  • Allows a cool-roof option for additional energy savings

Carlisle offers a number of roof system options that can be directly installed over a metal roof, fully encapsulating the rooftop without the need for prepping, priming or costly removal. This helps to speed up installations while creating a more durable rooftop void of any gaps in coverage. What’s more, every Carlisle roof system is backed by the roofing industry’s most comprehensive warranties, with terms as long as 20 years.


Re-roofing Systems

Carlisle LogoWhen it comes to retrofitting a metal rooftop, no one offers more membranes or attachment options than Carlisle. With a versatile lineup of EPDM, TPO and FleeceBACK® membranes, Carlisle offers a durable, long-lasting system for any region or climate. These membranes can be mechanically attached or fully adhered with a variety of fasteners or adhesives, allowing you to personalize your retrofitted roof system to the specific needs of your project.

Carlisle’s HP Purlin Fastener

Carlisle’s HP Purlin Fastener is specially designed to anchor into the structural purlins – the strongest part of the roof. With its unique self- drilling point, it can penetrate 12-18-gauge steel. HP Purlin Fasteners are used with Pressure Sensitive RUSS strip to secure the membrane panels to the structure.

Carlisle’s FAST™ Adhesive

Carlisle’s FAST™  Adhesive can be used to attach both insulation and FleeceBACK membrane to the deck without any fasteners or penetration. This system is the ultimate solution for light-gauge metal roofs that typically do not provide acceptable pull-out resistance. FAST adhesive’s insulating qualities offer superior performance since thermal bridging from fasteners is eliminated.

Enhancing the Rooftop and the Bottom Line

A key component to Carlisle’s metal retrofit systems is insulation. Thanks to its inclusion, buildings experience drastically increased R-values and decreased energy costs. With those energy savings, installation costs are easily recouped in just a few years’ time.

Insulation also moves the building’s dew point to where it belongs – above the roof. This helps to eliminate the problems associated with deteriorating BAT insulation that has been installed underneath the roof deck.

Offering a Bright Future for Ageing Metal

Extended roof life, increased energy efficiency, reduced lifecycle costs … for a metal roof, the solution is clear. Choose Carlisle and reap the benefits of more than 45 years of experience and innovation.

Filling in the Blanks

A key component of the metal retrofit process is the addition of custom-fit insulation. Carlisle offers flute-fill insulation consisting of closed-cell, lightweight expanded polystyrene (EPS). It offers a long-term, stable R-value and has excellent dimensional stability, compressive strength and water resistance. Carlisle’s custom-cut flute-fill EPS insulation makes the installation a snap, reducing on-site cutting and fabrication. That equates to less time and expense for installation.


  • Versatile. Can be manufactured in a range of sizes, densities, thicknesses and profiles to meet any job-specific needs.
  • Cost Effective. Reduces concerns with flute span-ability and minimizes the need for additional insulation. Minimizes the use of insulation above the flutes and reduces the possible need to raise curbs and other roof top units.
  • Environmentally Friendly. Contains no formaldehyde or ozone-depleting CFCs, contains recycled material and is 100% recyclable if ever removed and replaced.
  • Stable R-value. Maintains stable thermal properties over the entire service life. Eliminates “thermal drift” and is eligible for a thermal-performance warranty.
  • Water Resistance. Does not readily absorb moisture from the environment.
  • Proven Performance. Uses the same fundamental EPS chemistry that has been in use since the mid-1950s, so the actual performance of the product is time tested.

Typical Metal Roof Cross Sections



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