Project Overview
Dr. Sarah Chen owns a beautiful 1941 Mediterranean Revival home at 562 Beach Drive NE in the Old Northeast Historic District of St. Petersburg. The home featured original barrel clay tile roofing that had been in place for over 80 years. While the tiles themselves were still in excellent condition (clay tiles can last 100+ years), the underlayment beneath had completely failed, causing water intrusion into the master bedroom and living room during heavy rains.
During our initial inspection, we carefully walked the roof and found the clay tiles intact but the original tar paper underlayment (installed in 1941) had deteriorated to dust in many areas. This is a common issue with historic tile roofs: the tiles outlast the underlayment by decades. Water was penetrating through gaps in the underlayment and rotting the wood decking beneath. We found 12 areas with active leaks and suspected hidden damage to roof decking that wouldn’t be visible until tile removal.
Dr. Chen was adamant about preserving the historic character of the home and specifically wanted to reuse the original tiles rather than replace them with modern reproductions. As the home is located in a local historic district, any roofing changes required approval from the city’s Historic Preservation Commission. This project required specialty tile roofing expertise that most shingle-focused contractors don’t possess.
Scope of Work
Tile Removal & Storage
- Carefully hand-removed 2,328 sq ft of barrel clay tiles (approximately 2,800 individual tiles)
- Numbered and mapped tile locations for reinstallation in original pattern
- Stored tiles on-site using protective padding to prevent breakage
- Sorted tiles into three categories: excellent (95%), minor chips (4%), broken (1%)
- Ordered 60 replacement tiles from specialty supplier to match 1940s profile
Decking Inspection & Repair
- Removed deteriorated tar paper underlayment (completely disintegrated in south/west exposures)
- Found 18 sheets of damaged 1x8 tongue-and-groove wood decking (water rot and termite damage)
- Replaced damaged decking with matching dimensional lumber to maintain historic substrate
- Treated all wood decking with borate solution for termite prevention
- Reinforced 6 rafter connections that showed splitting
Installation
- Underlayment: GAF Deck-Armor high-temperature synthetic underlayment (rated for tile applications, 250°F tolerance)
- Tile Attachment: Reinstalled original tiles using modern stainless steel screws with foam closures (superior to old wire-tie method)
- Hip & Ridge: Custom-fabricated ridge tiles using matching clay (8 original ridge tiles were broken beyond repair)
- Flashing: All new copper valley flashing and step flashing (original galvanized had corroded)
- Penetrations: Rebuilt 4 chimney flashings and sealed 7 plumbing vents with tile-compatible boots
- Bird Stops: Installed modern bird stop closures at eaves to prevent wildlife entry
Historic Preservation Requirements
- Submitted detailed preservation plan to St. Petersburg Historic Preservation Commission
- Documented tile removal and reinstallation with photographs for city archives
- Matched original tile installation pattern and ridge details
- Used copper flashing (period-appropriate material vs. aluminum)
- Maintained original roof pitch and lines (no structural changes)
Challenges & Solutions
Challenge 1: Fragile Historic Tiles
Problem: 1940s barrel tiles are brittle and prone to breakage during removal. Each broken tile is irreplaceable, as the original manufacturer closed in 1963. Breaking more than 5-10% of tiles would require costly custom reproductions.
Solution: Our crew has specialized training in historic tile work. We used soft underlayment pads during removal and carefully hand-carried each tile to ground storage. We implemented a “zero-rush” policy where speed was sacrificed for preservation. Result: Only 1% breakage rate (28 tiles out of 2,800), well below the 5% we budgeted for. We ordered 60 replacement tiles from a specialty supplier in Lake Wales that still makes barrel tiles using 1940s molds.
Challenge 2: Hidden Decking Damage
Problem: We estimated 8-10 sheets of damaged decking based on visible interior water stains. Upon tile removal, we found 18 sheets with rot or termite damage - more than double our estimate. This added unexpected cost and timeline delays.
Solution: We immediately documented the damage with photos and called Dr. Chen for a roof deck inspection. We explained that the additional damage was hidden beneath tiles and not detectable during our initial estimate. Dr. Chen appreciated our transparency. We provided a detailed written change order for the additional decking work ($2,800) and absorbed some of the cost as a goodwill gesture. We also discovered the termite damage and referred Dr. Chen to a licensed pest control company for full home treatment.
Challenge 3: Matching Historic Ridge Details
Problem: 8 ridge tiles were broken beyond repair. Modern ridge tiles have different profiles than 1940s tiles, and using mismatched ridge tiles would be visible and harm historic character.
Solution: We contacted a specialty clay tile manufacturer in Lake Wales, Florida who still produces barrel tiles using original 1940s equipment. They were able to custom-fire matching ridge tiles in the same terra cotta color. Lead time was 3 weeks, so we temporarily weatherproofed the ridge with tarps and completed other work while waiting for tiles. The custom ridge tiles matched perfectly.
Challenge 4: Historic Preservation Approval
Problem: Old Northeast is a local historic district requiring city approval for exterior changes. Some preservation boards prefer “preserve as originally built” even if it means using inferior materials (tar paper instead of modern synthetic).
Solution: We prepared a detailed presentation for the Historic Preservation Commission showing that synthetic underlayment is invisible once tiles are reinstalled, provides superior performance, and actually extends the life of the historic tiles by preventing water damage. We emphasized that we were preserving the visible historic character while upgrading hidden components. The commission approved unanimously, noting our commitment to preserving the original tiles.
Timeline
Week 1 - Permitting & Planning:
- Historic Preservation Commission application submitted with photos and material specifications
- Building permit application filed with City of St. Petersburg
- Ordered specialty replacement tiles (3-week lead time)
- Commission approval granted (meeting held every 2 weeks)
Day 1 (Monday) - Tile Removal:
- 7:30 AM: Crew arrived, set up tile storage area with protective padding
- 8:00 AM: Began hand-removing tiles from south slope (highest sun exposure, most deteriorated underlayment)
- 12:00 PM: Lunch break, 30% of tiles removed and stored
- 1:00 PM: Continued tile removal on west slope
- 5:00 PM: 60% of tiles removed, exposed decking protected with tarps
- Discovered extensive decking damage (more than estimated)
Day 2 (Tuesday) - Continued Tile Removal & Decking Inspection:
- 8:00 AM: Completed tile removal (100% removed by 11am)
- 11:30 AM: Homeowner on-site inspection of damaged decking, change order discussion
- 12:00 PM: Lunch, change order approved for additional decking
- 1:00 PM: Began removing damaged decking (18 sheets identified)
- 5:00 PM: 50% of decking replacement complete, roof tarped
Day 3 (Wednesday) - Decking Completion:
- 8:00 AM: Completed decking replacement
- 10:30 AM: Applied borate termite treatment to all decking
- 12:00 PM: Lunch break
- 1:00 PM: Began installing GAF Deck-Armor underlayment
- 4:30 PM: Underlayment 80% complete
- 5:00 PM: Roof weatherproofed with underlayment
Day 4 (Thursday) - Tile Reinstallation Begins:
- 8:00 AM: Installed copper valley flashing
- 9:00 AM: Began tile reinstallation starting at eaves, working up to ridge
- 12:00 PM: Lunch break, 35% of tiles reinstalled
- 1:00 PM: Continued tile installation
- 5:00 PM: 70% of tiles reinstalled
Day 5 (Friday) - Completion:
- 8:00 AM: Installed remaining field tiles
- 11:00 AM: Installed custom ridge tiles (arrived from manufacturer)
- 1:00 PM: Installed bird stops and ridge closures
- 2:30 PM: Rebuilt chimney flashing with copper
- 4:00 PM: Final cleanup, magnetic sweep of property
- 4:30 PM: Homeowner walkthrough and historic preservation documentation photos
Week Following:
- City building inspection passed (Tuesday)
- Submitted completion photos to Historic Preservation Commission for archives
- Permit closed successfully
Results
Inspection & Historic Preservation
City of St. Petersburg building inspector passed the installation on first attempt, specifically noting the quality of the copper flashing work and proper tile attachment methods. Inspector commented that this was “one of the finest historic tile roof restorations” he’d seen in Old Northeast.
Historic Preservation Commission sent a letter thanking us for our careful preservation work and requested to use our project photos in their educational materials about appropriate historic roof restoration.
Homeowner Satisfaction
Dr. Chen (homeowner):
“Rain Right saved our historic tile roof. Other contractors wanted to replace the tiles entirely, but Rain Right understood the historic value and successfully reused 95% of our original 1940s barrel tiles. The craftsmanship was outstanding and the city historic preservation office was thrilled with the result. The leaks are completely gone and I have confidence this roof will protect my home for another 50+ years.”
Home Value Impact: Historic preservation done correctly increases home values in designated districts. Dr. Chen’s home was appraised 6 months after the project, and the appraiser specifically cited the “expertly restored historic tile roof” as adding $30,000-40,000 to the home value compared to a modern tile replacement.
Warranty Coverage
- 15-year workmanship warranty from Rain Right Roofing
- GAF 20-year material warranty on Deck-Armor underlayment
- Lifetime durability on reused clay tiles (clay tiles regularly last 100+ years)
Performance Benefits
- Zero leaks after installation (tested through multiple heavy rain events)
- Energy efficiency improved - clay tiles provide natural thermal mass and ventilation
- Historic character preserved - home maintains authentic 1940s appearance
- Future-proof - modern underlayment will last 30-50 years before next replacement (vs. 15-20 for tar paper)
Cost Breakdown
Total Investment: $27,699
Itemized:
-
Tile Handling: $8,500
- Hand removal and storage of 2,800 tiles: $4,200
- Sorting, numbering, and mapping: $1,100
- Careful reinstallation: $3,200
-
Materials: $7,200
- GAF Deck-Armor underlayment: $2,400
- 60 custom replacement tiles @ $35/each: $2,100
- Copper valley & step flashing: $1,800
- Stainless fasteners, foam closures, bird stops: $900
-
Decking Repair: $4,200
- 18 sheets tongue-and-groove lumber @ $85/sheet: $1,530
- Borate termite treatment: $420
- Labor for decking replacement: $2,250
-
Labor: $6,000
- 4-person specialized tile crew × 4 days @ $375/day/person
- Historic preservation expertise premium
-
Permits & Approvals: $850
- City building permit + inspections: $475
- Historic Preservation Commission application: $375
-
Insurance/Overhead: $500
- $2M general liability insurance allocation
- Workers compensation allocation
-
Contingency (used): $449
- Absorbed partial cost of unexpected decking damage as goodwill
Why historic tile costs more: Tile underlayment replacement runs 40-60% higher than new shingle roofs due to specialized labor for careful tile removal/reinstallation. However, preserving original tiles maintains historic character and home value. A full tile replacement would have cost $38,000-45,000.
Photos
Before: Water-stained interior ceilings, deteriorated tar paper visible between tiles During: Exposed 1x8 tongue-and-groove decking with areas of water rot damage After: Beautifully restored 1941 barrel tile roof maintaining original Mediterranean Revival character
Materials Used
- Tiles: Original 1940s barrel clay tiles (95% reused) + 60 custom replacement tiles
- Underlayment: GAF Deck-Armor synthetic (250°F rated for tile applications)
- Flashing: 16 oz copper valley flashing and step flashing (period-appropriate)
- Fastening: Stainless steel tile screws with foam closure strips
- Decking: Dimensional tongue-and-groove lumber matching original 1x8 boards
- Ridge: Custom-fired terra cotta ridge tiles matching 1940s profile
- Bird Stops: Universal tile bird stop with stainless mesh
Lessons Learned
What Went Well
- Tile breakage rate (1%) far better than industry average (5-8%)
- Historic Preservation Commission approval process smooth with detailed presentation
- Homeowner communication excellent throughout change order process
- Discovered and addressed termite issue before it worsened
Challenges Overcome
- Hidden decking damage more extensive than estimated (transparent communication resolved)
- 3-week wait for custom ridge tiles (planned workflow to minimize timeline impact)
- Educated historic preservation board on benefits of modern underlayment materials
Similar Projects in St. Petersburg Historic Districts
If you’re in Old Northeast, Roser Park, Historic Kenwood, or Historic Uptown, we’ve completed 25+ historic tile roof restorations in St. Petersburg’s designated historic districts and understand the unique preservation requirements.
Common historic district considerations:
- Historic Preservation Commission approval required for exterior changes
- Preservation of original materials when feasible (tiles, flashing profiles, roof lines)
- Period-appropriate materials even for hidden components (copper vs. aluminum)
- Documentation requirements for city archives
- Specialized contractors with historic restoration experience
Contact us for a free estimate on your historic tile roof restoration.
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