Metal retrofit strengthens Baltimore cruise terminal roof

By Jesse Sanchez. 

Engineered metal-over-metal retrofit improved wind performance efficiency and long-term durability for a high-traffic waterfront facility. 

In 2011, Metal-Fab Manufacturing and Roof Hugger delivered a complex metal-over-metal retrofit for the Port of Baltimore Cruise Terminal, completing a much-needed public infrastructure upgrade. The 65,000-square-foot facility serves cruise passengers traveling with Royal Caribbean, Celebrity and Carnival Cruise Lines and required a roofing solution aligned with coastal exposure demands. 

The Maryland Port Authority selected an engineered approach that both preserved the existing structure while also increasing performance. Metal-Fab supplied the complete retrofit framing and roofing package, installed by Xpert Xteriors, using a system tailored for speed, precision and structural reliability. 

Jamie Fick described the decision path clearly, sharing, “There was only one way to retrofit the existing metal building and that was to use factory-notched sub-purlins supplied by Roof Hugger, Inc.” The sub-framing system allowed installers to work directly over the original roof while maintaining alignment and load continuity. 

Beyond constructability, the sub-purlins delivered structural advantages. The ease and speediness of installation, combined with components that increase the load carrying capacity of the existing building’s roof purlins, offset added system weight. That balance proved essential for completing the retrofit without operational disruption. 

Above the framing, they installed jobsite roll-formed 22-gauge Met-Fab III standing seam panels with a bare Galvalume finish. The heavier gauge addressed elevated wind requirements while the 16-inch structural profile and mechanically locked ribs supported long panel runs up to 120 feet. 

Thermal performance was improved through the decision to install fiberglass insulation placed between the original ribbed panels and the new roof assembly. Roof Hugger also engineered a specialized hat-over-zee system at edges and corners, enabling clip placement between existing purlins spaced five feet on center. 

Careful staging and coordinated system selection allowed the installation to proceed smoothly, delivering durability, efficiency and resilience for a critical transportation asset. 

Learn more about engineered metal retrofit systems supporting complex facilities through Roof Hugger and Met-Fab!