A panel sold as 26 inches covers 21½ on a roof
This is the number that makes every other number on the page wrong if you get it from the label. A corrugated steel sheet is sold as a 26 inch panel and measures about 25⅝ inches across. Lay it as siding and it covers 24 inches, because siding laps one corrugation. Lay it on a roof and it covers 21½ inches, because a roof laps two.
Gibraltar's own detail manual prints both figures. Count a roof at 24 inches and you are 12% short; count it at 26 and you are 21% short. On a 40 by 30 foot gable at 6:12 that is the difference between 46 panels and 40. A panel does not run round the ridge, so each 40 foot eave is counted on its own: 23 panels a side at 21½ inches, where dividing the whole 80 feet at once gives 45 and leaves the roof a panel short on each side.
| Width you count with | Panels for two 40 ft eaves | Result |
|---|---|---|
| 21½ in — roof coverage | 46 | right |
| 24 in — siding coverage | 40 | 6 panels short |
| 26 in — the name on the label | 38 | 8 panels short |
A rib panel — R-panel, PBR, Panel-Loc Plus — is the other common profile and it is simpler: the sheet is wider than its coverage, and the coverage is 36 inches flat. Centria, McElroy and Central States all publish 36.
Panels are cut to the roof, not divided into it
A panel runs in one piece from the eave to the ridge. That length is not the roof width: on a gable the plane climbs half the width, up the slope. A 40 by 30 foot roof at 6:12 climbs 15 feet of plan times the 1.118 slope factor — 16 feet 9 inches from eave to ridge.
So the question is not "how many square feet", it is "which length do I buy, and what is left of each one". That is what the cutting list on this page answers. Buy 20 foot panels and each one is cut to 16 feet 9 inches and leaves 3 feet 3 inches. Buy 12 foot panels and no panel reaches: each run takes two pieces with a lapped seam between them.
Every lap is a seam
Where no length sold is long enough, panels lap end to end — 6 inches is the minimum the install guides give, with sealant in the lap. It works, and roofers do it on long slopes. But a lap is a horizontal joint on a water surface, and it is the first place an exposed-fastener roof leaks.
This page therefore prefers the shortest length that reaches the ridge in one piece, even where a shorter panel costs less. The shorter panel keeps its row on the list and you can still pick it; the page just will not choose it for you. If the length you want is not on the list, a supply yard will roll panels to your exact length — Centria publishes 5 to 38 feet as standard — and that is usually the right answer for a slope over about 16 feet.
Slope: panels are not shingles
Asphalt shingles need 2:12. An exposed-fastener panel is published for 3:12 without sealant in the laps; McElroy allows 1:12 for R-panel with sealant, and Central States puts Panel-Loc Plus at 2½:12. Below the figure in the assumptions block this page says so rather than passing a roof nobody checked.
The code chapter this cluster checks — IRC Chapter 9, R905.2 — covers asphalt shingles and nothing else, so on this page all four of those clauses come back "not checked" instead of pretending. What holds a panel roof up is the maker's own data sheet for the profile, the purlin or deck spacing and the wind zone, and your local building department has the last word.
Screws, and the ones this page does not count
Budget about 80 gasketed screws per square — fastener lines 24 inches apart on a 36 inch panel, which is the planning rule Western States Metal Roofing publishes. Midwest Manufacturing specifies 75. Edges and corners take more, and a high-wind zone takes more again.
The stitch screws that fasten the side laps and the trims are not on this list. Sources give 20 to 40 a square and no single figure, so the page says it is not counting them rather than inventing a number. Add a bucket.
Hip roofs waste more
On a hip roof the two end planes are triangles, so each panel there is cut at an angle and the offcut cannot be used anywhere else. This page counts a full-length panel for every panel width across the eave, which is how the panels are ordered, but the real waste on a hip is higher than the figure the cutting list shows. A hip roof in standing seam is a job to get quoted.
What this page does not do
It does not lay out standing seam, which is sold by the clip and the coverage width of the specific panel rather than off a shelf. It does not count closures, butyl tape, pipe boots or the valley metal for a roof of several planes. And it does not price anything it has no shelf price for: the rib panels have no reference price in this repo at all, because they are ordered rather than carried out of a store.
We are not affiliated with any of the manufacturers named here. Every figure on this page is in the assumptions block, with where it came from, and every one of them is a box you can type over.