Clay Tile Roof Restoration — Montclair
Project Intro
Alpha Pro Construction LLC was engaged to restore the original clay tile roof on a 1924 Tudor Revival home in Montclair’s historic district. The home’s barrel-roll clay tiles were a century old — many still in excellent condition — and the owner wanted to preserve as much of the original material as possible while resolving chronic leak points at valleys and dormers.
We carefully removed and catalogued all existing tiles, salvaging over 70% for reuse. Damaged tiles were replaced with period-matched clay tiles sourced from a specialty manufacturer. All valleys received new lead flashings and a completely rebuilt mortar bed, restoring the roof to better-than-original condition.
- 70% Original Tile Salvage & Reuse
- Period-Matched Clay Tile Replacement
- New Lead Valley Flashings
- Mortar Bed Rebuild Throughout
Challenge & Solution
Working on a century-old clay tile system required extreme care during removal to avoid cracking salvageable tiles. The original mortar had carbonated and failed in many areas, and two sections of the hip system had collapsed inward from prolonged water infiltration that had rotted the underlying deck boards.
Our crew developed a custom tile-removal protocol using padded pry tools and individual tile staging trays. Rotted deck sections were sistered and sister-boarded before new underlayment was applied. We also repointed all exposed mortar ridges with a matching hydraulic lime mortar that is both historically appropriate and highly durable.
- Careful Tile Removal Protocol
- Rotted Deck Replacement
- Hydraulic Lime Mortar Repointing
- Period-Accurate Restoration Methods
Working Process
Tile Survey & Removal
Every tile catalogued and sorted; salvageable tiles cleaned, stacked, and covered for reuse.
Deck & Flashing Rebuild
Rotted deck boards replaced, new underlayment installed, and custom lead valley flashings formed.
Tile & Mortar Reset
Salvaged and new tiles re-laid with fresh mortar beds; hips and ridges repointed with lime mortar.
Delivering Results
The restored clay tile roof looks indistinguishable from the home’s original 1924 installation while performing dramatically better — all leak points resolved, decking fully renewed, and proper drainage established at all valleys.
By salvaging over 70% of the original tiles, Alpha Pro Construction LLC saved the homeowner significant cost compared to a full tile replacement while preserving the irreplaceable character of a historic New Jersey home.
