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Metal Roof Recovery – the best way and less costly

Metal Roof Recovery – the best way and less costly

Commercial Metal roof recovery

There are many methods on salvaging a metal roof that has gone past its life cycle. Most ideas are to spray a coating over a metal roof. When you look and listen to all the coating manufacturers, they all claim to do a good job. From our experiences, we have not found any coating that can last a long time. When applied they all look good, it’s like new painting in a building. but that’s all it is.

We have developed a method that we have to learn from doing flat roof installation. The idea is to install a rubber membrane directly to the metal.  On all our roofs, the biggest challenge is to attach the rubber to the flashing. over the years we have come up with a proven method and we have applied that principle to metal roof recovery.

This method of ours works so well for several reasons.

  1. We use a petroleum based sealer and adhesive.
  2. The metal can be rusty and dirty, the tar will stick and seal all of that.
  3. It’s less expensive than silicone or epoxy coatings.
  4. After we applied our sealant/ adhesive, we add a rubber membrane over that sealant that adheres to the sealant.
  5. The membrane gives added strength and protection against UV’s.
  6. The membrane also can take the expansion and contraction of the metal.

Watch this video and see how we do it.

DIY Flat Roof Repair Videos and Instructions - determine type of flat roof

DIY Flat Roof Repair Videos and Instructions

Before making a Flat Roof Repair, determine what type of roof you have

Help me with Google - please!

Click the 5 Stars at the top. If you have time write a comment at the bottom - Thanks

Metal Roof Recovery – the best way and less costly

/ / Metal Roof repair
Metal Roof Repair and Recovery
Metal Roof Recovery – the best way and less costly Commercial Metal roof recovery There are many methods on salvaging a metal roof that has gone past its life cycle ...
Read More/ Videos

Metal Roof Recovery

/ / Metal Roof repair
Metal Roof Vent leak - Longview TX -Flat roof repair/materials
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Metal Roof Repairs

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Metal Roof Gone Bad – Video – Pittsburgh – Silicone sealants are the worst

Metal Roof Repair - Pittsburgh PA
Metal Roof Gone Bad - impossible to make a Flat Roof Repair This "metal roof gone bad" was treated with a silicone sealant approximately three years ago. From the evidence, it ...
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Metal Roof Repairs or Recovery – we specialize in fixing metal roofs

/ / Metal Roof repair
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Metal Roof Repairs or Recovery We have formulated a unique rubber adhesive combination to make metal roof repairs. Even if the roof has rusted holes and seams or joints are ...
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This video explains why it's not a good idea to coat a metal roof with silicone spray. This video demonstrates how we went about to save a metal roof. The Growth ...
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Metal Roof Recovery

Metal Roof Recovery

Options on the Proper Repair of a Leaking Metal Roof

Metal roofs need coatings to give them a further life cycle.

Based on the research conducted by Metal Building Manufacturers Association (MBMA), it showed that in the U.S, pre-engineered metal buildings constitute over half of all the latest, low-rise one- and two-story, none- residential structures. Based on this vast quantity of constructions with metal roofs, there are also numerous metal roofing problems that are present.

A conventional metal building roofing system includes a 24- to 26-gauge coated steel roof panels installed on purlins (structural steel members) that comes in a variety of 14 to 18-gauge in thickness. These purlins are usually cold-formed “C” or “Z” members installed 5-ft. On the middle.  With the use of screws, metal roof panels are firmly locked on the purlins; while in standing-seam metal-panel systems, hidden clips are secured to the purlins. These screws are not just mainly used to lock the panels; instead, they also serve to ‘stitch’ the panels altogether at the sides and end laps. On the other hand, rubber or neoprene washers are installed beneath the fastener heads, and then a sealant or tape is applied to waterproof the panel side laps and end laps. A Caulk or tape is typically inserted to fashion a hydrostatic joint.

Metal roofs that are over ten years old are more likely to suffer from failure due to some causes. One well-known area of weakness is found at the end and side laps of the metal panels where the initial butyl tape or caulk seals get old and collapsed. Fasteners are also a metal roof’s weak spot. This is because metal structures tend to get bigger and contracted due to temperature changes; hence leading to enlarged fastener holes and causing ruin to the fastener seals, which then allows water into the building. Further metal roof repair issues are that of the side, and end laps of the panels since Caulks and sealant applied in these corners gets typically weaken, or the sealant is gone, subjecting the structure to weather.

Other factors that account for the need of metal roof recovery include insufficient drainage; poor workmanship or low-quality materials, poor design and detailing, as well as tattered coatings on metal panels.

In an attempt to properly conduct a metal roof repair which includes an old or leaking metal roof, those faulty panels must be taken away and restored.  Moreover, every fasteners and flashing must be regularly inspected and get replaced as needed. Doing this repair project is not only expensive but will also cause loss of valuable business hours since it’s time-consuming. Sometimes, it’s more practical to replace the damaged roof instead or to retrofit it with BUR (built-up roofing), single-ply membranes, coating systems or new metal roof panels. The following are five options available when dealing with a leaking metal roof issue:

Often you will see a roof like this that has been coated but the coating did not last.

Metal-roof Replacement

The old metal roof will be removed and replaced with a new one; hence it’s very costly and is normally done in cases wherein it’s unlikely or no longer possible to restore the existing, metal roof. Although this is the most expensive out of the 5 options, the benefit of it is that the owner of the construction can start fresh with a brand new roof. The known disadvantages of this option are that it’s pricey (roughly of $10 per SQ. ft), cause disturbances to building users or business, and the probability that this new roof will once again experience similar issue just like before which will call for another costly replacement.

If the roof is sturdy enough to endure the additional weight, a metal roof recovery – which involves the installation of new metal roofing over the existing one – is a great option. Despite the fact that a metal roof recover presents similar durability and advantages found in the original metal roof, it is still susceptible to the same issues that originally caused the original roof to weaken, plus this option is also expensive.

Coatings or Liquid-applied Systems

  • Polyurethane-foam Recover

This option uses sprayed polyurethane foam that is directly applied to the existing metal roof, in a manner just like how a coating is applied. Following the replacement of damaged panels and fixing of surface corrosion, the foam is normally sprayed/applied in a number of passes to attain a thickness of at least 1 in. A special surface coating is then applied to the metal roof, safeguarding the foam from any ultraviolet damage. The benefit of spraying a polyurethane foam is that it can add R-value to the metal roof, plus it does not call for reinforcing fabric at the laps and fasteners.  However, the foam’s inability to accommodate thermal expansion and contraction very well, including its uncertain weather ability are some of the disadvantages.

Coatings look impressive when applied. But it is very deceiving.
  • Single-Ply Recover

This is a very expensive method to recover a metal roof. First, ou fills the valley’s with a fiberboard and then you add another layer on top of that before you install the rubber membrane.

A single-ply membrane, like that of a hot-air weldable TPO (thermoplastic polyolefin), will be installed over the existing metal roof. Prior to installing this system, damages metal panels must be replaced first. Once the replacement is done, strips of insulation are then installed between the ribs or flutes of the existing metal roof surface, followed by a second layer of insulation which is installed over the entire roof to give a uniform and level substrate. This insulation will enhance the R-value of the roof, as well as bring a strong substrate for the single-ply system. The hot-air weldable membrane is then automatically secured or completely adhered directly over the insulation, while the seams are merged altogether with the use of hot-air. A mechanically fastened system is held to the structural purlins with fasteners.

Some advantages of using the single-ply option in metal roof repair include reducing cooling costs since membranes are available in white or light colors. TPO membrane is flexible, enabling it to accommodate the movement that is natural in metal roofing, including any plane changes in the roof. Another benefit is that the cost of added insulation is already included in the total cost of the roof installation, which is typically similar to the cost of applying coatings. Moreover, these single-ply systems are usually not as sensitive to weather conditions as coatings during the installation procedure. Lastly, compared to roof coatings which normally only offer a 5- to 10-year maximum warranty period, some single-ply systems installed over metal roofs come with a 20-year warranty.

Deciding on how to recover, replace or repair a failing metal roof is not easy, sometimes confusing too. Knowing which ideal solution to have will surely help enhance the value, look and efficiency of a construction in a long period of time; that’s why it’s essential that you know which metal roof repair or metal roof recovery option to get.

This is a very expensive method to recover a metal roof. First you fill the valley’s with a fiberboard and then you add another layer

Metal Roof Recovery – the best way and less costly

/ / Metal Roof repair
Metal Roof Repair and Recovery
Metal Roof Recovery – the best way and less costly Commercial Metal roof recovery There are many methods on salvaging a metal roof that has gone past its life cycle ...
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Metal Roof Gone Bad - impossible to make a Flat Roof Repair This "metal roof gone bad" was treated with a silicone sealant approximately three years ago. From the evidence, it ...
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Metal Roof Repairs or Recovery – we specialize in fixing metal roofs

/ / Metal Roof repair
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Metal Roof Repairs or Recovery We have formulated a unique rubber adhesive combination to make metal roof repairs. Even if the roof has rusted holes and seams or joints are ...
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This video explains why it's not a good idea to coat a metal roof with silicone spray. This video demonstrates how we went about to save a metal roof. The Growth ...
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Metal Roof Repairs

Certain industrial facilities like steel, chemical, and ice plants must stay safe, operates effectively without any malfunction, and no unintended maintenance requirement or replacement for decades. In order to safeguard the equipment from untimely deterioration, standard three separate coating are used, usually in epoxy, zinc or urethanes. Although this metal roof recoating system is commonly used, it’s not always the best choice.

With regards to safety, urethane topcoats are not that great since they have glossy walking surfaces that attribute to slip and fall risks, specifically if the walking surfaces are moist, humid or wet. Also, the usual exterior roof coating like that of epoxy and urethane can release harmful VOCs, HAPs, as well as odors while being applied, and can possibly contain flash points that call for further distance or proper care once used around hot or flammable processes.

There are several types of coatings on the market. None of them come close to the durability and strength of a coating with a rubber membrane on top of it.

Precaution is not the only concern when using traditional roof coatings but also time since their application can also hamper production for days as they generally need extensive metal surface preparation, a prime coat and two topcoats with no less than eight hours of drying time – also referred to as ‘minimum recoat time’ – between each coat. In addition, unfavorable weather or environmental conditions can further hold up the production, and may even demand re-blasting of the surface when an environmental delay go beyond the coating’s maximum recoat time.

According to Mobley Industrial Services (a multi-service specialty contractor serving the chemical, petrochemical, and refining industries) project manager Jay Harris, “Traditional coatings in some cases have significant drawbacks. They need extensive surface prep and must meet specific conditions, including minimum and maximum recoat times before they can be applied. Due to this, it can take a few days or longer to apply three coats, depending on the size of the job and environmental conditions. To avoid overspray issues, hand rolled application is often required.”

After applying the sealant/adhesive to the metal, we lay a rubber membrane that adheres to the roof. This will protect and recover the roof for 30 years or more.

In search of a much better solution at a petrochemical facility on the Gulf Coast, Harris recently utilized a newly developed roof recoating product called the ‘EonCoat’ by a Wilson, N.C.-based company with similar name, that will help improve the workplace safety and bring back roughly 35,000 sq. ft. floating roof tank to service in approximately half the time needed by standard coatings.

This type of corrosion coating is included in the latest group of sturdy, Chemically Bonded Phosphate Ceramics (CBPCs) that can end corrosion problems and lengthen equipment life. Unlike the usual typical paint polymer roof coatings which sit on top of the substrate, the anti-corrosion coating attaches through a chemical reaction with the substrate, and minor surface oxidation will in fact enhance the reaction. Due to this, corrosion promoters like oxygen and humidity will not be able to go through behind the coating, like they normally do with regular paints.  This corrosion barrier is covered by a genuine ceramic shell which defies corrosion, fire, water, abrasion, chemicals, and temperatures of up to 1,000 degrees F.

Ceramic coatings like this sort comes with two, safe ingredients that don’t interact until applied by a plural component spray gun such as those normally utilized when applying polyurethane foam or polyurea coatings. Due to the ingredients not blended, and that they do not come together before application, the need for harmful VOC-generating component is avoided, same goes for HAPs and hazardous odor. This safe characteristic of ceramic roof coatings means that working on them can be done even in populated/occupied locations.

The concern for possible accidents is also lessened when choosing ceramic roof recoating as Harris explained that “Unlike a slick urethane surface, the hard ceramic surface provides better footing and minimizes the risk of slip and fall hazard, particularly on wet, moist, or humid surfaces.” He also added that, “With no VOCs, HAPs, odors, or flash point, it’s also safer for the applicator and work environment.”

Compared to the customary roofing recoating systems that calls for three coats, a mere single application and small prep for the protective ceramic coating are already enough; hence giving facility maintenance managers with noteworthy, upfront savings. If the substrate is made of steel, sandblasting until there is a bright metal surface for the coating to stick is no longer needed because using a brush blast is already enough to efficiently remove loose rust. After the application of the ceramic coating, it can quickly get dry in just a matter of minutes, safe enough to be walked on in only 15 minutes and the roof back on its function in roughly an hour.

Although the Mobley Industrial initially made an estimate of more than 20 shifts to blast and coat the floating tank roof with a customary three-coat roof recoating system, the entire project was fully completed in just ten shifts with the use of the ceramic coating. Harris explained that this happened because “With EonCoat surface prep was minimal, and there was no need for a primer or multiple topcoats because one coat did the job.” He then added that “Unlike traditional coatings, there were no minimum or maximum recoat times, and we were able to spray the ceramic coating instead of hand roll it. Since it dry falls within ten feet, there was no concern of overspray. This expedited the application process with much less labor.”

When it comes to the comparison of ceramic roof coating versus the standard coatings for petrochemical plants, Mobley Industrial Services Quality Control Manager, Wesley Newburn addressed some of the great benefits that can make the application and quality assurance process more efficient.  Newburn said that “For traditional coating application, the first step is to remove soluble salts to a permissible level, which includes site checks for chlorides, nitrates and sulfates.” He then further explained that, “If they are above the maximum levels allowed by the refinery, they must be removed by chloride and pressure washing. This normally will take at least one 10 hour shift. With the ceramic coating there is no need for soluble salts to be removed, which is an advantage over any other coating in the industry.”

Using the customary roofing recoating system, extensive surface preparation will be necessary and it’s often done gradually to avoid chances of surface oxidation, which will then demand re-blasting. As Newburn puts it, “Typically you need to keep an SP-10 throughout the entire blast operation, cleaning operation, and painting operation with traditional coatings. You may need to rent D-H equipment because humidity above 60 percent will oxidize the surface and require re-blasting.”

The Mobley Industrial Services manager then shared, “Perhaps the biggest advantage with EonCoat is that there’s no worry about surface prep. Newburn explained why, saying that “You can blast the entire surface, then coat it without concern over losing an acceptable blast. There’s no need for D-H equipment because the ceramic coating can be applied when it’s wet, humid, or even raining. A little surface oxidation makes it adhere better.

Newburn believes hydrocarbons are the main root of roof coating delamination at petrochemical facilities. To avoid possible delamination at refineries with customary coatings, every hydrocarbon like oil and grease should be detected by black light methods, then successfully eradicated by chloriding until black light passes. This hydrocarbon removal process is not needed when using ceramic coating since it will not stick on hydrocarbons; therefore the coating will ‘bubble” once applied on dirty surfaces or on the poorly prepared substrate.

It’s not difficult to detect a weak substrate or messy roof surface because as Newburn explained it, “You can immediately identify and correct poor surface prep during application.” He also suggested that “For quality assurance, you can also take the coating’s dry film thickness as early as 15 minutes after application at 75 degree F. That means the coating can be performed and corrected at the same time, which makes work quicker and gives a more predictable outcome.”

Lastly, Harris of Mobley Industrial Services made a strong and valid conclusion that “For enhanced corrosion protection, production uptime, as well as workplace and environmental safety, any industrial user who uses traditional coatings should consider EonCoat.” That said, it’s would be great to choose a roof recoating system that is not only of high quality but also safe and will offer upfront savings.

Metal Roof Repairs

Metal roof repairs
DIY Flat Roof Repair Videos and Instructions - determine type of flat roof

DIY Flat Roof Repair Videos and Instructions

Before making a Flat Roof Repair, determine what type of roof you have

Help me with Google - please!

Click the 5 Stars at the top. If you have time write a comment at the bottom - Thanks

Metal Roof Gone Bad – Video – Pittsburgh – Silicone sealants are the worst

Metal Roof Gone Bad – impossible to make a Flat Roof Repair

This “metal roof gone bad” was treated with a silicone sealant approximately three years ago. From the evidence, it is clear that the company applying the sealant didn’t know what they were doing.

After investigating and making tests:

  1. The silicone sealant was cracked where the two metal plates joined.
  2. Water got trapped and caused the metal to rust. In some areas, it has rusted and corroded to where the insulation underneath was visible
  3. Most fasteners had water trapped around it and was rusting the metal
  4. The silicone is peeling around the vent units. No sealant or coating will stick properly on a petroleum product.

What we take from this is, that the surface was not prepared properly before the coating was applied. From our experience, no matter how well the surface preparation, silicone sealants do not last more than two years at best.

Why do metal roofs start leaking?

A metal roof should last a long time. Most leaks on a metal roof start with the fasteners. With metal roof installation, screws are used to fasten the roof sheets to the trusses. Thes screws have a rubber or neoprene washer that would make the seal between the screw head and the metal plate.

Over time these rubber or neoprene washers hardens, becomes brittle and crack, compromising the seal and is the beginning of a small drip leak. At first, no one might be aware of it. But over time the water that accumulates around the screw under the washer will cause the metal to rust or corrode making the fastener hole, larger.

Also, with the constant expansion and contraction of the metal, the washers are worn down. For this reason, it is wise to have a metal roof inspected every five years to make sure that the screws are still at the proper torque strength and to ensure the washers are still holding up.

 

Metal Roof Screws and rubber or neoprene washers are the cause for leaks

Watch this video to see how water gets trapped under the silicone causing the metal roof to rust.

Why we decided that a repair is not wise

  1. We could repair it, but because of the silicone coating, we might miss many areas, and this would mean we will have to make numerous trips after the repairs. That could frustrate the client and us
  2. After the repairs, the silicone could loosen up in other areas, trap water and cause new leaks
  3. The cost of repairing will be more than a 1/3 of the cost of replacing it with a new roof
  4. A proper warranty is not possible
  5. Money and time spent on any repairs will be a waste
  6. Our name and reputation is on the line – one bad job and unhappy client can cause more damage for us to potential customers in the future
No Thanks – it’s not worth it
Before considering a metal roof repair, a careful examination of what’s on it and what others have done to it must be taken into account.

Our solution to this metal roof:

Step 1- Preparing the roof for a plywood installation

Remove all debris and screws on top of the risers. Remove and clean silicone sealant from the air conditioner and vent flashing. After preparation, to install 19/32 CDX plywood fastening it to the risers with metal screws.

We use a thicker plywood than a 1/2″ because of the metal roof flexibility.  Install support 2 x 4’s in areas where needed.

Plywood installation over metal roof

Smooth surface ready to install a Rubber Roof Membrane

This image shows what it looks like once the plywood is installed over a metal roof.  The plywood creates a flat surface for a rubber roof installation. The space under the plywood is left open so that air can move freely through. The air movement keeps the roof much cooler.

Plywood installed over a metal roof

Step 2 – Installation of a Self-Adhering Base

Install a self-adhering Modified Bitumen Base sheet over the entire surface of the plywood.

Install aluminum drip edge. We use a heavy gauge aluminum drip edge.

Modified Bitumen self-adhering base sheet is installed

Step 3 – Modified Bitumen Cap sheet installed

After the installation of the metal edging, it’s time to install the cap layer. To Install a white granular Modified Bitumen Cap sheet. The ceramic granules protect the rubber membrane from ultraviolets and also reduces heat absorption.

A special primer is used to secure the cap sheet to the metal drip edge.

Modified Bitumen Rubber Membrane installed over the base sheet

Step 4 – Flashing

After the installation of the cap sheet, installation of flashing follows on all the air conditioners and vent units. Removal of silicone coating that covers all the metal for proper flashing.

Flashing around all the vents and drains are made

Metal Roof Gone Bad

Metal roof gone bad – The image shows what it looks like when you peel back the silicone from the seams on a metal roof. It is wet and rusted. We have seen this over and over where an attempt was made to seal a metal roof with disastrous results.

The reason why silicone coatings or other types of coatings will not work are:

  1. The metal can never be 100% clear from all debris, dust, oils, and rust. Especially around fasteners and seam overlapping.
  2. Where two metal plates overlap is constant movement from the expansion and contraction of the metal. The constant movement will cause the sealant to either crack or peel off.
Metal Roof Gone Bad - peeling back silicone reveals the problems

Silicone Coating over a metal roof seam

Notice the small crack that has developed on the silicone surface. This layer is the 3rd attempt repairing the seams. You can see that by the different colors of sealant applied on top of each other. The constant movement of the metal under the silicone will always cause it to crack.

Silicone coating developing crack over metal roof seam

Metal Roof Gone Bad around Fasteners

When peeling back the silicone coating that was covering the screws on the metal roof, we found them all wet and rusted. By just looking at the surface it wasn’t apparent that there were any problems, but a closer investigation revealed the truth. The screws or fasteners is where most “metal roof gone bad” issues are.

Metal Roof Gone Bad - fasteners are rusted and all wet

Metal Roof Recovery – the best way and less costly

/ / Metal Roof repair
Metal Roof Repair and Recovery
Metal Roof Recovery – the best way and less costly Commercial Metal roof recovery There are many methods on salvaging a metal roof that has gone past its life cycle ...
Read More/ Videos

Metal Roof Recovery

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Metal Roof Recovery Options on the Proper Repair of a Leaking Metal Roof Based on the research conducted by Metal Building Manufacturers Association (MBMA), it showed that in the U.S, ...
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Metal Roof Repairs

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Read More/ Videos

Metal Roof Gone Bad – Video – Pittsburgh – Silicone sealants are the worst

Metal Roof Repair - Pittsburgh PA
Metal Roof Gone Bad - impossible to make a Flat Roof Repair This "metal roof gone bad" was treated with a silicone sealant approximately three years ago. From the evidence, it ...
Read More/ Videos

Metal Roof Repairs or Recovery – we specialize in fixing metal roofs

/ / Metal Roof repair
Metal-Vent-stack-flashing
Metal Roof Repairs or Recovery We have formulated a unique rubber adhesive combination to make metal roof repairs. Even if the roof has rusted holes and seams or joints are ...
Read More/ Videos

Metal Roof Repair: Leak Causes and Fixes – Watch Video

Metal Roof Repairs - Flat roof repairs
This video explains why it's not a good idea to coat a metal roof with silicone spray. This video demonstrates how we went about to save a metal roof. The Growth ...
Read More/ Videos

Metal Roof Repairs or Recovery – we specialize in fixing metal roofs

Metal Roof Repairs or Recovery

We have formulated a unique rubber adhesive combination to make metal roof repairs. Even if the roof has rusted holes and seams or joints are causing the leaks, our rubber membrane patches will be able to take care of any leakage.

Many leaks are due to the transition from an obstacle like a vent pipe, skylight to the roof. The seams created in these transitions will sometimes open up or cause water to stand to rust the metal making it leak.

Metal Roof Repair Videos

Watch the videos where we show how we repair or recover a metal roof. As long as there is no paint on the surface, we can install a rubber membrane over the entire surface extending the metal roof lives expectancy.

If there is a coat of paint or sealant, then we can patch areas where the leaks are by removing the painted area.

Metal Roof Recovery – the best way and less costly

/ / Metal Roof repair
Metal Roof Repair and Recovery
Metal Roof Recovery – the best way and less costly Commercial Metal roof recovery There are many methods on salvaging a metal roof that has gone past its life cycle ...
Read More/ Videos

Metal Roof Recovery

/ / Metal Roof repair
Metal Roof Vent leak - Longview TX -Flat roof repair/materials
Metal Roof Recovery Options on the Proper Repair of a Leaking Metal Roof Based on the research conducted by Metal Building Manufacturers Association (MBMA), it showed that in the U.S, ...
Read More/ Videos

Metal Roof Repairs

/ / Metal Roof repair
Metal Roof Repair - Coating extends life expectancy - Roofing Material
Certain industrial facilities like steel, chemical, and ice plants must stay safe, operates effectively without any malfunction, and no unintended maintenance requirement or replacement for decades. In order to safeguard ...
Read More/ Videos

Metal Roof Gone Bad – Video – Pittsburgh – Silicone sealants are the worst

Metal Roof Repair - Pittsburgh PA
Metal Roof Gone Bad - impossible to make a Flat Roof Repair This "metal roof gone bad" was treated with a silicone sealant approximately three years ago. From the evidence, it ...
Read More/ Videos

Metal Roof Repairs or Recovery – we specialize in fixing metal roofs

/ / Metal Roof repair
Metal-Vent-stack-flashing
Metal Roof Repairs or Recovery We have formulated a unique rubber adhesive combination to make metal roof repairs. Even if the roof has rusted holes and seams or joints are ...
Read More/ Videos

Metal Roof Repair: Leak Causes and Fixes – Watch Video

Metal Roof Repairs - Flat roof repairs
This video explains why it's not a good idea to coat a metal roof with silicone spray. This video demonstrates how we went about to save a metal roof. The Growth ...
Read More/ Videos

Metal Roof Repair: Leak Causes and Fixes – Watch Video

This video explains why it’s not a good idea to coat a metal roof with silicone spray.

This video demonstrates how we went about to save a metal roof.

The Growth of the Metal Roof Industry

Based on the research conducted by Metal Building Manufacturers Association (MBMA), pre-engineered metal buildings constitute over half of all the latest, low-rise one and two-story, none- residential structures in the U. S. Based on this huge quantity of constructions with metal roofs, there will be a need for repairs in the near future.

Click here to learn about “How to find a Leak and make a Flat Roof Repair”

Causes of Metal Roof Leaks

The expansion and contraction, of metal roof structures, is caused by temperature changes. The stress of movement to the screws and neoprene washers, against metal panels, leads to leaks when the torque tolerance weakens. Another cause of leaks can be found at the end and side laps of metal panels, where the initial butyl tape or caulk seals, shrinks and creates gaps. A more obvious cause of leaks comes from the accumulation of standing water which leads to rust and eventually corrosion.

To learn more about coating product properties as well as see the additional usage applications, go to EonCoat learn more about the product properties as well as see the additional usage applications. Our website also includes updated industry news and blog posts about protective coatings.

 

Repair Solutions

Silicone Spray 

There are a couple of methods that we have seen used to recover or repair a metal roof. One popular method is to spray the entire roof with a silicone coating, even though there are only a few areas that leak. Despite the surface preparation, the application of a primer, the fantastic appearance, and the cost-effective claims, this type of coating only lasts 3-5 years. During this time, pinpricks and expansion and contraction cracks develop causing water to collect between the coating and the metal. This water accumulation is not detected until the compromised area of the roof has rusted through.

Rubber Membrane

We have developed a method, of metal roof recovery, by using a technique that we perfected, from many years of installing flat roofs. It is relatively inexpensive and involves the combination of rubber membranes and adhesives. Repairing rusty metal with liquid or elastomer products is a challenge because these materials do not stick to metal permanently. We have overcome this challenge by developing a method that attaches a rubber membrane to the metal with little surface preparation. The rubber not only adheres to the metal, but it also expands and contracts, where all other coatings have less elasticity and tend to crack, after only a few years. This method of repair is also cost effective because our repair technique extends the life of the roof significantly. It doesn’t matter how many leaks a roof has or how rusty it is, as long as it can be walked on, we can fix leaks with a rubber membrane, at a fraction of the cost for a replacement.

Beware of Temporary Fixes!

Every metal roof has its own challenges, but we’ve always had success repairing roofs that have had the fewest repair attempts. When those repair attempts include the use of silicone caulking or sealants, as a fix, the removal of such sealants becomes labor intensive. These materials are very difficult to remove from the metal to achieve the best bond for our materials.

Metal roof recovery. We covered this entire metal roof with a rubber membrane.

Our Repairs Work

  1. We use a petroleum-based sealer and adhesive that adheres to metal even when it is rusted.
  2. Repairs with our method are less expensive than the costs of silicone or epoxy coatings.
  3. The rubber has embedded ceramic granules for protection against harmful UV rays.
  4. The rubber expands and contracts with the metal.

This metal roof was covered with a Modified Bitumen Membrane and the life is extended to another 40 years

The image shows that water cannot flow past objects freely, so the ponded water will cause the metal roof to develop rust.

Metal Roof vent- The flashing rusted around this vent causing it to leak

The image shows rust where standing water remained because it was not able to flow past the seam in the roof. 

The image below shows rust where water was standing because it was not able to flow past the seam in the roof.

Caulking to Repair a Metal Roof

Notice that in the image below, caulking is used to seal flashing, which is not a permanent repair.

Caulking is used to seal flashing. This is not a permanent repair.

Tar is Used to Repair Leaks around a Skylight on a Metal Roof

A common material used to repair leaks, around roof top units, on a metal roof, is tar.  This method is very temporary because the tar will dry out and crack very rapidly.

A common material used to repair water leaks, around roof top units, on a metal roof, is tar. This method is very temporary because the tar will dry out and crack very rapidly.

In the image below, we removed the old tar and cleaned the flashing around the skylight. It is important that old caulking and sealants be removed before our rubber membrane can be applied.

we removed the old tar and cleaned the flashing around the skylight. It is important that old caulking and sealants be removed before our rubber membrane can be applied.

After everything had been cleaned, we installed our rubber membrane with a special bonding agent. This type of repair will outlast any other sealant, caulking or tar. It covered all the seams and any area that had rusted through. The surface is now smooth and water can flow freely.

We installed the rubber flashing all around the skylight .

Pooling Water on a Metal Roof

Below is another example of the damage caused by ponded water. The tar around the vent pipe, has dried and cracked and began to leak. We repaired it by installing a rubber membrane around it.

Vent on Metal Roof.

The flashing around this vent stack was tarred. The tar eventually dried and cracked. After we removed the old tar and cleaned the metal surface, we installed our rubber flashing around the vent stack. This will last for many years to come.

The flashing around this vent stack was tarred. The tar eventually dried and cracked.

Rooftop Units on a Metal Roof

Whenever there are rooftop units like vents, skylights, or fans, the chances are that water will accumulate around the flashing, causing the metal to rust and increase the potential for leaks.

Temporary Repairs

Below is another example of a temporary repair using tar to seal open space around flashing. The tar dried and cracked and needed to be permanently repaired.

Water ponding above the vent stack causing the metal to start rusting

Repairs to Vent Pipe Flashing 

This is another example of a temporary repair using tar to seal open space around flashing. The tar finally dried and cracked and a permanent repair is needed.

temporary repair using tar to seal open space around the flashing. The tar finally dried and cracked and a permanent repair is needed.

The edging where the metal roof ends at the gutter can also start leaking. Fasteners and bolts that hold the metal to the frame start to rust or the neoprene washers deteriorate and causes leaks.

The edging of a metal roof is also prone to leaks. The gutters and gutter hangers are fastened to the edge of the roof with screws.

Edging of a Metal Roof

The edging of a metal roof is prone to leaks. The gutters and gutter hangers are fastened to the edge of the roof with screws. Those screws and brackets sometimes loosen up and cause the roof to leak. We use the same rubber membrane to repair the edging.

The edging of a metal roof is also prone to leaks. The gutters and gutter hangers are fastened to the edge of the roof with screws.

We install a rubber membrane over roof joints, flashing and any areas where metal has corroded. This is the best solution for any metal roof.

This is the best solution for any metal roof. We install a rubber membrane over roof joints, flashing and any areas where the metal has rusted through.

Metal Roof Recovery – the best way and less costly

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This video explains why it's not a good idea to coat a metal roof with silicone spray. This video demonstrates how we went about to save a metal roof. The Growth ...
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