you are here: Home » How to Determine the Type of Flat Roof Membrane to make roof repairs » Metal Roof leak Repairs » METAL ROOF LEAK REPAIR: Leak Causes and Fixes

Repair a Metal Roof Leak in 8 easy steps -Turbo Poly Seal

Repairing metal roof leak with Turbo Poly Seal

A METAL ROOF LEAK is an issue most metal roof owners have to deal with. Trying to fix leaks with an entire acrylic or silicone coating will cause more problems. The best way to fix leaks is to only make repairs where the leaks are.

How to repair a leak on a Metal Roof with Turbo Poly Seal

Turbo Poly Seal or Super Silicone Seal is one of the few products on the market that can repair metal roof leaks effectively

Total Time Needed :

30

Minutes

Total Cost:

65

USD

Required Tools:

– Disposable Brush
– Scissors
– Cordless Screw Gun
– Wire Brush
– Cordless Angle Grinder with a wire brush wheel

Things Needed?

– Turbo Poly Seal or Super Silicone Seal
– Pan head screws
– Lacquer Thinners and Rags

Steps on How to repair a metal roof leak:

Clean surface with a wire brush

Step 1

Remove old tar and caulking – it is important to prepare the surface properly

Use a angle grinder to remove any rust, tar and caulking

Step 2

Use an Angle Grinder with a Hardwire wheel brush to clean the surface from rust and unwanted debris

Lacquer Thinners with Rags - Flat Roof Repair Latrobe PA

Step 3

Wipe clean with lacquer thinners

replace the hexagon fasteners with pan head screws

Step 4

a) Replace existing hex fasteners with pan head screws to get a lower profile
b) Screw tight the 2 joining overlapping panels

Apply first coat of Turbo Poly Seal covering 2 inches of each side of leak area

Step 5

Take a disposable brush and paint a coat of Turbo Poly Seal or Super Silicone Seal covering approximately 2″ on each side of the joint

Install the Polyester Fleece over the freshly painted sealant

Step 6

Install the polyester fleece o0ver the freshly coated sealant

Apply a final coat of Turbo Poly Seal over the Polyester Fleece

Step 7

Apply a top coat of sealant over the fleece making sure the fleece is not exposed

Step 8

If you chose Turbo Poly Seal for the repairs, we recommend that you add an oil-based paint as a protective coating against ultraviolet rays

Turbo Poly Seal and Super Silicone Seal

Turbo Poly Seal / Super Silicone Seal

Both of these products are very good at repairing a metal roof leak. We recommend painting an oil-based paint over the Turbo Poly Seal repair to protect it against ultraviolet rays. Super Silicone Seal does not need any protection

Watch the following video to see what acrylic coating can do to a metal roof. it will destroy your metal roof in no time.

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

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”

What cause a metal roof leak?

The expansion and contraction, of metal roof structures, is caused by temperature changes. The stress of moving 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 to 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.

Vent stacks on a metal roof can prevent water flow on a metal roof
Vent stacks like these can block the water flow between channels causing water to pool

Our Repairs Work

  • We use a petroleum-based sealer and adhesive that adheres to metal even when it is rusted.
  • Repairs with our method are less expensive than the costs of silicone or epoxy coatings.
  • The rubber has embedded ceramic granules for protection against harmful UV rays.
  • 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
Metal roof coated with Modified Bitumen Membrane

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 vent is blocking water from flowing

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.
A little ridge or seam can cause water to pool causing rust

Caulking to Repair a Metal Roof leak

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.
Caulking used for sealing seams will never last

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

A common material used to repair leaks, around rooftop 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.
Tar is used to seal the flashing around this skylight

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.
We removed all the tar and prepared the surface for a new transition

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 .
This is the final result after installing a Modified Bitumen Rubber Membrane over the flashing

Pooling Water causing a Metal Roof Leak

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.

Vents can cause a Metal Roof Leak.

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.
A little water can cause rust on a metal roof

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
More rust due to standing water

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.
Tar around the vent flashing will dry and crack

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 cause 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.
We did the same repair on the edge of the roof with a Rubber Membrane

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.

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.
A close-up look of the rubber membrane over the metal seam or edge
0
0.0 rating
0 out of 5 stars (based on 0 reviews)
Excellent0%
Very good0%
Average0%
Poor0%
Terrible0%

Thank you for writing a review

Review Peeper
Please write a review on Metal Roof Repair or leaks

There are no reviews yet. Be the first one to write one.

2 thoughts on “METAL ROOF LEAK REPAIR: Leak Causes and Fixes”

  1. Hi Naas,

    I have not seen that you use any rust converter/remover in your videos: just wire brush cleaning and polyurethane seal.

    Does rust converter/remover have any benefit?

    Groete uit Pretoria,

    Markus.

    1. I personally think that it is better not to have any paint between the Turbo Poly Seal and the metal. The Turbo Poly Seal will block any oxygenation causing rust.

Comments are closed.