Metal roof waterproofing and metal roof coating to stop metal roof leaks

Steel / metal roofing waterproofing and metal roof coating to stop metal roof leaks; commercial & industrial metal roofs

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Stopping metal roof leaks is the surest way to extend the life of a metal roof.  As a metal roofing contractor, we have sealed and coated thousands of leaky commercial & industrial metal roofs over the past 20 years.  Our process is metal roof sealing and coating process is described below.  We stop metal roof leaks by using our rubberized urethane sealant in a process that includes a reinforced polyester membrane. This creates a field prepared, self leveling membrane.  When applied correctly this process really works, our supervisors make sure we maintain the highest installation quality levels, and we back it up with warranties. The system also includes replacing fasteners, replacing damaged metal, replacing damaged vent boots, and doing any other necessary repairs.  We use metal roof coatings designed specifically for metal roofs to stop rusting and extend the life of the sealants. We also replace metal roofs when they cannot be restored with a roof coating.

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The Starting point is to ensure that the existing metal, steel, roof is solid.  First, the surface is checked to make sure there are not any areas too far along in the aging process where the panels require replacement. If there are panels that are rusted thru, or too weak for walkable traffic, the metal roof panels must be replaced. For most roof panels, the rusting is the most advanced on the side of the panel facing the inside of the building. The damaged areas are found during a close physical inspection, and may not be obvious at first.  One of the signs that advanced rusting has started is if you hear a crunching noise when walking on a panel lap seam over a purlin. The crunching noise is the sound of rusted metal. When too much of the roof is rusted-thru a total roof replacement might be necessary.  

A common area of premature roof rusting is at the eave. Often, due to improper installation of the water barrier between the bottom of the roof panel and the substrate at the eave, water gets trapped below the metal roof panel.  Manufactures instructions dictate that the eave insulation is folded back to create a hem, using closures and caulk tape.  Without this fold the insulation wicks water between the metal roof and the eave strut. This trapped water causes rust to develop.  

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Another factor in deciding to replace a roof is if new insulation is desired. During a roof replacement, when the panels are removed, the insulation is exposed. The insulation is sandwiched between the roof panel and the roof purlins.  When the panels are removed the insulation will most likely fall or tear during the process.  This is the perfect time to give the inside of the building a bright new look.  The thickness of the insulation is also typically increased, increasing the R-value.

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In some situations, the insulation might still be acceptable, however a new roof may be required.  In this case it might make sense for a new metal roof to be installed over an existing metal roof. This may be the only option in some cases. This solution ensures that there is not any disruption to the production requirements of the business operations below.

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To waterproof a roof, all compromised panels must be removed and replaced, even if it's just a section of the panel.  For small rust holes a patch might be sufficient.  If the existing panel profile is no longer produced design changes must be made.  Fasteners are inspected and replaced and added as necessary.  To locate fasteners that require replacement we walk the purlin lines, replacing as necessary.

After the integrity of the roof has been achieved, the roof is cleaned. All of the old, loose, materials are removed along with dirt and other debris.

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All areas of the roof that may possibly leak are then sealed.  Fasteners, ridge cap, rake, internal gutter, skylights, vents, stacks, HVAC units, and any other roof penetrations.    When required, seams are sealed..

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When sealing around penetrations, ridge caps, skylights, rake edge, and other areas prone to leaking, the sealing material is reinforced.  One or two layers of polyester scrim cloth are laid between multiple coats of the urethane sealing material. Multiple coats are necessary in some areas because the desired thickness/millage necessary can't be achieved with a single application.  Urethanes will not cure properly is they are too heavily.  The scrim adds additional, required, strength to these areas.  While it is desirable to never have foot traffic on the roof it is impossible to avoid many routine maintenance activities.

This foot traffic, the natural expansion and contraction of the metal due to temperature changes, and the UV rays of the sun are the ingredients that cause roof leaks. 

This is why it is very important the sealing material include features that can help keep a facility dry.  There are a few products that can provide the desired results.

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If you just have a few leaks, you might eat to visit our Metal roof leaks repair page.  We also have a service team for minor leak repairs.

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The most important element in stopping metal roof leaks is the care during the sealing/waterproofing process.  The roof must be clean or the material will adhere to the dirt and not the roof.  Some old materials can be sealed over, others require removal. The roof must be dry to bond with the roof.   The sealing material must have the required strength to withstand the movement and abuse expected in that particular area.

There are two types of professional metal roof coatings, aluminum and elastomeric.  Some people also use paints.  Paint will work as long as it is an elastomeric paint and you will never have snow and ice on your roof.  Snow and ice will cause a paint coating to delaminate from a metal roof.

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Aluminum roof coating products vary widely.  There are inexpensive versions sold at home improvement stores, try them at your own risk.

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The aluminum coating products we use are asphalt based and fibered.   The coating not only includes a high quality aluminum flake, but also a high quantity of flakes.  The quality and quantity of the aluminum flakes directly relates to the brightness and longevity of the coating.   The product itself contains a rust arrestor, helping to make this a very cost effective option.  The base of the coating stays soft and flexible for years because it is protected by the surface accumulation of the aluminum flakes.  The system is bonded together by fiberglass threads.

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Elastomeric white roof coatings have a slightly higher reflectivity rating than aluminum.  They are able to be tinted for a color match.  If a rusty roof exists, a rust primer must be applied prior to the roof coating.  Elastomeric roof coatings typically have a higher level of aesthetic appeal than an aluminum roof coating. 

Regardless of the coating used, the coating protects the sealing materials, and extends the life of the metal roof.

We provide NON-PRORATED warranties on all of our work.  The warranties can extend up to 10 years and includes labor and material.

Benefits

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• 10 years manufacturer’s Guarantee

• Waterproofing and thermal insulation in one system

• Approved by Dubai Central Lab Certified insulation

• Holds DCL product conformity mark for PU foam

• Fully bonded to the surface

• Perfect solution for new and existing industrial sheds and warehouses