When undertaking any Essex Roofing project, safety is a primary consideration. A hole in a roof system may signal that there are other structural difficulties, such as decking decay. Conduct a thorough under-deck safety inspection and roof analysis before performing this or any other roof repair.
Disinfect the Repair Area
Cleaning the surface of any metal roofing material is the first step in repairing it. A hole in a metal roof system may be created by degradation and rust, or by anything falling onto the roof surface, such as a huge branch. Whatever caused the hole; the region surrounding it is almost certainly unclean and will require cleaning.
Clean the metal panel’s surface thoroughly with Simple Green or similar cleaner, until the roof panels are entirely clear of dirt, film, and/or algae development. Any cleaner residue can jeopardize the roof repair’s integrity, so be sure to wipe it away with a moist towel once the cleaning process is complete.
Abrasion the Metal
After cleaning the metal panel’s surface, scuff the area where the repair will be done using a wire brush. Scuffing the surface of the metal will aid in the sealant’s adhesion to it. Use the wire brush solely on the patched area; brushing beyond that may remove the protective coating from the metal panel’s surface, resulting in further degradation.
Measure and Cut a Patch for the Repair Area
Cut the sheet metal to fit the mended area. The sheet metal patch should extend at least 2 inches beyond the damaged area’s margins. After cutting and fitting the sheet metal patch to size, round the patch’s corners using a file or emery cloth to avoid any sharp corners becoming a catching area for snow or ice.
After measuring the patch, lay it over the hole to be mended. Apply a pencil to the roofing and trace the patch. Remove the patch and inspect the outline to ensure that it overlaps the damaged area by at least 2 inches in all directions.
Complete the Repair Patch Installation
Apply a color-matched urethane sealer to the repaired metal panel’s surface, remaining just inside the pencil-marked line. Apply a liberal amount of sealant to the area, ensuring that there are no gaps or holes at the patch’s leading edge.
Over the injured area, press the patch firmly into place. Along the edges of the patch, the sealant should squeeze out from the edge. If there are regions where the sealant is not seeping, there are areas where moisture may get beneath the patch, resulting in the patch deteriorating. Apply a little amount more sealant here to ensure that there are no gaps.
After pressing the patch into position, use pan-head sheet metal screws to secure it to the surface of the metal roof panel. Around the perimeter of the patch, space the screws every 3 to 4 inches. Screws should be placed within 1 inch of the patch’s edges to impart consistent pressure on the patch’s edges and the sealant beneath the patch. Screws should be no longer than necessary to attach the patch to the underlying roofing panel. Never screw the patch through the Franklin Roofing panels and into the decking or rafters of the roof.
Retool any sealant that is seeping from the patch’s edge as necessary with a putty knife once it has been applied. This ensures that the sealant adheres correctly to the patch’s borders and prevents moisture penetration. Allow the roofing sealant to cure according to the directions on the package. It may take a day or more to skin over, but it might take up to a week to completely cure.
Coat the Patch in the Roof’s Color
The patch’s surface can be painted to match the metal roof panels’ color if desired, to do this, softly wire-brush the patch’s surface and the metal panel slightly beyond the patch’s margins. Coat the patch’s surface and the underlying panel with paint. It may be important to allow the sealer to cure completely before painting over it. Additionally, ensure that the paint you used is compatible with the sealant.