If rust has pin-holed through metal-roof panels, theres no question its time for roof restoration. But just how much of the roof needs to be replaced?

Even on problematic metal roofs, the majority of panels retain their integrity. Leaks develop at seams, fasteners and around penetrations. Replacing damaged panels and following a complete maintenance program can return a roof to its original performance. The combo substantially reduces the expense of a full roof replacement.

Nip Budding Problems

Comprehensive maintenance means more than stopping rust or leaks. Stringent measures can help cool buildings, making them more energy efficient. Roof surfaces can also reduce thermal movement and related maintenance costs.

For years, storage owners have hired maintenance crews to stop leaks with plastic roof cements, often considered an economical solution. But after just a few freeze-thaw cycles, the problem returns, and its usually worse this time around. New leaks pop up, and fasteners rust and pull out because theyve lost their seals. Owners postponing inevitable roof replacement are now in dire straits. The truth is, ignoring problems just exacerbates the situation. Its best for owners and managers to face roof repairs as they crop up, preventing the need for premature replacement.

Some owners think tearing off an old roof and replacing the whole thing solves every problem. But a new roof usually has a construction warranty only, nothing covering leaks. New roofs cost nearly three times more than restoration and have to be amortized over 39 years of the expected roof life.

Downtime and lost rents must also be considered. A facility cant rent units without roofs. If panels are being replaced, the only units affected are those nearby; for full roof replacement, all of them must be vacant. Plus, with a warranted restoration system, leak repair is much less expensive. For all these reasons, more owners are selecting quality roof restoration, with lowest costs over the life of the warranty and an immediate deductibility.

A Comprehensive Approach

To get the most bang for the buck, a roof needs a comprehensive maintenance program. Do your research and find products that prevent rust; keep fasteners tightened; eliminate future roof leaks by guarding seams; and coat the entire roof with a durable and weather-resistant barrier. Todays advanced elastomeric coatings provide long-term solutions for metal-roof problems. To simply overcoat a metal roof or take pot shots at repairs just doesnt make sense.

Check with contractors to see what they recommend. Theyve worked with numerous roof systems and products, so theyre in the best position to offer advice. Ask contractors and manufacturers for referrals, too. No amount of effort can equal the power of a testimonial from one satisfied customer.

Some manufacturers offer certification programs in which contractors are trained to the standards of their application procedures. Advertising, sales tools, product specifications and technical support is provided for the contractor to complete projects skillfully.

Follow-up is just as important. Manufacturers should require yearly inspections to identify problem areas before they lead to costly leaks or permanent damage.

Start to Finish

The process should always start with a complete and thorough examination of the roof surface. Consult facility managers and maintenance staff about past problem areas. Also check insulation and the underside for wet insulation or condensation; these are major causes for callbacks due to improper ventilation. Fasteners should be inspected to see if they are loose or stripped, then tightened to torque or replaced with larger fasteners. Extra fasteners must be added to areas where gaps are present, especially at end laps.

After the roof is repaired mechanically, restoration begins. All rust must be treated according to the coating manufacturer and power washed to obtain a clean dry surface. Seams and fasteners deserve specific attention; reinforce them with compounds for the greatest elongation and tensile strength to expand and contract with the roof as temperatures change.

HVAC units, stacks, vents, etc., must be similarly reinforced. Before the first application of the field coat, the roof should be walked and additional repair material applied. After the project is complete, your roof should be leak-free, seamless and quieter.

All roofs need a preventative maintenance program. They should be inspected at least once a year for clogged drains, gutters and downspouts, and the effects of time and weather. Penetrations, seams and fasteners need to be monitored and fixed when necessary. A comprehensive approach provides constant peace of mind for the building owner. This is a perfect example of how a stitch in time saves nine! 

Arlan Kopel is president of Topps Products. Based in Overland Park, Kan., the company manufactures Topps Seal, a liquid-applied 100 percent rubber system for protecting metal roofs in all climates. For more information, call 800.867.7177; e-mail [email protected]; visit www.toppsproducts.com.