Reliable Commercial Metal Roofing Repairs

Why Commercial Metal Roofs Leak (And Why Repairs Fail)

Commercial metal roofs, while durable, have their own set of challenges when it comes to preventing leaks and widespread damage. Metal roofs are built to shed water, not hold it. Unlike flat roofing systems designed to be fully waterproof, metal roofs depend on proper slope, drainage, and controlled water flow to perform correctly. They are not designed to tolerate ponding or standing water for extended periods.

Another key factor is movement. Metal roof panels expand and contract as temperatures change. This natural movement places stress on seams, fasteners, penetrations, and repair materials over time. Repairs that do not account for this movement can crack, pull loose, or fail prematurely, even if they appear effective at first.

This is why metal roof repairs require a different approach than traditional flat roof repairs. Successful repairs must accommodate panel movement, protect vulnerable connection points, and avoid introducing rigid materials or unnecessary penetrations that can create new failure points.

Understanding how metal roofs function is critical to accurately diagnosing leaks and selecting repair methods that extend roof life rather than shorten it.

Common Commercial Metal Roof Leak Sources

Several factors can contribute to commercial metal roofing issues.

Surface Rust

Rusted metal doesn’t necessarily mean immediate leaks, but unattended rust can peel the coating, leading to holes and scaling. This neglected rust can escalate into major structural damage. Using a rust inhibitor won’t eliminate the rust but can prevent its spread.

rusted panels

Deflection

Holes, crimping, or creasing of metal panels, often caused by foot traffic, can result in ponding water, leading to rust and eventual leaks.

panel deflection

Movement

A metal roof should have designed movement to allow water to flow off properly. If a repair product lacks proper elongation or flexibility, the panels will continue to move, causing more issues than the original leak.

roof panel movement

Incompatible Materials

Using specific materials with proper elongation properties is crucial to prevent corrosion and rust. Dissimilar metals can react negatively when in proximity, leading to further complications.

incompatible roof materials

Punctures

Foot traffic or HVAC equipment installation can cause holes, creases, and crimping. For example, dragging HVAC units across the roof can leave a trail of tears and punctures.

punctures in roof

Fastener Issues

Fasteners with rubber washers, used to attach metal panels, may back out over time, leaving holes or gaps between the metal and the rubber washer. This can expose the roof to water intrusion.

fastener issues

Open Laps

Improper installation can result in lifted seams along metal panels, providing openings for water and, ultimately, causing structural damage.

open lapping in roof panels

Missing Parts

Over time, wind, debris, or deterioration can cause pieces like foam closures, vent flashings, boots, edge metal, gutters, and downspouts to fall off, potentially leading to water intrusion and leaks.

missing edge on metal roof

When these issues become widespread or recurring, addressing individual leak points may no longer be the most effective long-term approach.

When Metal Roof Repairs Lead to Restoration

Commercial metal roofs expand and contract with temperature changes, and every fastener, seam, and penetration must accommodate that movement over time. While targeted repairs can be effective, repeated invasive repairs can introduce new risks.

Traditional layover systems or re-roof approaches often require additional penetrations through existing metal panels. Each new fastener or attachment point increases the potential for future leaks, panel movement issues, flutter, or wind-related failures. Over time, these added penetrations can compromise the performance of an otherwise serviceable metal roof.

In many cases, a non-invasive, liquid-applied metal roof restoration provides a smarter long-term solution. Liquid-applied systems are installed directly over existing metal panels without introducing new penetrations. This preserves the roof’s ability to move naturally while sealing seams, fasteners, and surface irregularities.

Not all coatings are created equal. The performance of a metal roof restoration depends heavily on coating quality, adhesion, durability, and flexibility. High-performance acrylic coatings are engineered to bond to metal substrates, withstand environmental exposure, and flex with roof movement without cracking or pulling away over time.

For metal roofs experiencing widespread wear, recurring leaks, or fastener- and seam-related issues, restoration can extend roof life, improve watertight performance, and reduce disruption compared to invasive re-roofing methods.

Regular inspection, maintenance, and addressing these issues promptly can significantly extend the life and functionality of metal commercial roofing.

Color Match Repairs on Commercial Metal Roofing

Metal roofs can be an important element to the overall aesthetic of a facility. When roof repairs are needed, they can be a major eyesore – think: large white square on a green paneled roof. That’s why Simon Roofing developed our Wite Brite™ Colors formula to offer a custom-colored waterproofing solution.

Color pigments are carefully blended with Wite Brite, one of the industry’s top waterproof coatings, to maintain its proven performance standards. Instead of repairing the roof surface and then painting over it, using Wite Brite Colors combines both steps into one. In addition, this process offers much better adhesion and improved elongation compared to repair/paint method.

Ready to Get Started?

If your metal roof is starting to age or rust, contact Simon Roofing today and we'll put you in touch with our Metals team. We'll be happy to answer questions and get a technician dispatched to resolve your issue.