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  • Writer's pictureRaim Yestayev

Dealing with Metal Roof Seam Leaks: Causes and Comprehensive Solutions

Metal roofs are renowned for their robustness and long-lasting performance. However, over time, metal roof seams may develop leaks, posing potential challenges for homeowners. In this informative guide, we will explore the common reasons behind metal roof seam leaks and provide a detailed step-by-step solution to effectively address and repair these issues.

Understanding the Causes:

Metal roofs are typically installed with gaskets positioned between overlapping panels. These panels are secured using hexagon screws equipped with neoprene washers, offering initial protection against water intrusion. Nevertheless, extended exposure to the elements can lead to the gradual deterioration of these neoprene washers. When this happens, water can find its way through the fasteners, resulting in complications within the seams.

Spotting the Issue:

Detecting metal roof seam leaks may involve observing water droplets seeping through the fasteners into your building and the emergence of rust in areas where water accumulates between panels. Trapped water between the panels can corrode the fasteners and cause rust to permeate through the upper panel.

Steps to Repair Metal Roof Seam Leaks:

Addressing leaks in metal roof seams entails the following essential steps:

1. Hexagon Screw Removal: Begin by carefully removing the hexagon screws with neoprene washers that are responsible for the leaks. Ensure you have the appropriate tools for this task.

2. Rust Cleanup: Once the screws are removed, diligently clean the rust from the affected areas. You can choose to use a wire brush or, for a more efficient job, an angle grinder. This step is pivotal for a robust and enduring repair.

3. Pan Head Screw Replacement: Substitute the hexagon screws with pan head screws, which feature a flat profile that minimizes the likelihood of water penetration. Secure the panels firmly together using the new screws.

4. Application of Super Silicone Seal: To establish a water-resistant seal, generously apply a high-quality super silicone seal along the seam. Ensure that you cover the entire seam, extending the sealant at least two inches on each side. This forms a potent barrier against water infiltration.

5. Mesh Reinforcement: Enhance the overall strength and longevity of the repair by embedding a mesh material into the super silicone seal. This reinforcement provides additional structural integrity to the repair.

Benefits of This Repair Technique:

Utilizing the outlined steps for fixing metal roof seam leaks offers numerous advantages:

1. Long-Term Resilience: By addressing the root cause of the leaks and replacing deteriorated components, this repair method guarantees lasting protection against water ingress.

2. Rust Mitigation: The rust-cleaning process and the use of pan head screws help avert future rust formation, preserving the structural soundness of the metal panels.

3. Cost-Efficient Solution: This repair approach proves to be cost-effective, reducing the necessity for expensive replacements or extensive roof renovations.


Comprehending the origins of metal roof seam leaks and knowing how to adeptly tackle them is vital for safeguarding the durability of your metal roof. By adhering to the steps presented in this comprehensive guide, you can confidently rectify seam leaks, prolong the life expectancy of your roof, and relish the advantages of a watertight, sturdy metal roofing system. Keep in mind that consistent maintenance and timely repairs are essential for maintaining your metal roof's exceptional condition over the years.

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