Metal Roof Leaking At Every Screw...ideas?

 
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Old 05-28-2010, 03:59 PM   #1
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Metal Roof Leaking At Every Screw...ideas?


I replaced screws on an existing exposed screw roof with 3" plastic back insulation on a "pole barn" (garage) in order to stop leakage through old and damaged screw holes. I pulled out #9x1" and replaced them with #14x2" neoprene washer screws.

Six months later, I went back to replace some damaged panels, and noticed that the leak I thought I had fixed by replacing screws still leaked. Also, I found moisture in the insulation at most of the screw heads we replaced at the purlins.

Anybody have any ideas as to why or what I can do to make this roof water tight? Any suggestions?
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Old 05-28-2010, 04:23 PM   #2
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Re: Metal Roof Leaking At Every Screw...ideas?


don't take this the wrong way but did you over tighten your roofing screws with rubber washers?

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Old 05-28-2010, 04:37 PM   #3
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Re: Metal Roof Leaking At Every Screw...ideas?


No...I use a deWalt 12 volt screw gun w/clutch and set it so that the gaskets are tight, but not overly tight or broken.
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Old 05-28-2010, 04:44 PM   #4
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Re: Metal Roof Leaking At Every Screw...ideas?


and its dripping down each screw on the inside?
that's odd. the metal is old and rusted on the outside?
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Old 05-28-2010, 04:50 PM   #5
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Re: Metal Roof Leaking At Every Screw...ideas?


I'm with ApgarNJ, it sounds like you overtightened the screws. Before you try anything else, I'd pull out the screws and try putting in new ones hand tight.
The simplest solution, is almost always, the right solution.
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Old 05-28-2010, 04:51 PM   #6
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Re: Metal Roof Leaking At Every Screw...ideas?


I don't know if it's literally dripping, but the insulation is moist/wet where each screw touches it. The roof is not rusted, it's 29ga galvalume type, bare (no paint). Most of the old screws/washers definately needed replacing, so I replaced them all.
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Old 05-28-2010, 05:08 PM   #7
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Re: Metal Roof Leaking At Every Screw...ideas?


is the building heated? if not. i could just be sweating. is the insulation touching the metal? and it's fiberglass? i know polebarn builders recommend rigid foam sheets under the metal roofing to keep buildings from sweating inside. so what may seem like a leak could be vapor or moisture collecting under the metal and the screws are just acting like dripping spots. without seeing it in person, that is my best estimate of the situation.

the 3 inch insulation you put on with plastic backing is fiberglass?
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Old 05-28-2010, 05:26 PM   #8
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Re: Metal Roof Leaking At Every Screw...ideas?


I didn't put in the insulation, it came with the building, but, yes it is Fiberglass and is touching the metal. The building has not been heated, although the owner wants to add more insulation and heat this summer. We are in the NorthWest, so we do have lots of moisture and temperature variation.

Sweating is a very interesting thought...any suggestions on what I can look for to determine that? I'm frustrated because the original leak we looked for has not been fixed by replacing screws and still leaks when it rains. I can't see any reason why it should be...there is nothing obvious, no damage or open seams...
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Old 05-28-2010, 05:38 PM   #9
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Re: Metal Roof Leaking At Every Screw...ideas?


Quote:
Originally Posted by labgal View Post
I didn't put in the insulation, it came with the building, but, yes it is Fiberglass and is touching the metal. The building has not been heated, although the owner wants to add more insulation and heat this summer. We are in the NorthWest, so we do have lots of moisture and temperature variation.

Sweating is a very interesting thought...any suggestions on what I can look for to determine that? I'm frustrated because the original leak we looked for has not been fixed by replacing screws and still leaks when it rains. I can't see any reason why it should be...there is nothing obvious, no damage or open seams...
Did you screw into the flat or into the corrugated part?
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Old 05-28-2010, 05:44 PM   #10
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Re: Metal Roof Leaking At Every Screw...ideas?


Flat
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Old 05-28-2010, 05:51 PM   #11
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Re: Metal Roof Leaking At Every Screw...ideas?


Quote:
Originally Posted by labgal View Post
Flat
Good, you followed instructions.

I am wondering if the sheets are properly aligned, which could potentially cause some problems.

Without seeing your roof I can't think of anything else.
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Old 05-28-2010, 06:08 PM   #12
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Re: Metal Roof Leaking At Every Screw...ideas?


Ya there are proprly aligned. The leak is in the middle of the roof in the middle of the run on both sides there is no moisture under the ridge cap.
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Old 05-29-2010, 06:29 AM   #13
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Re: Metal Roof Leaking At Every Screw...ideas?


The flat is what some of the manufactures recommend. Most likely for wind uplift resistance. IMO thats the worst place to put screws in a exposed fastener system for waterproofing purposes. I avoid it whenever possible. Wedont do many, but the ones we do, the screws go on the ridges. except on the eave.

Anyway, what kind of use is the pole barn? If its livestock, they generate all kinds of moisture. Other then whats been mentioned it sounds like the fasteners.
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Old 05-29-2010, 06:34 AM   #14
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Re: Metal Roof Leaking At Every Screw...ideas?


a totally empty building can sweat really bad as the temps change even from daytime to night time. Ever go in a metal trailer when it's humid out? it's like a rainforest.

red cedar. i agree. i never could understand why screwing on the flat is the better way. my roofer says it's recommended to screw close to the rib so it helps hold down the sheet next to it. I would also think the ridges are the place to screw as less water is running on them. I can't see why that would be wrong but the roofing manufacturers think it is.

maybe people were over tightening them and causing deformation of the metal?
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Old 05-29-2010, 08:40 AM   #15
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Re: Metal Roof Leaking At Every Screw...ideas?


Quote:
Originally Posted by ApgarNJ View Post
a totally empty building can sweat really bad as the temps change even from daytime to night time. Ever go in a metal trailer when it's humid out? it's like a rainforest.

red cedar. i agree. i never could understand why screwing on the flat is the better way. my roofer says it's recommended to screw close to the rib so it helps hold down the sheet next to it. I would also think the ridges are the place to screw as less water is running on them. I can't see why that would be wrong but the roofing manufacturers think it is.

maybe people were over tightening them and causing deformation of the metal?
My understanding is that it is more than recommended. It is the proper installation technique. I do know you nail the ribs and screw the flats.

I think the problem goes to the condensation. I think we have a problem with that and the contractor is over thinking.
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Old 05-29-2010, 09:33 AM   #16
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Re: Metal Roof Leaking At Every Screw...ideas?


I agree, it's a moisture problem.

Pole barn steel, you fasten with screws on the flat, but on the overlap you fasten on the corrugated part.

That roof needs to be vented, especially with no poly inside. There is usually a ton of moisture in garages. With the fiberglass touching the metal it is not venting. Always a problem in northern areas with all the temp changes and moisture.

Any pictures?
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Old 05-29-2010, 10:16 AM   #17
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Re: Metal Roof Leaking At Every Screw...ideas?


Elastomeric roofing sealant on each and every screw, then a power wash to remove resideue, a rust inhibitor and then a seamless monolithing elastomeric liquid applied roof coating. NO leaks for 10 years guaranteed.

Last edited by Grumpy; 07-09-2010 at 09:52 AM.
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Old 05-29-2010, 05:02 PM   #18
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Re: Metal Roof Leaking At Every Screw...ideas?


grumpy. that sounds good but that isn't going to stop it from sweating and looking wet on the inside.
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Old 05-29-2010, 07:23 PM   #19
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Re: Metal Roof Leaking At Every Screw...ideas?


Quote:
Originally Posted by Grumpy View Post
Elastomeric roofing sealant on each and every screw, then a power wash to remove resideue, a rust inhibitor and then a seamless monolithing elastomeric liquid applied roof coating. NO leaks for 10 years guaranteed.
Grumpy what would something like what you describe cost per sq. ft. on say a walkable roof?
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Old 05-30-2010, 09:05 AM   #20
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Re: Metal Roof Leaking At Every Screw...ideas?


Quote:
Originally Posted by ApgarNJ View Post
grumpy. that sounds good but that isn't going to stop it from sweating and looking wet on the inside.
Sorry I must have missed that in the original post. I admit I did read none of the replies. Wouldn't that sweating be some kind of ventilation problem? I am no metal expert but would assume metal roofs require some kind of ventilation. Much of the metal roofs I see (which are few), have a kind of reinforced batt or rigid insulation applied directly to the bottom.

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