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Common Issues in the field

Our team has had the privilege of working on hundreds of roofs. No roof system is perfect and each roof has it's own unique characteristics. Performance and evidence based practice will always be prioritized. Below you'll see some of the common problems we've personally seen in the field and ways to mitigate these risks.

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Repairs done with different types of material

One of the main problems we encounter in leak repair is the use of different materials applied directly to work done previously. In these images you'll see 3 repairs executed with Tar, Silicone, and caulking compound. 

You'll notice that the materials have not cured correctly. At each application not only has the leak not been repaired, but has been made more difficult to find. 

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What to know/Solutions

  • Silicone only sticks to itself. Once silicone sealant/coatings are used, any repair must be made with silicone

  • It's recommended repairs be made with like materials

  • When large areas of your roof are done in the same manor above, leaks can turn into damaged insulation/ponds

  • We will always recommend that previous material be removed in order to have a clean substrate

  • Verify with your roofer the type of material to be used in the repair and it's compatibility with your roof

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Maintenance

Perhaps the most encompassing issue we encounter is neglected maintenance. Routine maintenance and inspections could help in preventing premature roof failure and other common issues such as ponding, debris build up, punctures/splits/tears, and of course leaks. 

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In the images above you'll see instances of hail damage, excessive debris build up, unchecked shrinkage/blistering that has split seams wide open, and a pond deep enough that vegetation has sprung. 

The second row shows the effects of an unrepaired leak to a metal deck. 

We believe this is most vital when your roof has a light weight concrete deck. Because of it's porous form, leaks can cause chunks of the substrate to lose it's structural integrity. For reference a 25 (5ft x 5ft) square foot pond with a depth of (1/2) inch contains over 800 lbs. of water. This can be a hazard to people walking your roof and could result in costlier repairs where the concrete decking needs to be re-poured.

Lastly, it could be something as simple as removing a clog to the roof drain. The final two images shows a clog caused by a soccer ball and the effects to the surrounding area where insulation is generally less thick.

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What to know/Solutions​

  • Yearly inspections are recommended and immediate repair to these different types of issues, when discovered

  • Optimal times to asses your roof's condition: HVAC or other work is performed, after storms, before winter, and beginning of spring.

  • We pride ourselves in not just re-visiting projects to asses performance, but also building a continuing relationship where yearly visits can help in reducing the risks mentioned above and elongate your roof's life substantially.​

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Improper Installation Methods

We believe fabric is best practice when building a waterproof coatings system. Proper installation is vital to the life of this fabric most significantly on non-flat surfaces. As mentioned, before we execute a repair or full roof system we prefer a clean substrate. In the first image we went forth and removed fabric applied to a metal roof over 10 years ago. The seam where fabric was installed lacked the proper prep work and was plagued with pin holes at the bottom corners of the ridges harboring water and allowing it to eat at the metal. Pin holes, trampolined fabric over grooves, and air pockets lead to fabric failure and a weak point in the bond between the roof and coatings. 

 

The last image shows an excess use of material. With most curing products, more product doesn't mean more protection. Manufacturer guidelines specify these details. 

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What to know/Solutions

  • When applying coatings with/without fabric embedded, you want the coatings and fabric to bond to a clean roof

  • The acrylic coatings we use are breathable. It is our opinion that this is the best type of product as they allow moisture from within a building to escape through the roof, preventing issues like mold and mildew growth while protecting the roof from excessive moisture buildup

  • Make sure your roofer has been trained by the manufacturer of the product to be used

  • Request specification sheets for information on millage (Thickness) and other important details

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Single-ply and Asphalt 

PVC and TPO single-ply do not fair well with petroleum base products (Tar, Rubberized asphalts). These products can cause the single-ply to become brittle and crack. The plasticizers in PVC can also react with the asphalt, causing the asphalt to soften and "bleed".  Although tar may be on hand and provide short-term leak relief. The long-term effects can lead to costlier repairs where portions of the single-ply need to be replaced. 

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What to know/Solutions

  • When re-roofing make sure a proper separation layer is installed such as foam insulation or a cover sheet

  • Make sure you are aware of the product being used to repair your roof if it's PVC, TPO, or similar product

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Aluminum Roof Coatings

Our team encounters aluminum roof coatings frequently here in the mid-west. Common issues with these coatings is poor water protection, susceptibility to cracking and bubbling due to inflexibility, potential for improper adhesion, blistering from trapped moisture, and a relatively short lifespan compared to other roofing materials. 

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These images present all these concerns. Unless the roof can be stripped of these coatings it is our belief that applying a different type of long lasting coating system would be unwise. Stripping a roof of these coatings can prove to be challenging. Contracting a sand blaster will result in large amounts of sand, and a hard power wash can lead to roof damage. 

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What to know/Solutions

  • Unless you are planning to re-roof or install a new roof we recommend you continue with frequent re-coats and leak repair. 

  • We see instances where these coatings look solid. But more often than not when we meet with clients it's to repair leaks a couple years after these coatings have been applied. 

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