Leaking Steel Roofing

Properly installed, there is truthfully no reason for a through screwed steel roof to leak. The key being “properly installed”.

Here is a report from a less than totally satisfied with his builder’s installation client:

“Sorry to report I have numerous leaks in the steel roof of my Hansen pole building.  In examining the roof, the workmanship of the screw application left a lot to be desired.  I have read your suggested fix in the manual and done some research on roof repairs etc.  Most suggestions are the same as specified in your manual using a larger and longer size screw method.  

I removed a couple screws where the leaking was taking place and discovered the screw had been rescrewed more than once on the initial install which reamed out the wood in the purlin and made the hole in the steel extra large (my little finger would fit in it).   My Fix method:  First a block was fastened to the existing purlin to give more wood as the screw tip  had broken out on the side of the purlin indicating the screw was not inserted  perpendicular to the roof and purlin.  Then I attempted to fill the hole and placed a second little larger neoprene washer (so the original washer was on the top and the larger one was on the bottom and reinserted the screw.  My thinking was the smaller washer on the top would exert enough pressure on the bottom washer which would cover the hole and provide the needed water seal.  This did not work and I think a larger size head on the screw would have been better.  In your opinion would a 14 or 16 x 2″ solve the problem?

Would appreciate any ideas on repairing the leaks.”

Mike the Pole Barn Guru Writes:

For any hole larger than 1/4″ the steel panel needs to be replaced, there is just no getting around it and no practical fix. For smaller holes, a #14 x 2″ screw will probably provide a fix. If it appears the hole in the purlin is large due to any one of a plethora of reasons, a small diameter wooden dowel or wooden matchstick driven into the hole prior to inserting the new screw will certainly aid in getting a good seal.