Metal Roof Repair - How we Fix leaky stacks and curbs on metal roofs

Introduction

This tutorial provides a comprehensive guide on how to repair leaks around stacks and curbs on metal roofs. It highlights the importance of a permanent solution involving the installation of a PVC membrane and custom flashing rather than relying on temporary fixes like caulking. This approach ensures long-lasting protection against leaks, particularly for HVAC units and exhaust pipes.

Step 1: Assess the Existing Condition

• Inspect areas around stacks and HVAC curbs for previous repairs.
• Look for signs of leakage, such as water stains or corrosion.
• Identify any materials previously used (e.g., tar, caulking, coatings) that have failed to stop leaks.

Step 2: Prepare the Roof Surface

• Clean the area around the stacks and curbs to remove debris and old materials.
• Fill the flutes of the metal roof to create a flat surface. This helps in proper water drainage.
• Install one-inch thick rigid insulation over the entire surface to provide an additional layer of protection.

Step 3: Install the PVC Membrane

• Lay down the PVC membrane over the prepared surface.
• Secure the membrane using screws and plates to ensure it adheres well to the insulation.
• Make sure the membrane covers the areas around the stacks and HVAC curbs adequately.

Step 4: Add Custom Flashing

• Design and fabricate new flashings specifically for the stacks and curbs.
• Install the custom flashing around the stacks, ensuring it fits snugly and is sealed properly.
• Use stainless steel bands to further secure the flashing, applying a high-quality sealant at the joints for added waterproofing.

Step 5: Final Inspection

• Check all newly installed components to ensure there are no gaps or exposed areas.
• Test the integrity of the repairs by simulating water flow or waiting for rain to observe any leaks.
• Regularly inspect the repairs over time to ensure their longevity.

Conclusion

Repairing leaks around stacks and curbs on metal roofs requires a systematic approach that goes beyond temporary fixes. By assessing the current condition, preparing the roof, and installing a PVC membrane with custom flashing, you can achieve a durable and leak-proof solution. For ongoing maintenance, regularly inspect the repaired areas to catch any potential issues early on. Consider consulting with professionals if you are unsure about any steps in the process.