Legacy Roofing, Inc. 972-217-1127

SYSTEM THEORY:

FACT:
Metal roofs have a very limited amount of area that is susceptible to water intrusion compared to their overall size.  Water can only enter the building through construction joints, fasteners and penetrations.  It is impossible for water to enter through the sheet metal surface of the roof.

FLAWED REPAIR SYSTEMS:
All existing commercially available products used for repairing a metal roof are based on the principle of encapsulating the construction joints, screws and penetrations.  The products consist of a flexible seal coating over a polyester cloth membrane reinforcement.  The problem with this is the metal construction joints are constantly moving due to hot/cold cycling of the roof surface.  In short order, the sharp edge of the roof panels simply shear through the coating due to panel movement.  This allows water to enter under the membrane where it can not readily evaporate and the roof system begins to rust under the repair.  Eventually the leak will return except this time there will be no metal under it to repair.  These systems can and do destroy what would otherwise be a perfectly good roof.

OUR SYSTEM:
The manufacturers of metal roof systems designed them to be waterproofed IN-BETWEEN the overlapping components.  The fasteners used in their construction are designed to mechanically lock the components together and self seal  with built in neoprene washers.  Weathering protection of the roof system is provided by the galvanized surface of the panels.  Should leaks occur, there are only three possible flaws to inspect for.  (1) Open construction joints due to loose screws.  (2) Failed sealant between the panel laps.  (3) Loose or deteriorated washers on the fasteners.  The original system is designed this way because it proves the greatest strength to maintain a water tight seal between the components and to simplify diagnosis of leak problems.

Our repair system simply takes the manufacturers design and strengthens it.  All old repair materials and fasteners are removed and the system components separated.  The original sealants are cleaned from the surface of the steel and the steel inspected for rust damage.  Any rust damaged areas are repaired by fabricating a metal patch panel on site.  New modern urethane sealants are applied and the metal reattached with new properly sized fasteners.  This restores the repair area back to a new condition.  Just the way the manufacture designed it to be.   

This equipment curb is a good example of a failed repair attempt.  A membrane was applied to encapsulate the fasteners, panel laps and construction joints.  It appears to be sound but  it leaks onto the production floor of this manufacturing facility.  The piece of equipment under it had to be shut down until the leak was repaired.










In the second photo we have removed the old repair materials.  Everything covered by the membrane has rusted through and even rusted away as shown at the BLUE ARROW.  This was senseless because before this repair the only possibility for a leak was at the panel laps or the fasteners as shown at the RED ARROWS.  Had this repair not been installed this entire area would still look like the remainder of the roof as shown by the GREEN ARROWS.




After cleaning the area and painting any rusted petal with zinc rich paint, patch panels were fabricated and installed.  All overlapping metal components are installed in a bed of urethane sealant and secured with new fasteners.  The tan sealant seen in this photo is simply the excess sealant that was squeezed from between the components.  The excess is tooled with a putty knife to provide better water flow over the panel laps.  All of the fasteners are still visible so this equipment curb should stay reliable for years and years to come.