Metal Roof Corrosion
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What to Do When Metal Roofing Starts Corroding
There are a lot of benefits to having a metal roof, and longevity is one of them. Metal roofs can last 40-80 years, which is very impressive when you consider that roofing material is exposed to the elements 24/7/365.
One of the top questions we get asked about metal roofing is if it will corrode or rust over time. The truth is, it's possible. Metal roofing systems are extremely durable, but they aren't indestructible. And some types of metal are more resistant to corrosion than others. Although galvanized steel and aluminum roofs are corrosion resistant, rusting can occur and needs to be corrected quickly.
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What Causes Metal Roofs to Corrode
Over time metal roofing will corrode. The worst form of corrosion is rust. Iron alloy metals like steel can rust if they're exposed to moisture, which can be a serious problem for roofs that are out in the rain.
Steel metal roofs rust because of chemical reactions. Rust is an iron oxide that forms when iron and oxygen from water or air moisture are combined. The atoms in the iron are oxidized, which weakens the metal and actually causes the metal to slowly dissolve. Iron alloys may seem much tougher than water, but in the long run they aren't. They appear solid, when in actuality they have microscopic scratches and pits that are porous.
Other types of metals that are used for roofing undergo chemical corrosion when they're exposed to moisture, but damaging rust won't develop. For example, copper oxide will form on the surface of copper roofs and turn to patina, but it's actually protective.
While understanding the exact chemical process isn't necessary, property owners should know what causes detrimental corrosion on metal roofs so they can prevent it if possible.
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Issues When the Roofer is Installing Underlayment Material
A roofer must install underlayment properly or there could be major problems even if the surface materials are in perfect condition. It's crucial that the roofers roll out the underlayment smooth so that it lies perfectly flat when it's installed. The underlayment also needs to be snug but not too tight in order to function properly.
The underlayment might not be properly sealed during the installation, which leads to other problems. Without good sealing, the underlayment won't be a waterproof layer. However, there still needs to be adequate ventilation with synthetic underlayment or moisture can get trapped underneath.
One other issue to watch out for with roofing underlayment installation is how the material is stored and handled. If the underlayment is exposed to the heat prior to installation it can degrade the material and increase the risk of cracking and blistering after it's installed.
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Corrosion is Common When the Roof's Protective Coating Has Worn Away or Become Damaged
Steel metal roofs have protective coatings that are added to prevent the corrosion process from occurring. If the protective coating becomes damaged or wears away corrosion can happen. No protective coating can last forever, but it will wear away quickly if branches are rubbing the roof surface or there's a lot of foot traffic.
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Corrosion is More Likely If the Metal Roof is Exposed to Salt or Acids
Moisture is bad enough, but if you add salt or an acid to the mix it can make corrosion much worse. Salt is an electrolyte that causes metal to lose its electrons, which speeds up chemical reactions of the corrosion process. Acidic pollutants in the air also accelerate rusting by breaking down the oxide layer of the metal surface.
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The Metal Roofing is Touching Another Metal
There's something called dissimilar metal corrosion that property owners should know about before installing a metal roof. When dissimilar metals come in contact with one another it isn't a problem - unless moisture is present. If it is, it will cause a chemical reaction known as galvanic corrosion that accelerates rusting where the metals meet.
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Scratches and Damage to the Metal Surface
If the surface of a metal roof is damaged corrosion will soon follow. Scratches and holes allow moisture to penetrate deeply into the metal beyond the surface.
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Storm Damage
Hail and high winds can do a lot of damage to roofs, even below the surface. If the top layer suffers storm damage or is torn off, the underlayment is exposed and can be damaged as well.
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Stress Cracking From High Winds
High winds can also cause issues that increase the likelihood of rust and corrosion on a metal roof. If strong winds happen frequently it can create tiny stress cracks on the roof surface. Moisture can get into the cracks and corrode the roofing material.
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Improper Installation
Like virtually any other roofing issue, rusting roof materials could be the result of a roofer that didn't know what they were doing. One of the most common errors that leads to rusting is when a roofer cuts the metal panels and doesn't protect the exposed edges. They may also install the metal panels incorrectly so that the roofing isn't watertight.

How to Repair Corroded Metal Roofing Materials
Rust and corrosion is something that can't be ignored. If corrosion isn't addressed it will eventually compromise the roofing system and roof replacement will be necessary. Here are the steps to take to prevent a worst case scenario.
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Get a Roof Inspection
The first thing that needs to happen is a roof inspection. You'll need to know the extent of the corrosion and identify the cause to properly address the problem.
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Replace the Corroded Metal Panels
If the damage is limited to one area, the corroded metal panels can be replaced. However, it's important to work with an experienced roofer that knows how to install the panels properly to avoid even worse problems down the road. You'll also want to replace the corroded parts with a durable metal material. Consider replacing galvanized steel panels with galvalume steel that has an aluminum and zinc coating for extra durability.
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Apply a Protective Coating
A protective coating should be applied to steel panels every 5 to 12 years. It's also important to reapply the right type of coating that contains aluminum, zinc or a combination of the two.
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Perform Regular Roof Maintenance
Catching corrosion quickly is key to preventing major issues. Make it a point to have annual roof inspection that looks for scratches in the protective coating, dents and damage to the metal roofing material, gaps in the panels and tree limbs that need to be cut back away from the roof line.
The team at LOA regularly corrects corrosion issues on all types of metal roofs. We even provide free roof inspections to assess the situation. Take the first step in getting corrosion under control by scheduling an inspection with one of our roofing professionals.
