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How to repair small section of corrugated roof?

I have discovered a small section of corrugated roof that has rusted through. The area is less than 20cm x 20cm. The section is above the eave near the edge to the guttering. I don’t want to replace the entire sheet as there are solar panels installed. Any suggestions for best way to repair? Thanks

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MitchellMc

Welcome to the Bunnings Workshop community @Burnside7. It's terrific to have you join us, and many thanks for your question about repairing a roof.

That's really past the point of repair, and the two sheets should be replaced. That being said, you could give the area a good scrub down with a wire brush and then paint the area with rust converter. Unfortunately, you won't be able to access the underside of the sheet, so the corrosion will continue under your repair. Once the converter has dried, I'd recommend you cut a patch section out of a full sheet and glue that over the area with Sikaflex 11FC around all the edges. Alternatively, if you don't want to go with a solid patch, you could attempt to use Butyl flashing tape over the holes and area.

Please let me know if you have any questions.

Mitchell

Burnside7

https://www.workshop.bunnings.com.au/discussion/comment/33273#Comment_33273

Thanks Mitchell.

i’m loathe to replace the sheets as there are solar panels installed further up the sheets. I’ll try the patch and silkaflex. Does anyone sell small patches of corrugated sheets that you know of?

Thanks again.

Akanksha

Hello @Burnside7,

Our resident Bunnings D.I.Y. expert @MitchellMc is currently away and I'm sure he'll be happy to assist as soon as he can after he returns. In the meantime, let me tag our ever-helpful members @Jewelleryrescue, @Noyade and @DIYGnome to see if they have any thoughts about purchasing small sections of corrugated sheets.

Let me also extend a warm welcome to the Bunnings Workshop community. We look forward to seeing and assisting you in your home improvement and garden projects. Please don't hesitate to let me know if you need a hand getting the most out of the site.

Akanksha

Jewelleryrescue

https://www.workshop.bunnings.com.au/discussion/comment/33292#Comment_33292

HI @Burnside7

Bunning sells a range of roofing corrugated iron ingavlised or colour bond form shortest in your roof profile is 2400mm long $42 If you dont want to cut it put the whole sheet up as a time saver It will be helpfull to take out old roofing bolts first so the new sheet lays flat. You may need a few new roofing screws in case old ones corroded too. just seal top edge. if bolted down.

If you want to cut sheet and store some use nibbling tool best as angle grinder heats up the cut end and new corrosion has an entry point so clean cut and spray paint the edge.

Normally if one spot corroding others arnt too far away in time.

DIYGnome

Hello @Burnside7 looking at the photo it would appear that the rust contamination likely started due to swarf from the roofing screw hole being drilled (the surrounding sheeting looks decent) although there is that unusual localised debris on the site as well, it's just my preference but I would cut all of that rust out because it will only undermine any repair you do IMHO and thus would follow the suggestion by @MitchellMc to cut a patch (allowing for overlap) and after removing the damaged section and adequate surface preparation adhere the new section with the Sika Flex adhesive/sealant in the same approach you would to patching a bicycle inner tube.

BTW that is a lot of water pooling in your gutter there, where you cleaning out the gutters at the time you took that photo?

Burnside7

https://www.workshop.bunnings.com.au/discussion/comment/33348#Comment_33348

Thanks @DIYGnome

I was cleaning out gutters when I noticed the rusted patch. The guttering has partially come away from the facia board and now doesn't drain properly. I'm on rainwater not town water, so it'll definitely need to be fixed. Currently tossing up whether to try and re-attach to facia or replace the whole of the gutter. (Repairs never seem to stop!!)

Regards,

Jewelleryrescue

https://www.workshop.bunnings.com.au/discussion/comment/78977#Comment_78977

Hi @Burnside7

Thank you for your vote of support.

Can I add if you run an angle grinder you can cut the rusty sheets out as other helpful suggestions meantion it may protect the new sheet from early cancer and slow cancer spread in the other sheets but once its out of the rain it should slow or stop any how in theory as rust is a chemical reation.

Hope this is the last rust spot for many years.

Burnside7

https://www.workshop.bunnings.com.au/discussion/comment/103794#Comment_103794

Me too, @Jewelleryrescue .

Thanks for your help.

islandmob

https://www.workshop.bunnings.com.au/discussion/comment/118949#Comment_118949

Hi Burnside, I was wondering how this was going?

I have a similar situation and was considering the possible solution by Mitchell "I'd recommend you cut a patch section out of a full sheet and glue that over the area with Sikaflex 11FC around all the edges", I note he has mentioned for the patch to go on top which is probably the only way it can be done. My worries about this method is that it will create a catch as the water runs down, and if the initial breakdown was caused by trees and debris (from the neighbours in my situation) then it will gather at the join and reinfest. Ideally the new piece would fit underneath so the water and debris flows straight down, however I have not been able to come up with an idea to work that.

EricL

https://www.workshop.bunnings.com.au/discussion/comment/128322#Comment_128322

Hello @islandmob

Welcome to the Bunnings Workshop community. It's fabulous to have you join us.

Let me tag @Burnside7 to make them aware of your question. There is that possibility of creating a catch at the edge of the patch, but I believe that if the application of the Sikaflex 11FC is not overly excessive you should be able to get a low-profile finish which minimizes the risk of creating a catch.

Another possible way to create a take-off wedge on the patch is to put a strip of Butyl flashing tape at the top of the patch creating a smooth edge that will allow water and debris to flow over it.

Let me call on our experienced members @Dave-1 and @JacobZ95 for their recommendations.

If you have any other questions we can help with, please let us know.

Eric

Dave-1

Afternoon @islandmob

I have the same issue... And its due to get fixed lol (I had "forgotten" about it until you mentioned it)

I had "silasticed" over the hole to stop water coming in and then have forgotten about the quick repair. (been two years at least since I looked at it)

The plan is to cut off the lower part of the sheet and remove, replace it with a new section that fits up under the last batten so it can be screwed through and fastened to the timber underneath. Because its underneath the existing sheet for a distance the water will fall properly. The rust wont spread because of my dodgy quick fix and it being left insitu.

Just re-reading your question to make sure I have it right 🙂 Could you post a photo of the area?

Dave

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