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How to stop roof screws rusting?

Hi my colorbond roof is 12 years old . l live 4 km from the coast. Theres no noticable rust on my roof but l noticed about 10%-15% of the roof screws have some rust on them , All the rest look normal . l think the rust just stated a couple of years ago. l was thinking just replace the rusted screws and treat the remaining screws that are not rusted with some sort of rust inhibitor product or paint to stop them from rusting. Could l do that or should l replace all the screws not just the rusted screws, What is the better option ? and what product to use to prevent the screws from rusting. My concern is if the rust could spread from the screws to the roof, but they have rubber washers under them which would help, how urgent do you think the problem is , could l wait a year to replace them, thanks

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MitchellMc

Welcome to the Bunnings Workshop community @Amrad79. It's terrific to have you join us, and many thanks for your question about replacing roofing screws.

Are the existing screws powder-coated and painted or just straight galvanised? It sounds like they could just be galvanised steel, so my recommendation would be to pull them out and replace them with powder-coated screws in the same colour as your roofing. This painted coating provides additional protection from the elements and salt water.

Provided the rust is only on the heads it doesn't sound like replacing them is something that needs to be done immediately.

Please let me know if you have any questions.

Mitchell

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/35783#Comment_35783

thanks, the screws are the same color as the colorbond roof , l dont know if that means they are power coated or galvanized , Do you think because only about 10% of them look to be rusted would it be possible just to have those rusted ones removed and the reamaining screws painted or treated so they dont rust in the future which might be cheaper then removing them all ? or do all need to be removed . ls it something plumbers do ? l was also thinking of using a handyman from ' Hire a hubby' is that a job for a handyman or would someone with more special skills be needed from a roofing company . Would you have any idea of the sort of cost it would be for an average sized house to replace all the screws, l guess it wont be cheap. But as only 10% look to be rusted it must be early stages and do you think l should have alteast a year before l need to do anything

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/80154#Comment_80154

Are you able to share a picture of one of the worst rusted screws, @Amrad79? Bearing in mind that your safety is the top priority. Please don't go onto the roof unless you are confident in doing so. If there is minimal rust on the screw head, just a spot here and there, they might be fine for the next ten years. If they are heavily corroded, they'll need to be replaced before they become so disintegrated that they can't be removed.

I think your best move at this point would be to have a roofing specialist company come in and inspect them. They'll be able to advise on the best course of action and provide an estimate on the work.

Did you have the roof installed? If so, I'd be contacting the installer to see if there is any warranty on the screws that have been used. Typically, if they had a Colorbond coating added, they would have a significant warranty.

Mitchell

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/104559#Comment_104559

l have a couple of photos how bad is it , should l replace soon, The house was built 12 years ago so the roof came with the house and the company went out of busines so l dont know how to contact them to get the warranty. l applied some rannex rustbuster on one of the screws and all the rust totally disappeared, l was thinking if l got someone to apply rannex rust killer on them and then painting over them it could give them a few more years life before replacing

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/119364#Comment_119364

Given how heavily corroded those specific screws are, when others don't even have the beginning signs of corrosion on them, my money is on that there is something wrong with those rusting screws @Amrad79. If they were new screws when installed, then their coatings were not applied correctly by the manufacturer. There's no reason why some screws are not affected at all, and some are extensively corroded. When you have two entirely rusted screws next to one that's unaffected, it tells me something is wrong with the rusted ones. All screws on the roof should be rusting at a similar rate. Let me mention @Dave-1 and @Nailbag for their thoughts.

My advice would be to have the corroded screws replaced. It's not worth risking the roof sheets when you could have someone replace all the corroded screws in a day. I think it would cost you more to have someone treat and paint the screws than replace them. It takes about 20secs per screw to remove them and screw in the new one, whereas it would take several minutes to treat and paint them.

Mitchell

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/128284#Comment_128284

thanks , so you think just get the rusted screws replaced and leave the good screws ,or should l get them all replaced, l was thinking of calling my local plumber but do you think a roofing specialist would be better. also from the photo do you think the roof itself still looks good and non rusted , just the screws

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/134041#Comment_134041

I think a handyman could do this job, might be worth getting a couple of quotes @Amrad79.

There is just such a stark difference between the rusted and others that appear perfectly new. It makes me think something is wrong with the rusted ones, and the others are fine. It might just be your image, but when I see rusted screws in that condition, the fact the other ones are not speckled with rust and are on their way out, too, is weird.

Roof looks fine to me, but I'd pull out one of the heavily rusted screws to check if the threaded shaft has rusted and check to see if the edge of the hole in the sheet has started to rust.

Mitchell

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/137668#Comment_137668

thanks , yes some are rusted and others totally normal, they have a rubber washer underneath would that stop the rust from spreading , do you think l need a roofing specialist to look at it or just a plumber or handyman will be oK, l think l will get a quote from my hire a hubby handyman and other from my local plumber unless you think l should get a roofing specialist to look at it also , so from the look of the photos is it something l should get to more urgently rather then wait, my fear is the rust spreading to the roof

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/140146#Comment_140146

It would be great to have at least a quote from a roofing specialist, @Amrad79. Provided the roof sheeting hasn't been comprimised, then I think this is a simple case of needing the screws replaced, which doesn't require the expertise or associated cost of a specialist. However, if the roofing specialist quote comes in close to your other alternatives, I've been inclined to go with them as they'll likely get the job done much faster.

Mitchell

Nailbag

Hi @Amrad79 Looks like either those rusting screws are mixed with higher quality powder coated ones, possibly from 2 roofers fixing the roof off. If you feel safe/confident on the roof yourself, it's a very easy job of using a drill/driver or impact driver with the right sized hex bit and you could replace them yourself. Otherwise any handyman (cheapest option) could easily do this task for an hourly rate plus the fixings.

Personally, I would get this task completed sooner than later. If the body of any of the screws is also rusting and making contact with bare metal in the holes it's made through the colour bond roof, could be the beginnings of corrosion spreading. At the moment from your photos, I would be very confident that simply changing the screws over will all that be required.

Nailbag.

Dave-1

https://www.workshop.bunnings.com.au/discussion/comment/140146#Comment_140146

Evening @Amrad79

Sorry I just logged in and saw the question now about the screws. @MitchellMc has nailed it, well screwed it lol Id be only replacing the ones with rust on them and would be thinking its a bad batch of screws. As he mentions, maybe take one or two out to check how bad the rust is and if its spread.

I wouldnt class it in an "urgency" class, I would class it in a "have to get that sorted sometime tho.

Dave

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/141904#Comment_141904

Hi can l ask you advice l spoke to my plumber he said theres two options they can paint the screws with cold gal paint which is only a few hundre dollars but will only last a few years or they can replace all the screws for $2,000, which is a better option, l was thinking as only about 20% of the screws have rust on them and the other 80% look normal it might be better just to have them painted and check them in a year. l mentioned to the plumber about just have the rusted ones removed but he said its better to either remove allof them or paint them and check them in a year. My main concern is that rust does not spread from screws to the roof, if the screws are painted will that contain the rust for a couple of years

EricL

https://www.workshop.bunnings.com.au/discussion/comment/143199#Comment_143199

Hello @Amrad79

It will probably work if the heads were painted with cold gal. The issue I have with this repair option is that you 'll have to check again in a few years to see if the cold gal is still holding up. Whereas if the screws were properly replaced then you would be confident that the screws are not deteriorating.

I suggest going with a full replacement rather than a half measure where you'll need to check down the line if it is still in good condition. Another problem with that scenario is if the cold gal fails rust could spread on your roof.

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

Eric

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/144147#Comment_144147

Thanks, yes l think l will go with either a full replacement or just the rusted screws pulled out, someone on the forum mentioned it could be a case of the rusted screws being defective and the rest normal, ? is that possible or unlikely ?. Also when you replace the screws you will take the old screws out of a hole and insert the new screws in the same hole, does that mean that the screws wont have the same strong grip as the old screws and theres a risk the roof could come lose in the wind, if that happens then does the person who installed the screws responsible or would l have to pay the cost of fixing that

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/144850#Comment_144850

Hi @Amrad79,

Galvanised screws should not have deteriorated to that state in 12 years, so it indicates to me they could be defective, given there are screws right next to them that are perfectly fine.

The replacement screws will hold the roof sheets down just as well and have the same strong grip as the current screws.

Mitchell

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/145392#Comment_145392

thanks l live 4km from the coast, so should they still not have rusted after 12 years, so your advice is not to replace all the screws on the roof, just replace the rusted screws. , even if the cost of a total replacment is similar to just replacing the rusted screws?

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/145814#Comment_145814

My opinion is based on the fact that some have drastically rusted, and some have not at all @Amrad79. If 12 years were the lifespan of those screws 4km from the coast, then all the screws would have rusted equally. The fact that only some of them have rusted adds credence to the theory that there was an issue with their corrosion protection.

If the total replacement cost is similar, I would be doing all of them to be safe. There is no point working off theories when total replacement would solve the issue entirely.

Mitchell

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/146137#Comment_146137

Thanks for your help , just to update , My plumber said his going to replace just the rusted screws and it will only cost a couple hundred, he said the vast majority are rust free and could be OK for a few more years so its not worth replacing all of them now, he will just replace the rusted ones and then check the roof screws again in a year

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/146137#Comment_146137

Thanks for your help l have another question, l think the plumber said he is going to use stainless steel screws but l read on the internet that they are not suitable for colorbond roofs and can cause rust, should l tell him not to use stainless steel screws or would they be OK? , what type of screws should l ask him to use for a colorbond roof. My other question is would it be OK for him to use the same sized screws as the old ones as they are going into the same holes, should he use a slighly larger screw so it has a better grip

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/146413#Comment_146413

Hi @Amrad79,

Stainless steel fixings and fixings containing copper should also not be used with ZINCALUME® steel or COLORBOND® steel.

The same-size screws are fine to use, and they should be painted COLORBOND® 12 X 65 Type 17 Class 3 Screws. Alternatively, galvanised screws can be used.

Mitchell

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/146635#Comment_146635

THanks, , l spoke to the plumber he is putting in colorbond screws, l think theres about 800 - 1,000 screws on the roof and no more then 100 look like they have rust, the rest look normal, so lm just having the rusted ones replaced which is alot cheaper then a full replacement. What is the normal lifespan of colorbond screws before they should be replaced for people who live a few KM from the coast, l think you said its not normal for them to rust after only 12 years, should they last more like 20 years before they need to be replaced.

Dave-1

https://www.workshop.bunnings.com.au/discussion/comment/146817#Comment_146817

Evening @Amrad79

Thinking of your question Id say its very hard to judge, 12 years to me alreay sounds good without any deterioration (But we know that some of that batch have already rusted) 20 years sounds like something it should be. Factoring in the coastal enviroment would be hard to do. I would suggest every year have a look and just note if you see other indicators of screws showing signs of rust. Or whenever you clean your gutters (for me its evry 6-9 months ish) have a squiz and check them out.

Dave

EricL

https://www.workshop.bunnings.com.au/discussion/comment/146817#Comment_146817

Hello @Amrad79

If you have authentic Colorbond screws with B8 coating, they come with up to 30 years of corrosion protection warranty. But @Dave-1's analysis and suggestion is a good one, a 20-year life span sounds reasonable, but it is difficult to factor in the coastal environment.

A semi-annual check of the screws when cleaning your gutters is an effective way to keep an eye on your roof screws status.

If you need further assistance, please let us know.

Eric

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/146964#Comment_146964

l didnt know they had a 30 year warranty, could l try to get them to pay the cost of replacing the screws, How would l go about it, who do l contact, the company that build my house and installed the roof 12 years ago went out of business years ago so l cannot contact them

EricL

https://www.workshop.bunnings.com.au/discussion/comment/147082#Comment_147082

Hello @Amrad79,

That's an excellent question, I'm afraid it will require you to track down the builder who has the dockets for the materials used for your roof. But if the building company that built your house has already closed its doors, it will be a challenge to try and track down where all the paperwork is for the construction of your home. This is on the assumption that they kept all their building records and receipts.

You could probably call Colorband direct, but they would probably ask for proof of purchase. Another thought that comes to mind is what if the builder did not use authentic Colorbond screws to begin with. It's a shame that the building company has already closed its doors, you would have been able to go directly to them.

Let me give Colorbond a call on Monday and inquire for you. as soon as I have more information, I'll get back to you.

Eric

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/147189#Comment_147189

thankyou for doing that for me. Just having the rusted screws replaced will only cost me $200 so it would not be worth the trouble just for that, but a total screw replacement costs $2000 so it would be worth tracking down the warranty if l can get a total replacement. The roof itself is still rust free and its only 12 years old but if the roof itself starts to rust within the warranty period and needs to be replaced then l for sure want the warranty as that would be a $25,000 cost not something most people can afford

MitchellMc

https://www.workshop.bunnings.com.au/discussion/comment/147278#Comment_147278

So sorry for the delay in our response @Amrad79.

To clarify, Colorbond is a coating; they don't manufacture screws themselves. I've contacted Buildex, one of our suppliers of roofing screws that have a Colorbond coating, to get a better understanding of what the warranty process would be. The first hurdle you'd need to overcome in a warranty process is determining who was the manufacturer of your screws, as your warranty is with them, not Colorbond. For instance, if the screws were from Buildex, then their assessment team would come out and take a look at the screws for warranty purposes. Another one of our suppliers is Lysaght, who can be contacted at lysaghtacabun@bluescope.com. You could certainly send them through an email with your pictures, and they'll be able to identify whether they were the supplier.

Without being able to identify the manufacturer of the screws and no recourse with the installer, the issue is really that your screws could be from any number of the multitude of suppliers in the market. The painted coating might not even be Colorbond.

Please let me know if you have any questions.

Mitchell

Amrad79

https://www.workshop.bunnings.com.au/discussion/comment/147365#Comment_147365

thanks sounds like it would be very hard or impossible to get the warranty, atleast its just the screws and not the roff thats rusted then it would be really expensive , l have booked a plumber to come next week to replace the rusted screws, l think its under 80 that have rust, it will only cost a few hundred dollars, hopefully the majority of the screws that dont have rust will last a few more years

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