I have been fighting a losing battle with a screen porch roof that is
made of aluminum panels butted against each other. Sealants on the
seams last about a year (18 months if lucky) before leaks start
again. Each time I clean the old sealants off down to bare metal with
a wire brush. I have tried the normal latex, silicon, polyvinyl etc
but they all fail. The roof gets full Florida sun so it is UV
intensive and hot.
Any experts have a recommended product? I have not yet tried an epoxy
based sealant fearing how hard it could be in the future to remove
it. The panels are very tight together (no visible gaps) yet water
pours through in spots in heavy rains. Is there a low-viscosity
product that will get between the panels and then expand?
Have you thought about applying a strip of aluminum over the seams? I'm
thinking 2-3" wide, bedded in a good caulk (urethane?) and fastened with
sheet metal screws with a gasket. Like "board and batten".
Being under the batten and thus protected from UV, the bedding material
should stay good. I've never tried this, just a thought. BTW, I wouldn't
Just wire brushing wont remove everything that can contaminate it and
ruin a bond, a strong solvent is needed like alcohol or laquer
thinner, Silicones have expiration dates, Ive had silicones not get
hard or not bind from using old stuff sitting on store shelves to
long. I would think a good fresh silicone would work,also temperature
of the roof and humidity will affect a bond.
Post some pictures somewhere with a link back here, and we can give much
better advice. Kinda surprised there isn't a lap joint of some kind up
there to prevent exactly this problem. Most metal roof panels I have
seen, the panels overlap by 1 bump. The interlocking bumps always give
the water a lower spot to run to.
Typical Florida screen rooms use "pan roof". There are 2 common
styles. The cheaper one, usually just for car ports, uses bent over
edges on top of the seam and a drive flange. The better style for
"rooms" uses a curved lip that locks over a lip on the preceding piece
and they usually also have another pan cap over that with 3" of foam
in between. That style installs with a screw and a rubber backed
Neither requires any kind of sealant.
I am betting the OP has another problem, like perforated panels,
missing washer screws or a missing drive flange if it is that style..
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