Leaking Metal Roof Repair: Complete Guide to Fixing Leaks Yourself (Or When to Call a Pro)
Is your metal roof leaking? You're not alone—leaking metal roof repair is one of the most common issues homeowners face. Metal roofs are renowned for their durability and longevity—lasting 40-70 years with proper maintenance—but even the best can develop leaks. The good news? Most metal roof leaks are repairable, often at a fraction of the cost of replacement. Whether you're dealing with a dripping ceiling after a storm or discovered water stains during a routine inspection, this comprehensive guide will help you identify the cause, fix it yourself when appropriate, and know when to call a professional.
With 25+ years of experience repairing metal roofs throughout Essex County, NJ, we've seen every type of metal roof leak—from simple fastener failures to complex flashing issues. This guide shares that expertise, giving you the knowledge to make informed decisions about your metal roof repair. For commercial metal roofing issues, see our dedicated commercial metal roof repair guide.
Active Leak Emergency?
If water is actively entering your home, call R&E Roofing at (667) 204-1609 for 24/7 emergency service. While you wait, place containers under drips and move valuables away from the leak. See our emergency roof repair guide for immediate steps.
What You'll Learn
- 1. 7 Common Causes of Metal Roof Leaks
- 2. How to Find Where Your Metal Roof is Leaking
- 3. 10 Ways to Repair a Leaking Metal Roof
- 4. Best Products for Metal Roof Leak Repair
- 5. When to Stop DIY and Call a Professional
- 6. Metal Roof Leak Repair Costs (2025)
- 7. Metal Roof Repair in New Jersey: What's Different
- 8. Preventing Future Metal Roof Leaks
- 9. Frequently Asked Questions
1. 7 Common Causes of Metal Roof Leaks
Understanding why metal roofs leak is the first step to fixing them. Unlike asphalt shingle leaks which typically come from damaged or missing shingles, metal roof leaks have distinct causes:
1Loose or Failed Fasteners (60% of Leaks)
This is the most common cause of metal roof leaks. Metal roofing screws have rubber EPDM washers that create a watertight seal. Over time, these washers degrade from UV exposure and temperature cycling. Additionally, thermal expansion causes metal to move, gradually backing screws out of their holes.
Signs: Visible raised screw heads, water stains directly below fastener lines, screws lying in gutters
2Panel Seam Separation
Where metal panels overlap or interlock, seams can separate due to thermal movement, improper installation, or sealant failure. Standing seam roofs are less prone to this than exposed fastener systems, but all metal roofs can experience seam issues over time.
Signs: Visible gaps between panels, water stains following seam lines, drafts in attic along seam locations
3Rust and Corrosion
While modern metal roofs have protective coatings, rust can develop where the coating is scratched, at cut edges, or where dissimilar metals contact each other (galvanic corrosion). Rust weakens the metal and creates holes.
Signs: Orange/brown discoloration, flaking metal, pinhole leaks, rust streaks on siding below roof
4Flashing Failures
Flashing around roof penetrations (vents, pipes, skylights, chimneys) and transitions (valleys, edges, walls) is critical for waterproofing. Improperly installed or deteriorated flashing is a major leak source.
Signs: Water stains near penetrations, visible gaps at flashing edges, rust around flashing
5Storm Damage
Hail can dent metal panels and crack protective coatings. High winds can lift panels or tear them from fasteners. Flying debris can puncture metal roofing. After any major storm, inspect for damage.
Signs: Visible dents, lifted panel edges, punctures, missing trim pieces
6Poor Installation
Installation errors are a leading cause of premature metal roof leaks. Common mistakes include incorrect fastener placement, missing sealant, improper panel overlap, and inadequate flashing.
Signs: Leaks appearing within first 5 years, leaks at multiple locations, visible installation defects
7Condensation Issues
Metal roofs can experience condensation on the underside when warm, moist interior air meets the cold metal surface. This isn't technically a leak but causes the same water damage. Inadequate ventilation and missing vapor barriers are common causes.
Signs: Water stains without visible exterior damage, issues worse in winter, damp insulation throughout attic
2. How to Find Where Your Metal Roof is Leaking
Locating the source of a metal roof leak can be challenging because water often travels along panels, purlins, or rafters before dripping into your living space. Here's a systematic approach:
Start in the Attic
If you have attic access, this is your best starting point. With a bright flashlight, look for:
- Water stains on the underside of the roof deck
- Wet or discolored insulation
- Rust stains on metal components
- Daylight visible through the roof (indicates holes)
- Water trails along rafters or purlins
Important: Follow water trails UPWARD—the entry point is usually above and upslope from where you see damage.
Check Common Leak Points First
Before examining the entire roof, focus on areas where leaks commonly occur:
- Fasteners: Look for raised, missing, or rusted screws
- Seams: Check where panels overlap
- Penetrations: Vents, pipes, skylights, chimneys
- Transitions: Where roof meets walls, valleys, ridge
- Edges: Drip edge, eave, and rake areas
The Water Test Method
If you can't find the leak source, try the water test:
- Have a helper stationed in the attic with a flashlight
- Using a garden hose, spray water on one section of the roof at a time
- Start low and work upward, isolating small areas
- When your helper sees water entering, mark that area
- Allow 15-20 minutes per section—some leaks are slow to appear
Safety Warning
Never walk on a wet, icy, or damaged metal roof. Metal roofing is slippery, especially when wet. If you need to inspect the roof surface, wait for dry conditions and use proper fall protection equipment. When in doubt, hire a professional with safety equipment and experience.
3. 10 Ways to Repair a Leaking Metal Roof
Many metal roof leaks can be fixed with DIY methods if you're comfortable working at height and have basic tools. Here are 10 repair techniques, from simplest to most complex:
Method 1: Tighten Loose Fasteners
The simplest fix for metal roof leaks. If screws have backed out but washers are still good:
- Use a drill/driver to gently tighten loose screws
- Stop when the washer compresses slightly—don't overtighten
- Check all fasteners in the leak area
Cost: Free if screws are reusable | Time: 15-30 minutes
Method 2: Replace Damaged Fasteners
When washers are cracked, compressed, or missing:
- Remove the old screw completely
- Use a screw 1/4" longer or one size larger diameter
- Apply a dab of sealant in the old hole before inserting new screw
- Use screws with new EPDM washers rated for metal roofing
Cost: $20-75 for screws | Time: 30-60 minutes
Method 3: Seal Small Holes and Punctures
For holes under 1/2" diameter:
- Clean the area with a wire brush and solvent
- Apply metal roof sealant (silicone or polyurethane)
- Build up multiple thin layers, allowing each to cure
- Extend sealant 1" beyond the hole in all directions
Cost: $15-40 for sealant | Time: 30 minutes + cure time
Method 4: Re-Seal Panel Seams
When seams have separated or sealant has failed:
- Remove old, failing sealant with a putty knife
- Clean seam thoroughly with solvent
- Apply butyl tape or polyurethane sealant under the seam
- Press panels together firmly
- Add additional sealant on top if using caulk-type products
Cost: $25-75 | Time: 1-2 hours
Method 5: Patch Larger Holes
For holes larger than 1/2" or areas with multiple small holes:
- Cut a metal patch 2-3" larger than the damage on all sides
- Match the metal type (steel, aluminum) to avoid galvanic corrosion
- Apply sealant to the patch underside
- Secure with screws around the perimeter
- Seal all edges and screw heads
Cost: $30-100 | Time: 1-2 hours
Method 6: Address Rust Spots
To stop rust from spreading and causing leaks:
- Remove loose rust with a wire brush or grinder
- Sand the area to bare metal, feathering edges
- Apply rust converter/inhibitor and let dry
- Apply metal primer designed for your roof type
- Finish with matching roof paint or sealant
Cost: $30-75 | Time: 2-3 hours including drying
Method 7: Re-Seal Flashing
When flashing around penetrations is leaking:
- Remove old, failed sealant completely
- Clean surfaces with solvent
- Apply new roofing cement or flashing sealant
- For rubber boot vents, consider replacement if cracked
- Use flashing tape for added protection at edges
Cost: $25-100 | Time: 1-2 hours per penetration
Method 8: Apply Roof Coating
For widespread minor issues or preventive maintenance:
- Clean entire roof surface thoroughly
- Repair obvious damage points first
- Apply elastomeric or silicone roof coating per manufacturer instructions
- Typically requires 2 coats with 24-hour cure between
- Creates a seamless waterproof membrane
Cost: $100-500 DIY / $3-7/sq ft professional | Time: Full day
Method 9: Replace Damaged Panels
When a panel is too damaged to repair:
- Source matching replacement panels (color, profile, gauge)
- Remove fasteners from damaged panel and adjacent panels
- Carefully remove the damaged panel
- Install new panel with proper overlap and sealant
- Secure with new fasteners
Note: This is best left to professionals unless you have experience
Method 10: Address Condensation
For moisture issues caused by condensation:
- Improve attic ventilation (add ridge vents, soffit vents)
- Install or repair vapor barrier below roof deck
- Ensure bathroom/kitchen fans vent outside, not into attic
- Add insulation to reduce temperature differential
Cost: $200-1,000+ | Time: 1-2 days
4. Best Products for Metal Roof Leak Repair
Using the right products is crucial for lasting metal roof repairs. Here are our recommendations:
| Product Type | Best For | Top Brands |
|---|---|---|
| Silicone Sealant | Seams, small holes, flashing | GE Silicone II, Geocel 2320, DAP |
| Polyurethane Sealant | High-movement areas, structural bonds | Sikaflex, Loctite PL, OSI Quad |
| Butyl Tape | Seams, overlaps, under flashing | Eternabond, Cofair, Dicor |
| Roof Coating | Full roof restoration | Henry, Gaco, Kool Seal |
| Roofing Screws | Fastener replacement | Metal Sales, Grabber, ITW Buildex |
Product Selection Tip
Always match your sealant to your roof material. Using aluminum-compatible sealant on steel (or vice versa) can cause galvanic corrosion. When in doubt, silicone is generally compatible with all metal roof types.
5. When to Stop DIY and Call a Metal Roof Repair Pro
While many metal roof leaks are DIY-friendly, some situations require professional expertise:
Call a Professional When:
- ✗Leak source isn't obvious after inspection
- ✗Multiple leaks throughout the roof
- ✗Structural damage suspected (sagging, rot)
- ✗Widespread rust or corrosion
- ✗Panel replacement needed
- ✗Steep or high roof (safety concerns)
- ✗Roof is under warranty
- ✗Insurance claim is involved
DIY May Be Appropriate When:
- ✓Single, identifiable leak source
- ✓Loose fasteners that need tightening
- ✓Small holes or gaps needing sealant
- ✓Low-slope, safely accessible roof
- ✓Minor rust spots to treat
- ✓You have proper safety equipment
If your metal roof has widespread rust, multiple panel failures, or is nearing 30-40 years old, replacement may be more cost-effective than ongoing repairs. Compare roof replacement companies to find the best contractor for your new roof installation.
Need Professional Metal Roof Leak Repair?
R&E Roofing provides expert metal roof repair throughout Essex County, NJ. We offer free inspections, honest assessments, and quality workmanship backed by our warranty.
6. Metal Roof Leak Repair Costs (2025 Pricing)
DIY Repair Costs
| Repair Type | Material Cost |
|---|---|
| Sealant (tube) | $8-20 |
| Replacement screws (50-100 pack) | $20-50 |
| Butyl tape (50 ft roll) | $15-40 |
| Metal patch kit | $25-75 |
| Roof coating (5 gal) | $100-250 |
| Rust treatment kit | $30-60 |
Professional Repair Costs
| Repair Type | Cost Range |
|---|---|
| Minor repairs (fasteners, sealant) | $150-400 |
| Moderate repairs (flashing, seams) | $400-1,000 |
| Major repairs (panels, structural) | $1,000-3,000+ |
| Roof coating system | $3-7 per sq ft |
| Emergency repair | +25-50% premium |
For more detailed cost information, see our roof leak repair cost guide.
7. Metal Roof Leak Repair in New Jersey: What's Different
New Jersey's climate presents unique challenges for metal roofing:
Nor'easter Damage
New Jersey experiences 10-15 nor'easters annually, bringing high winds (60+ mph), heavy rain, and wet snow. These storms can back out fasteners, lift panel edges, and drive water into seams. After any major storm, inspect your metal roof.
Freeze-Thaw Cycles
Essex County experiences 40+ freeze-thaw cycles per winter. This constant expansion and contraction stresses fasteners and sealants, making them common failure points. Use products rated for temperature extremes (-40°F to 180°F).
Ice Dam Considerations
While metal roofs shed snow better than shingles, ice dams can still form at eaves if attic insulation is inadequate. Ice dam-related leaks require addressing ventilation and insulation, not just sealing.
Coastal Corrosion
Properties near the Jersey Shore face accelerated corrosion from salt air. If you're within 5 miles of the coast, more frequent inspections and rust treatment are essential.
8. Preventing Future Metal Roof Leaks
Annual Inspection
Inspect your metal roof annually, ideally in spring. Check fasteners, seams, flashing, and look for rust. Address small issues before they become leaks.
Post-Storm Checks
After major storms, visually inspect from the ground for lifted panels, debris damage, or missing trim. Schedule professional inspection if damage is suspected.
Gutter Maintenance
Keep gutters clear to prevent water backup at eaves. Clogged gutters can cause water to back up under metal panels, especially in winter.
Trim Overhanging Branches
Branches can scratch protective coatings and drop debris. Keep trees trimmed 10+ feet from the roof.
9. Frequently Asked Questions
Can you repair a leaking metal roof from inside?
You can apply temporary fixes from inside the attic, such as using roofing tar or sealant on the underside of the roof deck. However, these are only temporary solutions. Permanent metal roof leak repair must be done from the exterior by addressing the actual source—replacing fasteners, sealing seams, or patching holes.
What is the best sealant for metal roof leaks?
Silicone-based sealants are generally best for metal roof leaks because they remain flexible through temperature changes, resist UV degradation, and adhere well to metal surfaces. Top options include GE Silicone II, Geocel 2320, and Dicor Lap Sealant.
How long does metal roof leak repair last?
A properly done metal roof leak repair can last 10-20 years depending on the repair type. Fastener replacement with quality EPDM washers lasts 15-20 years. Sealant repairs typically last 5-10 years before needing reapplication. Professional roof coating systems can extend roof life by 15-25 years.
Can Flex Seal fix a metal roof leak?
Flex Seal can provide a temporary fix for small metal roof leaks, but it is not recommended as a permanent solution. For lasting repairs, use products specifically designed for metal roofing like silicone sealants, butyl tape, or professional-grade roof coatings.
Does insurance cover metal roof leak repair?
Homeowners insurance typically covers metal roof leak repair if the damage was caused by a sudden, covered event like a storm, fallen tree, hail, or fire. Insurance usually does NOT cover leaks from normal wear and tear, lack of maintenance, or rust from age.
How do you find a leak in a metal roof?
Start in the attic with a flashlight, looking for water stains, wet insulation, or daylight. Trace water paths upward—leaks often appear far from their source. Check common leak points: fasteners (60% of leaks), seams, flashing around penetrations, and rust spots.
Can you patch a rusted metal roof?
Yes, you can patch a rusted metal roof if the rust hasn't caused structural failure. Remove loose rust with a wire brush, apply rust converter, then use sealant or a metal patch. If rust is widespread, consider roof coating or full metal roof replacement.
What causes metal roof screws to back out?
Metal roof screws back out primarily due to thermal expansion and contraction. Metal roofs can expand and contract significantly as temperatures change, gradually loosening fasteners. Over-driven or under-driven screws during installation also contribute to this problem.
How much does it cost to seal a metal roof?
DIY sealant for spot repairs costs $15-75 in materials. Professional sealing of seams and fasteners runs $200-800. Full roof coating systems cost $3-7 per square foot installed ($3,000-$14,000 for a 2,000 sq ft roof). In New Jersey, expect 10-20% higher than national averages.
Should I repair or replace my leaking metal roof?
Repair your metal roof if damage is localized (less than 20% of surface), the structure is sound, and the roof is under 25 years old. Replace when rust is widespread, structural damage exists, or the roof is 40+ years old. A professional inspection can help determine the best option.
Fix Your Metal Roof Leak With Confidence
Metal roof leaks are frustrating, but they're usually fixable—often at a fraction of replacement cost. Armed with the knowledge from this guide, you can tackle simple repairs yourself or make informed decisions when hiring a professional. Remember: the key to preventing expensive damage is addressing leaks quickly, whether that means grabbing some sealant for a weekend DIY project or calling a trusted roofing contractor.
For general roof leak information, see our complete guide to repairing leaking roofs. If you're considering a new metal roof, check our metal roof installation guide.
Expert Metal Roof Leak Repair in Essex County, NJ
R&E Roofing specializes in metal roof repair for homes and businesses throughout New Jersey. With 25+ years of experience and quality workmanship guaranteed, we'll get your roof watertight fast.
- Free metal roof inspections and estimates
- 24/7 emergency leak repair service
- All metal roof types: standing seam, corrugated, R-panel
- Licensed, insured, and certified
- Workmanship warranty on all repairs