Metal Roof Repair: 7 Common Issues & Their Fixes

Metal roof repair is something every homeowner should understand, especially if your property is protected by this durable and efficient roofing material. While metal roofs are known for their longevity, they aren’t completely immune to damage or wear. When problems do arise, catching and fixing them early is the key to avoiding expensive repairs or premature replacement.

In this post, we’ll walk you through:

• Top metal roofing problems: What to watch out for as your roof ages
• Reliable fixes: Solutions that prevent minor issues from growing worse
• When to call in the pros: Signs it’s time for expert help

Let’s break down the most common metal roofing issues and what can be done to repair them.

💧 Leaks and Water Intrusion

Water is the enemy of any roof, and even metal can let moisture in under the wrong conditions.

Panel Seams and Fasteners

The seams where metal panels overlap and the screws that hold them down are common leak points.

• Worn sealants: Sealants used at seams or flashing can degrade over time, leading to leaks.
• Loose fasteners: Screws may back out due to temperature changes or vibration, leaving holes that allow water entry.
• Poor installation: If panels were installed without proper alignment or overlap, water may slip through.

How to Fix It

• Re-sealing: Use a metal roof-compatible sealant to reinforce vulnerable seams.
• Replace fasteners: Install new, oversized screws or those with neoprene washers for a tighter fit.
• Panel realignment: Adjusting misaligned panels or replacing severely damaged ones can eliminate leak paths.

❌ Corrosion and Rust

Although most metal roofs are coated for protection, rust is still a threat—especially in coastal or humid environments.

What Causes It?

• Standing water: Water that pools and doesn’t drain quickly wears down protective coatings.
• Scratches and dents: These expose bare metal to oxygen and moisture.
• Mixed metals: Contact between incompatible metals can cause galvanic corrosion.

Repair Strategy

• Rust removal: Light rust can often be wire-brushed and treated with a rust converter.
• Surface coating: Applying a primer and metal roof paint helps restore protection.
• Panel replacement: Severely rusted panels should be swapped out entirely.

🛢️ Oil Canning

This cosmetic issue causes visible waviness in the flat parts of metal panels.

What’s Behind It?

• Thermal expansion: Metal expands and contracts with temperature changes, causing panels to buckle slightly.
• Improper installation: Over-tightening fasteners or uneven panel spacing can increase oil canning.
• Thin metal: Lower-gauge panels are more prone to visible movement.

What Can Be Done?

• Preventive design: Using ribbed or textured panels can minimize the appearance of oil canning.
• Loosening fasteners: In some cases, adjusting screw tension helps reduce panel stress.
• Professional assessment: A roofer can determine whether appearance adjustments or replacement is best.

⭐️ 7 Common Metal Roof Repairs

Here’s a quick breakdown of the most common repairs homeowners face:

1. Replacing missing screws: Fasteners can loosen or fall out, especially during wind events.
2. Fixing minor panel dents: Hail or debris may dent panels; small ones can often be flattened without replacement.
3. Repairing flashing: Bent or lifted flashing around chimneys and vents can lead to water leaks.
4. Treating rust spots: Small corroded areas should be sanded, primed, and recoated promptly.
5. Patching punctures: Small holes can be sealed with patching kits specifically designed for metal roofs.
6. Reapplying sealants: UV exposure degrades caulking and tape at joints and ridges, requiring touch-ups.
7. Cleaning clogged gutters: Overflow from blocked gutters can back up under panels and lead to interior leaks.

💥 Noise and Expansion Problems

Many homeowners notice loud popping or ticking sounds with metal roofs—usually caused by natural movement.

Why Does It Happen?

• Thermal cycling: The expansion and contraction of panels create stress at fasteners or joints.
• Inadequate spacing: Lack of allowance for movement during installation increases noise.
• Incorrect underlayment: Hard decking underneath metal can amplify sound.

How to Address It

• Install slip sheets: These allow smoother panel movement.
• Upgrade fasteners: Floating clip systems may help reduce stress noise.
• Add soundproofing: A layer of insulation or sound-deadening underlayment can quiet creaks and pops.

⛈️ Wind and Storm Damage

While metal roofs are highly wind-resistant, extreme weather can still cause issues.

Damage You Might See

• Lifted panels: Strong gusts may catch edges if fasteners were improperly installed.
• Flying debris dents: Branches or hailstones can leave visible marks or cause structural stress.
• Torn flashing: Wind-driven rain may pull away loose flashing at valleys or roof penetrations.

Storm Repair Tips

• Inspect immediately: Don’t wait—check for damage after every major storm.
• Replace bent panels: Dents that break protective coating should be replaced to prevent corrosion.
• Call a pro: If you’re unsure how severe the damage is, a licensed contractor can inspect and recommend a fix.

🤔 When to Repair vs. Replace

Not every issue requires a full replacement, but knowing when repairs aren’t enough is key.

Repair Is Enough When…

• Leaks are localized: One or two problem areas can usually be patched.
• Panels are structurally sound: If there’s no warping or widespread rust, repairs are viable.
• Damage is cosmetic: Minor dents or paint loss don’t require full replacement.

Time for Replacement If…

• Extensive corrosion: Rust spreading across multiple panels may indicate system failure.
• Repeated leaks: If problems keep returning, the underlayment or roof deck could be compromised.
• Old age: After 40–70 years, even the best metal roofs may need full replacement.

🤝 Trust Buckeye State Roofing for Lasting Repairs

Whether you’re dealing with leaks, rust, storm damage, or annoying roof noises, catching these issues early makes metal roof repair faster and more affordable. At Buckeye State Roofing, we’ve built a reputation for trustworthy, high-quality work across Ohio. Our expert team understands the unique needs of metal roofing systems and delivers timely, honest solutions every time.

Don’t wait for a small issue to grow into an expensive problem. Contact Buckeye State Roofing today for a free inspection and get the peace of mind your home deserves.