Repairing Rust Holes on a Corrugated Roof

Corrugated metal roofing is made of with aluminum, galvanized steel and occasionally copper. Although these metals are designed not to rust even after extended exposure, rust sometimes develops anyway. Rust often forms at locations where the metal is damaged, thus breaking the protective outer coating. If it's not repaired, the rust can eat a hole through the entire metal sheet. Repair rust holes by patching them with a special compound and a mesh.

Ladder
Wire brush
Urethane roof cement
Plastic putty knife
Acrylic mesh
Scissors

Instructions

- 1
  Access the corrugated roof panel by placing a ladder next to the roof and climbing up.
- 2
  Scrape the rusted hole area vigorously with a wire brush to dislodge the rust. Continue scrubbing until you see new shiny metal emerge from the brown or red rust spots.
- 3
  Open a bottle or spray can of rust-inhibiting primer and apply a thin 1/4-inch coat over the entire area to saturate it. This substance prevents the rust from continuing to eat through the metal roof panel.
- 4
  Open a urethane roof cement tub and scoop up 1/8 to ¼ cup using a flexible plastic putty knife. Smooth the cement onto the edges of the rust hole, extending it outward at least 1 inch from the actual hole.
- 5
  Cut a piece of acrylic mesh into a square using scissors. Make the mesh square 1 inch longer and wider than the size of the hole in the roof.
- 6
  Place the mesh patch over the hole and press the edges down into the roof cement to hold it in place.
- 7
  Wait one to two hours, until the roof cement dries, so the acrylic mesh patch doesn't move. Apply another coat of roof cement over the mesh to create a watertight seal. Ensure that no portions of the mesh remain exposed and that there are no holes that can allow moisture penetrations.

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