Leaking Metal Roof? 4 Effective Repair Options
Quick Summary: The four options, from least to most comprehensive, are targeted sealant repairs, reinforced tape systems, silicone coating restoration ($3.50–$7.00/sq ft), and spray foam plus silicone ($5.00–$10.00/sq ft).
A leaking commercial metal roof doesn't always require replacement. Here are 4 effective options from least to most comprehensive.
Option 1: Targeted Sealant Repairs
For isolated leaks at specific fasteners or seams, targeted sealant application is the fastest and lowest-cost fix. Clean the area, apply compatible metal roof sealant, and seal the specific failure point. Best for: one or two isolated problems on an otherwise sound system.
Option 2: Reinforced Tape System
Reinforced fabric tape embedded in compatible sealant is used to seal longer seam runs, flashing transitions, and areas with multiple small failures. More comprehensive than point repairs but still targeted. Best for: a section of roof with concentrated failures.
Option 3: Silicone Coating Restoration
A full silicone coating restoration seals the entire roof simultaneously — all fasteners, all seams, all rust spots — under a continuous new waterproof membrane with a 10–20-year renewable warranty.
Best for: roofs with widespread fastener and seam failures across large areas. Cost: $3.50–$7.00/sq ft.
Option 4: Spray Foam Plus Silicone
When insulation improvement is also needed, spray foam applied before the silicone topcoat adds R-6.5 per inch. Best for: metal roofs with both leak and insulation problems, particularly when the building has high energy costs. Cost: $5.00–$10.00/sq ft.
When Replacement Is Required
If the metal panels themselves are structurally compromised — severe corrosion, panel collapse, or structural failure — replacement is necessary. Get a structural assessment before investing in restoration.
Frequently Asked Questions
How much does it cost per square foot to restore a metal roof in Ohio and get it under warranty?
A ballpark cost for a roof coating system over an existing metal roof is $4-$6 per square foot. A ballpark cost for a spray foam roofing system installed over an existing metal roof is $5 - $7 per square foot.
Should I go with a roof coating system or a spray foam roofing system?
It depends on your needs. If you need added insulation, go with spray foam as silicone has no R-value and spray foam has the best R-value per inch of any roofing insulation.
If there's a lot of rust, go with spray foam.
And it depends on the metal profile. If the ribs are deep, go with a coating system. Spray foam may crack if it has to go up and down in such a small area. Plywood into the ribs and then spray foam might be a cost-effective option.
How long of a warranty do you get?
For both coating and foam roofing systems, the warranty is the same:
- For a 10-year warranty, 20 total dry mils of coating are installed
- For a 15-year warranty, 25 total dry mils of coating are installed
- For a 20-year warranty, 30 total dry mils of coating are installed
A spray foam roofing system is protected by installing a silicone coating over the foam.
Metal Roof Restorations in Ohio
Bearing Manufacturing
Location: Strongville, Ohio
Size: 63,950 square feet
Job: Silicone roof coating system over metal
Warranty: 10-years
Completed Date: May 2026
Elyria Ice Rink
Location: Elyria, Ohio
Size: 56,100 square feet
Job: Silicone roof coating system over metal
Warranty: 10-years
Completed Date: August 2025
