July 25, 2023



OOPS – Accidents and Mistakes…Happen


From transportation and delivery, to unloading and installation, your new metal roof will be exposed to multiple environments that could cause minimal to major damage. Metal roof panels serve as a protective shield against external elements, keeping buildings insulated and secure. However, over time, these panels may sustain damage due to weather conditions, impact, or general wear and tear. Repairing or replacing damaged metal roof panels is essential to maintaining the integrity of your roof and preventing further damage. Below are some common processes for repairing damaged metal roof panels.

Types of Metal Roof Panels

There are several types of metal roof panels available in the market with unique characteristics and installation requirements. Some of the most popular metal roof panels include standing seam, corrugated, and ribbed panels. Before repairing a damaged roof panel, it is essential to identify the panel type to ensure that the repair process is appropriate for that panel.


The first step in repairing a damaged metal roof panel is to inspect the entire roof to identify any other areas that may require repair. The inspection should include checking for loose or missing fasteners, rusted or corroded panels, and any signs of water damage. Once the inspection is complete, the next step is to reach out to the manufacturer of the metal panel to request guidance and/or literature addressing the damage to your roof panels.

Installation Damage Photos

Crease and Fractured                                                 Bent over and Fractured

The creased panels are caused by improper handling while unloading or moving a stack of panels – bouncing the load. The bent vertical seam is caused by lowering a snorkel lift onto the roof.

Repair Process

The repair process for a damaged metal roof will depend on the extent of the damage. If the damage is minor, such as a crooked screw, missing sealant, or even bullet holes, the roof can be repaired with simple inexpensive techniques. However, if the damage is severe, such as a large hole or tear, it may require an entire panel replacement or a material-compatible patch, which is a short panel that is installed into the roof (usually only done at the eave or ridge). For system installation problems, such as the panels being out-of-plane or square, multiple points of fixity, or clip issuer and seam problems, replacing multiple panels may be the only option. For warranted roof systems – full panel replacement may be required to maintain the warranty.

  1. Start with a roof inspection – self-performed or hire a qualified inspector. Take notes and take photos. When communicating with the manufacturer or contractor the photos will prevent a lot of confusion
  2. Next, contact the roof panel manufacturer for repair instructions, manuals, and any additional support they offer.


Screws Driven Through Vertical Seam- A new panel will be required.
Fasteners Overdriven, Washers Damaged- New screws required to prevent leaks.
  1. Assemble the appropriate tools and materials needed to make the repairs. We also suggest including materials to protect the roof from scratches, dents, and marring by foot traffic. As always, safety first – make sure to include the equipment needed for safely working on a roof. The same is to be required if a contractor is doing the repairs.
  2. Make the required repairs – this may range from screw replacement to panel patches or replacement, and everything in between.
Treated wood in contact with panels.
Plastic equipment support base.

Water leaches chemicals from the treated wood. The plastic base traps moisture against causing chemical reactions and corrosion. the panel causing accelerated corrosion.

  1. Remove everything from the roof and document the repairs with photographs.


In a perfect world you will only be performing a casual visual inspection of your metal roof twice a year for the next 60 years. Some important things to look for during your visual inspection include open screw holes, screws that are not seated snugly to the panel, dents, scratches, debris on the roof, algae on the panels, clogged gutters, or ANY type of corrosion. Each of those should be addressed when you find them on your roof panels.

Additional Notes

Paint fades with time and ultra-violet exposure. Unless you are repairing a brand-new roof, a roof patch or original touch-up paint will not match the aged panels. We suggest making a visit to your local paint supplier with a small sample of your roof panel. They will be able to assess the aged color and suggest a new color for the best possible color match.

Once rust has formed on your metal roof, it does not stop when it is covered. The corrosion will continue under the paint until it resurfaces, but it is important to clean, scrub, and wire brush it, before putting any paint over it. Contact your panel manufacturer for tips and instructions on how to address this problem.

If making the repairs yourself, keep in mind that sealants are likely to be an essential part of the repair process. Do not skimp on the quality of the sealant. We suggest that you get the manufacturer’s recommended type of sealant and always remember that surface-applied sealant is a short-term solution. When applying sealant, it should always be installed between two pieces of metal and secured with long-life fasteners to keep the sealant in compression.

Metal Minutes Podcast

Check out the Metal Minutes Podcast to stay up to date on news and learn more about frequently asked questions!

Find a sales representative