Many homes have an outside deck / patio over a living space, and so far, the solution to waterproof such roof decks was to install rubber membrane roof and a wooden deck on slippers over the rubber. On some older roofs, instead of a rubber roof, a Tar / Built-up roofing material is used for waterproofing. Problems with this assembly is first and foremost the roof leaks which often occur within few years of roof deck installation.

Often the seams on the roofing membrane pop open, or water starts to pool under the deck, and the only way for this water to drain is into your home. If you need to repair such roof deck, you will have to take the deck completely apart to seal the seams or redo the roof flashing, and then put the wooden deck back together.

Another issue is the cost of such roof deck (even without the high costs associated with roof repairs) – the rubber roof by itself is somewhat not expensive, but when you add the cost of a pressure treated wood deck (a fiber decking, mahogany or some other premium deck is rather rare, and most people do choose to go with PT wood), your roof deck ends up costing you a small fortune. Then you also have to install and seal the railing posts.

On a rubber roof, pieces of uncured flashing must be glued to the rubber roof and the post to make the post penetration watertight, and on a Tar / BUR roof, liquid tar or roof cement is used to seal around the post. Both rubber roof flashing and tar flashing around the post will begin to fail after 5-7 years, so once again to stop the roof leaks, you will have to disassemble the deck and repair the flashing.

IB Deck Shield – the long lasting, beautiful and cost effective solution for roof decks

IB Roof Systems saw the need for a long-lasting waterproofing membrane for roof decks, patios and balconies, and based an their excellent PVC roofing membrane, created a Deck Roofing product which will last for decades, is easy to repair (if such need arises) and has a special, slip-resistant, beautiful surface which make it possible to walk on this membrane, eliminating the need for a wooden deck over the membrane and making the whole roof seamless and watertight.

IB Deck Shield was created based on IB Roofs’ proven PVC roofing membrane, designed for flat roofs, and featuring hot air welded seams, which make membrane overlaps sealed permanently, ensuring long-lasting watertight roof. IB roofing membrane can withstand ponding water, and is an excellent choice for any flat roof. IB roofs also have a complete line of flashing accessories – inside and outside corner flashings, pipe flashing ranging in size from 1/4″ to over 12 inches, for extra wide exhaust pipes and furnace stacks. Because of fast and easy installation in all tight spots, any roof penetration can be flashed quickly and any installation defects are eliminated.

IB took it’s existing it’s existing PVC roof product (IB Flat Roof), and added a special surface to it, making it slip resistant, even when wet, and added a beautiful texture, which resembles small pebble surface often used as a swimming pool deck. All components of IB Deck Shield roof are color matching and will produce a uniform, great-looking final product.

IB Deck Shield roof installation:

Because IB Deck Shield is exposed to constant foot traffic, deck furniture, outside BBQ grills, etc., it must withstand all this abuse and last for many years without any leaks. To be able to do so, IB deck Shield is installed over a dense, moisture resistant substrate – DensDeck, which is attached to the roof deck.

Once DensDeck substrate is installed, all seams are taped and “plastered” with special joint compound to provide a universal, smooth surface, to which Deck Shield membrane is glued using either a water-based or solvent based adhesive (we use water based glue, as it is environmentally “safer” than solvent based product).

When a a joint compound cures, we apply a layer of IB water-based adhesive and lay down the IB Deck Shield membrane, which was previously aligned to be wrinkles free and to have exactly a 2″ overlap with the previous sheet of membrane. Once adhesive is applied and membrane is laid down, it is mechanically fastened at all roof to wall connections, but never in field.

After a few minutes, when adhesive cures, all seams are welded and it’s time to install roof to wall flashing as well as all pre-fabbed inside / outside corners, as well as flash all post penetrations. IB Roof manufactures special post flashings which can either be pre-welded or split and it is the choice of a contractor which one to use.

We prefer to use split post flashings – although the split post flashing requires more welding, it is actually easier to install split flashing rather then a welded flashing, because when we order them, we specify the post size – usually 3 5/8″ x 3 5/8″ (a standard 4×4′ railing post), and a welded flashing sits pretty tight around the post so it is rather difficult to pull it all the way down.

Durability of IB DeckShield flat roof decks:

Once all DensDeck is installed, all DeckShield is glued down, seams welded and all flashings are installed, the roof is complete, and now you have a durable, completely water-tight roof deck, where you can spend nice summer days, invite your friends over for BBQ, and not worry about roof leaks any more. IB DeckShield is VERY durable, and very resistant to puncture damage. Because it is glued to the DensDeck substrate, the surface under it is very hard and most sharp objects that fall on this roof will bounce off leaving very little or no damage – we accidentally dropped sharp tin snips, that just bounce off and did not cause any damage.

Of course you want to be careful with your new roof and not drop any sharp objects purposely, but small accidents do happen, and you can be confident that IB DeckShield will withstand all normal wear and tear – foot traffic and most accidental drops, which would usually puncture a flat roof such as rubber roofs.

If your roof is damaged – in most cases it should be leaking for a long time, as membrane is glued to the substrate and even if some water gits in, it won’t be able to spread and leak inside your home. It is also very easy repair IB Deck Shield roof – a small patch of color-matching membrane will be welded over damaged area, making the repair virtually invisible, unless looked at from close distance. IB DeckShield roof will remain weldable for decades, just like other IB Flat roofing products.

Roof deck prices – how much does IB DeckShield cost to install?

IB DeckShield is a premium flat roofing product and is rather expensive by itself. However, when you consider the alternative of a rubber roof with a PT wooden deck over it, IB DeckShield will usually be less expensive, as PT wood deck will add a significant amount to the total roof deck cost.

Because IB DeckShield installation is rather complicated and involved, it will cost more than the flat roof prices provided by our roofing calculator. IB Deck Shield takes considerably longer to install than regular IB flat roofs, and costs a lot more than standard 50-mil or even 80-mil IB roofing membrane. Therefore installation prices per sq. ft. of your roof deck will be higher than those of an 80 mil roof deck option (eg. flat roof deck in Wellesley, MA)

Price of IB Deck Shield installation will also depend or roof difficulty, number of roof penetrations and whether the existing roof needs to be removed. In case of a roof removal, the roof deck must be installed in sections, and sealed at the end of each work day, to prevent roof leaks from overnight rains.

IB Roof Deck prices:

A basic price to install IB DeckShield starts at $14-15 per sq. ft. (assuming that your roof deck is approximately 200-300 sq. ft., which is what most roof decks are), and includes a 1/4″ DensDeck Substrate, with all joints sealed using joint compound, and up to 5 post flashing penetrations. All other flashing and penetration details will be priced assuming other aspects of your roof, and the entire project.

Roof tear-off will be priced in a range of $300+ per 100 sq. ft. of roof area, plus cost of the dumpster. Reason for this price structure is as follows: Roof decks are usually rather small, but the tear off greatly intensifies the installation difficulty and slows down the overall process. Also, we separate dumpster fees, as on a small roof we would still need the smallest (10 or 15 yards) dumpster which costs about $300.

To give you and example – it took us about 5 days to complete the roof in the first picture on this page, with 4-5 guys working 8-10 hours per day. The roof size there is approximately 1200 sq. ft. So assume that 4-5 guys removed and installed about 240 sq. ft. of roof in 1 day.

The pricing above is approximate and reflects general price stricture that we use fordeck roofs installation in Massachusetts and the rest of New England states (Roofs in CT, RI, NH, ME and VT).

We will price each roof deck separately, but this will provide you with a pretty accurate pricing guide-lines, so you would know how much to expect to pay for IB DeckShield roof.

As a comparison, a rubber roof would cost you $8-10 per sq. ft. plus the cost of PT wooden deck which can range from $13-20 per sq. ft., often without the material costs.

Additional roof decks and flat roofing resources:

Roof deck installation using 80-mil IB PVC roof with a wooden deck over it.

RoofDecks.org – general information about roofing materials, roof deck prices and installation methods of waterproofing products for roof decks, balconies and patios.

Flat Roofing – informational resource about flat roofing materials – Learn about EPDM Rubber roofing, PVC and TPO roofs and Tar & Gravel, Modified Bitumen and other Built-Up roofs.

Roof calculator – estimate roofing prices in your state for different roofing materials – asphalt shingles, metal roofs, and various flat roofing membranes. Learn how contractors price their roofs and pros & cons different roofing materials. Find out how to measure and estimate a roof using extensive step-by-step roof estimating guide and roofing calculator software.

Cool Roofing Blog – Our official blog were we post our roof installation reports, new roofing and green building products and technology reviews, metal roofing system comparisons, IB Roof installation tutorial, Roof Do-it-yourself guides and our customers’ comments about our work. Experience what a cool roof installation is like, and how we would install your roof.

Roof Learning Center provides helpful roofing guides for Do It Yourself enthusiasts. Features educational roofing articles that address common roofing problems including Ice Dam build up, failing shingles, valley roof leaks, and roof repair articles. Find out thing you should know when choosing a roofing contractor.

Flat Roofing Guide:

IB Flat Roofs – IB PVC single-ply membrane roofing – Products, Installation methods, system component and benefits of installing IB Cool roof.

Flat roofing prices – Detailed guide into the price-structure of flat roof installation. Discover why there is such a discrepancy in pricing from different roofing contractors bidding on the same roofing job. Learn the consequences of hiring the lowest-bidding roofing company that does not carry any insurance and does not stand behind their work.

Flat Roofing technology guide – Overview of different flat roofing products and systems present on the market today and installed on flat roofs throughout New England and US.

Roofing cost calculator – Calculate the cost to install an new IB roofing system and get instant quotes for other flat roof types such as Epdm rubber, Tar and Gravel and built-up roofs. You will also be able to estimate approximate annual energy savings that you will receive if you install a cool white IB single ply roof.

Roof Repair Guide – When a flat roof leaks, it is advisable to know all your options and what to expect from temporary flat roof fixes. This flat roofing repair guide outline the possible scenarios and cost involved in patching of flat roof as compared to a complete replacement.

Rubber roof repair – DIY guide to fixing rubber (EPDM) roof systems.

Tar&Gravel roof repair – DIY guide to fixing Tar & Gravel / Built-Up roof systems.

Single-Ply Roofs – Brief overview of different single ply roofing membrane technologies such as PVC (Poly-Vinyl Chloride) or CPA (Co-polymer alloy) – chemically IB’s CPA is equivalent to PVC, Epdm rubber and TPO (thermoplastic olefin roof)

PVC vs. TPO roofing – Detailed comparison of major differences between seemingly identical PVC and TPO membranes. Here we discuss the major issue of TPO’s curing after just a few years in service and its consequential inability to be welded, once membrane is cured.

Green Flat Roofing – Green roof benefits for urban heat-island effect, design and costs guide.

Flat Roofing Insulation – Recycled Insulation, ISO, Styrofoam and EPS insulation technologies.

Flat Roofing Deck – Overview of roof deck waterproofing products, leak elimination and installation methods. Choose between IB DeckShield and conventional install using 80-mil IB membrane and wooden deck + railings system

EPDM Rubber Roofing – Overview of flat rubber roofs, contractors installing rubber for residential customers and why homeowners should avoid using rubber as a flat roofing option on their homes.

Our Services, Job Profiles & Contact information:

Connecticut Flat Roofs – Overview of installation, repair and consulting services that we provide in the state of Connecticut to homeowners and businesses. We specialize in Commercial and Residential roof replacement using IB cool roofing technology. Check out the job profiles for the roofs that we installed in CT including picture gallery and a short video clip

Massachusetts Flat Roofs – Installation, repair and consulting services for flat roofing projects in MA. We specialize in Commercial and Residential projects. Also you can view some of flat and Metal Roofing projects that we’ve completed recently. Picture gallery of each roof installation from start to finish.

Flat Roof Installation & Consulting Services

Roofing Estimate Request

Residential Flat Roofing

Commercial Flat Roofing

Contact Us / Information

Job Profiles:

Some of the Flat Roofs we installed:

Asphalt Shingle textured flat roof – This beautiful IB Traditions roof looks like asphalt shingles, yet it will never leak and will provide energy savings for this gorgeous house in Arlington, MA

Residential Flat & Metal roof (New) This house in Old Lyme, CT had a badly-leaking tar and gravel roof which caused rotten plywood and some framing. Now it has a Lifetime 80-mil White IB roof and Tamko metal slate.

Flat roof house 80-mil grey IB roof was installed on this residence in Wallingford, CT.

Industrial Flat Roof – TesTex Corporation manufacturing facility in Central Falls, RI

Restaurant Flat Roof – Deli / Meat market located in the tourist attraction of Hampton Beach, NH

Condominium Flat Roof – Residential condos on the East Side of Providence, RI

Apartment Building with Restaurant / Deli Beautiful brick building in the center of North Attleboro, MA had flat roof leas for years and patching did not help. IB roof solved all the problems!

Flat Metal Roof – Metal roof acrylic coating – Power Generation Plant in Bellingham, MA

Restaurant Metal Roof – Permanent Aluminum Roof on an IHOP restaurant in Hyannis, MA

Stone-Coated Metal Roof – Beautiful Spanish Tile metal roof on Venus De Milo Restaurant / Reception / Wedding Capitol of Rhode Island located in Swansea, MA

Solar Flat Roofing, Solar PV Guide and Rebates:

Solar flat roofs – IB SolarWise – Building-Integrated Solar PV for flat roofing

Solar PV guide – Prices, ROI, system design & installation guide includes cost break-down for residential and commercial solar systems in MA, CT and RI

Solar Rebates / Incentives – Summary of Federal Tax Credits and State rebate programs for Solar PV and other renewable energy installation in MA, CT, RI

Massachusetts Solar Rebates – Overview of all available Rebates & Incentives for Residential, Commercial and Public buildings solar PV systems

Green Construction Directory and eco-friendly resources:

Green Building Directory – Lists Eco-friendly resources, green construction web-sites, green and solar blogs and construction companies that build green building and use energy-saving technologies.

IB Roof Contractors in US and Canada

Green-Living Directory – Sustainability, Eco-Friendly and Renewable links.

DIY Green Home Improvement – List of websites for do-it-yourselfers with the emphasis on green technologies and energy efficiency.

Home Improvement Sites – General home improvement sites with good number of eco-friendly categories.

Metal Roofing Directory – List of manufacturers and contractors specializing Cool, Recyclable and Permanent Steel, Aluminum and Copper metal roofs.

Suppliers of Metal products – Metal Buildings, Specialty metals suppliers and manufacturers

Energy Efficient Siding and Windows – Manufacturers, Distributes and Contractors installing energy-saving Wood, Aluminum and Vinyl Windows and Siding.

Green home & garden

Roofing Contractor / Manufacturers

Uncategorized / Coming Soon pages:

IB Flat Roof Warranty

Solar PV Price Calculator – Interactive tool to estimate the cost of installing Solar PV for your home or business

IB SolarWise Pay-off / ROI guide

If you live in Massachusetts and your rubber roof leaks, you can also hire us to professionally repair your EPDM Rubber Roof – fill out the Roof Repair Request form bellow. We will also provide you with an estimate to replace your old rubber roof with Lifetime IB PVC roofing membrane. We provide our rubber roof repair service for a very reasonable fee of $350, which includes 2 hours of repair work as well as high quality, peel-and-stick Rubber Roof flashing materials made by best names in the EPDM roofing industry – Firestone and Carlisle.

We recommend that you also read our guide to residential flat rubber roofing, which describes why your roof could be leaking, how most residential roofing contractors get into flat roof installations, their “training and experience” background and most importantly why you should avoid installing another EPDM rubber roof on your house.

If you are unsure if you are better off fixing your rubber roof yourself or hiring a roofing contractor like us – read our guide DIY rubber roof vs. hiring a roofing contractor. This article will explain advantages of both options as well as show you how much it costs to buy EPDM flashing materials, adhesives and required tools as well as describe step-by-step process of rubber roof repair using newer peel-and-stick EPDM flashing materials.

Rubber roof repair services in Massachusetts fill out form bellow or call: 617-444-9020

Roof repair service cost – $350 flat fee for first 2 hours of roof repair work, including peel-and-stick rubber flashing materials. Any work after initial 2 hours will be discussed and priced accordingly.

Find out more about our Rubber Roof Repair in MA – prices on projects over 2 hours, materials used, geographic area which we cover and warranty information.

We want you to also be aware that rubber roof repair can (should) be performed when the outside temperature is above 40 F. Otherwise the EPDM glue and/or primer will ether freeze or will not apply properly. In some cases contractors will keep the adhesives warm inside their trucks, and only take it out right before they actually use it. While this method somewhat works, we do not recommend it, as such repair can fail prematurely.

Rubber roof repair request form:

Name:	*
Address:
City:	*
State:	Massachusetts Connecticut Rhode Island New Hampshire Maine Vermont Other
Zip:	*
Phone:	*
E-Mail:	*
	Please describe your roof, leak problems (e.g. near skylight or at the roof-to-wall flashing, etc), and any additional information that would help us better prepare for your roof repair.
Roof Details:

You can also request an estimate to replace your existing roof. Select one or more products. You can select multiple products by clicking on multiple boxes.

IB Standard Membrane: IB 50-mil White IB 80-mil White/Color IB 80-mil ChemGuard

IB Specialty Membrane: IB DeckShield IB Tradition Classics IB Solar PV Roof

Other Roofing products: Metal Roofing (Standing seam, Steel or Aluminum Metal shingles) Thermo White Spray-On Roofs (For steel standing seam)

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DIY rubber roof repair guide – learn how to fix rubber roof using black rubber glue.

This do-it-yourself rubber roof repair guide will walk you through a simple rubber roof seam patching process, using old rubber glue. Please note, that due to accelerated “black rubber glue” failures, EPDM industry has switched to newer and better Peel-and-Stick method of gluing the seams between rubber membrane and flashing material. Peel-and-stick method uses special flashing material and a so called “rubber primer”, which gets tacky faster than rubber glue and hold the seams better and longer. Still, even the seams “glued” together using the newer peel-and-stick plashing method, will fail after about 7-10 years. After that period, most EPDM rubber roofs will require some kind of roof repair and in some cases complete “re-seam” job. Re-seam repair means that all seams are covered with a peel-and-stick cover tape of 6-12″ in width. This will usually buy you another 3-5 years of roof life, after which you will have to repair it again.

Therefore we recommend that instead of installing (or in some cases even repairing) the rubber roof, you install a new, Lifetime IB PVC Roofing system, which is installed using hot-air welded seams instead of being glued together. Once IB roof seams are welded, you cannot pull them apart without tearing the membrane itself.

This ‘Rubber Roof Do-It-Yourself repair guide’ is intended to give you the basic knowledge of how to
repair a flat rubber roof. However, such repairs are NOT considered DIY projects by the roofing industry professionals, and we recommend you to seek help with your roof repair from a professional roofing company specializing in Flat Roofing. If you are located in Massachusetts, Connecticut or Rhode Island, you can contact us by filling out Free Roof Estimate Request form, and we will provide you information and options to solve your roof leaks problems.

Rubber or Epdm roofs came to existence in 1960′s and since then, billions of sq. feet of rubber roofs have been installed all over United States. Rubber roofs are probably the Most used flat roofing technology, mainly due to its Very Low cost. Epdm roofs are very cheap to produce, so most commercial roofing manufacturers jumped the band-wagon and started making them in mass quantities. While Epdm rubber-like membranes are very common, so are the roof leaks associated with them.

Epdm membranes themselves are a decent roofing product, hence most of them carry warranties that range from 30 to 40 years. However, those warranties ONLY cover the membrane itself, which unless is physically damaged, will usually remain intact through it’s service life.

However, the long warranties of Epdm DO NOT cover the cause of 99% of all flat roof leaks – the seams between sheets of membrane. Seams are the inherited flaw and a weakness of not only Epdm rubber roofs, but most other flat roofing technologies available today. Seams are put together with adhesives, and lately with peel-&-stick tapes, which after some time on the roof just comes apart, and the roof starts to leak. Unfortunately there is nothing that can be done to prolong the life of seam adhesives, and the only two options to deal with leaks are: Repair or Replace

Rubber roof repair How-To in 4 steps.

Note: Do not attempt to repair you rubber roof if the outside temperature is below 35-40 degrees, as it might be too cold for the adhesive to dry properly. Consult the sales people at the roofing supply warehouse listed below. Also request installation documents for adhesives and/or seam tape that you will need to purchase. These document will give you exact application requirements and directions.

Step 1: Locate the source of leaks

Tools you will need: Ladder, Paint-Brushes, Rubber gloves, Seams Probe Tool and Silicone hand roller. These tools can be purchased from the roofing supply warehouse like Bradco Supply or Harveys Industry or from a local lumber yard. We recommend getting the brushes from the roofing warehouse, to make sure it is compatible with the adhesive and cleaning solution. Home Depot and Lowe’s will probably not
have the hand roller on the probe tool, but you can find something similar there. They will certainly have ladders, and will usually have a better price on them.

You will also need the solvent-based cleaning solution for seams and Epdm seam adhesive and/or seam tape. These should be purchase from the roofing warehouse. Home-Improvement stores do not have what you need.

Caution: Do not use ‘Ice&Water tape’ – you should only use the seam tape made for Epdm rubber roofs.

Seam Probe Tool

2″ Silicone Hand Roller

As we stated previously, most of flat roof leaks occur at the seams, so we you will need to inspect all seams on your rubber roof. Once you acquired the needed tools and supplies, you will need to find the source of leaks. To locate the leak in your rubber roof, you will need to actually get on the roof and with a simple probe-tool check all the seams to find the place where adhesive no longer holds the membrane together. Also check all roof penetrations (Pipes, Vents, etc.) and curbs such as Sky-lights and HVAC units. Mark the spots where the seams are broken.

If you have loose gravel on the roof, you’ll need to sweep it off the seams with a heavy broom, so it is not in your way. Do not use shovels or any thing that has metal edges as you may cause additional damage to the membrane.

Step 2: Prepare your roof for repair

Now that you’ve located the source of your roof leaks, you need to clean the surface of the rubber, so you can apply the adhesive and/or seam tape. With cloth and warm water, thoroughly wash off as much dirt as you can and let it dry. Do not use gasoline to clean the rubber membrane. Although many installers will tell you it is safe – any manufacturer’s warranty prohibits cleaning epdm rubber with gasoline.

I’ve found a rubbing alcohol to be a good and inexpensive solution. There are also cleaners available from the manufacturer, and these are the best to use, but they are expensive and only come in 1 gallon cans. So if you have a very small area to clean, get the rubbing alcohol.

Once the roof surface is clean and dry, pull the seams apart about 1 foot away from the location of the leak. According to manufacturer’s directions, thoroughly clean seams with the cleaning solution, making sure you remove all existing adhesive and let it dry. The procedure may have to be repeated.

This and next steps are MOST crucial to the quality of the repair and elimination of the future leaks.

Step 3: Applying Adhesive and/or Seam Tape

Use the brush to apply the adhesive to both surfaces of the seams. Try to get the adhesive as deed as you can under the top sheet of membrane (6-8 inch wide seams a recommended). Also thoroughly apply adhesive to ‘corners’ – where you pulled seams apart and the new adhesive comes in contact with the old one.

Once you’ve applied adhesive, put the seams together and use the silicone roller to apply pressure to the seams. This will ensure a quality seam repair. Let the new seams completely dry. Do not attempt to test them with the probe tool just yet. Wait 24 hours until the next step.

Step 4: Testing the seams and applying the Seam Tape

Now your newly-repair seams should be dry and ready to be tested. Use the seam probe to test all seams that you have repaired. If you followed the previous directions and used the silicone roller, your seams should be like new, and the probe should not be able to split the seams. If you do find imperfect adhesive bond, repeat Step 3 by reapplying the adhesive and using the silicone roller to apply pressure.

At this stage, we recommend to also use the seam tape to further ensure quality of your repair job and extend the length of time which the repair will last. Apply the seam tape with the silicone roller, extending it by 1 foot in each direction from the end of your seam repair. Use the edge of the silicone roller to make sure there is good adhesion where there is a slight elevation change from one sheet of rubber to another. If your seams job was done well, there is no need to test the seam tape. You are now done!

Conclusion

Now that you have done the seams repair, you eliminated the leaks. However, even when done by a professional, such repair job usually lasts up-to one year. Sometimes as little as only 6 month. There are many factors affecting the length of the rubber roof repair.

To name a few:

• The quality of the repair itself
• Presence of ponding water (which will greatly reduce the length that such repair will last)
• Moisture and condensation trapped under the rubber will also speed up the occurrence of more leaks

There are many more reasons why your roof may and probably will begin to leak again. Check out our Flat Roof Repair Guide for more info regarding the causes of leaks and what to do when they happen.

To minimize your Costs associated with flat roof repair we recommend you to contact us to get IB Cool Roof. IB Roofs differ from the regular rubber roofs in the way the seams are
attached together. IB PVC roofing system uses Hot-Air fusion welding process, to permanently attach the seams together. With IB roof, you will never face the same problems associated with the rubber roofs, hence, to need to repair, unless there is some sort of physical damage puncture through the membrane. But even in case of such damage, repair is as easy as welding a patch over the damaged area – no need to use solvent cleaners and adhesives.

To back up its products, IB Roof Systems is the only roofing manufacturer to offers the Lifetime Residential Warranty. IB roof can also be upgraded with IB SolarWise BI-PV – the only Fully Integrated Solar PV system available for flat roofing Homes and Commercial buildings.

Disclaimer: This ‘Rubber Roof repair guide’ is intended for informational and reference purposes only. We do not recommend implicitly or explicitly, to anyone, performing any of the procedures described in this guide. We are also not responsible for any property damage or personal injuries resulting from following this informational guide.

Copyright © CoolFlatRoof.com – 2006-2008. All rights reserved. Reproduction of the content of this guide is against the law. You may only place direct URL link to this guide.

Complete roof replacement is highly recommended to avoid / prevent the ‘sunk cost’ – costs that have been incurred and which cannot be recovered to any significant degree (or simply – waste your money). An analogy can be drawn with an old car, where you keep on fixing small thing, one after another, until something major breaks, and all the money put into fixing it, are lost.

Before you begin – getting tools, supplies and materials

These can be purchased at your local roofer’s supply warehouse, lumber yard, Home Depot or Lowe’s. Roofer’s warehouse is a preferred place to buy your supplies, as they’ll have the best selection and knowledge of products you’ll need.

Try Bradco Supply, ABC roofing supply, Beacon supply or Harvey Industries (in New England only). These are all either regional or national roofing supply warehouse, and they usually stock everything you may need, and also have somewhat knowledgeable staff, to answer some of your question.

These are the places where most roofing contractors shop, so you should be able to find what you need!

Tar & Gravel flat roof in Lynn, MA

Tools you will need:

1. Utility knife with a few spare blades
2. A bucket (or two) of tar
3. Asphalt saturated fabric (cotton or fiberglass, it doesn’t matter too much)
4. Plastic trowel for spreading the tar
5. Few dry towels / rags.

Finding the leak

This is the essential step in patching of the roof. The nature of flat roof leaks makes it difficult to identify the spot where the water is coming in, since it may ‘travel’ under the roofing membrane until it finds the lowest spot, and only then you see the stains on your ceilings.

Easiest way to find a leak is to start at the lowest spot, where the water may be collecting and sitting for days after each rain – this is called ponding water, and it is one of the most common leak spots. You will need to shovel off the loose gravel to the high spot and clear at least about 100 sq. ft of roof area. If you have ponding water under gravel, you can use old clothes / rags and a dust pan to put it in a bucket and get it off the roof.

Now it’s time to do some repairs – a 10 steps process:

1 ) Once the area is clear of water and dry, look for blisters, cracks and openings in the tar, or other signs of water entering spots.

2 ) Cut out the blisters with the utility knife – make a large ‘X’ cut & pull it back a little. Let it dry out, then open up the cracks and let them dry out also.

3 ) When everything is dry, use a plastic trowel to apply a thick layer of tar under the area you cut and set the sliced portions of the roof back in the tar.

4 ) Use the towels to clean up the area under the X. Sweep away all dust and dirt under, over and around the cut area. This will greatly improve the quality of your repair.

5 ) Now spread an even coat of tar over the patched area approx 1/8 inch thick or a little more, so that it goes at least 6 inches beyond the repair area.

6 ) Cut out a piece of fabric that would be enough to cover the repair area and place the piece of fabric in the tar. Use the trowel to set it in, so that the fabric gets saturated with the tar until you see it coming through the fabric.

7 ) Apply another thin and smooth coat of tar over the fabric and beyond its edges.

8 ) Feather the edges into the old roof.

9 ) Put back the gravel with your hands, over the repaired area – make sure you do not use a push-broom, as that will disturb your new patch. This gravel will protect the repair from the devastating sun light.

10 ) This is a 3 course tar and fabric patch. Add another layer of fabric then tar and it is a 5 course.

Afterwards: Roof Repair or Replacement

Bear in mind that this repair will last you about 3-6 months, after which another repair in the same spot will be required, and at the same time more leaks will probably appear elsewhere. The purpose of such repairs is not to get rid of leaks all together, but a temporary stop of leaks, while you gather resources and information to install new roofing systems. Due to nature of tar and gravel roofs, there is no permanent cure for roof leaks, as tar dries up it turns in a ‘dust compound’ which helps de-lamination of the patch from existing tar roof. Therefore, unless you are willing to take the continuous roof leak and repair cycle, which not only have direct repair costs, but also does hidden damage to the structure of your home or building, which in effect will increase your out of pocket costs when you go with full roof replacement.

Also, if you do not feel comfortable performing these repairs yourself, we recommend that you hire a professional roofer specializing in flat roofing – not Joe the shingler that your friend knows. Flat roofs are completely different from regular shingle roofs, and require special training/experience when dealing with them.

What you should do when your flat roof leaks:

First of all put up buckets to collect water, so the leak does not cause more damages than is already done. Once the dripping water is not causing any more damage to the interior, consider the following steps:

Step 1) If your roof is fairly new, call the roofing company that installed it and have them fix it.

Step 2) If it is an older roof, or the original installer will not fix it for some reason, you will have three options – either fix the roof your self, have a repair performed by a roofing contractor, specializing in flat roofs, or if your roof is near the end of its life, it is best to replace it, and not through any more money away, repairing it.

Step 3) To prevent more damages to your roof, interior of your home, or the inventory and the equipment of your business, it is a good idea to put up a tarp on you roof, until you choose a course of action – either fixing a roof your self or choosing a roofing contractor to repair or replace your roof.

Step 4) Estimate real cost to repair flat roof. Learn what’s involved, what hidden costs and fees there are and why we consider flat roof repair to be “sunk cost”. This comparison will help you decide if it is time to finally replace your flat roof, or if repair is a feasible option.

NOTE: If your rubber roof is leaking, we are offering Rubber Roof Repair services in MA, RI and CT, and can usually fix your EPDM rubber roof during first roof inspection / repair visit. Some rubber roofs can be repaired and you can extend the life of your roof by few years, for relatively low price.

DIY Flat Roof Repair guides

Because of wide scope of flat roofing materials and different roof problems that cause leaks, it is virtually impossible to caver everything related to flat roof repair in one article. For your convenience, we have several DIY roof repair guides for specific flat roof type and specific repair methods. This guides are easy to follow and are aimed at both home and business owners.

Identifying and repairing leaky roof:

• Rubber roof repair – our original article about fixing EPDM rubber membrane roofs using “black glue” or rubber seams adhesive.
• EPDM Rubber peel & stick repair – Part II of rubber roof repair guide above, concentrating on the more advanced and more efficient way to fix rubber roofs, using EPDM primer and Peel-n-Stick flashing and Seam tape, instead of just using glue.
• Tar & Gravel roof repair – Learn how to detect and repair leaks in your Built-up or Tar-and-gravel roof, using inexpensive supplies from Home Depot, Lowe’s and other Home improvement stores.

What you should know about Flat Roof Repair, before you spend any money.

Flat roof reality check: Roof leak, is an inevitable outcome for 99% of flat roofs in service today. If you have a flat roof, chances are that it is already leaking or will begin to leak soon – even if your roof is fairly new and was installed within 5-10 years.

This article is an overview of issues related to flat roof leaks. Here we review the cost of flat roof repair, actions you should take to get your flat roof fixed, and outlook of what will happen after your roof is fixed.

Purpose of this Flat Roof Repair Guide, is to help you avoid the costly mistakes many home and business owners make, when their roof leaks, and also to help you choose the best solution for your particular roof and budget.

Note: Due to a wide variety of different flat roofing technologies, this
article cannot cover all aspects of flat roof repair. For specific DIY ways to repair your flat roof, refer to our Epdm or Rubber Roof repair and Tar roof repair How-To articles.

Stop before you waste any more money fixing your flat roof!

Whether your roof just started leaking or the water has been coming in for some time now, we recommend that you stop repairing it, read the article and make the smart choice.

Have you seen ads like this in the Yellow Pages, on the Web or stapled to a light pole?

Home Improvement Contractor

“XYZ Construction Company” proudly offers all services relating to home contracting. This includes, but is not limited to: Roofing, Commercial Roofing, Rubber Roofing, Flat roofing, Roof Repair, Siding, and Deck builders, Gutters, Additions, Dormers and Remodeling. All types of residential roofing – we fix it all!

Here is what happens when you have the “we do it all” roofers fix your flat roof:

As a result of unprofessional flat roof repair, the homeowner had to pay extra for the roof repairs, sheet rock replacement, painting and a deck repair. The longer you let the water to come it, the more repairs the will be.

General purpose roofing and home-improvement companies that offer roof installation and repair services may do a decent job foxing your regular, asphalt shingles roof. But when it comes to a flat roof, these folks, who “DO IT ALL”, will waste your money and your roof will still be leaking.

Why? – Answer is simple: Flat roofs are VERY different from pitched roofs and require professional to install and repair them. You want to work with a roofing contractor that specializes in Flat Roofs, and flat roofs ONLY. There are such contractors, but 99% of them only do commercial work. For residential market, there is not enough business to keep a crew busy with just flat roofing. That is why you see these “do-it-all” establishments.

Another thing to keep in mind is that there are more than a dozen different flat roofing product types which are often incompatible with each other. When a “do-it-all” company comes to fix your flat roof, chances are, they will use a “fix-it-all” solution for any roof – the roof cement. Well, there is a catch – roof cement is not compatible with black rubber (Epdm membrane). Once roof cement hardens, its expansion/contraction ratio is much smaller than that of rubber. As a result, the seal will break after just a few weeks, and your roof will leak yet again. This is just one example among many others.

One more example of neglecting the roof leaks can be seen here – total deterioration of roof deck:

These folks just neglected the fact of roof leaks and now over 25% of their 2×4 tong & grove decking is rotted and has to be replaced.

Do not let the “do-it-all” roofers profit at your expense!

What you need is a professional roofing contractor who specializes in Flat Roofs, and knows it well. You also want this contractor to install a quality flat roofing product with proven track-record.

We are such a contractor. We install just one product and we do it well! Our flat roofing product of choice is IB flat roof – a cool PVC single ply membrane that comes with Lifetime Residential and 25 years Commercial warranty. The performance of IB Roofs is unmatched by any other roof technology or manufacturer. The secret to such a performance is IB’s own formulation and hot-air welded seams that create a permanent bond between separate sheets of membrane.

We specialize in flat roofing installation and repair services for both Commercial flat roofing and Residential flat roofing customers and we know all the aspects of our flat roofing product.

The nature of Flat Roof Leaks

Flat roofs in New England have for decades posed problems for home and building owners. Harsh climate, outdated roofing technology, and very often – standing water, are the major factors affecting the lifetime and performance of flat roofs.

When your roof starts leaking, repair is the first option that comes to mind. Second, you begin to think about the costs of repair, and how to minimize them. Depending on severity of the leak these cost may be just a few hundred dollars, or few thousand of dollars. Here is why: When you begin to see stained ceiling in you bedroom, it is the last stage of the leak. It means that your roof has been leaking for some time now and finally after last heavy rain it showed up on that ceiling. It also means that water had to completely soak the insulation, roof deck and rafters before you could see it on the ceiling. So if you choose the cheapest and most common solution which is patching the flat roof, you will leave behind the moisture trapped under the under your roof. This will cause the rotting of your deck and rafters, since there is no way for that water to escape.

What happens if you ignore roof leaks for some time?

Once a flat roof starts leaking, the inside damages will span from stained ceilings in the best case scenario to thousands of dollars in damages. Falling sheet-rock, electrical system damages, popping hardwoods and destroyed carpets, damaged furniture and home goods; these are only some of the outcomes of those leaks. Patching these leaky roofs may seem like the best solution, and the cheapest way out, but in reality, it usually proves to be the worst solution. Consider the following: the cost of patching the roof + fixing whatever damages the leak caused to the interior. Then, in 3-9 months, depending on the type of roof covering and quality of the patch work (which by the way, no contractor will ever warranty or uphold), your roof starts leaking again -
maybe in the same place, maybe in a different one, but the process is irreversible. Patch is only a temporary fix and usually won’t last, the roof will keep on leaking, and every time you patch it, you through away your money.

Majority of flat roof systems were not ‘designed’ with repairs in mind – best you could do to repair a flat roof was to pour some tar on the leaky spot. In fact, tar was pretty much the only feasible option. Unfortunately, after a short period of time you had to fix it again, as tar would dry up, crack and let the water in. New leaks would form elsewhere. So it was a constant repair, until a new leak begins and more money is spent. Such repairs are a perfect example of sunk costs, which cannot be recovered, and the fix lasts only a short period of time. After a series of such repairs, the owner would get sick & tired of it, and get a ‘new’ roof. Maybe a different type of flat roof, which unfortunately had the same inherited problems as the old one, but carried a different name and was made of different materials. Seems like a very sad situation for somebody with such a roof, doesn’t it?

Many people are faced with a choice to either continue this cycle for the lack of other options, or to build a pitched frame roof with asphalt shingles on top of their flat roof and be done with it. However there are two problems involved here. First one – such an ‘upgrade’ is very costly and you would still have to re-shingle your roof every 12 to 15 years. The second one is more complex. While it might be pretty straight-forward process if you have a small, rectangular house, that is not always the case. Many houses have odd shapes, multiple levels and mixed pitched and flat roofs. Now, if you have a 200′ x 100′ factory, that task becomes extremely difficult to implement, and I will not even try to guess the costs involved.

The REAL cost of a flat roof repair:

Repairing a flat roof in Massachusetts can and often will cost more than you anticipate (In other parts of the country, market conditions may be different, but the following prices should be just about right). Let’s see what goes into the price of flat roof repair.

• First: is the cost of patching a flat roof – you can expect to spend anywhere from $300 to 500 or more. If some one offers you to fix a flat roof leak for less than $300, that person either desperately needs money or in not a Pro, and does not really know what is involved and what to do (unless all that has to be done is to apply s bead of caulking, something you – the homeowner can usually do yourself).
• Cost of interior repairs – fixing wet sheet-rock, painting ceiling, etc, – $250-400. If it’s just a stain on the ceiling, then you could pick up a can of white paint at Lowe’s or Home Depot and do it yourself.

Above, are your direct coats of flat roof repair. Let’s also consider the indirect cost, to which most people don’t
pay attention:

Cost of Your Time. When your roof starts leaking, you don’t usually wait until the weekend to take care of it. You grab a phone book and start calling local roofers, or someone in the trade, whom you know already. You set up earliest time for the roofer to look at it and give you the price. You may get a few more people too look at your roof leak, but since it is more of an emergency, you need to fix it fast. So you give the job to the first reasonable bidder. Unfortunately leaks usually start when it is least convenient – during the week, at night or when you are away. So now you have to take a day off at work to meet with the roofer- thus you use your sick or vacation day. If you make $20/hour, you just lost $160.

Lets do the math. I will be conservative and use the low numbers – so you are looking to spend at least $300+250+160 = $710 in direct and indirect sunk costs which you cannot recover. Keep in mind it is usually won’t be that cheap. You also get what you pay for. And when six month later your flat roof starts leaking again – double that $710.

Bottom line: Flat roof repairs are a waste of money. They last only a short time and are not covered under warranty. If you opt for a more expensive repair such as aluminum powder-based coating form Home Depot, you might face an issue of incompatibility, as well as others. In the end, when you finally decide that you are sick and tired of repairing your flat roof and wasting money, you may have spent as much as it would cost you to get a new IB Flat Roof. This is the what happened in our second Case Study. Replacing a flat roof is what we recommend 99% of the time.

But I cannot afford a new roof now…

Although there are different payment options, new IB Flat roof can be costly, and might not always be able to afford one. When that is the case, we recommend the following steps to minimize costs and aggravation.

• Only hire a roofing contractor – not a handy-man. You need a professional, who knows the aspects of flat roof repair, not a jack-of-all-trades.
• If you are not in a big rush and can wait a day or two, ask your friends and neighbors if they could recommend someone. See if there are flat roof houses nearby, and talk with the owner. They must have encountered a problem with their flat roof in the past.
• Use Angie’s List – people there discuss local service businesses, including roofers. Contractors have no say in what others write there, and cannon buy advertisements.
• Do not use referral services like Quality Smith or Service Magic, as contractors go to them when they cannot find any work – maybe due to bad reputation. Their so-called pre-screening is nothing more than obtaining a copy of Contractor’s License. All these companies really care about is getting paid – not your satisfaction. Contractors pay for these appointments anywhere from $35-75. That is how you get ‘free estimates from 3 contractors’.
• Finally, replace your flat roof as soon as you can afford it. Stop the endless repair cycle once and for all. Choose a new flat roof that you can trust – not the inferior, but cheaper option like Epdm rubber – which most roofers will offer you. For more information on different flat roof choices, visit our guide to Flat Roofing technology and see what your options are.

Do-It-Yourself Flat roof repair articles:

Rubber EPDM roof repair – Procedures involved in repair of Epdm rubber roofs. Solutions that should be use, that those you should avoid.

Tar & Gravel roof repair – Options that you have when you need
your Built-Up Roof fixed.

Single-Ply Flat Roofing – Stop repairing you old flat roof that has exceeded its service life, and wasting your money. Learn about Single-Ply – roofing technology of the future.

IB PVC roof – Finally, there is a solution to the endless repair cycle, and it has been around since 1978 with a proven track record of zero material failure and leak-free service for 30 years.

Case study: how IB roof eliminates a constant repair cycle.

Case One: Home-owner’s struggle with a 1 year old Epdm rubber roof.

In October of 2006 we received a call from a homeowner living on the East Side of Providence. We had just completed a flat roof near the Miriam Hospital, and the person calling us happened to live in the same neighborhood. We scheduled an appointment with them and at the meeting the said that they just had a new roof installed a year ago. However this new roof was leaking like a sieve and they actually had to remove a skylight to get rid of the major leaks. It did not eliminate their problems though, as there were other leaks here and there – mainly around a hot-stack pipe.

After thoroughly examining their roof we came to a conclusion that repairing the roof was not an options as the system installed there was not up to the job. First, due to the roof’s shape, two large puddles of ponding water would form in the center of the roof, including the spot where a badly leaking sky-light once was. The Epdm rubber was not designed to withstand the ponding water accumulating on the roof, and the water was slowly coming inside the house. Second problem was the mentioned above round-shaped hot-stack pipe that was patched a number of times, and was still leaking.

50-mil white IB roof was chosen to replace this nearly new, yet badly-leaking rubber roof. With IB’s pre-made pipe flashings, the leaks around hot stack pipe were eliminated. The ponding water was no longer an issue, as hot-air welded seams created a permanent, water-tight protection for this roof. The cool roof properties also made this house more energy-efficient than before. In the end, the customer finally eliminated all their roofing headaches and is now covered by the best roof and the best life-time residential warranty. You can find more photographs of this roof here: Flat roof in Providence, RI.