Installing a flat roof (PVC single ply roofing membrane in this case) can be a pretty straight forward process, or a very confusing endeavor because each component must be installed in order of events. Otherwise the system my not work the way it should. Of course there is an installation spec manual from IB roofs, which we always keep handy, and actually had to use it once or twice. But this manual only shows particular flashing detail or a general way of how membrane and insulation ought to be installed. It can’t possibly cover all the specifics of the roof installation that come up in the field.

Flat roof installation – mechanically attached assembly:

A reinforce PVC single ply roof allows installers a choice of installing the roof in a fully adhered assembly (sheets of membrane glued to the insulation) or a mechanically attached assembly where each sheet or roll of the roofing material is screwed to the roof deck substrate with heavy duty, corrosion resistant roofing fasteners, and barbed plates. Each roll is screwed to the roof deck on one side, and then the next roll, overlaps a row of screws, and is welded to the first roof, right next to the screws. Then the process continues in the same manner until the whole roof is covered by the membrane.

As you can see in the roof installation picture above the narrow roll of membrane ins installed around roof perimeter and wider rolls are in place, and are ready to be installed. However, before you get to this point, there is a lot of prep work that has to me done first, and the actual membrane installation is the easy part.

Lets start looking at the prep work, and the in which order things actually happen.

Flat roof installation – prep work – insulation, wood nailer and penetration flashing.

PVC Roofing is a very durable and long lasting flat roofing material. However it should never we in direct contact with any oil and asphalt (also oil) products, and since most other roofing materials are made with oil or asphalt, we always install a protection layer between PVC membrane and either old roof or the roof deck. We usually use insulation to protect membrane from being in contact with asphalt and also from deck fastener punctures. Roof insulation also serves its primary purpose of improving thermal insulation properties of your roof.

Before we install insulation though, we first install a perimeter wood nailer, that serves as a rigid nailing base for the PVC-coated drip edge. Once wood nailer is in place, we lay out the insulation sheets and fasten them to the roof deck, using FM Global 60 or 90 mph wind rating standard – 8 or 10 plates + fasteners per 8×4 feet insulation board (although this is unnecessary, since it is a mechanically attached system). Once the wood nailer and insulation are in place we install one or more row of perimeter half sheet, which is a 3 foot wide roll of membrane, vs and standard 6 feet width for field rolls. The perimeter half sheet is installed to prevent wind uplift, and is fastened either 12″ o.c. or 6′ o.c. (for high wind areas).

Flat roofing – tapered insulation:

If there is a ponding water situation, the fastest and most cost-effective way to solve the ponding is to install a so called tapered insulation system which creates slight roof pitch, which helps diver the water in required direction and improves roof drainage.

Tapered insulation is basically the same thing as extruded PolyISO insulation with a fiberglass facing. The only difference is that tapered insulation is wider along one edge and narrower along the other. Tapered insulation system can have a roof slope ranging from 1/8″ per one foot run, to 1/2″ rise per one foot run or more. Normally we use a 1/4″ tapered insulation system which raises roof level 1″ for every 4×4′ insulation piece.

Flat roof installation – drip edge detail:

As we mentioned the perimeter half sheet is installed along roof edges, and fastened on the inside with screws and plates – what is holding the half sheet along its outer edge? Well, this is the question that homeowners often ask me. The way IB PVC roof system is designed, allows us to attach the outer edge either directly to the drip edge or run in over the roof edge by a couple of inches, nail it to the fascia board and install a drip edge metal over the membrane.

Both ways are acceptable, but most of the time we use the second method – especially in high winds area. Once the roofing material is installed and flipped down, over the edge of the roof, we install 10 foot sections of 22 ga PVC coated galvanized or stainless steel drip edge, and fasten it to the deck with the roofing screws, either 12″ or 6″ o.c. Then we weld a 5″ wide cover strip of the membrane to the roof and to the drip edge, to seal the screw holes and bake the whole detail water-tight.

Check out our video on how drip-edge metal is installed:

Once the 10-foot sections of drip-edge are installed, the joins are sealed using an aluminum tape and a PVC patch to mack the joint water-tight and protect the patch from metal expansion and contraction. After the joints are complete, the cover tape is welded to drip edge starter and the roof itself and its now time to do the rest of the roof.

As a side note, there are many options for drip edge detail. Although the most used drip edge is the 2 or 3″ wide face, white starter, you can also choose it to be as much as 8 or more inches wide as well as in gravel stop style (if you need divert water flow or prevent it from going over the edge of the roof.

Gravel stop drip edge has a 1″ bump-out, which stops water from spilling over, and makes it run down the roof – toward a drain or a gutter. Drip edge comes in two colors – white and dark bronze, and also can be painted any other color with acrylic paint. IB roofs also offers 16 oz. copper drip edge, with PVC material adhered to the flange, and can produce any style drip edge, with different angles, kick-in or kick-out face and in various widths.

Flat roof installation – field sheets, roof penetrations and roof to wall termination:

After all edge detail is complete, we install the field rolls of membrane and all penetration flashings, such as pipes, drains, HVAC / Skylight curbs, roof hatches, chimneys, etc.

IB Roof Systems produces wide variety of flashing accessories, which allow installers to quickly easily flash almost any roof penetration. Since all roof components are made of PVC, they are all welded together, and use of any adhesives or glues is completely eliminated, as well as most installation errors by roof mechanics.

All curb and up-the wall flashing is installed using two step process. First, the roof is terminated that the wall, and then a separate piece of membrane is installed up the wall and welded to the roof.

After the flashing is installed and welded to the roof, the inside or outside corner flashing is welded to make a permanent watertight joint.

All IB flashing accessories are made of 60-mil non-reinforced flashing membrane and can stretch to perfectly adhere to any shape of a penetration on the roof. Pipe flashings and drains have a reinforced flange to be welded to the roof.

Bellow is a video demonstrating the curb flashing installation around a skylight:

As you can see in the video, the roof penetration flashing is a very clean process, and a chance of a leak is minimum to non. Unlike flashing details on a rubber roof, where membrane cannot and should not be terminated at the base of the curb, due to high possibility of a leak caused by adhesive failure, the hot air welding process used in sealing overlaps and seams on a PVC roof, eliminates leaks as well as membrane pull-out caused by contraction of the roofing material in a cold weather.

Flat roof installation – special flashing details:

IB roof spec manual does not cover all installation details as in real world you often run into situations where you have to “improvise”, while your roof must still be watertight. One such example is the ridge vent detail on flat / low slope roofs such as shed dormers. While many low slope roofs are considered “flat”, they were built as sloped roofs with ridge / soffit ventilation in mind. However, many roofing contractors that install EPDM rubber roofs, block the ridge vent opening completely, to prevent roof leaks.

We’ve developed a special assembly method which allows us to still use the ridge vent, and keep the roof watertight. We run our roof up-to the ridge opening, weld additional strip of membrane, install a 2×4 wood to raise the level off the roof, flip the strip of membrane back and wrap the 2×4 with it. This prevents wind driven water from penetrating the roof, and ridge vent + ridge cap is installed on top, 2 inches up.

As you can see, IB PVC roof can be adjusted to virtually any type of flat roof, and roof penetrations. We recommend that you check out more roof installation videos on our Roofing Videos channel on YouTube.

You can see more examples of flat roof installations that we have done all over New England: Roofing in Massachusetts and roofs in Connecticut. We provide residential roofing and commercial roof installation services in all New England states. However most of our work takes place in MA, CT and RI.

Also, if you have a flat roof deck, that is leaking, check out our roof deck section, to learn more about IB roof installation on flat roof decks, patios, and balconies, using special slip-proof roofing material called IB DeckShield.

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.

We provide Residential and Commercial roofing services for businesses and home owners, using the best flat roofing material available on the market today – IB Flat Roofing systems – PVC single-ply cool roofing membrane. Any roofing system, no matter how good it is, can leak if installed improperly – that is why we install all our roofs in accordance with IB installation requirements, MA building code, and special attention to details and geographic location of the roofing job.

For example, a roof located near the ocean is more prone to strong wind blow-offs, uplift and wind-driven water leaks. That is why in coastal areas, we double the number of heavy-duty fasteners used to hold down the roofing membrane securely attached to roof deck.

We will treat your roof like it is our own:

Our Moto is ‘to install every roof right, so we won’t have to go back for a service call’. This may sound a bit selfish, but it is the most beneficial for your roof, and for you. Since we match the labor warranty of our installations for the same period as the product warranty, we install every roof to be sure there will be no leaks.

Getting IB roof installed for your home or business in MA:

We will closely work with you or your builder/architect to provide the best long-term roofing solution for you. We invite you to use our interactive roofing cost calculator to get an instant price quote to replace your roof. To schedule roofing project in Massachusetts, fill out the roofing estimate form.

Recent roofing jobs we’ve completed in Massachusetts:

Roofing Massachusetts – a series of mini roof installation reviews, covers a few flat and metal roofs that we’ve recently completed in different cites in Massachusetts – Framingham, Westminster, Hingham, Boston, Wellesley, Wayland. We will update this list as well as publish more roof installation reviews as we get more time to do it. New reviews will include flat and metal roof installations in the following cities:

- Metal Roof in Attleboro, MA – A slate impression steel interlocking shingles metal roof installed on a roof of a single-family home on a quiet street in Attleboro, Mass.

- Metal Roof in Revere, MA

- Standing seam metal roof in Plymouth, MA

- Residential IB traditions roof in Arlington, MA

- A flat roof on apartment building in downtown North Attleboro,  MA

- A roof deck installed in Brighton, MA

- A metal roof installed in Haverhill, MA

Massachusetts roofs installed during Winter 2009:

Flat Roof in Lowell MA – We removed old and leaking EPDM rubber roof, installed new 4″ ISO insulation with 24-r value and a new 50 mil IB PVC flat roofing membrane. Besides the IB roof installation overview, we point out the inherent defects in rubber roofing systems, and why homeowners should avoid installing EPDM roof on their home and dealing with shady roofing contractors “specializing” in rubber roofs.

New flat roofs, installed in August 2009:

Solar Decathlon house with IB flat roof & Solar PV panels: Team Boston (Tufts and BAC) built a solar home with innovative green construction technologies such as: 6.4 KW Solar Photovoltaic system, solar hot water and a Trombe wall – a solar-thermal-mass window/wall systems to compete in 2009 DOE Solar Decathlon. Cool Flat Roofs, together with IB Roof Systems sponsored and installed a 50-mil white IB PVC roofing membrane, with water collection system using IB U-flow drains, and helped the team install the solar PV / solar hot water array.

Old rubber roof replaced with 80-mil IB roof in Boston : The old roof was replace, and extencive brick work on parapet walls was perforemed to ensure highest quality of installation and long-lasting protection for this house in Boston / Roxbury. Roof size was just over 400 sq. ft. and it took 8 days total to install this roof. Read the complete review of this roof installation with many picture and videos.

Flat roof deck in Wellesley, MA: A new construction addition was built and a flat roof deck was installed over a garage roof. We used an 80-mil grey IB roof to ensure permanent water tightness. A new deck will now be installed over sleepers, for which we welded down 2″ wide strips of membrane to protect main roof. Also a prefabricated post flashings were installed over 4×4 railing posts to insure that post would not leak. Roof installation was completed in one day.

Sanding seam metal roof in Wayland:

In the middle a of June 2009, we’ve completed a standing seam metal roof installation. Roof was installed on a residential house in Wayland, Massachusetts. As some may recall, May and June of 2009 had lots of rainy days, so we had to cope with weather as well as many unnoticeable complications which this roofing job has posed for us.

In a nutshell, the roof was constantly subjected to Ice Dam related roof leaks, due lo relatively low roof slope and some heat loss from inside the house, falling ice which would tear off the gutters in the winter and pose danger to people living and visiting the home. One of the most strange things we’ve encountered was the masonry chimney which had a wood frame built around it and stucco installed on the outside, for visual effects. This was actually the first such chimney I’ve seen. Usually stucco is installed right over the chimney, which I though was the case here. Later, after the job was complete, we;ve discovered that the stucco shell of the chimney had cracks in it and was leaking. Where as before such leak would be attributed to old roof, now we could easily pinpoint and eliminate the source of leaks.

You can read more about this project on our roofing blog: Metal roofing in Wayland, MA

Home owner’s remarks after the job was completed and chimney leak eliminated:

Leo,

I did manage to find some time to seal and refinish the chimney. The moment of truth came yesterday when I went into the attic after a long steady rainfall to find the former leak site completely dry. The spot I suspect is at the joint between the concrete cap and the stucco on the front side of the house. There was a crack there that lined up with water flow marks down the side of the chimney. I think the water was able to curl under the cap to that crack and then pass behind the stucco to cause the leak.

I am now very happy to have a completely watertight roof that should stand up to winter ice and snow for a long long time. Thanks again for your work and for the trip you made to assess the leak. With any luck, you won’t hear from me for a long time about the new roof. I wish you and your crew success in your business and in life

Glenn.

EPDM Rubber Roof repair service in Mass.

Rubber roof repair in Massachusetts – we now offer a service to repair your leaking rubber flat roof (EPDM rubber roofing), for a fraction of the cost to install a new IB roof. Although it is usually a better idea to replace the roof as leak damages will only progress and throwing money away or roof repairs that last a short period of time in not economical, it may sometimes make sense to repair a rubber roof if it is only a small flashing that is leaking because of a bad seam, or a failed rubber components.

We can repair corner flashing (inside and outside corners), fix in-field leaking seams  with rubber seam tape, or re-seam the existing seams with 9″ cover tapes, to dramatically extend roof service life.

For these rubber roof repairs we use only the best flashing components such as Carlisle and Firestone peel-stick flashing and cover tapes in 6″, 9″ and even 12″ width – this allows us to be able to repair nearly every type of rubber roof leak, as well as install new flashing around skylights, chimneys and other flat roof penetrations and curbs.

We also do custom copper flashing work when performing a rubber roof repair. As you can see in the picture above, a new copper counter-flashing was installed after a rubber corner patch was applied to the chimney flashing. The couterflashing  was replaced after squirrels chewed and ate the lead flashing that was originally there.

Some of the Flat Roofs in Massachusetts, that we have done recently:

Some of Metal Roofs we have done recently Massachusetts:

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.

Roofing systems we install:

• Flat roofing: IB PVC flat roofing membrane – flat and low-slope roofs and roof decks.
• Metal roofing: Steel and aluminum shingles, Standing seam metal roofs.
• Roof repair: Rubber (EPDM), PVC / TPO membrane and Metal roofs

Roofing estimate and Free Price Quote:

Please complete all fields marked as * To simplify estimating process, we ask that you also email us the photographs of your roof if available: This will help us better asses your roof’s condition and will eliminate extra back & forth emails. Please send roof pictures to: estimate@coolflatroof.com

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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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Roofing Estimate Policy: Please Read.

Examples of our work: A short list of recent roof installations in Massachusetts (both Flat IB roofs and Metal roofing) that we’ve done. See how we work and what you can expect from us, read our customers’ commentary and learn about roof installation process.

Additional information about roofing estimates – quick navigation:

• Roof estimate request form – Fill out the form to schedule an roof inspection / estimate. To get the most accurate online price quote provide as many details about your roof as possible.
• Roof inspection & estimate policy – Please read about our inspection and estimating policy, and how we work to provide you with the lowest roofing cost AND best quality of products and installation.
• Roof Inspections & Repairs – Information for Roofing services for Realtors, Property Managers, Home Buyers, etc.
• For price shoppers: – If you are looking for general flat roof pricing information or “just shopping around” we welcome you to read below or check out our flat roofing price guide .

Roof Repair:

We provide rubber roof repair services in Massachusetts, Connecticut & Rhode Island.

If your rubber roof leaks, we can professionally repair it using the best materials and our expertise in flat roofing. Though roof repair may not always be the best option in some cases it can temporary stop the leak and provide you the necessary time to get the funds and choose the right roofing system and a roofing contractor for your roof replacement.

Here is the what we can do to stop your rubber roof leaks and how much it will cost:

Our rubber roof repair service consists of a roof inspection where we locate the sources of roof leaks, 2 hours of roof repair work, identifying any additional roof problem (eg, ponding water, improper ventilation, water drainage, etc) and providing you with a quote to replace your old roof with a ne IB PVC roofing membrane. Also there will be an average 2 hours of driving to and from the job site.

Cost of rubber roof repair is $350. If we are not able to completely repair your roof in the first one and a half hours, we will provide you with an additional quote for the rest of repair (this would usually be the case with large roofs and multiple roof leaks).

If you know where the leak is but know not how to fix it and want to hire us to do it, we suggest that you use warm water and a rag to clean basic dirt and debris off the suspected roof leak spot. This way, when we arrive to your roof site, we will not spend the time your are paying for, to clean off dirt and will do what we do best – fix roofs. You will get the most bang for your buck.

Roof inspections service:

If you are a Realtor, Property manager or home buyer, etc. and need a quote for a roof replacement OR need an independent expert opinion regarding your roof leaks, or any other type of roof inspection, we offer such inspection services.

In a nutshell, if you are looking to buy or sell a home or a property, or are engaged in a legal action involving roof leaks and need a detailed roof inspection report and estimate to replace the roof, completed by a roof expert, we will gladly provide you with it.

We assume that such inspection report and replacement estimate will be used to negotiate a better price in a real estate transaction or to get better terms in a legal action, and solely for that purpose. Therefore we have a mandatory $399 roof inspection and report fee. This includes on average 2 hours of driving to the roof site, 1-2 hours of thorough roof inspection and 1-2 hour of preparing the roof report, thus we believe that the $399 roof inspection fee is more than fair, when you will on average gain thousands of dollars using our expert report.

Please refer to our Flat Roofing Services section for more information and pricing

If you are looking for the lowest price roof, stop!

We want to work with educated home and business owners who are looking for the best flat roof available on the market. If the main criterion for you is the cost, we probably would not be the best roofing company for you. We do not compete with other roofers on price, so if that is the deciding factor, we recommend that you contact your local home-improvement or roofing company.

We provide our customers with the best materials, installation and customer service at a reasonable cost. So if you want to have the longest-lasting, energy efficient roof, than you are our kind of customer, and we want your business.

We recommend that you use our interactive roofing price calculator to estimate approximate cost of your re-roofing project, compare prices to other common flat roofing systems, and also get an idea of energy costs savings you can enjoy by getting an IB Flat Roof

Are you located outside of New England?

We are a Massachusetts based roofing company and we do not provide roofing services outside of New England area – we only service states of MA, RI, CT, NH, and in some cases Maine and Vermont. We also do not sell IB roofing material.

If you are located in any other state, we will refer you to our affiliates – a certified IB Roof installer near you. You may also refer to our IB Roof Installers directory. There you will find a certified IB installer in your area, which would be able to show you the product and answer any questions you may still have about IB Roof.