A system solution for sealing a metal roof

Construction of a tight membrane to prevent roof leaks

Using the example of a roof covered with trapezoidal aluminum sheet, we will show how to create a tight membrane to prevent leaks.

As you can see, the roof was in poor condition. It had been patched with strips of roofing felt, which didn't adhere well and didn't provide a seal. The roof also leaked at mechanical fasteners, flashings, and vents.

Replacing such a roof is a large and expensive undertaking. To avoid this, we proposed a system based on the Neoroof .

Neoroof is a water-based elastomeric paint that creates a waterproof membrane on your roof without any joints that could potentially leak. The paint is applied using a brush, roller, or sprayer.

The first step is to prepare the surface by thoroughly washing it. This is crucial, as any dirt left on the surface can impair the adhesion and durability of the coating. Proper preparation of the surface is always half the battle for any painting job.

For cleaning metal surfaces, we recommend Emulsol RN-1 . Dilute it with water to a concentration of 2-3%. It's best to pressure wash the roof. One liter of the product can clean up to 100m² ^of roof! Then, rinse the roof with water only and allow to dry.

The next step is to apply a suitable primer. For aluminum sheet, a layer of Wash Primer W . This single-component, water-based primer offers excellent adhesion to aluminum and galvanized steel. It should be diluted with 15-20% water and applied with a roller. Theoretical consumption is 95-115 ml/ ^m² .

Revinex primer to the felt surface . It will stabilize the grit on the felt and ensure good adhesion of the topcoat. The product is diluted with water at a ratio of 1 part Revinex to 4 parts water. Theoretical consumption after dilution is 0.08 kg/ ^m² .

On the presented roof, the next step was to fill all the gaps/gaps with Jointex .

Next, we move on to the final layer, the Neoroof . In the case of this roof, three layers of Neoroof with Neotextile . This system is used on roofs that leak and have visible gaps, and when the investor wants the coating to last as long as possible. If the roof has no visible cracks and there's no need to bridge the various materials, one layer of primer + two layers of Neoroof .

When using a reinforcing mesh, apply one coat first, then glue the mesh in place while wet, and immediately paint over it with a second coat, preferably applied perpendicular to the first. It's crucial not to trap any air bubbles under the mesh – at higher temperatures, the air will expand and could damage the coating. Apply the third coat after it dries (at least 24 hours). Expected coating durability depends on the number of coats:

• primer + 2 layers of Neoroof – 10 years
• primer + 3 layers of Neoroof – 12 years
• primer + 3 layers of Neoroof with Neotextile mesh – 15 years

These are of course the minimum durability times, in reality if properly applied the coating will last longer.

Repairs using mesh can also be made locally, there is no need to spread it over the entire roof.

Below are some photos of the protected roof. As you can see, the resulting coating is completely airtight, with no seams. Furthermore, the white color is certified for solar reflectivity – it reflects 88% of sunlight, which can reduce roof temperatures by as much as 40%!

Advantages of sealing the roof with Neoroof membrane:

• much lower cost than replacing the entire roof covering
• easy-to-use materials that do not require a specialized team
• a homogeneous membrane is created on the roof, without any joints through which water could leak
• sealing of all sheet metal flashings, fireplaces, skylights, etc.
• The white color is certified for reflecting solar radiation, the coating allows you to reduce the temperature on the roof by up to 40%
• very long durability of the coating

We always include technical data sheets with your order. You can also find them on our website, under each product description. Please read them carefully before starting your painting project.