Industrial roof leaks can start with something as small as a failed fixing or blocked gutter, but if they’re left alone, the damage can quickly spread and become more costly. Water getting into a factory, warehouse or agricultural building can affect stock, machinery, insulation and the building itself, so it’s worth finding the cause early on.
One thing we often find is that the leak inside the building isn’t always directly below the problem on the roof, this is because water typically enters further up the roof and travels along sheets, insulation and/or steelwork before it eventually becomes visible inside because water runs to the lowest point. This is why we recommend finding the problem and fixing the cause rather than sealing the area above a wet patch.
What Causes Industrial Roof Leaks?
There isn’t one common cause that applies to every roof as you can expect, it can be a combination of things. Industrial roofs are made up of sheets, fixings, flashings, gutters, rooflights and other details, and a problem with any one of these can allow water into the building.
Older roofs can also have more than one issue at the same time. A leaking gutter might be causing trouble at one end of the building while damaged sheets are responsible for water getting in somewhere else. A proper inspection helps separate individual repairs from signs that the roof as a whole is starting to deteriorate.
Damaged Roof Sheets
Roof sheets can become damaged through age, corrosion, weather or impact. Even relatively small areas of damage can eventually let water through.
This doesn’t necessarily mean the whole roof needs replacing. If one or two sheets are damaged and the rest of the roof is sound, replacing those sheets may be all that’s required. It becomes a different situation when damage is appearing across large areas of the roof. At that point, it’s worth looking at whether continued repairs are still the best use of your money.
Cut Edge Corrosion
Cut edge corrosion is common on older metal roofs. It tends to develop around the edges of coated sheets and at overlaps where the exposed metal starts to corrode.
Caught early, the affected areas can often be treated before the corrosion becomes more serious. If it’s left for too long, the metal can continue to deteriorate and eventually allow water through.
If you’ve noticed rust or deterioration around sheet edges, we’ve covered what to look for in our guide to spotting cut edge corrosion and fixing it.
Leaking or Blocked Industrial Gutters
Sometimes what looks like a roof leak is actually a gutter problem. Industrial gutters have to deal with large amounts of rainwater. Leaves, moss and other debris can restrict outlets, while older gutters can develop corrosion or leaks around joints.
If the water can’t drain away properly, it can back up and find its way into the building. This can be particularly noticeable during heavy rain when the drainage system is under more pressure.
Depending on their condition, gutters may be cleaned, repaired, lined or replaced. Our guide to industrial gutter failure explains the different options.
Rooflights
Rooflights are another area we check when looking for the source of an industrial roof leak. As they get older, rooflights can become brittle, damaged or cracked. Problems can also develop around the fixings, seals and areas where the rooflight meets the surrounding sheets.
A problem around one rooflight doesn’t mean the main roof has failed. In many cases, the rooflight or the area around it can be repaired or replaced without carrying out major work elsewhere.
Flashings and Fixings
Flashings are used around roof edges, changes in level and other parts of the building where sheets meet. If they become loose or damaged, water can find its way underneath.
Fixings can cause similar problems. Over time, fixings and the seals around them can deteriorate, particularly on an older roof that has been exposed to years of changing weather. These are often fairly localised problems, but they still need to be identified properly before repairs are made.
Finding Where an Industrial Roof Leak Is Coming From
Finding an industrial roof leak isn’t always as simple as standing inside the building and looking directly above the drip. Water will take whatever route it can. It may enter through a damaged area higher up the roof, run along the underside of a sheet or follow part of the steelwork before dropping into the building somewhere else.
We therefore look at the surrounding roof rather than just the point where water is visible inside. The condition of the sheets, gutters, rooflights, flashings and fixings all need to be considered. It also helps to know when the leak occurs. A problem that only appears during very heavy rain may point us in a different direction from one that happens every time it rains.
Does a Leaking Industrial Roof Need Replacing?
Usually, no. One or two leaks on an otherwise sound industrial roof can often be repaired without replacing the whole roof. The important thing is whether the problem is isolated or part of wider deterioration.
If leaks keep appearing in different parts of the building, previous repairs are failing or there is widespread corrosion, it may be time to look at the roof as a whole. At that stage, industrial roof refurbishment, overcladding or replacement may make more sense than continuing to repair one problem after another.
Our industrial roof repair or replacement guide explains how we approach that decision.
Can Industrial Roof Leaks Be Repaired While the Building Is in Use?
Many industrial roof leaks can be repaired while a factory, warehouse or other commercial building remains in use. The work still needs to be planned around what’s happening on site. We need to consider where people are working, what is underneath the area being repaired and how we can access the roof safely without causing unnecessary disruption.
Larger repairs may require more planning, but keeping a site running while roofing work is carried out is nothing unusual. If you’re concerned about disruption, you can also read our guide to factory roof replacement without shutting down.
Any work on an industrial roof also needs to be planned and carried out safely, particularly where there are fragile roof areas or rooflights. The Health and Safety Executive provides guidance on safe roof work for those responsible for managing and carrying out roofing work.
What About Leaks on Asbestos Cement Roofs?
Older industrial and agricultural buildings may still have asbestos cement roof sheets. A leak doesn’t automatically mean the asbestos roof needs to be completely removed, but its condition needs to be taken into account before deciding how the problem should be dealt with.
If you have an older asbestos cement roof, our guide to asbestos cement roofs and your legal duties explains the subject in more detail.
Industrial Roof Leak Repairs Across the UK
Robinsons Roofing & Cladding carries out industrial and agricultural roof repairs throughout the UK. From our West Midlands base, we’re also well placed for work across Wolverhampton, Birmingham, Staffordshire, Shropshire, Worcestershire and the surrounding areas.
If you have water coming into a factory, warehouse, workshop or agricultural building, the first step is finding out where it’s coming from. Once we know the cause, we can explain whether a straightforward repair will deal with it or whether the roof needs further attention.
Speak to our industrial roofing team if you need help finding or repairing an industrial roof leak.
