Where metal building roofs leak
- Exposed fasteners. Screw-down panels are held by thousands of screws, each with a rubber washer. The sun dries and cracks those washers, and water follows the screw in.
- Backed-out screws. Panels expand in the afternoon heat and shrink at night. Over years, that movement loosens screws and enlarges the holes.
- End laps and side laps, where panels overlap and the sealant has failed.
- Ridge, eave and rake trim loosened by wind.
- Skylight panels that have turned brittle and cracked in the sun.
- Curbs and penetrations for HVAC, vents and exhaust fans.
- Gutters that rust out and overflow into the wall.
Rust on the coast
Salt air from the bay and Gulf speeds up rust, starting at cut panel edges, fastener heads, laps and gutters, and anywhere water and dirt sit. Near the water in Ingleside, Aransas Pass, Port Aransas, Rockport and North Beach, it moves faster. Surface rust can be cleaned and treated. Rust that has eaten through a panel means that panel has to be replaced.
Repair options, from small to complete
Fastener and lap repair. Replace failed or backed-out screws with new fasteners, often a larger size for worn holes, and reseal laps and trim. Good for roofs with isolated leaks and sound panels.
Coating restoration. After cleaning, treating rust and sealing fasteners and seams, a coating system can renew the whole roof surface and add reflectivity. It fits a metal roof whose panels are still solid.
Single-ply retrofit. A new single-ply roof, such as TPO, PVC or Duro-Last, installed over the existing metal, usually with insulation to create a flat surface. This gives the building a new roof, can improve energy performance, and avoids tearing off the metal.
Panel replacement. Rusted-through or badly damaged panels are replaced, either as spot repairs or across the roof.
Which one fits your building
It depends on how much of the metal is still solid, how widespread the leaks are, what is stored or happening inside, and how long you plan to keep the building. We will look at the whole roof, test the problem areas and lay out the options honestly.
Signs your metal roof needs attention
- Rust streaks running down from screws, laps or the ridge.
- Screws that are loose, tilted or missing, or washers that are cracked or gone.
- Daylight visible through the roof from inside.
- Drips along purlins or at the same lap every time it rains.
- Skylight panels that are cloudy, yellowed or cracked.
- Gutters with rust holes or water spilling down the wall.
- Panels or trim that rattle or flap in the wind.
Coating or retrofit: how they compare
A coating restoration keeps the existing metal as the roof and seals it with a new surface. It is often a good fit when panels are solid, the building is used as it is today, and the goal is to stop leaks and slow rust. A single-ply retrofit turns the metal into a deck for a new roof. It is a bigger project, but it gives the building a new roof surface with heat-welded seams, and adding insulation in the retrofit can help a building that is hot inside. We will show you both when both make sense.
Wind and metal roofs
On the Coastal Bend, loose fasteners and trim are not just leak risks. In a hurricane or strong front, they are where wind gets a grip. Tightening and replacing fasteners and securing trim before hurricane season protects the whole roof. Our hurricane prep guide has the full checklist.
Whichever option fits, the work starts with a clean, sound surface. Loose rust is removed, rusted fasteners are replaced, and any panel that has lost its strength is changed out before anything new goes on top. Skipping that prep is why some coatings peel within a few years.
Metal roofs from the Port to the farm
Nelson Roof Contracting works on metal roofs on warehouses and plants around the Port of Corpus Christi and the refinery corridor, and on shops and ag buildings in Robstown, Sinton, Odem, Kingsville and Alice. Over 50 years of hands-on experience, every job supervised. Call (361) 683-1733.
Meet the owners
Nelson Roof Contracting is owned by Nelson and Esperanza Alvarado. Nelson brings over 50 years of hands-on roofing experience to Corpus Christi and the Coastal Bend, and every job is supervised. When you call, you are calling a family business that has been on these roofs for decades.
Office (361) 683-1733
24/7 line (361) 320-3131
Updated October 2026 by Nelson Roof Contracting, Corpus Christi, TX.