Common Causes of Metal Roof Leaks & Repair Options
Built to last and hold up well under pressure, metal roofs are especially suitable for residential and commercial buildings. But even the most resilient roof can develop leaks — especially in a place like Texas, where the combination of heat, humidity, and violent storms can push materials to their limits.
What is the biggest problem with metal roofs in Texas? Two issues rank at the top: leaks caused by climate stress and installation flaws. Understanding what causes these issues and how to fix them can help you keep your building dry and energy efficient. This guide covers the main reasons metal roofs fail, how they are repaired, and how to maintain your roof to protect it in Texas’s climate.
Why metal roof leaks are unique in Texas
Regional weather patterns across Texas put metal roofs under intense stress and makes leaks more likely:
- Temperature swings – Hot afternoons and cool nights cause metal to expand and contract rapidly — a repetitive and forceful movement that stresses joints and fasteners, sometimes opening up gaps for water to get in.
- Hail and wind storms – Large hailstones can dent panels and chip away protective layers. Strong winds may also loosen panels or tear off flashing that wasn’t properly installed or maintained.
- High humidity – Coastal and central Texas often experience high moisture levels. When the protective finish on a metal roof wears down, exposed areas can begin to rust, weakening the structure and inviting leaks.
If you’re wondering what are the disadvantages of a metal roof, the climate-related wear and potential for corrosion in high-moisture areas like Texas top the list.
Detailed leak causes
Several recurring issues directly lead to metal roof leaks:
- Corrosion and rust – When coatings degrade due to sun exposure or physical wear, the underlying metal becomes vulnerable to moisture and airborne pollutants. This leads to rust, which can thin out the panels or create pinholes.
- Loose or missing fasteners – Screws and clips hold metal panels in place. But as temperatures fluctuate, the panels shift slightly, which can loosen these fasteners. Once a screw lifts or falls out, it leaves an entry point for water. Strong winds only increase the stress on these attachment points.
- Panel misalignment and seam failure – Metal roofing systems depend on tight seams to remain watertight, and even slightly misaligned panels or shifting over time can cause separations in these seams. Even a small opening can let water in during a storm.
- This risk also applies to standing seam systems. What is a standing seam metal roof? It’s a concealed fastener system designed to reduce the number of exposed screws. While this design lowers the risk of fastener-related leaks, it isn’t leak-proof. Poor installation, seam separation, or neglected flashing can still lead to water intrusion if not regularly inspected.
- Sealant and flashing breakdown – Sealants are used to create a waterproof barrier around roof penetrations like vents, skylights, or HVAC equipment. They don’t last forever — they can dry out, shrink, or crack under sun exposure. Flashing may also corrode or move out of place. When these components fail, water follows the path of least resistance.
Repair options at a glance
| Leak Type | Potential DIY Repair | When to Call a Professional |
| Small puncture or hole | Clean the area thoroughly, then apply roofing-grade sealant or a metal patch designed for roof repairs. Make sure that the surface is completely dry. | If the hole is large, in a critical area (like a seam), or if you’re uncomfortable working on the roof |
| Loose or missing fastener | Replace the missing fastener with a matching screw or gently tighten the loose one. Don’t overtighten, as it can strip the metal. | If many fasteners are loose or missing, indicating a larger underlying issue |
| Minor sealant cracks | Scrape away old, failing sealant, clean the area well, and apply a fresh bead of roofing-grade sealant. Let it cure fully. | If the sealant failure is extensive, involves flashing, or is difficult to access safely |
| Panel misalignment (slight) | If safe to do so, gently shift the panel back into alignment and reattach it using compatible fasteners. Only attempt this if you’ve done roof work before. | If the misalignment is significant, affects multiple panels, or involves damaged panels. Improper realignment can worsen the problem |
| Corrosion spots (small, localized) | Scrub the rusted area with a wire brush, clean it, then apply a rust-inhibiting primer followed by roof paint or sealant designed for metal surfaces. | If the corrosion is widespread, has weakened the metal significantly, or is in a difficult-to-reach area |
| Flashing issues | As a temporary fix, use roofing sealant to plug small gaps around flashing. This buys time until a professional can assess and repair. | Always call a professional for flashing repairs or replacements. Improper flashing repair can lead to significant water damage. |
| Leaks at seams | Use compatible seam tape or sealant to close the gap. Make sure that the surface is clean, and follow manufacturer instructions carefully for proper adhesion. | If the seam separation is significant, affects a large area, or if you lack experience with seam repairs |
Important Note: Working on a roof can be dangerous. If you are uncomfortable or lack the necessary safety equipment and experience, always err on the side of caution and contact a qualified roofing professional.
Preventative maintenance tips
- Inspect twice a year – Check your roof each spring and fall. Look for rust, loose screws, cracked sealants, and other early warning signs.
- Clean gutters – Blocked drainage can cause backflow into seams or under flashing. Clear out debris to prevent water from pooling.
- Reapply coatings every 5 to 7 years – UV exposure in Texas can wear down roof coatings quickly. Keep the protective layer intact to guard against corrosion.
- Check fasteners after storms – High winds and hail can shake or loosen screws. After a major weather event, walk the roof and check that everything is still secure.
- Fix drainage issues – If water pools in any area, find a way to improve runoff. Ponding water speeds up corrosion and increases the risk of leaks.
Conclusion
Leaks in metal roofs often result from a mix of long-term wear, installation issues, and extreme weather events that are all too familiar in Texas.
If you’re asking what is the biggest problem with metal roofs, the answer often comes down to water infiltration triggered by poor sealing or weather-driven stress.
You can rely on our commercial and residential steel roofing experts here at Clark Roofing for installations, repairs, and storm damage assessment across Central Texas and beyond. We’re manufacturer-certified and bring decades of construction experience to every project.
