How to Spot & Prevent Roof Penetrations Issues

If you look at the top of a commercial roof, you might be surprised at what you see. Unlike a residential roof that probably doesn’t have too much going on, aside from some bathroom vents, a chimney, and maybe solar panels, commercial building roof types typically have many penetrations. These include vents, HVAC units, skylights, pipes and ducts, and communication equipment.

“Penetrations are most common on flat roofs, because these types of roofs often require pipe access, drainage, and ventilation,” said Merv Fisher, CEO of Capital Coating and Capital Roof Care. “Almost every commercial roof will require some type of penetration for the building to function properly.”

What most people don’t realize is that roof penetrations can become the starting point of several commercial roof problems that can quickly evolve into the need for an emergency roofing repair. That’s because roof penetrations create weak points in a commercial roofing system. To prevent roof penetration problems, it’s essential to be aware of the most common issues and how to mitigate them.

Common Roof Penetration Problems

Unfortunately, penetrations can be the cause of many roofing issues. Here are the six most common roof penetration problems.

Improperly Sealed Penetrations

The first most common roof penetration problem is one that is improperly sealed. A roof penetration that isn’t sealed properly can allow water to bypass the roof membrane, resulting in leaks. Improperly sealed penetrations are typically the result of improper installation, do-it-yourself errors, or normal roof wear and tear. Even small gaps around flashing, caulking, or boots can allow moisture to enter.

Improperly designed or installed penetrations can also block drainage pathways, resulting in ponding water. This standing water can increase the weight load and accelerate membrane deterioration, leading to a commercial roof leak. Unfortunately, most leaks develop slowly over time and may go unnoticed until they cause significant interior damage.

Membrane Damage

The second most common roof penetration issue is damage to the roof membrane.

“Every commercial roof has a membrane, which is a durable, waterproof layer of material that serves as the outer ‘skin’ and protects the building’s structure from water, weather, and UV radiation,” said Fisher. The most common membrane types are single-ply—such as EPDM, TPO, and PVC—which are large sheets installed together, and built-up roofing (BUR) and modified bitumen membranes, which are made from multiple layers of asphalt and reinforcing materials.

Cutting or puncturing the roof membrane creates vulnerabilities that occur when roof penetrations are made. Over time, stress at the penetration points can cause cracks, splits, or tears. To make matters more difficult, roof penetrations often expand and contract at different rates than the roof membrane itself. This movement stresses the sealant and flashing, creating gaps over time. Ultimately, all of these issues can result in leaks and structural damage.

Flashing Failures

The third most common roof penetration problem is flashing failure. A roof flashing is a thin, protective sheet, often made of metal, which is installed to seal vulnerable areas of a roof and prevent water penetration.

Roof flashing is essential for waterproofing joints and transitions where any roof penetration occurs. Over time, flashings around penetrations can degrade from UV exposure, thermal expansion, or poor installation. Once flashing pulls away or cracks, water can easily seep into your facility.

“Some older commercial roofs may also have pitch pans, which are metal boxes that surround the penetration and are filled with grout,” said Marlin Fisher, President of Field Service for Capital Roof Care. “Most commercial roofing companies no longer build new pitch pans, because they can leak.” Unfortunately, pitch pans can lead to the need for a commercial roof leak repair.

Movement and Settling

The fourth most common roof penetration problem is movement and settling. Roof expansion and contraction—also known as “thermal movement”—is not easily seen at first. The degree of change over a short period can be small, but the constant movement over repeated seasonal cycles of temperature fluctuations can cause severe damage.

This fluctuation is dependent upon what type of roofing material you have on your commercial roof. Metal roofs, for example, have been shown to exhibit expansion and contraction of nearly 1.25 inches over a 40-foot section. Consistent roof expansion and contraction, a common occurrence in the northeast due to its four seasons, can result in gaps and leaks.

Structural Deterioration

The fifth most common roof penetration issue is caused by structural deterioration. Over time, all commercial roofs will weather and deteriorate, resulting in cracks, stress, and areas where water can penetrate. Long-term water infiltration around a roof penetration can corrode metal decking, rust fasteners, saturate and damage insulation, and compromise a roof’s overall structural integrity. Moreover, wet insulation loses its R-value (energy efficiency) and can promote mold growth and rot.

Ice Dams

The final, most common roof penetration problem is ice dams. During winter in the Northeast, ice is a regular occurrence, often accompanied by snow. Ice dams form at a roof’s edge when melted snow and water freeze and prevent water from draining. If you have penetrations on the roof, ice dams can be more problematic. That’s because it’s easier for water, snow, and ice to accumulate here. The weight of the ice dam and any pooled water can then subsequently cause stress or damage to a roof’s structure.

As a result of the issues created by roof penetrations, facility managers may experience increased maintenance costs. More penetrations require more points of inspection and will likely result in the need for resealing and repairs. If regular maintenance is not performed, neglected penetrations on a commercial roof can result in an emergency roof repair service and/or drastically shorten a roof’s lifespan, necessitating an industrial roof replacement.

How to Prevent Roof Penetration Problems

To prevent exorbitant maintenance costs and emergency roof repair costs, facility managers should follow these tips to avoid roof penetration problems.

Ensure Proper Roof Penetration Installation

Ensure that each roof penetration is installed correctly. Often, facility managers attempt to save money by hiring a subcontractor to install rooftop equipment, rather than consulting a roofing expert. Unfortunately, if your subcontractor is not a trained roofing professional, they may not be able to assess the structure properly and make informed decisions to prevent future roof penetration issues.

Have a Roof Inspection Plan

Virtually all of the roof penetration problems outlined earlier—improperly sealed penetrations, membrane damage, flashing failures, movement and settling, structural deterioration, and ice dams—can be prevented by having an industrial roof assessment plan in place. An annual roof maintenance plan assesses each component of a commercial roof and provides the opportunity to address any potential problems before they arise. Contact Capital Roof Care to set up a commercial roof maintenance program to confirm your roof is functioning properly.

Install Quality Materials

If you aren’t using the right materials, you could be setting your commercial roof up for failure. Be sure to use roofing products that have a good reputation, such as American Weatherstar, a top supplier of Capital Roof Care materials and an industry-leading manufacturer of fluid-applied roof restoration solutions. American Weatherstar provides facility managers with high-performance roofing solutions, quality craftsmanship, and outstanding value; so, if something does go wrong, you can rely on them to deliver a solution.

Ensure Proper Sealing

If the penetrations on your roof are not properly sealed, future leaks are likely to form. That’s why it’s crucial to confirm that the sealant your roofer used continues to be durable year after year.

Confirm Positive Drainage

A roof that isn’t draining properly could result in water damage, among other issues. To ensure your roof drains correctly, contact a professional roofing company to inspect for any drainage issues or leaks.

Be Aware of Roof Expansion & Contraction

To prevent a potential emergency roofing service call, facility managers should be aware of the four most common conditions related to roof expansion and contraction problems: shrinkage, moisture, temperature fluctuations, and weather conditions. They should then regularly monitor these issues. For help, contact Capital Roof Care.

Prevent Ice Dams

To stop ice dams from forming, you should have a qualified professional conduct a regular commercial roof inspection every winter to ensure there aren’t any issues.

Roof penetrations are unavoidable on most commercial roofs; but, by being aware of the six most common roofing penetration problems and preventing them, facility managers can save on labor and material costs. The two most important things you can do to protect your roof are to have an annual industrial roof inspection plan in place and to have it performed by a licensed roofing technician.

“Be sure to do your research,” said Bill Morgan, President of Capital Roof Care. “The technician you hire should have undergone extensive training, be committed to producing quality work, and carry the proper licensing. The right roofing professional should also have specialized expertise in the numerous types of roofing systems that are available, in addition to knowing what repair materials to use for every type of roof substrate.”

To set up an annual commercial roof maintenance plan or hire a licensed roofing professional, contact Capital Roof Care.

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