How to Repair a Galvanized Metal Roof


Although galvanized metal roofing has an average life expectancy of 50 years, weather and objects can cause the metal roof to leak. The damaged caused by a water leak can be substantial and you need to address the issue quickly. When it comes to repairing a metal roof, there are different methods to seal a water leak, but the majority of these methods are not permanent and you may need to fix the repair in intervals. One repair type remains strong for the life of your galvanized metal roof.

Things You'll Need

  • Tape measure
  • Piece of galvanized metal
  • Permanent marker
  • Aviation snips
  • Scribe
  • Sheet metal hand seamer
  • 120-grit Sandpaper
  • Flux
  • Acid brush
  • Two-pound weight
  • Soldering Iron
  • Lead-free solder
  • Measure the length and width of the hole in the galvanized metal roof with the tape measure. Add at least two-inches to both dimensions you measured.

  • Mark both dimensions you calculated on the piece of galvanized metal with the permanent marker.

  • Cut the piece of galvanized metal with the aviation snips and set the scribe to 1/2-inch.

  • Run the scribe along all four edges of the cut galvanized patch and snip each corner of the patch on a 45-degree angle with the aviation snips. Make sure that the 45-degree cut crosses the intersection of the 1/2-inch scribe lines.

  • Fold over each side of the galvanized metal patch with the sheet metal hand seamer, using the scribe lines as reference marks for the bends. Each fold needs to bend back onto the surface of the metal patch.

  • Clean each fold of the metal patch with the 120-grit sandpaper until the metal shines.

  • Clean the area around the hole in the galvanized metal roof with the 120-grit sandpaper. Apply flux to the cleaned surface of the roof and the cleaned folded edges of the metal patch with the acid brush.

  • Set the metal patch over the hole and place the two-pound weight on top of the patch to hold it in place.

  • Rest the hot soldering iron against one edge of the metal patch.

  • Rub the lead-free solder on the tip of the soldering iron and allow the melted solder to flow under the metal patch. Pull the soldering iron along each edge of the metal patch, while applying solder to the tip of the soldering iron.

  • Allow the solder to cool before removing the two-pound weight from the metal patch to finish repairing the galvanized metal roof.

Tips & Warnings

  • Never work on a galvanized metal roof when the roof is wet or in windy weather.

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  • Photo Credit chicken on the roof image by Artur Blaszak from
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