How to Repair Aluminum Awnings

Aluminum awnings serve a dual purpose: keeping a space shaded and wind protection when folded down over a window. Though aluminum is extremely durable and weather resistant, it can be punctured or cracked. If this occurs on an aluminum awning attached to your home's exterior, you have two options: replace the aluminum awning or repair it yourself. The latter of the two is less expensive and is not difficult to do.

Things You'll Need

  • Leather gloves
  • Gloves
  • Ladder
  • Wire block brush
  • Aluminum snips
  • Aluminum
  • Butyl tape
  • Screw gun
  • Stainless steel screws
  • Caulk
  • Caulk gun
  • Cloth
  • Roof coating
  • Paint roller

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Put leather gloves on to protect from cuts while working with the aluminum awning. Place a ladder next to the aluminum awning.

Clean any grime and/or rust off the aluminum awning with a wire block brush to have a clean surface for the patch to stick against.

Make the damaged area square using aluminum snips.

Cut a square section out of a piece of aluminum with the snips about two to three inches larger than the hole in the awning.

Place the aluminum patch over the hole in the awning and tape down in place with butyl tape.

Fasten screws around the outside edges of the patch with a screw gun and stainless steel screws--putting at least two screws in each side.

Caulk around the edges with silicone caulk using a caulk gun, wiping away any excess silicone with a damp cloth. Allow the silicone caulk to dry for approximately 30 minutes.

Spread roof coating over the entire patch with a paint roller. Let dry as long as directed by the manufacturer.


  • "The Home Carpenter & Woodworker's Repair Manual "; William Perkins Spence; 2006
  • "Welding Fabrication & Repair: Questions and Answers"; Frank M. Marlow; 2002
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