Repair of a leaking copper roof panel on a Frank Lloyd Wright "Usonian" design house with Bermuda style roofing.
Copper Roof Repair
Damaged or leaking copper roofs can often be repaired, but whether to repair or replace will depend on several factors. These include the extent and severity of the damage, the location of the affected area, and the age of the roof. In cases of a leaking copper roof, the success of repairs largely depends on the original installation techniques, roof design, and the skill of the original installer.
Common causes of copper roof damage or leaks include falling tree branches during storms, loose roof slate or tiles sliding off from higher roofs, and even falling bricks from deteriorating chimneys. However, most leaks in copper roofs are typically due to installation errors.
Repairing a copper roof usually involves cleaning the existing roofing material and soldering new patches of comparable copper sheet over any holes or punctures. Alternatively, damaged roof panels can be replaced with new copper panels.
**Factors to Consider When Repairing or Replacing a Copper Roof**
1. **Age of the Copper Roof:**
As copper ages, it develops a layer of copper oxide known as copper patina. This patina begins as a thin coating with a dark bronze or olive hue and gradually thickens over time. Typically, it turns light green after about 15 to 20 years, depending on the local climate. The thickness of the patina varies based on the roof's design; areas with less exposure to erosion will have a thicker patina, while those with more exposure will have a thinner layer. For effective repairs, this patina must be removed mechanically to expose clean, bright copper of sufficient thickness before soldering a repair patch.
2. **Severity of Roof Damage:**
Small damaged areas can often be repaired quickly and efficiently. However, if a large portion of the roof is damaged, it's essential to evaluate whether it's financially sensible to repair it. In some cases, the cost of materials for repairing the existing copper may be higher than the labor costs associated with installing new copper roofing.
3. **Location of Damage:**
Damage located along standing seams and horizontal seams is particularly challenging to repair. The additional layers of folded or lapped metal make it difficult to open and clean the metal joints sufficiently for proper soldering or panel replacement.
4. **Roof Design:**
Sometimes, the roof area may be improperly pitched or too flat for a standing seam roof. Additionally, seams and panels may be installed incorrectly, such as seams running horizontally on a barrel-style roof.
**Examples of Repairable and Unrepairable Copper Roofing:**
Repairable copper roof.
Falling slate shingles damaged this 100-year-old copper flat seam roof. The copper has a thick layer of copper patina, which has protected the metal from wear and tear. With careful cleaning and preparation, a new copper metal patch can be soldered over the damaged areas for a permanent repair.
A poorly soldered leaking roof seam new enough to warrant repair.
Copper roof repair is in progress. The seam has been opened for cleaning the original copper patina to bare metal before fitting and soldering.
An example of an unrepairable copper standing seam roof.
An example of an unrepairable copper standing seam roof is one with an insufficient pitch or slope. This condition allows for snow and ice accumulation, which can lead to the formation of ice dams during winter. This can cause water to back up and enter the standing seams of the roofing. Furthermore, these roofing joints are caulked instead of properly folded together. The caulking can dry out and crack within a few years due to extreme heat and panel movement.
Original installation error.
Broken flat seam joint. Improper soldering technique led to this seam breaking and eventually causing a leak. All the seams on this roof were incorrectly soldered, and the entire roof was replaced.
Typical causes of broken seams are incorrect soldering.
Most broken seams look like the image below. There is only a small amount of solder at the seam edge, and no solder is present between the folded layers of copper. These seams are easily broken. If the majority of the roof were soldered in this way, it would be better to replace the entire roof.
And a well-soldered copper roof seam. The solder has flowed through the entire seam for a permanent, unbreakable joint.
This copper roof was damaged by a storm and further compromised by both the original and subsequent installation errors.
The roof was installed poorly the first time. The standing seams are single-lapped instead of double-folded, and therefore, they are easily pulled apart under pressure.
The same type of damage has occurred before; heavy snow slides have torn a snow guard from the roof, and a poor repair was installed. A repair patch has been screwed through the roof in a terrible attempt at roof repair. That repair technician then re-installed the snow guard without addressing the cause of the original damage.
Worn-out copper roofing sheet.
This roof has worn through near the soldered seam. A good indication of worn-out, too-thin-to-solder roofing is the presence of an orange coloring on the copper. The protective copper patina has worn off due to excessive weathering, revealing the bare copper beneath.
