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Round Rock Roofing | The Top Mistakes To Avoid When Installing Corrugated Metal Roofing

May 18


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Installing corrugated metal roofing can be challenging for even the most experienced DIY enthusiasts. While this type of roofing material is known for its durability, affordability, and low maintenance requirements, improper installation can lead to various problems, from leaks and rust to structural damage and even injury. This blog post will explore the top mistakes to avoid when installing corrugated metal roofing. By being aware of these common pitfalls, you can ensure a successful installation that will provide long-lasting protection for your home or building. So, whether you’re a seasoned pro or a first-time DIYer, learn the most critical errors to avoid when installing corrugated metal roofing.

Choosing The Wrong Material Or Gauge

When it comes to corrugated metal roofing, selecting the suitable material and gauge is critical to the longevity and efficacy of your roof. However, the wrong choice can lead to various problems, from rust and corrosion to structural damage and even safety hazards. So let’s take a closer look at the key considerations when choosing your corrugated metal roofing material and gauge and the consequences of getting it wrong.

Material Options

There are several options when it comes to choosing the material for your corrugated metal roofing, including:

  • Steel: The most common material choice for corrugated metal roofing, steel is durable and affordable. It comes in various finishes, including galvanized, stainless, and painted.
  • Aluminum: A popular choice for coastal areas or places with high humidity, aluminum is lightweight and rust-resistant.
  • Copper: A high-end option with a unique aesthetic, copper is incredibly durable and long-lasting.

Gauge Options

The gauge of your corrugated metal roofing refers to the thickness of the metal. The lower the gauge number, the thicker and more durable the metal. Here are the most common gauge options for corrugated metal roofing:

  • 29 gauge: The thinnest option, typically used for residential roofing projects.
  • 26 gauge: A thicker option is more suitable for commercial or industrial applications.
  • 24 gauge: The thickest option, often used for agricultural or industrial buildings with high wind and snow loads.

Consequences Of Choosing The Wrong Material Or Gauge

Choosing the wrong material or gauge for your corrugated metal roofing can lead to a range of problems, including:

  • Rust and corrosion: Using the inappropriate material can lead to rust and corrosion, compromising the roof’s structural integrity and causing leaks.
  • Inadequate durability: Choosing a material unsuitable for your area’s climate or weather conditions can result in premature wear and tear.
  • Safety Hazards: Using a material not strong enough to withstand high wind or snow loads can risk your property and safety.

Improper Roof Measurements

Accurate measurements are essential when installing corrugated metal roofing. Proper sizes ensure that the panels fit together seamlessly and that the roof is structurally sound. Failing to measure correctly can lead to problems such as leaks, improper panel overlap, and other structural issues. This section will discuss the importance of accurate measurements, common mistakes, and the consequences of incorrect measurements.

Common Measurement Mistakes

Some common measurement mistakes when installing corrugated metal roofing include:

  • Failing to account for the roof’s slope: The slope affects the length of the panels required for each row. It is necessary to account for the slope to avoid too long or too long panels.
  • Mismeasuring panels: Panels should be measured from the top of the rib to the top of the rib, not from the top of the panel.
  • Failing to account for overlaps: Overlapping panels are necessary for preventing leaks. Failing to account for overlaps can result in gaps between the panels, leading to leaks.

Incorrect Installation Techniques

Proper installation techniques ensure your corrugated metal roofing is installed correctly and performs as expected. Incorrect installation techniques can lead to various problems, including leaks, improper panel alignment, and other structural issues. This section will go over the significance of correct installation practices.

Fastening Methods

Fastening is a critical aspect of corrugated metal roofing installation. The most common fastening methods include:

  • Screws: Screws are the most common fastening method for corrugated metal roofing. They should be driven through the top of the rib at the correct angle to avoid damaging the panel.
  • Clips: Clips are used to fasten the panels together without puncturing the metal. This method is popular for roofs that require a high level of water resistance.

Panel Alignment

Proper panel alignment is essential to ensure your corrugated metal roofing is installed correctly. Panels should be aligned and leveled before being fastened to prevent leaks and other issues.


Overlapping is an essential part of corrugated metal roofing installation. The overlap required will depend on the roof’s slope and the panels’ pitch.


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Inadequate Roof Preparation

Proper preparation is critical when installing corrugated metal roofing. Inadequate preparation can lead to many problems, including leaks, structural issues, and a shorter lifespan for your roof. This section will discuss the importance of proper roof preparation, including roof cleaning, underlayment installation, moisture protection, and the consequences of inadequate roof preparation.

  • Roof Cleaning: Before installing corrugated metal roofing, it is essential to ensure the roof is clean and debris-free. This includes removing any old roofing materials, cleaning the roof’s surface, and repairing any damage to the roof. A clean and smooth surface is necessary to ensure that the metal roofing panels lie flat and that the fasteners can be installed appropriately.
  • Underlayment Installation: Underlayment is a critical component of a corrugated metal roofing system. It provides an extra layer of protection against leaks and helps to create a moisture barrier. Installing underlayment correctly, including overlapping the seams, is essential to prevent water from seeping through and causing damage.
  • Moisture Protection: Moisture protection ensures that your corrugated metal roofing system lasts as long as possible. This includes appropriately installing flashing around penetrations, such as chimneys and vents, and proper sealing around the roof’s edges.

Consequences Of Inadequate Roof Preparation

Inadequate roof preparation can lead to many problems when installing corrugated metal roofing. These include:

  • Leaks: Inadequate roof preparation can lead to gaps or weaknesses in the roofing system that allow water to seep through, leading to leaks and water damage.
  • Structural issues: Inadequate preparation can result in a roof that needs to be structurally sound, leading to problems such as sagging and buckling.
  • Decreased lifespan: A poorly prepared roof can shorten your corrugated metal roofing system’s lifespan, leading to premature replacement.

Poor Safety Measures

Installing corrugated metal roofing requires working at heights, which can be dangerous if proper safety measures are not taken. Following safety guidelines and using personal protective equipment (PPE) is essential to avoid accidents and injuries. This section will discuss the importance of PPE and ladder safety and the consequences of poor safety measures.

  • Personal Protective Equipment (PPE): PPE is essential for anyone working on a corrugated metal roofing project. This includes safety glasses or goggles, work gloves, a hard hat, and non-slip work shoes. Safety glasses or goggles protect the eyes from flying debris, while work gloves protect the hands from cuts and abrasions. A hard hat protects the head from falling objects, and non-slip work shoes provide a secure footing on the roof.
  • Ladder Safety: Ladder safety is also critical when working on a corrugated metal roofing project. Ladders should be placed on a stable surface, and the top of the ladder should extend at least three feet above the roofline to provide a secure handhold. The ladder should also be secured at the bottom to prevent slipping or sliding.
  • Consequences Of Poor Safety Measures: Poor safety measures can result in severe accidents and injuries, such as falls from heights and cuts from metal roofing panels. Falls from roofs can result in broken bones, head injuries, and even death. In addition to physical harm, accidents can result in costly medical bills, lost wages, and legal liability.

Failure To Follow Manufacturer Guidelines

When installing corrugated metal roofing, following the manufacturer’s guidelines is essential. Please do so to avoid problems such as leaks, corrosion, and a shortened lifespan for your roof. This section will discuss the importance of following guidelines and common mistakes made by failing to follow procedures.

  • Importance Of Following Guidelines: Manufacturer guidelines ensure that your corrugated metal roofing system is installed correctly and performs as expected. These guidelines provide information on everything from the materials to use, to the installation process, to ongoing maintenance requirements. Following these guidelines can avoid common mistakes and make sure your roof lasts long.
  • Common Mistakes Made By Not Following Guidelines: Some common mistakes made when not following manufacturer guidelines include using the wrong materials, improper installation techniques, and not allowing for proper ventilation. For example, incorrect fasteners can lead to corrosion and structural issues, while improper installation techniques can result in leaks and water damage.

Lack Of Experience

When it comes to installing corrugated metal roofing, experience is critical. Proper installation requires a deep understanding of the materials and techniques involved and the ability to work safely at heights. This section will discuss the importance of experience in building, the pros and cons of hiring a professional versus doing it yourself, and the consequences of a lack of knowledge.

  • Importance Of Experience In The Installation: Experience is essential when installing corrugated metal roofing. A skilled and experienced installer will have the knowledge and expertise to identify potential issues and overcome challenges that may arise during the installation process. They will also profoundly understand the materials involved, allowing them to choose the right products and tools for the job.
  • Hiring A Professional Vs. DIY: When installing corrugated metal roofing, you have two options: hiring a professional or doing it yourself. While DIY projects can be rewarding, they also come with risks. Hiring a professional with experience installing corrugated metal roofing may be better. A professional will have the skills and knowledge to complete the job correctly and safely.
  • Consequences Of Lack Of Experience: The implications of a lack of experience when installing corrugated metal roofing can be significant. If the installation is not done correctly, it can lead to leaks, structural issues, and other problems. These issues can be costly to repair and can also compromise the safety and stability of your roof. In addition, working at heights can be dangerous, especially for those without experience or proper safety training.

In conclusion, installing corrugated metal roofing requires careful attention to detail or adherence to best practices. Choosing the wrong material or gauge, incorrect measurements, improper installation techniques, inadequate roof preparation, poor safety measures, failure to follow manufacturer guidelines, and lack of experience are all common mistakes that can lead to issues down the line. To avoid these issues, you must work with an experienced professional who can guide you through the process and ensure that your roof is installed correctly and safely.


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