Don and Julie Beebe bought their waterfront home on the shores of Mobile Bay in 2002, and ever since then, they’ve been battling salt corrosion and other coastal weather elements.
Recently, their home insurance company gave them a mandate to replace their corroded metal roof. So, while the roofers install a new — quality — metal roof, we’re going to fix up some other weathered parts of their home.
The Projects
Replace Metal Roof
The first step to reversing the salt corrosion on this home is replacing the rusty metal roof. Once the materials arrive and the crew is on-site, they begin removing the old roof, which begs the question: Why didn’t the old metal roof last longer?
The existing metal roof was made with a lower-quality material and it wasn’t installed properly. But also, there’s a difference systematically.
What we’re replacing was an exposed fastener metal roof, which means the screw penetrates through the metal, and the head of the screw is exposed. Now, let’s be clear: metal doesn’t leak — but holes in metal can be an issue.
The new roof we’re installing is a standing-seam snap-lock roof produced through a Metal Roofing Alliance-approved manufacturer.
One way you can make sure that you don’t get burned by a bad metal roof is if you go through companies that have been vetted and approved through the Metal Roofing Alliance.
They will be the top-notch companies that have the credentials and skill sets to put your roof on properly.
With the main structure being a Fortified Roof, we went with a completely sealed roof deck. So it’s got a peel-and-stick membrane over all the decking.
The metal roof should never have water get past it, but if you know a tree hits it and punctures it, this type of membrane is self-sealing.
So, it actually will heal itself in the short term. Water will not get past it.
Replace Lattice Panels
Even PVC lattice panels are not immune to the damage caused by the salty breeze. Over time, the salt in the air can cause the PVC material to deteriorate and discolor, making it brittle and more susceptible to cracking and breaking.
Not only that, but the panels may also become discolored, turning yellow or brown as a result of salt corrosion.
The first step in replacing the panels is to remove the old ones. Start by cutting the existing lattice panels to remove them from the framing.
Then, we do some touch-up painting around the framing, before we install the new ones using stainless steel screws. These are rust-resistant, so they will be better protected from future corrosion.
Wirebrush Rusted Fasteners and Repaint
It’s no secret that salty air and water can wreak havoc on metal fasteners, and bolts are no exception. The salt in the air and water reacts with the metal in the bolts, causing them to rust and corrode.
Moisture is also a major factor, as it accelerates the oxidation process that leads to rust formation.
To make matters worse, if your bolts aren’t made from rust-resistant materials, like stainless steel, they are even more vulnerable to corrosion. Such is the case with these bolts on the Beebes’ home.
When painting any type of rusty surface, you got to get as much of the loose rust off as you can. To do this, we use a wire brush and a wire wheel on a power tool. The goal is to remove as much rust as possible without damaging the underlying metal.
Next, wipe down the area with a clean cloth to remove any dust or debris. Then, we spray paint it with a metal primer metal seal it in a little bit then with paint going on top to protect it from the elements.
Spruce Up the Pavillion
The area under the pavilion isn’t getting much use, so we’re freshening it up and creating a cozy spot to unwind after a long day.
First, we pressure washed to remove dirt and grime buildup. Once the picnic table was restored to its former glory, we applied a sealer to protect it from future damage. This will help maintain the table’s beauty and durability, even in the face of harsh outdoor conditions.
While we have our power washer out, we’re going to tackle the slab underneath the pavilion so it’s a nice clean slate for our updated picnic table.
Next, we turned out attention to the pavilion pylons. We found that the bases were rotting, which could compromise the structure’s stability if left unchecked. So, we got right to work by screwing on some hardware on the damaged spots to prevent further deterioration.
Next, we applied some Quikrete Fast-Setting Concrete to rebuild the deteriorated portions of the pylons. This material sets quickly and provides a durable surface that can withstand the elements, ensuring that the pavilion will remain standing strong for years to come.
Post-Production Thoughts
Don and Julie’s home is in a beautiful bayfront location, but that beauty comes at a price. The salt corrosion combined with the wind and the water of frequent storms has taken a toll on the structure.
There was rust on the old metal roof and on the exposed fasteners on the house and the stairs, even the plastic lattice had been battered by the elements.
But now, the house has a new lease on life. The rust is gone. There’s new paint new lattice and a brand new roof that not only looks great but will protect this family and their home from whatever Mother Nature throws at them for years and years to come.
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