Location: Johannesburg South, Gauteng
Service: IBR Metal Roof Rust Treatment, Waterproofing & Painting

This case study looks at a residential property with a large IBR (corrugated metal) roof that had gone years without maintenance. What started out as a straightforward repaint turned into a full rust-treatment and waterproofing job once the crew got up on the roof and saw the true condition of the sheeting.

The problem with the roof

From ground level the roof looked tired but manageable. Up close it was a different story. Large sections of the IBR sheeting had corroded down to a deep orange-brown, with the protective coating gone in places and rust breaking through the metal along the ribs and overlaps. The screw fixings and joint lines were the worst-affected areas — exactly where water finds its way in first — and a few pipe penetrations and gutter-box junctions had failing old sealant letting moisture track behind the brickwork. Left untreated, active rust like this doesn’t stay cosmetic for long: it eats through the sheeting and turns into leaks and structural replacement costs.

The SealAll solution

SealAll Roof Contractors, an approved SealPro applicator, followed a proper rust-remediation sequence rather than just rolling paint over the problem:

1. High-pressure wash – The full roof area was stripped of loose scale, chalking and surface contamination before any product touched the metal.
2. Rust conversion – Every corroded section was treated to chemically neutralise the active rust so it couldn’t keep spreading under the new coating.
3. Waterproofing the overlaps, joints and screw lines – The highest-risk points on any IBR roof were sealed with a reinforced waterproofing system, embedding fibre mesh into the coating over each screw head and rib joint for a durable, flexible seal.
4. Priming – The prepared sections were primed to give the topcoat proper adhesion and long-term rust resistance.
5. Two coats of a high-quality roof paint system – This gave the sheeting a uniform, weather-resistant finish that reflects heat and sheds water instead of trapping it.
6. Painting the gutters, fascias and pipe penetrations to match – The roof-edge detailing was finished as one consistent system rather than a patched-together repair.

The result

The rusted sections of sheeting are now sealed and neutralised instead of actively corroding, every screw line and overlap on the roof has a waterproof barrier built into it, and the gutter and edge detailing are cleanly coated and weather-tight. It’s the difference between a roof that’s merely been painted over and one that’s actually been treated at the source of the problem — which is what keeps a maintenance repaint from needing to be redone again in two years.

Metal roofs across the greater Vaal region face the same combination of intense summer sun, hail and seasonal storms that caused this damage, which is why catching rust early with a proper conversion-and-waterproofing sequence is far cheaper than waiting for a full re-sheet.

SealAll Roof Contractors is an approved SealPro applicator serving Vereeniging, Johannesburg South and the greater Vaal region.

Related SealAll Roof Contractors services: roof waterproofing · roof coating and painting · roof maintenance across the Vaal Triangle.

Contact SealAll Roof Contractors for a free inspection and quote: 072 694 9243 · roofcontractors.co.za

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