Problem
The inspection recorded a worn ridge cap, loosening lead-head nails, surface oxidation and an unused chimney penetration. Those items were included in the repair scope before coating.
Project Case Study
Pukehangi corrugated iron roof restoration: repairs before repainting
On this Pukehangi roof, painting came after the repairs. The work addressed a worn ridge cap, loosening lead-head fixings, surface oxidation and an unused chimney opening before primer and two finish coats were applied.
- Documented repair sequence
- Class 4 screw hardware upgrade
- Real Rotorua project photos
Outcome
The recorded work included ridge-cap replacement, removal and patching of the unused chimney, new fixings, rust preparation, primer and two finish coats. The final photo shows the completed roof.
Need a Similar Result?
Have a similar roof? Ask for an assessment of the repairs, preparation and coating scope before deciding what work is suitable.
Step 1
Initial Inspection: Deteriorated Ridge Cap and Loose Lead-Head Nails
The roof inspection identified several components to address before repainting.
The ridge cap was worn, and some old lead-head nails were backing out. Both were included in the repair plan.
The team assessed those details alongside the roof surface before preparing it for coating.
Stage 1: Inspection confirmed a worn ridge cap and aging nail fixings before leaks started.
Stage 2: The unused chimney was removed and its opening repaired.
Step 2
The Problem Area: Old Chimney Needing Removal
An unused chimney still passed through the roof. Its removal and the repair of the opening were part of this job's scope.
- Unnecessary penetration:
Roof penetrations and flashings need close inspection when planning repairs and coating. - Clean future surface:
Removing the chimney allowed us to reinstate a continuous galvanised iron surface before coating.
Step 3
Roof Preparation: Water Blasting and Addressing Oxidation
The roof surface was cleaned and visible oxidation was treated before primer.
- High-pressure water blast
The roof was cleaned before repair and coating work proceeded. - Oxidation treatment
Isolated rust and oxidation patches were treated before primer and topcoats went down.
Stage 3: Water blasting and oxidation treatment prepared the iron for repairs and coatings.
Stage 4: New ridge cap installed and the chimney opening patched with galvanised iron.
Step 4
The Fixes: New Ridge Cap Installation and Chimney Hole Patching
After cleaning, the team replaced the ridge cap and repaired the chimney opening.
- Ridge cap replacement:
The worn ridge cap was removed and replaced. - Chimney removal and patch:
The unused chimney was removed and its opening patched with galvanised iron.
Step 5
Upgrading Hardware: Class 4 Roofing Screws Throughout
Loosening lead-head nails were replaced with galvanised Class 4 roofing screws and EPDM washers as part of the recorded repair scope.
Replacing the old fixings addressed one of the visible defects before the roof was primed and painted.
Stage 5: Old lead-head fixings were replaced with Class 4 screws and EPDM washers.
Stage 6: Primer and rust treatment followed the metal repairs.
Step 6
Protection Phase: Full Roof Primer and Rust Treatment
With repairs and hardware complete, we thoroughly primed the entire surface and treated residual rust risk areas.
Primer was applied before the two finish coats. The coating specification for another roof depends on its material and condition.
Step 7
The Transformation: First Coat Application
The first finish coat was applied to the prepared corrugated iron surface.
A second finish coat followed. The completed roof is shown in the final project photo.
Stage 7: First coat applied across the fully prepared corrugated surface.
Stage 8: Second coat complete on the repaired corrugated iron roof.
Step 8
Final Results: Second Coat Applied and Finished Look
The finished work brought together the repairs and coating stages:
- A replacement ridge cap and a patched former chimney opening.
- Replacement Class 4 screws with EPDM washers in place of the old fixings.
- Primer and two finish coats over the prepared roof surface.
The sequence matters: inspect and repair the roof first, then prepare and coat a suitable surface.
Looking for Professional Roof Restoration in Rotorua?
If your corrugated iron roof has loose fixings, a worn ridge or surface rust, request a condition assessment. A useful quote should identify the repairs, preparation and coating system proposed for that roof. Read our Rotorua roof painting quote guide before comparing scopes.
Related service: Roof Painting Rotorua
Corrugated Iron Roof Restoration FAQs for Rotorua
Worn ridge caps, loose fixings and roof penetrations may need attention before coating. On this Pukehangi job, those items were repaired before primer and finish coats.
On this job, loosening lead-head nails were replaced with Class 4 screws and EPDM washers. The right repair scope for another roof follows an inspection.
This Pukehangi job included removal of an unused chimney and patching the opening with galvanised iron. Similar work needs a site-specific inspection and repair plan.
Yes. We assess roof condition and discuss the repair, preparation and coating scope before quoting work in our Rotorua and Lakes District service area.
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