It’s easy to think tighter is better, but like you said, that just ruins the seal.
Funny how that instinct kicks in, right? I’ve definitely overtightened a few and ended up with leaks later. I’m with you on the butyl tape trick—sometimes it’s the only way to get a good seal on those weird spots. But here’s what I’m wondering: have you noticed any difference in long-term performance between the screws with integrated washers versus the ones where you add your own? I’ve had mixed results, especially after a couple hailstorms.
- I’ve had the same debate with myself—integrated washers vs. separate ones. Honestly, after a couple years and a few nasty hailstorms, I’m not convinced the integrated ones hold up any better.
- The rubber on the integrated washers seems to dry out faster in our climate (I’m in north Texas, so we get those big temp swings). I’ve seen them crack and let water in, especially if they weren’t seated just right.
- The separate washers give you more control, but it’s easy to mess up the install if you’re moving fast or working at weird angles. I’ve had a few where the washer slipped and didn’t seal at all—didn’t notice until the next rain.
- Butyl tape is a lifesaver for odd spots, but I’ve noticed it can get gummy and attract dirt over time. Not a huge deal, but it looks messy if you care about that sort of thing.
One thing I’m curious about: have you ever tried those stainless screws with neoprene washers? I used them on a shed roof last year, and so far they seem to be holding up better than the standard galvanized ones. No leaks yet, even after a couple hail hits, but it’s only been 18 months.
Also, how are you handling insurance claims after hail? My last adjuster barely looked at the fasteners—just focused on dents and dings. Wondering if anyone’s actually gotten coverage for failed seals or leaks around screws, or if that’s always out of pocket.
Curious what others are seeing with different brands too. Some of the cheaper screws from the big box stores seem to rust way faster, even when they say “weather resistant.” Maybe it’s just our humidity...
Those stainless screws with the neoprene washers are actually what I recommend most of the time, especially for folks around here dealing with hail and wild weather swings. I’ve seen them hold up better than the standard galvanized ones, but like you said, 18 months is still pretty early days. The real test seems to come after about three or four years—by then, if they’re gonna fail, you’ll start seeing those little rust streaks or the washers shrinking up. I’ve noticed some brands use a thinner neoprene that just doesn’t last as long, so it’s not always apples to apples.
Insurance is a whole other headache. Most adjusters I’ve met don’t even look at fasteners unless you specifically point out leaks or visible damage around them. It’s usually all about the big stuff—dents in panels, torn-up flashing, that sort of thing. I did have one client who managed to get coverage for water intrusion around failed screws, but only because we documented active leaks and showed photos of the cracked washers right after a storm. Even then, it was a fight. Seems like unless there’s obvious water damage inside, they chalk it up to “maintenance” and leave you hanging.
I hear you on the cheap screws from big box stores too. Some of those “weather resistant” labels are pretty optimistic... I’ve pulled out screws that were rusted through in under two years, especially on south-facing slopes where the sun just bakes everything. Humidity definitely speeds it up, but honestly I think some of those coatings just aren’t up to Texas weather.
Curious if anyone’s tried those ceramic-coated fasteners? I keep seeing them pop up at supply houses but haven’t had a chance to check how they hold up long-term. Are they worth the extra cost, or just another marketing gimmick?
Funny thing about those stainless screws with neoprene washers—everyone swears by them, but I’ve actually seen a few letdowns, especially when they’re used on roofs with a really steep pitch or in spots that get hammered by wind-driven rain. The neoprene’s supposed to be the hero, but sometimes it just gives up early, especially if the installer over-torques and squishes it too thin. I’ve pulled a handful of screws where the washer looked like a pancake after just a couple seasons... not exactly confidence-inspiring.
I get the appeal of stainless, but honestly, I’ve had better luck with some of the newer galvanized fasteners that use a thicker EPDM washer instead of neoprene. They seem to hold their shape longer, and the EPDM doesn’t get brittle as fast in the sun. Maybe it’s just the brands I’ve run into, but the difference is noticeable—no little black crumbs under the screw heads after a couple Texas summers.
On the insurance front, yeah, it’s a circus. The one time an adjuster actually cared about fasteners was when I pointed out water stains running down a rafter right below a row of failed screws. Even then, he acted like I was showing him Bigfoot. Unless you’ve got Niagara Falls coming through your ceiling, they just shrug and call it “wear and tear.” Makes you wonder if they’ve ever actually looked at a roof up close.
As for ceramic-coated fasteners, I tried them once on a shed project—figured I’d be the guinea pig before using them on someone’s house. Two years in, no rust, but I haven’t exactly put them through hurricane season either. They were pricier, and the coating seemed tough, but who knows how they’ll look after five years of Texas sun and hail. Sometimes it feels like every “new and improved” fastener is just a fancier way to separate you from your lunch money.
Anyway, I’m not totally sold on one type over another yet. Seems like no matter what you pick, if the install’s sloppy or the washers are junk, you’re gonna be chasing leaks eventually.
I’ve seen the same thing with over-compressed neoprene washers—sometimes folks just crank them down way too hard and then wonder why they’re leaking a year later. EPDM definitely seems to last longer in the sun, at least here in central Oklahoma. Curious if you’ve noticed any difference in noise with the different fasteners during hail or heavy rain? I’ve had tenants complain about “pinging” on metal roofs, and I’m not sure if it’s the screw type, washer, or just the roof design itself...