I have a 40ft x 26ft polycarbonate sheet roof that is leaking like a sieve. The main cause of the leak is that the hardware store strategically placed the wrong sized screws next to the panels. These screws are too short to barely cut into the wood purlins and the EPDM rubber washers are too small. Another reason why a roof leaks is due to the capillary action of water being sucked up between the horizontal and vertical parts of the ceiling. Panel. The leak is so bad that when I see a screw that isn't leaking water, I get up to check. So I replace all 1400 screws and put butyl tape on each overlap. I'm only half done, but it works. I think I actually need 24 rolls of this stuff. So if you add the cost of heavier bolts I'm looking at an $800 repair not counting my labor. However, this repair is cheaper than the original one. with metal roof.
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