RV roof repair is a material-specific job that starts with identifying the roof material and the type of damage. Last reviewed:. Small tears and punctures can often be repaired with a compatible RV roof patch. Cracked sealant requires removal of the loose material before new sealant is applied. A soft, spongy roof may have water-damaged plywood or framing, so a surface patch will not fix the underlying problem.

RV Roof Repair at a Glance

Problem Correct repair DIY suitability
Cracked or peeling sealant Remove loose sealant and reseal the joint Suitable for most DIYers
Small tear or puncture Install a compatible roof patch and seal its edges Suitable for most DIYers
Leaking vent, skylight or antenna Replace failed sealant and, if needed, the butyl tape Moderate
Soft or spongy roof Replace damaged decking, insulation or framing Advanced
Large hole or widespread membrane failure Replace part or all of the roof membrane Usually professional

RV roofs commonly use EPDM rubber, TPO, PVC, fiberglass or aluminum. The repair product must match the actual roof material.

Check Whether the RV Roof Is Safe to Walk On

Do not assume that every RV roof can support foot traffic. Check the owner's manual, manufacturer specifications or the roof's weight-rating label.

If the roof is not designed for walking, work from a secured extension ladder. You can also use a properly supported sheet of plywood to spread your weight, provided it does not damage the roof or shift while you work.

Choose a dry day with moderate temperatures. The repair area must be clean and fully dry before you apply tape, adhesive or sealant.

What You Need

For a basic RV roof repair, gather:

  • Compatible RV roof patch or repair membrane
  • RV roof cleaner or mild detergent
  • Stiff-bristled brush or non-abrasive scrub pad
  • Plastic scraper or trim-removal tool
  • Small hand roller
  • Compatible RV lap sealant
  • Caulking gun
  • Utility knife and measuring tape
  • Disposable gloves
  • Painter's tape
  • Replacement butyl tape if you need to remove a roof accessory

Use self-leveling sealant on horizontal roof surfaces. Use non-sag sealant on vertical surfaces and taller accessory edges.

Do not use silicone on a Dicor EPDM roof membrane. Dicor states that silicone will not adhere properly to that membrane. Check the instructions for the exact roof and sealant products before beginning.

How to Identify the Source of an RV Roof Leak

Water can enter around one roof component and appear inside the RV several inches away. Inspect the surrounding roof instead of sealing only the location of the interior stain.

Check these areas:

  1. Roof vents and skylights
  2. Antennas and satellite equipment
  3. Plumbing vent pipes
  4. Air-conditioning units
  5. Roof seams and edge molding
  6. Ladder mounting points
  7. Cracked or lifted lap sealant
  8. Tears, punctures or bubbles in the roof membrane

Inside the RV, look for stained ceiling panels, damp insulation, mold, swollen wood and soft areas around the leak. Once you stop the leak, dry wet interior materials as soon as possible.

How to Patch a Small Tear or Hole in an RV Roof

A patch is suitable when the surrounding roof is structurally sound and the damage is limited to a tear, puncture or small hole. Commercial RV patch kits are available for many EPDM, TPO, PVC, fiberglass and metal roof applications. Follow the patch manufacturer's compatibility instructions.

1. Clean and Dry the Damaged Area

Remove dirt, grease, loose coating and other debris. Use the cleaner specified by the patch manufacturer. Some kits call for hot water, mild detergent and a stiff brush, while others require a manufacturer-approved roof cleaner.

Let the area dry completely before continuing.

2. Cut the Patch to Size

Cut the patch so it extends at least 2 inches beyond the damaged area on every side. Round the corners if the product instructions allow it. Rounded corners are less likely to lift than sharp corners.

3. Apply the Patch

Remove the backing and place the patch over the tear or hole. Start at one side and press outward to keep air from becoming trapped beneath it.

Do not repeatedly lift and reposition a pressure-sensitive patch. Doing so can weaken the bond.

4. Roll the Patch Firmly

Use a small roller to press the patch into the roof surface. Work across the entire patch, paying close attention to the perimeter and any textured areas.

5. Seal the Patch Edges

Apply compatible RV lap sealant around the patch when the repair product requires it. Dicor's EPDM repair membrane instructions call for lap sealant around the patch edge after the patch has been rolled down.

Do not cover a large roof area by joining repair strips edge to edge unless the manufacturer specifically permits that installation. Some repair membranes prohibit butt joints.

How to Reseal Cracked or Peeling RV Roof Sealant

Resealing is usually the right repair when the roof membrane is intact but the sealant around a vent, seam or accessory has cracked, shrunk or lifted.

1. Remove Loose Sealant

Use a plastic scraper or trim tool to remove sealant that is peeling or no longer bonded. Avoid cutting the roof membrane.

Sealant that remains firmly attached may sometimes be cleaned and covered. Remove any loose or failed material first.

2. Clean and Dry the Joint

Remove dirt and residue from the joint, then allow the surface to dry. Dicor specifies that surfaces must be free of dirt, loose material, oil and grease before sealant is applied.

3. Apply the Correct Sealant

Use:

  • Self-leveling lap sealant around horizontal roof fixtures, screw heads and flat roof joints
  • Non-sag lap sealant on vertical edges, corners and taller accessories
  • Butyl tape beneath a removed vent, skylight or other roof accessory before reinstalling it

Some sealants require primer on EPDM, TPO or polypropylene plastic. Dicor's Ultra Sealant, for example, requires its specified primer on TPO, EPDM and polypropylene surfaces. Follow the instructions for the sealant you purchase.

4. Allow the Sealant to Cure

Keep the repaired area dry and avoid travelling until the sealant has cured according to the product instructions.

Cure time varies with temperature, humidity, bead size and product type. Dicor states that its Ultra Sealant becomes dry in about two hours under specified conditions but may take several days to reach full cure.

How to Repair a Leaking Roof Vent or Skylight

A leak around a roof vent or skylight may require more than a new bead of sealant. Use this process:

  1. Remove loose sealant around the accessory.
  2. Inspect the flange for cracks or distortion.
  3. If the accessory must come out, lift it carefully without damaging the roof membrane.
  4. Replace the old butyl tape beneath the flange.
  5. Reinstall the accessory with suitable fasteners.
  6. Apply compatible lap sealant over the flange and exposed screw heads.

Dicor's retrofit instructions specify butyl tape beneath vents and accessories, followed by lap sealant over the perimeter and screw heads.

How to Repair a Soft Spot on an RV Roof

A soft, spongy area usually means water has damaged the plywood, oriented strand board, insulation or framing beneath the membrane. A patch may stop the leak, but it will not restore the roof structure.

A structural repair involves:

  1. Finding and stopping the original leak.
  2. Removing enough interior trim or roof equipment to inspect the substrate.
  3. Lifting or cutting back the roof membrane.
  4. Removing wet or rotted plywood, OSB, insulation or framing.
  5. Installing dry, exterior-rated replacement material.
  6. Making the replacement surface smooth and flush.
  7. Rebonding the existing membrane if it remains usable, or installing a new membrane.
  8. Resealing every edge, seam and roof accessory.

Use an RV repair professional if the membrane tears during removal, the damaged area is extensive or the roof structure feels unsafe. Repairing the structure is a different job from applying a patch.

When an RV Roof Needs Replacement Instead of a Patch

Replace part or all of the roof when:

  • The membrane has widespread cracking, shrinkage or delamination
  • Multiple large areas are torn
  • The substrate is extensively rotten
  • The membrane has separated from the deck across a large area
  • Previous repairs cover much of the roof
  • The roof remains soft after drying and localized repairs

A new membrane installation requires suitable adhesive, smooth roof decking, butyl tape beneath accessories and compatible sealants around the perimeter and roof fixtures. Dicor's installation system uses water-based bonding adhesive, butyl tape and lap sealant as separate components.

RV Roof Repair Mistakes to Avoid

  • Using ordinary household silicone on an EPDM or TPO roof
  • Applying sealant to a dirty or damp surface
  • Covering loose sealant instead of removing it
  • Using a patch that does not match the roof material
  • Applying self-leveling sealant to a vertical wall or edge
  • Ignoring a soft roof area beneath a visible tear
  • Walking on a roof that is not designed for foot traffic
  • Trapping moisture beneath a patch
  • Reinstalling a vent or skylight without replacing failed butyl tape
  • Travelling before the repair has cured