Repairing Fiberglass Roof Holes In A Pop-Up Camper

Owning a pop-up camper can be a great joy, but it also comes with its fair share of maintenance and repairs. One common issue that many owners face is dealing with holes in the fiberglass roof, which can be caused by physical damage or temperature fluctuations. While repairing a fiberglass roof can be labour-intensive and costly, it is possible to fix minor cracks and blemishes with some DIY know-how. This involves cleaning, drying, and sanding the affected area before applying repair sealants or a liquid rubber sealant. For more extensive damage, professional assistance may be required. Regular roof inspections and maintenance are crucial to preventing issues and extending the lifespan of your pop-up camper's roof.

Causes of roof holes

There are several factors that can contribute to the development of holes in a pop-up camper fiberglass roof over time. Here are some of the most common causes:

Temperature Fluctuations

The continual expansion and contraction of the fiberglass roof due to changing temperatures can lead to cracks or gaps. This is known as thermal expansion, and it occurs when the roof heats up during the day and then cools down at night. The problem can be exacerbated if the roof was not installed correctly, such as if there is no space between the perimeter edges of the roof and the timber boards underneath.

Physical Damage

Physical objects such as tree branches can scrape against and puncture the roof while the camper is in motion or parked under a tree. Additionally, strong winds can cause awning poles to damage the roof, and rocks or hail can also pose a threat.

Improper Installation

If the roof was not installed correctly, such as if the top coat of resin was not applied properly or if the wrong type of boards were used, it can lead to cracks and other issues.

Age and Weathering

Over time, the top coat of a fiberglass roof can lose its elasticity, leading to a shrivelled and cracked appearance known as alligatoring. This is a sign that the roof has reached the end of its lifespan and needs to be replaced.

Pinholes

Pinholes are small holes that appear in the top layer of resin on a fiberglass roof. They are typically caused by an improper application of the resin or an insufficient amount being used. While they may seem harmless, pinholes can lead to water ingress during rain and high winds, resulting in leaks.

Delamination

Delamination occurs when layers within the fiberglass material separate due to changes in temperature or moisture levels, causing adhesion failure between surfaces. This can lead to blistering and bubbling of the surface, which, if left unrepaired, can result in complete structural failure.

Types of camper roofs

There are several types of camper roofs, each with its own advantages and drawbacks. Here is an overview of the most common types:

EPDM (Ethylene Propylene Diene Terpolymer/Monomer)

EPDM is a type of rubber roofing that is widely used in commercial roofing. It is stretchy, durable, and easy to install. This type of roof is lightweight and resistant to dents, scratches, and scuffs. It has a long lifespan of 15-30 years and is economical to repair and replace. However, it is vulnerable to punctures and absorbs heat, making it less suitable for hot environments.

TPO (Thermoplastic Polyolefin)

TPO is a rubber-like material with heat-reflective properties, making it suitable for different climates. It is slightly more robust than EPDM but may be susceptible to damage due to aged or faulty caulking. TPO typically comes in a white finish and is installed by applying an adhesive to the roof's plywood and rolling out the rubber sheet. While TPO is more affordable than fiberglass or aluminum, it requires sealing and will wear down faster.

Fiberglass

Fiberglass roofs are made from thin fibers of glass woven together and set in a resin or epoxy, creating a smooth, strong, lightweight, and flexible material. This type of roof is durable, waterproof, and resistant to rust and rot. However, repairs can be labor-intensive and expensive, and it may not be heat-resistant, leading to thermal splits in hot weather.

Aluminum

Aluminum roofing is incredibly durable and can withstand damage that other materials cannot, including punctures. However, it is susceptible to dents and is the heaviest roofing material. It lacks the heat resistance offered by rubber roofs, and repairs or replacements may be less DIY-friendly.

PVC

PVC is another option for camper roofs, though less common than the above materials. It is similar to an inground pool liner and is constructed with a plasticizer to keep it flexible. PVC roofs are resistant to tears, dirt, and sunlight, and they are generally thicker and stronger than rubber roofs. They are also low maintenance and easy to clean.

Each type of camper roof has its advantages and considerations, and the choice depends on factors such as climate, desired maintenance level, cost, and weight constraints.

Regular roof inspections

Frequency of Inspections:

It is recommended to inspect your pop-up camper's roof every 30 to 90 days. This frequent checking can help detect potential issues early on, reducing the need for costly and time-consuming repairs. Set a schedule for inspections and stick to it to ensure the longevity of your camper.

Areas to Focus On:

When inspecting your pop-up camper's roof, there are several key areas that require your attention:

• Seams and Caulking: Pay close attention to the seams of the roof, looking for any signs of hardening or separation. Check if the caulking is intact and flexible.
• Vents, Air Conditioners, Antennas, and Solar Panels: Inspect the areas around these fixtures for any signs of leaks or damage.
• Leaks: Keep an eye out for any signs of water intrusion. Leaks can be tricky to spot, especially on fiberglass roofs, as the water may travel along the interior roof until it finds an opening.
• Exterior Condition: Check the roof for any physical damage, such as punctures, cracks, or gaps caused by falling branches or debris.

Cleaning and Maintenance:

Regular cleaning is an essential aspect of roof maintenance. Use a long-handled sponge mop or soft brush to remove dirt, grime, mold, mildew, tree sap, and bird droppings. Rinse thoroughly to prevent residue buildup. Keeping the roof clean will make it easier to spot issues during inspections and will help maintain the overall condition of the roof.

Record Keeping:

Maintain a logbook or record of your roof inspections. Note down any issues found, repairs carried out, and the dates of inspections. This record will help you track the condition of your roof over time and identify any recurring problems. It can also be useful when it comes to selling your camper, as it demonstrates a history of diligent maintenance.

Seek Professional Assistance:

If you identify significant damage or extensive wear during your inspections, don't hesitate to seek professional assistance. Repairs to fiberglass roofs, in particular, often require expert knowledge and tools. Getting a professional opinion can help ensure that the repairs are done correctly and safely, giving you peace of mind and prolonging the life of your pop-up camper.

Keeping the roof clean

Keeping your pop-up camper's roof clean is an essential part of its maintenance. Not only will it keep your camper looking good, but it will also help protect it from the elements and prevent damage. Here are some detailed tips to help you keep your camper's roof clean and well-maintained:

Choose the Right Time:

Clean your camper's roof early in the morning or later in the evening to avoid direct sunlight, which can cause water spotting and reduce the effectiveness of any wax treatments. Avoid cleaning in the rain, as run-off can mark the sides of your vehicle.

Prepare the Roof:

Before cleaning, seal any openings, such as air conditioning vents and roof windows, with waterproof fiberglass mesh tape to create a protective barrier. This will prevent water and cleaning products from trickling into gaps and causing damage.

Use the Right Tools:

Use a telescopic wash brush, soft-bristle brushes, laminating brushes, and a pressure washer or hose for efficient cleaning. Be cautious when using a pressure washer, and avoid directing high-pressure jets of water at seals.

Adopt a Methodical Approach:

Start cleaning from one corner and work in small sections, such as 3ft x 3ft areas. This will make the task more manageable and prevent you from accidentally stepping on freshly cleaned areas.

Clean Regularly:

Aim to clean your camper's roof at least once a month to prevent the build-up of dirt, bird droppings, tree sap, and other contaminants that can damage the roof over time.

Use the Right Cleaning Products:

Choose non-toxic, biodegradable cleaning solutions without harsh abrasives. These products will effectively remove dirt and grime while protecting the roof's finish.

Wax Treatment:

Apply a specialized wax treatment designed for fiberglass roofs every couple of months or at least once or twice a year. This will enhance the roof's appearance and protect it from UV damage.

Deal with Tough Stains:

If your roof has oxidation, which can make it look chalky and dull, use a specialist fiberglass stain remover or a high-quality stain-absorbing gel to refresh its appearance.

Apply a Roof Coating:

Consider applying a specialist RV fiberglass roof coating with acrylic fiberglass resins. This will create a protective layer and help the roof cope with expansion and contraction due to temperature changes. Choose a brilliant white coating to increase reflectivity and reduce the interior temperature during hot weather.

Keep it Covered:

If indoor storage is not an option, invest in a high-quality waterproof roof cover made from breathable fabric. This will protect your roof from the elements and prevent mold and mildew growth.

Remember, always put safety first when cleaning your pop-up camper's roof. Wear slip-resistant shoes, and if you're unsure about any aspect of the cleaning process, don't hesitate to seek professional advice or assistance.

Repairing a rubber roof

Rubber roofs are generally easy to repair. The first step is to clean the damaged area and inspect the extent of the damage. If the damage is minor, a self-levelling sealant can fill in any seam holes or cracks. For larger punctures or tears, a rubber roof patch or tape will be needed.

Locating the Leak

Before attempting any repairs, it is important to find the source of the leak. Water can travel some distance from the leak itself, so take your time and inspect carefully. Check for cracks or tears in the rubber membrane and loose or separated seams. Also, check the rooms directly below the roof for signs of water damage such as mould or mildew growth or water stains on the ceilings or walls.

Preparing for the Repair

Once you have identified the leak, gather your tools and materials. For a rubber roof, you will need EPDM rubber roofing material, high-density fibreboard substrate, rubber-to-rubber contact cement, screws and metal washers. Remember to prioritise safety by having someone hold the ladder for you, avoiding working in wet or windy conditions, covering any skylights, and wearing gloves.

Patching the Roof

The first step is to cut around the damaged area with a utility knife, creating a square or rectangular opening. Peel back the rubber roofing and expose the substrate. If the substrate is wet or damaged, remove it and replace it with a new piece of high-density fibreboard. Secure the new substrate with screws and metal washers.

Next, prepare the patch by cutting a piece of EPDM rubber roofing that is slightly larger than the repair area. Clean the roof area around the repair and the underside of the patch with a membrane cleaner to ensure proper adhesion.

Apply rubber-to-rubber contact cement to half of the repair area and half of the rubber patch with a paint roller. Allow it to dry for about 10 minutes, then carefully align and press down the rubber patch without stretching the material. Repeat the process for the remaining half of the patch.

Finally, seal the edges by applying a bead of lap sealant around the perimeter of the patch to create a watertight seal.

Maintenance

To extend the life of your rubber roof, regular maintenance is key. Clean the roof with a mild detergent and water to remove dirt and organic growth. Inspect your roof twice a year and after severe weather events. Keep the roof clear of debris, which can puncture the membrane. Reapply lap sealant to seams and edges every few years, and trim overhanging tree branches to prevent damage from falling limbs.

Frequently asked questions