If damage extends to within 2 inches (50 mm) of the roof edge or the header extension plate, extend
the patch to the edge of the roof or header extension plate and use the original fastener holes.
If a patch will terminate within 2 inches (50 mm) of another patch, combine the two patches into one
Patches must adhere to the underlying foam.
Do not drill through or rivet through roof bows when securing patches.
(1) Flatten the panel surface free from distortion, wrinkles and creases. If necessary, cut away damage until the
surface is flat, leaving a rectangular hole with even edges.
(2) Check foam insulation for moisture and damage. If foam is damaged, notify Direct Support Maintenance.
The patch material must be of the same type and thickness of material as the original roof panel.
(3) Prepare a rectangular patch with rounded or chamfered corners so that the patch will overlap the damaged
area by at least 2 inches (50 mm) on all sides.
If the damage to be repaired is within 2 inches (50 mm) of the roof edge, the patch must extend to the roof
edge and overlap the roof edge by 1/2 inch (13 mm) so the patch can be turned down over the rail to form a
seal. The side edge will be secured to the rail by drilling holes using the original rivet holes in the top rail as
(4) Center patch over damage and drill four holes, one in each corner of the patch, 1/2 inch (13 mm) in from the
edge. To reduce damage to the foam insulation, use a stop on the drill bit to limit depth of drill to 3/4 inch
(20 mm). Be certain that drill holes and fasteners will miss roof bows.
(5) Secure the patch with clips or clamps and drill the remaining holes around the border of the patch. Holes
should be drilled on 1 inch (25 mm) centers, 1/2 inch (13 mm) in from the edge.