Metal Building Maintenance 101: 5 Critical Checks Most Owners Forget

When it comes to metal buildings, the biggest threat isn’t a storm or a fire—it’s neglect. Proper maintenance doesn’t just extend the life of your building—it protects your investment, keeps occupants safe, and ensures your warranties stay intact.

Metal buildings are engineered for durability, but they still require routine upkeep to perform at their best. Skipping inspections or ignoring small issues—like rust at panel edges or loose fasteners—can lead to costly repairs, energy loss, and even structural failures over time.

This guide highlights five critical maintenance checks that building owners often overlook—plus practical steps to help you prevent problems before they start.

1. Roof Systems: Even Standing Seam Roofs Can Fail Without Maintenance

Standing seam metal roofs, especially high-performance systems like the Butler MR-24®, are some of the most reliable roofing systems available. But “reliable” doesn’t mean “set it and forget it.”

Commonly overlooked issues:

• Thermal movement loosening fasteners or clips
  

• Sealant failure around skylights, pipe boots, or HVAC curbs
  

• Blocked gutters or roof drains, leading to ponding water
  

• Mechanical damage from maintenance crews walking improperly on panels

Over time, even a small gap in a seam or penetration can lead to moisture infiltration, which damages insulation, rusts substructure, and promotes mold. In winter climates, freeze-thaw cycles can make this worse, especially along lap joints.

Best Practice: Schedule a professional inspection every 12 months—or after any significant storm event. We recommend checking:

• Panel seams and laps for movement
  

• Sealant at all curbs, vents, and penetrations
  

• Downspouts and gutters for clogs or backup
  

• Expansion joints in longer roof runs

If you’re under a roof warranty: Some manufacturers require annual inspections to keep coverage valid.

2. Foundations & Site Drainage: Structural Damage Starts at Ground Level

Poor site drainage can undermine your entire metal building. Water that collects at the base of your building can seep into the foundation, cause corrosion along base trim and panels, and even shift slab-on-grade systems.

What to look for:

• Cracks in the slab or movement in perimeter grade beams
  

• Water pooling near corners or where downspouts discharge
  

• Soil erosion near concrete pads or walkways
  

• Rust at the bottom edge of wall panels or base angles
  

Tip from the field: Buildings with severe base panel rust can require partial wall reconstruction—This can be caused by just one missing downspout extension and poorly sloped landscaping!

Drainage Checklist:

• Downspouts extended 5–10 ft from building
  

• Ground graded to slope away (minimum 5%)
  

• Check for vegetation overgrowth at drainage areas
  

• Inspect splash blocks, catch basins, and trench drains
  

Built with a pre-engineered system? Maintenance matters more.

Even if your facility was constructed using a pre-engineered metal building, regular inspections and upkeep are still essential. These buildings rely on tight system integration—from roof to wall to foundation—and a failure in one component can impact the whole structure.

3. Wall Panels & Protective Coatings: Damage Hides in Plain Sight

Wall panel systems are your first line of defense against weather, UV, and impact. But over time, even small imperfections in your panel finish can create long-term problems.

For pre-painted systems like Butler-Cote™, proper maintenance preserves not just the look, but the warranty. These finishes are engineered for up to 40 years of protection—but only if regularly inspected and cleaned.

Key maintenance actions:

• Pressure wash walls 1–2x per year to remove salt, grime, or bird droppings
  

• Inspect for dents, scratches, or cracks in the finish—especially around loading bays, trash enclosures, and walkways
  

• Touch up paint immediately to prevent exposed metal from oxidizing
  

Case in Point: Warehouses often have lower wall rust because forklifts frequently bump dock bumpers and scratch the panels—leading to quicker coating failure, often in under 5 years.

Use a flashlight during inspections. Rust often begins as subtle discoloration or bubbling around fasteners and trim.

4. HVAC, Rooftop Equipment & Penetrations: Gaps That Drain Performance

Most commercial metal buildings have at least a few penetrations in the walls or roof—HVAC units, gas lines, plumbing vents, or electrical conduits. These are some of the most commonly overlooked weak points in the building envelope.

If sealants shrink, fasteners loosen, or curb flashing fails, you’re left with water leaks, energy loss, and—in some cases—pest entry.

What to check:

• Pipe boots and curbs for hardened or cracked sealant
  

• Flashing integrity on rooftop units and wall-mounted exhausts
  

• Proper insulation and air-sealing of penetrations through conditioned walls
  

• Condensation around unsealed ducts (sign of energy inefficiency)

💡 Quick energy win: Infrared thermography or blower door testing can help detect leaks and inefficiencies in these areas—often used in LEED or high-performance buildings.

5. Fasteners, Doors & Operating Components: The Small Stuff That Breaks Big Things

Fasteners are the unsung hero of a metal building—but they’re often ignored until it’s too late.

Problems we see:

• Rusted fasteners that expand and deform wall panels
  

• Missing screws leading to wind uplift risks
  

• Overhead doors that drag or slam shut
  

• Hinges and egress hardware that don’t function properly during inspections
  

For example, a worn-out self-closing hinge on a personnel door could easily lead to a failed fire inspection—something as minor as a $20 part might delay occupancy approval if not addressed.

Checklist for fasteners and moving parts:

• Torque test random fasteners each year—especially on south and west walls
  

• Inspect overhead door tracks, seals, and guides
  

• Lubricate hinges and moving hardware semi-annually
  

• Ensure exit devices and panic hardware are code-compliant and operable

Bonus: Track Everything With a Maintenance Logbook

It may sound simple, but the best thing you can do for long-term building performance is keep a maintenance log.

This should include:

• Date of inspections
  

• Areas reviewed
  

• Notes on repairs or follow-up items
  

• Contractors used and materials installed
  

This documentation is crucial when filing insurance claims, proving compliance during inspections, or maintaining eligibility for roofing and wall panel warranties.

Schedule a Pro Maintenance Review With Seufert Construction

Seufert Construction has been building and maintaining commercial and industrial buildings across Southern Indiana for over 150 years. We’re a certified Butler Builder®, which gives us access to industry-leading metal building systems, roofing technology, and support.

We offer:

• Annual inspection packages
  

• Maintenance plans tailored to your building type and use
  

• Expertise across roofing, structural systems, and site drainage
  

Serving Ferdinand, Evansville, Louisville, and surrounding Southern Indiana towns. Ready to protect your investment? Request a building maintenance assessment with our team today.