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Roof Repair



Butyl Liquid Rubber Application

roof leaks

For a complete list of suggested applications, click here.

Preparation. Although light rain can directly fall on the Butyl Liquid Rubber 2-3 hours after it has been applied (assuming temps above 60°), we suggest you plan a day when rain is not in the forecast. Butyl Liquid Rubber may be applied at any temperature above 50°, but we suggest between 55°-80° for best results. Butyl Liquid Rubber needs a temperature at least 55° for the product to cure. Many people have asked us if they can apply it below that temperature. The answer is of course, "YES", but the curing process won’t commence until it is above 55°. Assuming you have a smooth surface that needs to be coated, the coverage per gallon is approximately 50 square feet. For rough substrates, the coverage is 40 feet per gallon. An example of a rough substrate is BUR (built-up roofing). After you have completed the application, we suggest waiting approximately 24 hours before walking on the surface. It will develop a skin within 2-3 hours. For any separation in the joints, we suggest filling them with Rubex caulk found on or order form. This caulk has been field tested and is compatible with Butyl Liquid Rubber and will not void its warranty. It is free of any solvents or isocyanates and is 100% volume solids.

Any rips in seams or spacing more than 1/15 of an inch, we suggest reinforcing with either poly-fabric or butyl two-sided tape. Both are available on our order form. Any holes, gaps, seams or tears (of more than 1/16-inch) should be repaired or reinforced. Rusted areas on your metal roof need to be brushed with a wire brush to remove as much of the oxidized rust as possible. Any light corrosion that is not loose is fine for applying Butyl Liquid Rubber over. For heavy rust, a rust inhibitor is suggested prior to coatings with Butyl Liquid Rubber.

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Before applying the product, ensure that the surface is clean from any debris that could be picked up in the application with the roller. Surface should be cleaned with Roof Protect to ensure proper adhesion. Roof Protect was field texted to be compatible with our product line and will not void the warranty. Roof Protect emulsifies contaminants and provides improved surface preparation by effectively removing oil, grease, mildew, dirt, and other soils from your roofing membrane. You can also use Roof Protect annually to further protect your roof allowing dirt and grease etc to be removed, further extending your roof's service life. Be sure that the surface of the roof is perfectly dry before applying Butyl Liquid Rubber. Butyl Liquid Rubber will not adhere to moist or damp surfaces, particularly on summer mornings, let the dew dry. Keep some Xylene or basic mineral spirits on hand just in case you get the Butyl Liquid Rubber on unwanted areas. The shelf life of the product is five years. We are not responsible for product that is not stored at room temperature or past the shelf life

This is a true one-coat application. There is no need for a second coat. Pour the material onto flat surfaces and then spread with a squeegee. Reapply over the areas with a short nap roller 3/8th inch thick. You want to be sure you apply the material at 20 mil.

Butyl Liquid Rubber Mixing and Characteristics

One of the more popular characteristics of Butyl Liquid Rubber is that it self-levels as the proper mill rate is achieved, versus the competition, where this needs to be addressed during the application.

An electric drill and a mixing shaft are needed, which are available on our order form for purchase. A rubber squeegee and short nap or medium roller 3/8th inch.

The short nap roller will smooth out any trapped air. The squeegee is used to evenly distribute the Butyl Liquid Rubber. Get a squeegee and a roller with a long handle to eliminate the need to do the entire project on your knees. Standing much easier.

When determining your overall square footage (surface area), be sure to measure the true area. For example, assume that you have a metal corrugated roof. You need to look at the square footage of the raised areas of the roof and add that to your total square footage. If this is your first-time applying Butyl Liquid Rubber, we suggest you chalk your roof off into either 50 sq. ft. or 200 sq. ft. sections. When you are done filling in the area you should be done with either a gallon or four-gallon pail. This is how you know you are applying it at the recommended spread rate.

We will use an example of two gallons for the remainder of this section. Imagine you just received two gallons and will be applying them to the first section - a pre-measured, 100 sq. ft. section.

The key is to spread the product evenly because you don’t want it too thick in some areas and too thin in other parts of the roof. Next, lets discuss curing temperature. In warm climates where daytime temps are in the 70s or 80s, Butyl Liquid Rubber will begin curing within an hour. As long as the lid is properly placed on the pail so air cannot get into it, the pot life is irrelevant since the shelf life is five years. This allows you to store the product in the event of an oncoming storm or unforeseen need to stop working for the day. You want to mix the Butyl Liquid Rubber so a vortex is created for about 3-4 minutes.

application liquid rubber coatings

Note: the product will take light foot traffic after it is fully cured for workers to get on the roof for inspections, air conditioning work etc.

Applying Butyl Liquid Rubber

Here is what you need:

  • Electric drill (cordless drills will be effective)
  • A mixer for a can or pail (paddle mixer), available on our order form
  • A long handle rubber squeegee.
  • One long handle short nap roller approx. 1/4”.
  • Chip brush
  • Rubber spatula
  • Mineral spirits or Xylene for clean up
  • Bag of Rags

Using long handles will allow you to apply the product standing vs having to work on your knees. The paintbrush is for the corners and hard to reach sections. Broadcast the material in a letter “S” manner and then spread it using the squeegee. Follow up with the 3/8th inch nap roller to smooth any trapped air and equitably distribute the Butyl Liquid Rubber®. Any mistakes such as drips or splatters should be cleaned off with rags. The Xylene and/or mineral spirits should only be used on the Butyl Liquid Rubber when it is still wet.


To avoid any potential bubbling during the drying process we suggest Appling a "flash coat" (a very light coat) YOU DO NOT NEED MORE THAN 0.75 gal per 100 square feet. The flash coat DOES NOT require purchasing additional material. Too thick of a flash coat may result in temporary bubbling of the material. But the bubbling will ALWAYS go down! A minimum 24-hour cure time is required before proceeding with main coat. Cooler temps or high humidity may retard your cure times. The flash coat should be completely dry before applying the final coat. After September, we suggest at least 36 hours between flash coat and main coat due to environmental conditions. Cooler ambient air temperatures and active dew points play a factor in the flash coat as they will also increase cure times.

This product is for outdoor use. If you choose to use it indoors, you will need a Niosh respirator, available at Home Depot or Uline. As the product begins to dry any brush or roller marks will disappear and what is left is a seamless coating. It will be as if someone just installed a custom fit piece of membrane, just for your RV. Apply today and drive away tomorrow! It’s that easy. Clean-up is with Xylene available at any paint store.

The product has a five-year shelf life as long as you affix the lid properly, so air does not get in.

Apply the Butyl Liquid Rubber

Now you are ready to begin. There is no need to wait for the product once it is mixed. Use the rubber squeegee to spread the product over the area as evenly as possible. An even application is important. Make sure that some areas are not thicker than others.

Use the squeegee again for broadcasting the Butyl Liquid Rubber and use the short nap roller to achieve even distribution and to release trapped air bubbles. Choose your application speed so the roller doesn’t pull materials along. Make several strokes with the roller to get an even and bubble-free application.

You may initially see some roller/brush strokes. After a few minutes, it will form a smooth seamless membrane.

Butyl Liquid Rubber will be somewhat tacky for a couple hours. It will still not be fully cured for 6-8 hours, but you will be able to walk on the roof/surface within 24 hours, assuming temps were 55° and above. Higher temperatures will decrease the curing time and lower temperatures will increase the time.

pricing and ordering

Spraying Butyl Liquid Rubber

There are more details on spraying in our brochure, which can be printed from our website. Airless equipment needs only one hose from pump to gun, but it must generate pressures of 3,500 to 4,000 psi, and specific hose length needs to be used due high pressure drops. Air-atomized equipment requires two hoses to the gun, making it more cumbersome to maneuver. It also requires the addition of a compressor.


Equipment Specifications

PUMP must be capable of delivering three to four gallons per minute at 3,500 to 4,000 psi HOSE with 3/8-inch ID max. Permissible length is 150 feet when using a .019 tip with 1/2-inch ID maximum. Permissible length is 200 feet when using a .21 tip.

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