Hi everyone, ive been working on a patio to room conversion this year and i finished recently, did not add the carpet yet. All goes well most of the time and my wife and I are able to sleep in there comfortably but for the past couple weeks there has been heavy rain fall and I do live in Florida so heat and expansion is also an issue as my walls are purely made of aluminum with foam insulation. I have caulked everything inside and out, even with the best exterior sealants I could find and somehow minor leaks still happen. Its like dribbles but it can obviously lead to bigger ones and mold and mildew. So if anyone has any ideas that would be awesome im open to anything, as a new home owner im finding out all kinds of things everyday.

 

There is not really a solution to that. You are expecting something to be better than what it was originally designed to be.

 

I really can't imagine that theres no solution..just one that hasn't been thought of yet, what about creating some kind of dam or overhead cover that keeps most of the rain out, im sure someone else out there has ran into the same issues and im hoping they share their ideas.

 

A little hard to give specific suggestions when we can't see the room. Post pictures if you want ideas. Otherwise your question is extremely vague.

 

Was a permit pulled? If so and you followed code, I would imagine the building inspector has seen these kinds of issues before and may have specific suggestions.

 

The op could describe the location of the leak better if you want us to understand the problem better.

He said it's a aluminum room, foam walls. These are more commonly known as 3 season rooms. (They were not designed to be living space... but more like a enclosed porch) The panels are modular, with sliding windows. The foam is usually covered with a anodized aluminum skin and the modular sections snap together... it's a kit. They sit in a aluminum sill track that quickly becomes filled with mud, and the weep holes that are supposed to allow water to drain out quickly get plugged with mud... or plugged by someone who caulked every hole shut with a caulking gun. The joints where the sill pieces butt together commonly leak... and at corners and end walls. The roof is usually a thicker 4" foam panel, usually 4ft wide x the length of the room. The roofs need to be maintained regularly with appropriate sealants to precent them from leaking. I put a few of these together, we used to sell and install them locally, so I know a bit about them.

That's why I said you are expecting more from the room than it was intended to be, if you expect it to be as comfortable or as leakproof as something that is standard construction.

Put a giant sun sail over the room to shade it from the rain, or maybe tarp it with those blue fema tarps. Or call a company that installs these sort of rooms and have them put a larger roof over it with larger overhangs. (The rooms we installed were by Mason Corporation.) You probably aren't going to fix your leaks with a caulking gun.