Common RV Flex Armor Problems and Their Solutions: A Comprehensive Guide

Recreational Vehicles (RVs) offer an unparalleled sense of adventure and freedom, allowing travelers to explore the world on their terms. However, like any complex machinery, RVs can encounter problems, and one common issue many RV owners face is related to their Flex Armor roofing systems. Flex Armor, a popular choice among RV enthusiasts for its durability and weather-resistance, can still experience a range of problems that require timely attention and expert solutions. In this article, we will delve into seven common RV Flex Armor problems, their underlying causes, and the best ways to address them effectively.

Problem #1: Delamination and Bubbling

Delamination and bubbling occur when the Flex Armor roofing material separates from the underlying structure, leading to the formation of bubbles on the surface. This not only impacts the aesthetics but can also compromise the integrity of the roof. Delamination can begin as a small bubble, but if left unattended, it can spread and cause significant damage to the roofing system.


  • Poor Installation Techniques: Improper installation, such as insufficient adhesive application or inadequate surface preparation, can lead to delamination issues.
  • Exposure to Extreme Temperature Fluctuations: Constant exposure to varying temperatures causes the Flex Armor to expand and contract, putting stress on the adhesive and leading to delamination.
  • Moisture Infiltration: If moisture finds its way between the Flex Armor and the underlying structure, it can weaken the adhesive, causing delamination.
  • Inadequate Adhesive Application: If the adhesive used during installation is of poor quality or not applied in the right quantity, it may fail to bond the Flex Armor securely.


  • Consult a Professional RV Repair Specialist: For significant delamination problems, it’s best to seek the help of a professional RV repair specialist. They can assess the extent of the damage and recommend appropriate solutions.
  • Minor Delamination: For minor cases, you may apply pressure to the bubble to re-adhere the Flex Armor to the roof. Then, inject adhesive underneath the bubble and use a roller to smooth out the area.
  • Severe Delamination: In severe cases, where the delamination is widespread or has caused structural damage, a complete roof replacement might be necessary to ensure a long-lasting solution.

Problem #2: Punctures and Tears

Punctures and tears in the Flex Armor membrane can occur due to various reasons, including low-hanging branches, hailstorms, or accidental damage while walking on the roof. These openings can allow water to infiltrate the roofing system and cause leaks.


  • Collisions with Branches or Other Objects: Low-hanging branches or overhanging obstacles can scrape or puncture the Flex Armor when driving through wooded areas or tight spaces.
  • Sharp Objects on the Roof: Tools, equipment, or other sharp objects placed on the roof can accidentally cause tears when stepped on or moved around.
  • Heavy Foot Traffic without Proper Precautions: Walking on the roof without proper care, especially in areas where weight is not evenly distributed, can lead to punctures and tears.


  • Clean the Affected Area and Allow it to Dry: Before attempting any repairs, thoroughly clean the area around the puncture or tear with a mild soap solution and water. Allow it to dry completely.
  • Apply a Patch Specifically Designed for Flex Armor Roofing: Use a Flex Armor patch kit to cover the puncture or tear. Follow the manufacturer’s instructions for proper application.
  • Seek Professional Help for Extensive Damage: If the damage is extensive, or if leaks persist despite patching, it’s crucial to consult a professional RV repair service. They can identify and fix any underlying issues and ensure a thorough repair.

Problem #3: Water Leakage

Water leaks are a common and serious issue that RV owners face. If not addressed promptly, they can lead to extensive water damage inside the vehicle. Detecting and fixing leaks early is crucial to prevent costly repairs and maintain the structural integrity of the RV.


  • Damaged or Cracked Seams and Seals: Over time, the seams and seals of the Flex Armor roofing system may degrade due to exposure to the elements, causing water to seep through.
  • Improper Installation of Rooftop Fixtures: If rooftop fixtures such as vents, air conditioning units, or antennas are not installed correctly or have worn-out seals, they can become entry points for water.
  • Deteriorated Caulking Around Roof Edges: The caulking around the edges of the RV roof can degrade over time, leading to gaps through which water can penetrate.


  • Regularly Inspect Seams, Seals, and Caulking: Perform regular inspections of all seams, seals, and caulking on the roof. Look for signs of wear and tear, cracks, or gaps.
  • Re-caulk Damaged Areas Using RV-Grade Sealant: If you identify any damaged or deteriorated caulking, remove it completely, clean the area, and apply a fresh coat of RV-grade sealant to ensure a watertight seal.
  • Consult a Professional for Persistent Leaks: If you continue to experience water leakage despite your best efforts, it’s essential to seek professional help. An experienced RV repair specialist can conduct a thorough inspection and identify the source of the leak, ensuring effective and lasting repairs.

Problem #4: Fading and Chalking

Fading and chalking refer to the discoloration and powdery residue that develop on the Flex Armor surface over time, mainly due to exposure to UV rays and harsh weather conditions. While these issues may not impact the roof’s integrity, they can detract from the RV’s overall appearance.


  • UV Radiation: Constant exposure to UV rays can cause the Flex Armor’s surface to fade and lose its original color.
  • Atmospheric Pollutants: Airborne pollutants, such as industrial emissions and car exhaust, can settle on the roof’s surface and contribute to chalking.
  • Harsh Weather Elements: Rain, snow, and extreme temperatures can accelerate the degradation of the Flex Armor’s top layer.


  • Regularly Clean the Roof: Wash the Flex Armor roof with a mild soap solution and a soft brush to remove dirt, debris, and pollutants that can contribute to fading and chalking.
  • Apply UV-Protective Coatings: There are specialized UV-protective coatings available for Flex Armor roofing systems. These coatings act as a barrier against UV radiation and help maintain the roof’s original appearance.
  • Use RV Covers or Park in Shaded Areas: When not in use, consider using an RV cover to protect the roof from direct sunlight. Parking the RV in shaded areas can also help reduce UV exposure and slow down fading and chalking.

Problem #5: Mold and Mildew Growth

Mold and mildew thrive in damp environments, and RVs can be susceptible to such growth, particularly if moisture accumulates on the Flex Armor surface. Besides being unsightly, mold and mildew can also pose health risks to occupants.


  • Poor Ventilation: Inadequate ventilation can lead to excess moisture accumulation inside the RV, creating an ideal environment for mold and mildew to grow.
  • Trapped Moisture Under the Roof Membrane: If water infiltrates the roof structure and gets trapped under the Flex Armor membrane, it can create a damp environment that encourages mold and mildew growth.
  • High Humidity Levels: Camping in areas with high humidity levels can increase the likelihood of mold and mildew formation inside the RV.


  • Improve Ventilation Inside the RV: Ensure that your RV’s ventilation system is functioning correctly. Use exhaust fans when cooking or taking showers to reduce humidity levels.
  • Inspect and Fix Leaks: Regularly inspect the roof and other areas of the RV for signs of leaks. Promptly address any leaks or water ingress to prevent moisture buildup.
  • Use Mold and Mildew Inhibitors: There are various mold and mildew inhibitors available on the market that can be applied to the Flex Armor surface to prevent their growth. Follow the manufacturer’s instructions for proper application.

Problem #6: Cracking and Shrinkage

Flex Armor roofing can experience cracks and shrinkage, especially when exposed to drastic temperature fluctuations or as it ages over time. Cracks can lead to water leakage, while shrinkage can cause stress on the roofing system.


  • Temperature Changes: Flex Armor roofing materials expand in hot temperatures and contract in cold temperatures. Over time, these continuous temperature fluctuations can lead to cracking.
  • Roof Aging and Wear: As the RV roof ages, the Flex Armor material may become less flexible and more susceptible to cracking and shrinkage.


  • Apply a High-Quality Elastomeric Roof Coating: To improve the roof’s flexibility and prevent further cracks, consider applying an elastomeric roof coating specially designed for Flex Armor roofing systems.
  • Ensure Proper RV Maintenance: Regularly inspect the roof for signs of wear and tear, and address any issues promptly. Proper maintenance can prolong the life of the Flex Armor roof and reduce the likelihood of cracking and shrinkage.

Problem #7: Poor Insulation and Energy Efficiency

Inadequate insulation and energy inefficiency can result in discomfort during extreme weather conditions and increased energy consumption within the RV. A well-insulated RV not only ensures a comfortable living space but also helps reduce energy costs during heating and cooling.


  • Insufficient or Damaged Insulation Material during Installation: If the Flex Armor roofing system’s insulation material is improperly installed or damaged, it may not provide adequate thermal protection.
  • Gaps or Leaks in the Roof Structure: Holes, gaps, or damaged areas in the RV roof structure can allow heat transfer, reducing the overall energy efficiency.


  • Consult an RV Specialist to Assess Insulation Quality: If you suspect poor insulation, seek the expertise of an RV specialist. They can assess the insulation quality and recommend necessary upgrades or repairs.
  • Consider Using RV Skylights and Vent Covers: Install skylights and vent covers to help regulate interior temperature and reduce the strain on the RV’s heating and cooling systems.

Wrapping Up

Owning an RV provides a gateway to unforgettable journeys and experiences. However, to ensure these adventures are not dampened by Flex Armor roofing problems, regular inspections and maintenance are essential. By understanding these common issues and their solutions, RV owners can preserve the integrity and longevity of their Flex Armor roofs, enabling them to embark on countless more road trips filled with excitement and memories. Always remember to seek professional assistance when dealing with significant roof repairs or replacements, ensuring the best outcomes for your beloved home on wheels.

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