The report follows a full roof replacement for our client using a two ply SBS Torch On system. The initial inspection determined that multiple application errors were causing the roof to fail and leak. Various issues with the roof are detailed in the report as well as information on the subsequent replacement.
The following communications are from one of our Red Seal inspectors:
Roof Report, January 7 2012:
We are going to go back to Evansburg today. We have to stop by the shop to pick up a few things (roll of torch-on, screws and plates, will bring my torches and propane). I did see some things that were done rather poorly, burn-outs, flashing, bad laps. I believe the fr board is installed in opposite direction of cap sheet.
We are leaving at day break and expecting freezing rain tonight. The truck is ready and we will be there between 930-1000. I don't think I can get it done in one day, we may have to return on Monday.
The client would like me to do a cut test to determine how and what material was installed, remove flashing around chimney to inspect and/or repair, replace 2 goose necks (may have to build up curbs). I have 3 b-vents and 2 stack flashings which will probably have to be installed, inspect laps and perimeter stripping.
There is a lot of ice and water that will have to be removed, time consuming to say the least. We will deal with one repair at a time and document everything.
Roof Report, January 8 2012:
As I thought, we spent the majority of the day clearing ice and water off the roof. Although we did find the source of many of the problems. The client's contractor was with us on the roof today. He is going to build four curbs to install, 2 are range hoods and 2 are bathroom fans. At the same time I can determine the roofing system (after I remove old curbs).
I'm 100% sure that the cap sheet runs the opposite direction from the FR board (first ply). I will also have to re-place 3-4" high cones with collar (like a b-vent). I also believe there is no self- adhesive stripping to existing curbs. I see the perimeter of roof is not stripped properly - transitions should always be at a 90 degree, not a 45.
Sorry to say, but as I see it, the leaks could be coming from almost anywhere: roof slopes to middle, no drains, scuppers are high and dry. I can likely stop most of the immediate problems but this roof will need more attention when it is warmer or a complete replacement.
Roof Report, January 9 2012:
We installed the two tall goose necks over the bathroom fans in question, tarred underneath the goose neck, mechanically fastened to deck, embedded granules six inches around base, primed flange, torched patch. Then, we replaced two curbs, embedded granules, installed fire tape, primed curb, installed 8" goose neck on top, fasten and prime, installed peel and stick base sheet, butter all laps. We also touched up two other goose neck curbs.
It took all day because as we ripped out curbs we were finding wet fiber board and rotten wood. The client's contractor took care of carpentry. The winds were blowing hard and I was having a hard time keeping my torch lit. We will have to go back at least one more time (Thursday or Friday) as I ran out of time. My work is watertight.
January 22, 2012:
Below are the pictures of the repairs I finished today, all went well. A continuation of the same noted previous.
March 16, 2012
Roof Observation Conclusions:
- Multiple application errors are causing roof to fail and leak.
- FR board runs north and south. Cap sheet runs east and west. They should run same direction and be staggered.
- Perimeter membrane is not stripped properly. Cap sheet is run straight up perimeter and cant edge. This section should be stripped in with another membrane.
- Curbs do not have first ply of stripping membrane – to have 2 plys. Located wet FR board upon re-placing two curbs.
- Multiple burn outs on cap sheet.
- One side lap has only 1 3/4" seal (roll must of drifted off line and wasn't cut and fixed).
- Some (8 – 10) end laps are not at 6" min. They vary at measurements less than the required 6”.
- All over laps were not cut at a 45 degree angle to avoid a tee joint and create a proper seal.
- Chimney flange is too big for curb and has created some heat loss (you can feel the heat escaping).
- Roof needs two more scuppers to drain water properly.
- There is no positive slope to existing two scuppers (they are high and dry).
- All plumbing flanges were installed over cap sheet and patched (should of been installed over FR board and patched with flam flam or peel and stick, then capped over to create a two ply seal).
- Perimeter does not appear to have enough mechanical fasteners, as per code, for wind uplift.
The initial repairs are completed but the roof still needs to be replaced at this point. The following emails between our project manager (in italics) and the client illustrate a willingness to provide the best possible customer service:
Attached you will find the final report with conclusion summaries, daily reports, and photos. Any problem downloading let me know.
As far as my apology is concerned.
Being so late is completely my responsibility. I'm not trying to make excuses but the truth is, and I think it is right that you know, I wasn't just not getting to it to blow you off or something stupid. More than somebody just not following through I know what it's like to feel like they're just blowing you off.
My humble excuses are that one of my workers really left me in a tight spot (even though I know that his situation is the most devastating anyone could imagine), but the reality is it took me this long to get caught up because I just couldn't double time fast enough. So I really am sorry. Anyway, I did get his position filled and I am getting caught up but the truth is I was running 16 - 20 hours a day and in future I need to have a better contingency plan for these things.
Not excuses just the truth and I'm really, really sorry.
Thanks for being so gracious with it.
There is an additional 5% rebate that would be issued to you at completion (it's a friends and family discount - considering your grief and my tardiness).
You will likely find the pricing to be more than the last outfit considering we would put on a whole system and not have the components that make up the roof (iso insulation, roof board, membrane, etc).
Anything else I can do please let me know. I've pretty much caught up and I am actually getting on top of the wave for the first time in months 🙂
Okay I have done some research and the 2 ply sbs is what I think I want.
Does this have a vapor barrier membrane?
Do we have a slope insulation package for drainage and R value?
Would the perimeters be built up and would this include new perimeter flashings?
Also I would need photos of what is really there as the roofing is being removed -and photos of the decking - I know it will be difficult to determine if any rotting decking is related to leaking from years ago or just from October but I do want the photos.
Looking forward to hearing from you
The insurance company will probably be done their inspection on the 16th so that means I would want the roof started soon after that.
The 2 Ply SBS Torch On is the most time tested in Alberta, so it is obviously a solid choice. The Tough Roof and Engineered Liquid Rubber are also in our thinking wise choices. The single ply's (EPDM, TPO, PVC) in Alberta we have had some issue with.
The specification for your roof would include (which will be specified on your Order Agreement);
- A vapor barrier fully adhered to the deck
- A sloped insulation package for drainage and R Value
- Perimeters would have to be built up for the sloped ISO insulation
- Flashing would be replaced as required to all parts of roof\
- Documentation daily of complete project including photos and daily Red Seal Journeyman Reports.
Availability is great for mid to end of this month, after that it is getting tight, however, you're one of my best clients and I will make it work:)
Anything else I can assist with let me know.
You mean one of your biggest pains!
I will let you know when the inspector confirms his date and then we can get this done.
Daily Report for June 3rd, 2012:
Upon arrival at the site, we immediately got to work preparing for capping:
Daily Report for June 4th, 2012:
- The area was cleared by moving materials from the North side of the roof to the South side of the roof.
- The area was swept so that the dirt could not interfere with the torching
- Curbs were built, and peel and stick was applied around them. After lunch, we brought some more capsheets onto the roof.
Pieces of materials were prepared:
- Blueskin was cut in preparation for application to the outside of the walls.
- Capsheet was cut to allow placing around the curbs. Blueskin was applied to the perimeter of both the North and East outside walls. Almost half of the entire roof is now capped; the worst part is over with regards to capping because of all the curbs in the way.
Daily Report for June 6th, 2012:
- Upon arrival at the site, capsheet was laid down on the Northern side of the building.
- Blueskin was laid on the Eastern side and Northern sides of the building.
- Most of the curbs were installed and completed on the finished section of the roof.
- Our missing slope package arrived at 11:50am.
- More walls were built and installed; all walls on the Eastern side of the building are now built and installed.
- We checked that everything was organized and watertight, as we are leaving for Calgary and returning on Wednesday.
We went to the site 3 times today, as it rained several times throughout the day. The day was primarily spent getting rid of water on the roof.
1st visit (~6:00am):
- The water was running down the entire Eastern side of the building, by the stairwell. The water appeared to be coming from 2 places: by the roof hatch, and above the stairs between the 2nd
- Upon arriving at the site first thing in the morning, we immediately got to work clearing off the pool of water on the roof by the roof hatch. There was probably close to 2 inches of water pooled around the roof hatch.
- We used the shop-vac to suck up the water.
- We used shovels to scoop the water off the roof.
- We used the push broom and squeegee to push the water off the roof.
- We patched up the area around the roof hatch with gum. By the time we left, there was no more dripping water on the inside of the building.
2nd visit (~3:30pm):
- After a short period of rain, we returned to the site to inspect the site.
- Water was pooled around the roof hatch again.
- There were still leaks, but they were not as intense as when we got there in the morning.
- After getting rid of the excess water and applying more gum around the roof hatch and walls, we left.
3rd visit (~6:00pm)
- There was more water pooled around the roof hatch because there was another brief (but more intense) period of rain.
- There was almost no dripping on the inside, only a little bit by the stairwell in between the 2nd
- We spent a while getting rid of the water on the roof.
Daily Report for June 8th, 2012:
- Upon arrival, we installed the last few pieces of sopa board. The roof is now 100% covered with sopa board.
- Peel and stick was applied to the rest of the inside of the walls. The inside walls are now 100% covered with peel and stick.
- An 8 inch curb was built around the roof hatch and then covered with peel and stick.
- When the rain started, we made sure everything was covered up and/or weighed down.
- We walked around the inside of the building for a few minutes, checking for leaks.
Daily Report for June 10th, 2012:
- The spots that were leaking before are now no longer leaking at all.
- Upon thorough examination of the interior of the building, we found a leak.
- Water was coming down the large roof vent and finding its way into apartment 8 on the 3rd floor, the maintenance room on the 2nd floor, and the utility room on the 1st floor.
- We identified the large roof jack in the South East corner of the roof as the source of the leak.
- The excess water around the roof jack was sucked up with the shop-vac and extra peel and stick was applied.
- As of the time we left there were no leaks whatsoever-We went back to the site later at night at around 8pm and there were no problems whatsoever; all the leaking has stopped.
When we arrived on site today, we got to work inspecting the building:
- There were no new leaks, and the leaking in apartment 8 has slowed down considerably.
- We spent the morning cleaning up the roof.
- We swept off any excess water, in preparation for capping later.
- We brought down extra unused materials (ie, plywood and 2x4s) from the roof, ready to be taken back for refund.
We started to lay capsheet:
- We managed to lay down 2 ½ rows of capsheet, but could not continue after this due to the rain.
- We tried to dry the area and try again once the rain stopped, but it would not stop raining for long enough for us to continue.
We gummed up the corners of the walls as a precautionary measure before leaving. We returned to the site later in the night (around 10:30pm) to monitor:
Roof Report, June 11 2012:
- There were no new leaks in apartment 8.
- We emptied the water buckets and mopped up the floors of the apartment.
- We swept some more water off of the roof.
Upon arrival at the site, we immediately got to work preparing for capping:
Roof Report, September 13 2012:
- We swept the water off of the uncapped area of the roof (Southern side of the roof).
- I went to the gas station and refilled the propane tanks.
- Another crew member arrived on site and helped to set the capsheets and cut the pieces. This continued for the majority of the day-The curbs were capped with the remaining pieces of capsheet. We will be getting 5 more rolls of capsheet tomorrow so that we can do the walls tomorrow-The drips in apartment 8 have slowed down considerably since the capsheet was laid down on the rest of the roof:
- The drips on the bedroom have stopped completely.
- The drips in the living room have slowed down to almost nothing.
- The drip in the bathroom has stopped completely.
- All the curbs and the roof hatch were stripped before we left.
- We returned later in the night to check up on the apartment after it rained lightly, and there was no more damage.
- Installed one new air vent.
- Capped off two plumbing vents.
- Job is 100% completed.
Today we got to the job site and were told that the client had the vents but she did not have any to be installed. We tried to find it at Rona close to the client’s address but it was a smaller store and there were no sizes available. That was the reason we had to head back to Edmonton to Roof Mart to get a new vent but they also did not have any. Instead we tried Sinclair Supply, we got there and picked up the vent we needed and headed back to job site in Evansburg to get the job done.
< End Report >
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