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Old 02-02-2012, 07:12 PM   #136
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Wavy roof! Need opinions/advice


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7/16 osb is the material

Looks like you either have bad osb or bad installation, either way you need to get an engineer involved, unless your builder will agree to dissect a portion of the roof to determine the problem.
As you will see in another post, they said they are going to do this, but they need to wait until it is consistently in the 80's to do this... That makes no sense to me... I think they are just stalling. Each day that passed is one day closer to the 1-year builder warranty expiring.

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Old 02-02-2012, 07:15 PM   #137
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It was noticed at the tail end of October. But looking back through th epics, I can see it in some of them.

The felt paper went on around 8/5 or 8/6. The shingles were put on sometime between 8/7 and 8/10.

This is a pic of the roof on 8/20. On the far left side, you can definitely see the outlines of each 4x8 sheet.

The house was definitely NOT INSULATED at this point and you can see the outlines in the roof.
OMG!!! This is a key piece of evidence! IMO, it takes the wind out of the sails as far as ventilation is concerned....

Stay tuned folks, the plot thickens....
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Old 02-02-2012, 07:21 PM   #138
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OK - so we had 2 roofing companies come out today.

They were both a bit surprised to say the least. Especially as they looked around the neighborhood and could see 20 houses within eye-sight that had the same exact problem.

After seeing the pictures, the first company brought 4 guys out here to evaluate. I suppose that this is something you professional roofers dont see everyday, so I think their curiousity was peaked - and that is why they sent so many people. I am interested to get their feedback and proposal.

The second company is apprehensive to take on this job until they figure out exactly WHY this has happened. The fact that I found pictures from 8/20 that shows humps leads me to believe this is probably not a ventilation issue. The house was still pretty open at that point - no sheetrock, no insulation, etc... Would you all agree?

The second company climbed up into the attic to have a closer look see. They found that the spacing between our rafters is not uniform at all. he found some that are 22.5", others that are 20", and others that are 18". He didn't crawl all the way down measuring, he will do that next time he comes...

He plans to bring in a few more experts to help assess the situation. they are being very thorough. He was also wondering about the "breathability" of the wood with that radiant barrier material on it.

Looking forward to getting him back out here soon.
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Old 02-02-2012, 07:24 PM   #139
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Oh - forgot to mention, I was chatting with the guy from the second company for a while. We were standing outside as the sun was going down and it provided some GREAT lighting to see many of the other houses in our neighborhood.

He looked me square in the eye and said, "I have never seen anything like this before... where you can see the outline of every 4x8 sheet on every house in your neighborhood." He said as a roofer, it felt a bit "surreal" to him - like he was in a bad dream or something.

I said: "man - this ain't no dream - this is my reality!"
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Old 02-02-2012, 07:26 PM   #140
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Sorry thought for some reason you were in Kentucky.

I could use a paid vacation to Bristol say when the race is
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Old 02-02-2012, 07:27 PM   #141
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Sorry thought for some reason you were in Kentucky.

I could use a paid vacation to Bristol say when the race is
You can definitely come stay with us. Bring your gear - I got a roof that needs mending!
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Old 02-02-2012, 07:30 PM   #142
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The bad news is I believe the reflective boards are the cause of your problem.

second, spacing of the rafters is not that critical as long as they don't exceed 24" centers
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Old 02-02-2012, 07:34 PM   #143
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The second company climbed up into the attic to have a closer look see. They found that the spacing between our rafters is not uniform at all. he found some that are 22.5", others that are 20", and others that are 18". He didn't crawl all the way down measuring, he will do that next time he comes...

He was also wondering about the "breathability" of the wood with that radiant barrier material on it.

Looking forward to getting him back out here soon.
As far as rafter spacing, odd layouts are not uncommon on a roof of that nature. To stick frame that is reasonably complicated and sometimes hip/valley jacks are cut in pairs for speed and they don't necessarily match the common rafter layout. This is not an issue unless the spacing is greater than 22.5" between 2 members, which is the maximum spacing as per the sheathing specs. There are other scenarios that can alter layout as well. The key is being within maximum spacing limits.

The roofer was justified in his concerns with the breathability of the product. That may be a key factor as this plays out.
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Old 02-02-2012, 07:34 PM   #144
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The bad news is I believe the reflective boards are the cause of your problem.

second, spacing of the rafters is not that critical as long as they don't exceed 24" centers
Do you mean the product itself is not good, or something happened with our particular boards (they got really wet and they installed wet product?)

My wife pointed out something interesting - one of the last couple houses is under construction and they have been leaving building stuff laying around - somewhat covered - somewhat not.

I am going to pay close attention to how the treat all the sheathing.
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Old 02-02-2012, 07:35 PM   #145
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You can definitely come stay with us. Bring your gear - I got a roof that needs mending!
Keeping a sense of humor in the midst of adversity. I commend you.
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Old 02-02-2012, 07:36 PM   #146
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The roofer was justified in his concerns with the breathability of the product. That may be a key factor as this plays out.
Interesting... I would hate to put the same stuff up again, only to have it swell again.
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Old 02-02-2012, 07:40 PM   #147
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Do you mean the product itself is not good, or something happened with our particular boards (they got really wet and they installed wet product?)

My wife pointed out something interesting - one of the last couple houses is under construction and they have been leaving building stuff laying around - somewhat covered - somewhat not.

I am going to pay close attention to how the treat all the sheathing.
You might want to take up a new hobby and document a few upcoming builds with lots of pics.
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Old 02-02-2012, 07:46 PM   #148
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OMG!!! This is a key piece of evidence! IMO, it takes the wind out of the sails as far as ventilation is concerned....

Stay tuned folks, the plot thickens....
I need to ask.... I assume that it is a GOOD thing that we may have ruled out this being a ventilation problem?
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Old 02-02-2012, 07:56 PM   #149
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I need to ask.... I assume that it is a GOOD thing that we may have ruled out this being a ventilation problem?
Well, as a whole, it makes me feel better about the general design of the building.

If it can be traced back to a product liability, you have a better chance of getting it rectified than you do by bankrupting the builder with a neighborhood full of warranty claims.
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Old 02-02-2012, 09:03 PM   #150
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Wavy roof! Need opinions/advice


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The bad news is I believe the reflective boards are the cause of your problem.
I somehow missed this thread till now. Just finished reading all the posts. Interesting to say the least. The above statement was one of my first thoughts when I first started in. I'm wondering if the foil is reflecting the heat right back up through the felt and shingles, causing them to swell up, not necessarily the sheathing. Your earlier pics with just the felt on show the roof sheathing looking pretty flat. Your finished pics show the horizontal swelling occuring right where the felt overlaps. I'm thinking the shingles are getting overly heated.
On a related note: Years ago, on new homes with vinyl siding, one of the local cities made you put foil paper on the sheathing prior to siding. The foil was on one side of the paper, with the other side being brown. Everybody was installing the paper with the foil side out. They had a lot of problems with the siding expanding too much due to being heated up from the reflective foil. This was before tyvek was around. Keep us posted and let us know what you find. I'm betting a total strip and resheat the roof with plywood and then reroof.
BTW, did the flashers ever caulk the mortar joints they cut into for the flashing returns?
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