Hello Guest!

Roof failure

  • 12 Replies
  • 8327 Views
*

donc13

  • *******
  • 1358
    • View Profile
  • OwnPC: Yes
  • NewUsed: New
  • PurchDate: 03/2015
  • Model: 2551
  • ModelYear: 2015
  • Slide: Yes
  • IntColor: Nightscape/Hickory
  • ExtColor: White/Nightscape
  • Location: Colorado
Roof failure
« on: August 05, 2020, 02:51:51 pm »
I just got off the phone with the RV/fiberglass repair shop.

A little background... In early June we were in Spearfish at the City campground when we got nailed with a severe hail storm. Hail was 2" and bigger, lasted about 5 minutes.   Bathroom vent and "skylight" were pierced by the hail, a/c shroud also, side view mirrors broken, dents in the hood.   Typical.   The good news is that the 2 roof vents over the main living area had zero damage because I have Fantastic Fan vent covers on them.

The bad news was I got on the roof and found at least 8 places on the roof where the hail cracked the fiberglass roof.  I covered the cracks with duct tape to keep rain out.

Like most (if not all) PC fiberglass roofs, ours wasn't firmly glued to the plywood underneath the fiberglass.  We've been told that that's normal to allow the fiberglass to expand and contract with temperature.

OK... That's the lead in...

Took it to the fiberglass shop, they found 5 more cracks and said we needed to have the fiberglass roof replaced.  They suggested with a rubber roof.  Hail doesn't crack rubber, among other things.  It does caulk and leave black marks on the side. Insurance company was fine with either fix.

We went with the rubber.   The phone call I just got was about the original roof.   It was essentially not glued down and as a result, left an airspace between the fiberglass and the plywood which over time allowed the moisture in the air to condense and ruin one of the plywood panels.  He specifically said that it wasn't a bad caulk or seal, it was condensation in the air space.

So just a warning to you all, not sure how you can check that, but at least keep an eye on the plywood under the fiberglass by having a good shop check it now and then for soft plywood underneath the fiberglass.

Don
---
Don and Patti

*

Ron Dittmer

  • *******
  • 5647
  • Ron and Irene
    • View Profile
    • My 2007 2350 Phoenix Cruiser
  • OwnPC: Yes
  • NewUsed: New
  • PurchDate: June 2007
  • Model: 2350 Ford
  • ModelYear: 2007
  • Slide: No
  • IntColor: Cherry Green&Gray
  • ExtColor: Full Body Gray
  • Location: N/E Illinois
Re: Roof failure
« Reply #1 on: August 05, 2020, 09:37:41 pm »
Don,

Please share pictures of your rubber roof after all your repairs have been completed.

I wonder what is it about South Dakota and all the hail storm stories.
« Last Edit: August 05, 2020, 09:40:04 pm by Ron Dittmer »
Ron (& Irene) Dittmer

*

Joseph

  • *******
  • 1053
    • View Profile
  • OwnPC: Yes
  • NewUsed: Used
  • PurchDate: 3/7/2015
  • Model: 2552
  • ModelYear: 2011
  • Slide: Yes
  • IntColor: Tan/Cherry
  • ExtColor: Gray / White
  • Location: California
Re: Roof failure
« Reply #2 on: August 08, 2020, 08:24:52 am »
Moisture build up under the roof?  For anyone living in a humid climate that could be a real concern if this isn’t just a one off incident.

Did they indicate the life expectancy of a rubber roof?

*

donc13

  • *******
  • 1358
    • View Profile
  • OwnPC: Yes
  • NewUsed: New
  • PurchDate: 03/2015
  • Model: 2551
  • ModelYear: 2015
  • Slide: Yes
  • IntColor: Nightscape/Hickory
  • ExtColor: White/Nightscape
  • Location: Colorado
Re: Roof failure
« Reply #3 on: August 08, 2020, 11:52:45 am »
No, but RV's that I have had before rated at least 10 years before "recoating" with a sealer

I don't live in a humid climate, I live in the high desert in  Colorado, but travel into high humidity areas a lot.

Don
« Last Edit: August 08, 2020, 11:56:25 am by donc13 »
---
Don and Patti

*

2 Lucky

  • ******
  • 393
    • View Profile
  • OwnPC: Yes
  • NewUsed: Used
  • PurchDate: 02/27/18
  • Model: 2551
  • ModelYear: 2010
  • Slide: Yes
  • IntColor: Cherry
  • ExtColor: Classic Umber
  • Location: Grand Junction, Colorado
Re: Roof failure
« Reply #4 on: August 08, 2020, 01:36:43 pm »
I'm curious as to where the roof plywood had rot, was it along the edge or elsewhere? It is so dry here in Western CO that I've never worried of wood rot anywhere, thinking anything would dry out between trips.
Dougn
Riding the fine line between bravery and stupidity since infancy.

*

donc13

  • *******
  • 1358
    • View Profile
  • OwnPC: Yes
  • NewUsed: New
  • PurchDate: 03/2015
  • Model: 2551
  • ModelYear: 2015
  • Slide: Yes
  • IntColor: Nightscape/Hickory
  • ExtColor: White/Nightscape
  • Location: Colorado
Re: Roof failure
« Reply #5 on: August 08, 2020, 09:21:38 pm »
He said one of the panels rIght at !he front.  Said it delaminated and warped.  That when in wet weather the billowing of the thin roof fabric would suck water in-between the roof and panels and it would stay wet.
---
Don and Patti

*

Ron Dittmer

  • *******
  • 5647
  • Ron and Irene
    • View Profile
    • My 2007 2350 Phoenix Cruiser
  • OwnPC: Yes
  • NewUsed: New
  • PurchDate: June 2007
  • Model: 2350 Ford
  • ModelYear: 2007
  • Slide: No
  • IntColor: Cherry Green&Gray
  • ExtColor: Full Body Gray
  • Location: N/E Illinois
Re: Roof failure
« Reply #6 on: August 08, 2020, 10:21:52 pm »
Is it possible that the moisture got under the roof from the hail damage cracks?  Maybe a/c water or rain water sneaked in underneath the fiberglass from a cut-out in the roof or the leading seam or from around the antenna.  Water might have entered from another area, then travel and settle in the unsuspecting location.
« Last Edit: August 08, 2020, 10:26:02 pm by Ron Dittmer »
Ron (& Irene) Dittmer

*

Joseph

  • *******
  • 1053
    • View Profile
  • OwnPC: Yes
  • NewUsed: Used
  • PurchDate: 3/7/2015
  • Model: 2552
  • ModelYear: 2011
  • Slide: Yes
  • IntColor: Tan/Cherry
  • ExtColor: Gray / White
  • Location: California
Re: Roof failure
« Reply #7 on: August 09, 2020, 10:39:22 am »
Ron, doesn’t sound like that’s a possibility if one of the panels was shot.  If it was just wet yes but it was beyond that which takes time.

*

2 Lucky

  • ******
  • 393
    • View Profile
  • OwnPC: Yes
  • NewUsed: Used
  • PurchDate: 02/27/18
  • Model: 2551
  • ModelYear: 2010
  • Slide: Yes
  • IntColor: Cherry
  • ExtColor: Classic Umber
  • Location: Grand Junction, Colorado
Re: Roof failure
« Reply #8 on: August 09, 2020, 11:06:52 am »
My guess is that it was leaking all along at the front cap/roof  seam.  If it was condensation, we would all have it.
IMHO...
Riding the fine line between bravery and stupidity since infancy.

*

Joseph

  • *******
  • 1053
    • View Profile
  • OwnPC: Yes
  • NewUsed: Used
  • PurchDate: 3/7/2015
  • Model: 2552
  • ModelYear: 2011
  • Slide: Yes
  • IntColor: Tan/Cherry
  • ExtColor: Gray / White
  • Location: California
Re: Roof failure
« Reply #9 on: August 09, 2020, 04:34:37 pm »
2lucky.  That would be my guess as well but on the flip side would any of us know if we didn’t have any interior stain?

*

Engineerlt

Re: Roof failure
« Reply #10 on: August 09, 2020, 05:40:28 pm »
Sorry to hear about your roof. I don't however agree with using a rubber roof and believe that PC was correct in installing the fiberglass roof material. In my opinion there are only two materials for a roof on an RV, aluminum and fiberglass. Anything else is used because its cheap and only designed to last long enough to get the coach sold and out of the warranty period. Production line RV's Forrest River, Thor, etc. chose rubber because its cheap and keeps costs down and profits high, they don't care what happens after a year. A rubber roof on an rv is a constant maintenance issue, from caulking the penetrations to rapid deterioration from UV rays. The RV companies that install rubber roofs don't even use a high quality roofing material like TPO. Have you ever saw a rubber roof on an RV going down the road look like a balloon because its being sucked off the roof by the passing air. I am sure that the shop wants to put on rubber as they have a good chance of seeing your coach in the future, for a patch job from a tree limb or a leak at caulked joint etc.

I had my roof coated with flex armor which eliminates all caulk and requires zero maintenance for the life of the coach. Its guaranteed against hail, UV deterioration etc. You won't find any product on the market as durable for a roof application. It is not cheap but you get what you pay for.

Good luck with your new roof and don't forget about that annual maintenance requirement to check all the seems and caulk joints.

*

jim.godfrey

  • *****
  • 293
    • View Profile
  • OwnPC: Yes
  • NewUsed: New
  • PurchDate: October 2019
  • Model: 2552
  • ModelYear: 2020
  • Slide: Yes
  • IntColor: Desert Sand
  • ExtColor: Nightscape w/ Burgundy
  • Location: South of Boston MA
Re: Roof failure
« Reply #11 on: August 09, 2020, 08:56:10 pm »
Lance: The Flex Armor looks awesome.
But wondering if you need to replace something on your roof like a vent, skylight or AC does that necessitate a trip back to the Flex Armor people?

*

donc13

  • *******
  • 1358
    • View Profile
  • OwnPC: Yes
  • NewUsed: New
  • PurchDate: 03/2015
  • Model: 2551
  • ModelYear: 2015
  • Slide: Yes
  • IntColor: Nightscape/Hickory
  • ExtColor: White/Nightscape
  • Location: Colorado
Re: Roof failure
« Reply #12 on: August 09, 2020, 09:41:21 pm »
We've had rubber roofs on 2 other units we owned.  And fiberglass on 2 others.   There have been discussions on the roof material used by PC, how very thin it is and how it is not glued down.   I agree aluminum is better, and steel even more so.  When is the last time you saw a car roof rust through?   Even when I grew up on the east coast, unless the paint and primer were seriously scratched, they never rusted thru.  This was cars made in the 30's,40's and 50's.

Yes,rubber has issues, but so does fiberglass.    I am aware of the issues and have successfully dealt with them.   If a branch would pierce a rubber roof, I guarantee it would pierce my PC's original fiberglass. 

Ron D,.... I can only repeat what the owner of the fiberglass shop told me, it was not due to leakage at a seam or sealed opening.    I can say for sure, where the Fiberglass was split, it was dried and double covered with duct tape.  So was the pierced skylight and microwave exhaust, neither leaked during the next day's rain and the patches I put on the roof were in good shape when I took it to the shop a week after the hail and after driving about 500 miles home.

Don
---
Don and Patti