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Patio Cover Repair

Due to October’s Hailstorm, the roofing industry in Arizona has been busy. Insurance companies have been opting to replace the shingle roofs rather than trying to repair them as the damage has been severe. Part of a quality roofing companies work is to warranty their work. To do this, they need to have a solid surface to attach their materials. In a tear off, defects may show up that require replacement of sheathing, fascia and or trim. This will affect the final cost of repairs. Structural repairs are not usually part of a roofers job.A recent project  I did as a residential project manager illustrates this.

Patio covers are a common addition to Arizona houses, and are made from light gauge steel to wood framing. This is a typical wood framed patio cover.

Because of the construction type and slope, this cover was roofed with roll roofing as the slope is too gradual to support shingles. Note that the fascia boards exhibit “dry rot” across the face as well along the side where it meets the house. Improper roofing and flashing allowed water to pond and seep into the fascia damaging it as well as the roof sheathing. This cannot be roofed without being repaired.

Investigation

Here is a closer view of the right side damage.

You can see where the corner has collapsed on the left side. On the right side the damage is more subtle but equally bad. The problem here is that there was no flashing installed under the original shingle roof where it meets the patio fascia. This is probably ignorance on the part of the guy who did this.

Here is the underside where somebody attempted to patch the problem rather than corrected it.

Once the tear off was complete this is what we found. A much more involved area than was seen from below.

Looking at the other side we find an ‘interesting’ repair. On the surface someone strapped the corner with sheet metal.

Underneath they blocked it.

In the center of the patio we saw on the surface of the fascia more dry rot.

Underneath we saw this.

Once the deck was exposed there was more damage then shown.

Repair

We start by replacing the fascia all around.  This is a shot of our problem corner.

The front pieces are in place, and it is time to insert the end rafter. The brown piece attached to the underside sticking out is acting as a third hand as I place the end fascia board.

Here is a detail shot of the inside.

The outside blocking was removed to get the fascia in place, which I fastened to the original roof with 3” deck screws. The 2×4” block inside supports the transition between the two roof planes.

In sheathing the deck I used plywood clips as shown.

Because the cover was framed at 24” centers with 1/2” plywood, clips are necessary to provide the support for the dead and live loads of this cover. Clips are a PITA, but are part of doing a good job.

A brief interlude regarding flat roofs.

A lot of flat roofing is done with standard roll roofing, which when applied correctly functions well. Unfortunately this is not the case in Arizona. This project illustrates this in spades. We will replace this with Torch Applied Roll Roofing. Below is a diagram of a typical construction detail and the roofing.

The major point of a  roof is to keep water out of your house . Regardless of the roofing style – hip, gable, flat, etc. the carpentry is the same. Rafters, fascia, sheathing, and or wood drip edges. The diagram below illustrates the preferred method of getting ready to roof.

The Torch Applied Roll Roofing system is different in a couple details. There is a base sheet, that is fiberglass rather than felt. The fiberglass sheet is nailed to the sheathing in case years down the road the roof needs replacement, and also  acts as a fire stop for the torch application of the roll roofing.

It is important to note in almost all asphalt roofing systems(shingle, roll), the base sheet(roofing felt) is covered with the metal drip edge and counter flashings were appropriate. This ties down the base sheet at the perimeter of the roof and provides a handy guide for the roofers in establishing the overhang when applying the shingles, etc. Trying to save them is an exercise in futility and foolishness  and is only done by bad roofers. You cannot get a quality job this way.

This is one of those deals where you may think you are getting a deal, but trust me, you are not.

The Torch applied roll roofing is heated with a torch and rolled onto the fiberglass base sheet where it bonds to it forming a waterproof roof giving you years of use. Highly Recommended.

Here is the almost finished fascia. On top of the 2×6” fascia we nailed a 1×2” which is called a drip edge/batten which brings the elevation flat to the top edge of the plywood. In this photo, the roof side is loose to allow the roofer to install the counter flashing which was not done in the original build and will prevent the rotting problem which led to this repair.

Here is our problem corner ready for roofing.

I mentioned counter flashing earlier. Here is a photo of it in action.

Note that it extends all the way down to the edge of the roof giving the water a clear path and not creating an area to rot the fascia which is one of the things that started this project.

And who are these roofing wizards? Collum Roofing.