You know, longer spanning panels would of flexed and absorbed the expansion and contraction by deflecting, but your short spanning panels were locked in between heavy timber beamwork which created a lot of shear stress in the panels. If you didn't have the intermediate support beam and had longer spanning panels you probably wouldn't of had this problem. If you replace the panels think about not clamping them down tight to the beamwork which would allow them to move a little and reduce the stress on the panel. However, letting panels move may cause a noise problem. There is a solution if you think it through.

That section of roof may just have experienced the "perfect storm" of variables that caused it to fail and not anybody's particular fault. It happens. Short spanning panels locked between heavy timber beams, dark colored roof shingles, roof plane perfectly angeled to the hot noon day sun, slightly underlaminated panels or lower density foam core, but still within specs, etc... It happens.

(Thanks Alton for the correction, yes, I meant exacerbate:-)

SimonD;

if it happens it is:

A.  product failure
B.  design flaw
C.  improper installation
D.  improper use

somebody is liable for the failure

You're right Chris. Between Hearthstone and Winter Panel they should make it right. If the warranty is 10 years and they have been in the house 11 years, that may legally let Winter Panel off the hook, but from a PR point of view, it looks bad for Winter Panel if they don't do anything to help. Now if Hearthstone is still in business, it would be in their best interest to remedy the situation. But whoever fixes it should understand that that section of roof needs 'special attention to detail', so the problem doesn't reoccur.

Simon and Chris.....I'm glad you are on the "case"!

Carl

Big Time Update:

I hired a forensic building engineer and once on site, I asked him to document a descructive test I wanted to make. I was sure that the SIP's had de-laminated, so I proceeded to cut a 1 foot square out of the ceiling, assuming if it was delaminated, the entire chunk of foam would be separated from the OSB. As it turned out the inside OSB was firmly bodned to the foam, but the roofside OSB was not bonded to the foam at all! There was barely any trace of bonding agent on either the OSB or the foam. The entire chunk was removed from the roof OSB once the foam was cutup to the roof OSB.

I then requested another meeting with Hearthstone, at which time they again visited the veltilation problem, and met with my HVAC contractor who advised them that my home's veltilation exceeded any city, county and/or state code. Once they agreed to move on from that, I presented them with my delamination findings, and let them examine the chunk that was removed. Within a few days, I received an e-mail for the owner of Hearthstone, advising us that they would propose and make all repairs, even if it broke them to do it! Winter Panels at this time is out of bankrupcy and apparently out of business and has refused to contribute to the repairs.

Hearthstone says they now no longer use SIP's on rooflines unless they create a vented roof to prevent the extreame heat buildup. I personally would not trust the SIP's for roof applications for more than a 5 foot span (requiring beam support below) and the vented roof concept. Hearthstone proposed removing the existing panels and replacing them, but I did not want to expose the home to the East Tennessee summer storm possibilities. Instead, I came up with an alternate plan to make the repairs. Since the rest of the home has 2" X 6" spruce Tongue and Groove (T&G) on the ceilings, I thought that would be a good start, supported by glue-laminated beams every 4 to 5 feet. This will straighten out the roofline and provide the needed support. Hearthstone will then tear off existing shingles, and install 2" x 4" "strapping" on 2' centers, covered by 3/4" T&G Avan Tech paneling, covered by 30# felt and new shingles. The key to the strength in this will be that they intend to use olylog screws thru the Avan Tech paneling, thru the 2" X 4" strapping, thru the existing SIP, and into the 2" X 6" T&G using up to 14" screws to tie everything together! They will do this for three rooms in the house effected by the SIP roof panels, not a small undertaking.

The reason I'm detailing this is to affirm what an extensive undertaking Hearthstone Homes of Dandridge, Tennessee is doing to honor their lifetime home warranty for the home they built for us 12 years ago. I would recommend anyone considering a home to look them up and talk to them, because right now they are pretty high on my list!

B A; Kudos to Hearthstone

So how does everyone feel about Hearthstones decision not to use SIP panels in a non-vented roof application, or BadAttitiude's recommendation of nothing greater than a 5' span? Not trying to stir up trouble, but both reactions to this problem seem like overkill to me. Isn't the problem directly attributable to the de-lamination issue? If not, then doesn't that pretty much exclude SIPS as a viable roofing option?

Posted By 3cityblue on 10 Jul 2011 12:14 PM
So how does everyone feel about Hearthstones decision not to use SIP panels in a non-vented roof application, or BadAttitiude's recommendation of nothing greater than a 5' span? Not trying to stir up trouble, but both reactions to this problem seem like overkill to me. Isn't the problem directly attributable to the de-lamination issue? If not, then doesn't that pretty much exclude SIPS as a viable roofing option?

Yes, a delamination issue, an unvented roof has got nothing to do with a batch of bad laminated panels, it has more to to with poor quality control or poor methodolgy in the manufacturing process. Bad attitudes recommendation was prior to the destructive testing that revealed the true problem. We have done many installations with SIPs spanning in excess of 20 ft. with no problems. There are literally millions of square feet of SIP roofs successfully in use.

Who would ever use SIP panels if they realized that there is only a 10 year warranty on them? DO any panel manufacture's warranty SIP's beyond 10 years? How long do you expect your $700K home to last? I trust it's longer than 10 years!

Carl

I think 10 years is a good amount of time for a manufacturing defect to show up and short enough time for a manufacturer not to get blamed for a construction/installation/act of God defect. I think Carl's problem was showing up before the 10 year mark, but either he didn't notice it or dragged his feet a little.