To correct the previous post, Premier does not press a 9X24' panel in the East or for Pulte. The panels are manufactured by a plant located 50 miles away in Winchester. The 9X24 foot OSB is available in single truckload quantities and is sourced in Canada from Norboard.
In addition, you appear to have missed the announcement several months ago that Pulte shut down the entire plant in Manassas due to a struggling housing market in the area.
The plant in Winchester Va has a 9X28 foot press that has been making 9X24' panels since 1997. They too have largely suspended production due to reported sluggish SIP sales.
As for shipping, 9X's are fairly easy. Beyond that it gets to be a DOT nightmare.

Al

Mike

My parents had a barn style, timber framed home built last year. As you can see from the attached photo we have the same problem. The joints inside were sealed with a rubber like 12" wide tape but clearly it is not stopping heat and probably moisture from working through the joint and out to the roof. The builder/installer of the panels is highly regarded in this industry (I won't name them here).

The response from the installer is that this is somewhat normal and that we should give it a few years to settle and hopefully it will stop. My father is not into confrontation so he has accepted this for now. I posted this on fine homebuilding's breaktime forum and got alot of similiar responses but none that matched the accuracy of the posts here regarding 2x material instead of splines. I honestly don't know which they used on this project but I thought they used splines on the roof and 2x along the wall joints.

The material and the installation have a warranty. My question is how should we approach this with the installer?

My understanding is that Pulte is (was) planning on building 13 of their own SIP plants under license of Premier. The one in the east that Al talked about may be one of these. My information is from the west and the Premier plant in Phoenix. This plant has supplied Pulte with 9x24 panels. They probably get the OSB from the same source but with the difference in locations they bring the OSB in by train, hence the quantity limitation. The long and short of it is, this plant can produce 9x24 panels but does not supply them to the general public. A 12x24 panel would also be great, especially in commercial applications. Maybe someday.

My project manager was looking over my shoulder at the roof photo and came up with a good solution. He suggests removing the roofing material, sanding down the joints, sealing the joints with a good silicon sealant, and then applying a layer of sheathing over the whole roof. Obviously, you would not align your sheathing joints with your SIP joints. A good coat of O’Henry roof sealant between the sheathing and SIP probably couldn’t hurt. He also said using tile instead of shingles would help hide it. 