Anyone know how this happened?

[Wing-in-it]

one trip during the summer I noticed the bed was wet just below the a/c unit in one spot, I blew it off as condensation.....then on Thanksgiving we were camping in a pretty bad rain storm and well the bed was soaked. So I climbed up on the roof and this is what I found. (See pics)

Anyone have any idea what could have caused this?

I’m thinking maybe when Keystone was installing the a/c unit they dropped it on the rubber roof and scored it and the change of temps (contracting and expanding) it tore?

Thoughts?

I have Eternabonded it for now.

[Ken / Claudia]

Your guess could be right, but whos knows for sure or can prove it. I would also say it have happened due to flexing of roof. The main thing is to fix it.
I would check the mounting screws and make sure it was installed tight.

[JRTJH]

I've seen several roofs with similar "cuts" or "damage". While I can't say for sure on any of them, one consideration that I've come to believe happens is that the A/C is installed, the foam gasket "sticks" the A/C to the roof membrane. Then while towing, the mounting screws (the 4 long ones that hold the A/C in position) loosen and as the trailer is towed, the A/C shifts around in the hole. That causes the gasket to pull on the TPO membrane, causing it to tear, leaving what you see....

The above is just one of my "theories" to explain what I think happens, at least in the ones I've seen. Yours may be different, but maybe this is a start in understanding what happened.....

Added: There are a couple of posts on the forum where members indicated that the drip pan edges and the A/C unit sit down onto the roof and, if the A/C is not positioned correctly, the sharp edges of the drip pan, will be driven into the TPO membrane. I have not seen that, but have read it happens.....

[wiredgeorge]

Find it odd that you haven't been on the roof taking a look a things prior to this on a 2015 trailer. Especially since you had water in the bedroom area previously. Glad you caught it; best keep an eye on the roof, penetrations and seams in the future would be a good idea.

[Wing-in-it]

Originally Posted by wiredgeorge

Find it odd that you haven't been on the roof taking a look a things prior to this on a 2015 trailer. Especially since you had water in the bedroom area previously. Glad you caught it; best keep an eye on the roof, penetrations and seams in the future would be a good idea.

Oh, I’ve been on the roof numerous times. I sweep the slides off before pulling them in. The first time it “leaked” it was minimal. It’s quite possible the tears weren’t visible then.

I was quite surprised when I saw it Thanksgiving, no doubt!

[roadglide]

My my impact did the same thing . I think air is coming from the cap seal lifting the rubber roof and cutting on the air conditioning edges . I repaired it once and it lifted ripping the patch out and cutting the other side . Looking at the pictures is the identical to what i had.

[vampress_me]

Originally Posted by roadglide

My my impact did the same thing . I think air is coming from the cap seal lifting the rubber roof and cutting on the air conditioning edges . I repaired it once and it lifted ripping the patch out and cutting the other side . Looking at the pictures is the identical to what i had.

This was going to be my best guess too. I haven’t had it happen, but remember someone posted a video on one of the forums I haunt that he took of the roofing membrane on his camper “billowing up” while he drove down the road. His A/C edges also cut the roof membrane like that. It was a few years ago, and I remember seeing the video was crazy since I would never have thought that could happen. The next week after seeing the video, I saw 2 fifth wheels in southern-western MN and SD on the interstate with their roof membranes a-billowing too. Unfortunately they were headed the opposite direction of us or I would have tried to tell them at a rest or gas stop.

[roadglide]

I have experienced the repair hard to repair the OP needs to put decor all around the edaibond tape , roof side seems and cap. If the edaibond tape comes loose there is a real problem on a second repair. I ordered 12 tubes dicor from Amazon and roll of edaibond tape . My repair was to use 4x8 16 th inch alumaumn sheets a lot of dicor and screws every 4 inches . I know it won't balloon around the AC. I also installed solar panels on top of the alumaumn sheets . BS but my impact may be the only one with alumaumn roof treated with edaibond paint that sticks like mad to clean alumaumn,.

[Dr.Ron]

I know what has happened, and it is going to be a bigger problem, from my experience. The roof material is not fastened to the wood deck below it, and when you are driving down the road, the wind is lifting it, and it cuts itself against the lip of the pan that is the bottom of the AC unit. I have already been through this, and K@*^%tone sent us a check, but refused to replace the entire roof. Now that it has been exposed, the wood under the roofing will continue to rot. I spoke with both manufacturers of the roofing material, they both said Eternabond was the only good short term solution, but in the spring I am going to cut out and replace the area from the AC unit all the way to the front and to the side, on a 2015 Fuzion 371. Roofing Manufacturers told me they train the installers, audit the work, but week to week, no one can trust they will put the roof on properly. The glue is an emulsion, and has to soak into the wood or it wont hold. I posted photos of mine in the past, and so have others, the AC unit is not moving, and the foam cant compress that much. The actual owner of the Fuzion had to sign a gag order to get the check, but I didn't. I also put chrome trim on that sharp edge, like people put on car doors, in case it raises up again before I do the full repair. I towed 50 miles on perfect new pavement, and it made scars on the eternabond. Clue is that the cuts are only on one side, and no where else. If AC was moving, it would be all around the perimeter. Good Luck with this, but dont let up on Keystone, the manufacturer says the only good repair is a total replacement, wood and all, due to the adhesive.

[Ruko]

I just brought my 2013 fuzion home from storage to do some spring cleaning and get ready for the season. Got up on the roof for my regular ispection and noticed this. I am not happy after reading some of these comments. What seems to be the best repair for this issue? I can't imagine replacing the roof but i do want to make sure i get it dealt with properly and soon.

[66joej]

Temporary fix would be to make sure it's clean and dry then a liberal coating of self levelling Dicor. Can be removed. Don't use eternabond tape as it's almost impossible to remove later.
Permanent fix would be to find out what caused this to happen to the roof material and repair it. JMO

[Ruko]

I am heading to the dealer now to get some dicor. It looks like fresh cuts in the roof so it may have just happened bringing it home today. I guess i will talk to them about it and see what they suggest for a permanent fix.

[busterbrown]

Personally, I would use Eternabond tape over it and Dicor the edges. I would go a step farther and make sure the AC unit is securely attached with no movement.

[Ruko]

The A/C is solid, there is no movement what so ever. My reason for being up there was to inspect all the seams and edges so I went ahead and cleaned and re-sealed everything that looked even remotely suspicions. I applied some Dicor over the cut for now. Luckily it is not that big. That will keep it dry until I come up with a better more permanent repair.