I posted some pictures in an earlier thread about my roof membrane becoming detached and it's getting repaired this week so I thought I'd post some details and pictures in case anyone else has a similar problem.
Summary so far:
- I first noticed the problem on the drive home from a long trip (Oregon to South Dakota).
- No problems noted before then even though I was on the roof frequently before and during the trip.
- I checked the front seal regularly and kept the roof clean, and added Dicor to any areas that looked cracked or loose.
- The insurance estimator said he couldn't find any areas of the seal that looked bad and said he thought it was a manufacturing defect that wouldn't be covered due to the membrane not being glued down properly. I thought it was odd at the time, but he looked under the pinbox to see if there were areas there where wind could get inside.
- Insurance eventually declined the claim saying that it was due to a lack of maintenance.
- Two different repair shops (my dealer and a local RV collision center) said I'd need a completely new roof with estimates from $8-10k. The dealer said Keystone wouldn't cover it since it would be claimed as a maintenance issue.
Given all of that I decided to get it repaired with the FlexArmor system at
https://pasco.rvroof.com/. It wasn't too far of a drive from home, and based on my research I liked their system a little better than the RV Armor roll-on system for two main reasons: They remove everything from the roof including the AC to make sure everything is fully sealed including replacing all components and re-screwing everything down, and the coating is a good bit thicker and stronger. Youtube videos show people jumping up and down on a skylight covered with the new coating, which I'm doing so I won't worry about needing to replace it ever. They also include a new AC seal and all new vent covers for the two regular vents and the MaxxAir fan, plus new tank vent caps. Basically, everything will be brand new and completely sealed by 3/16" of polyurea.
The shop owner at the repair shop says he sees roofs like mine frequently and it has rarely been due to an issue with the front seal. He says that air comes in the pinbox, runs along the front cap into the roof, and then out through the gap between two sheets of plywood roof where it bends around the roof radius. On mine since the membrane was removed you can clearly see the gap, and while the membrane was still on I could feel it and see it when on the roof. It was completely open to the inner roof and covered only by the membrane. The higher air pressure inside the trailer (or the lower air pressure above the membrane while driving due to the rounded shape like a wing) would be continuously pushing/pulling the membrane up and then it's just a question of how good the glue is holding it down.
I'm extremely impressed by the workmanship so far and everything is going exactly as described. I'll keep this album updated for anyone that has a similar issue and is interested in a sprayed on roof. The final cost will be significantly less than a new roof membrane, and it will be permanent with a lifetime warranty and no caulk anywhere that I need to do anything with. Worst case, if I need to replace any components, they can respray just that area to seal it back up like new.
https://photos.app.goo.gl/F7A9tGtyWdMGGZUQ7
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