RV’s roof membrane has ripples. Factory rep says it is normal. What?!

Dear Dave, 
After washing my roof and doing an inspection after it dried, I noticed “ripples” from the board particles underneath. Getting down on the roof, I noticed these were areas where the fabric was not glued to the board underneath. The entire roof is this way (see pictures). Is this a problem? It looks good otherwise. Thanks for your advice! —Phil, 2019 Coachmen Chaparral 381RD

I received this question from Phil a week ago and we have corresponded a few times since. Here is my original response:

Dear Phil,
I would have someone look at this. It is not normal, and I would suspect it will be a problem in the future. The ridges running across are the seams of the particle board underneath. Depending on how loose they are, they could cut through the roof material. I suspect all the ripples are particle board separations, which could also tear the membrane. It’s either a moisture leak or poor adhesive application. Contact Coachmen first to see what their structural warranty is and then contact a dealer. —Dave

I then got this back from Phil:

David,
Sent my roof pictures to Coachmen and below is their reply.  What is your opinion of that answer? Something else about the roof that I didn’t tell them. When I checked the roof early in the morning when it is cool out, it looks normal. It is when the sun starts heating it up that this occurs. We are in Arizona now, so high in 70s and lows in lower 50s.

I appreciate your expertise and responses, David! Thank you so much! —Phil

Response from Coachmen regarding RV roof

From Coachmen:

Good morning-

Per our plant manager:

I wouldn’t do anything if it is not leaking. Looks to me like the OSB is printing through the rubber. It will not cause a problem for the customer.

Thank you,

Kristyn Udell
Warranty Rep Coachmen Plant 110
Brookstone & Chaparral Fifth Wheels
Shasta Phoenix Fifth Wheels

Here is my response:

Phil,
It is obvious the OSB (Oriented Strand Board) underneath is expanding or swelling with the temperature changes and although it might not cause a problem currently, what happens further down the road? There really is nothing that can be done immediately other than a new roof however I would make sure the dealer has it documented as well as the Coachmen Rep. I don’t like the wait and see approach, but I know they won’t go to the expense of a new roof! I’ll post this later this week and see if anyone has gotten a manufacturer to participate. —Dave

From Phil

Thanks Dave!  Yes, I am keeping emails and pictures in my files. —Phil

My conclusion

This is not a normal roof and my concern would be the seams that are protruding up on the membrane will eventually tear it and the bubbles are OSB fibers that could do the same thing. It might not be this season, but I would bet it won’t be long. “Printing” is not a common term that I have come across. I would want it in writing that it will not cause a problem!

I did forward the contact information of Ron Burge at www.rvlemonlaw.com to Phil.

It might be time to get someone a little more excited about this.

 You might also enjoy this from Dave 

My RV’s TPO roof has some bubbles. Should I reroof?

Dear Dave,
I have noticed that on my RV’s TPO roof, which is now 13 years old, there are a couple of large bubbles that have appeared on areas that are not near any entry points. When walking on the roof I do not feel any spongy sections but do have these bubbles that have appeared. I have inspected all vents and do not find any loss of sealant or indications of leakage. Also, the bubbles do not appear to have any holes within the roofing material. Should I be concerned? Do I need to replace the roof soon? Or can it wait a bit until the rest of the roof needs replacement? The roof appears to be in good shape other than the bubbles. Your suggestions would be invaluable insight into this apparent issue. Thanks. —Steven the Canadian Glampur, 2010 Fleetwood Jamboree GT

Read Dave’s answer.

Dave Solberg is a leading expert in the RV industry and the author of the “RV Handbook.”

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