North roof needs replacement

[msimerson]

The shingled North roof is at End of Life. This was known when we bought the house in 2016. Now it is time, and is more difficult because I need to remove and then replace the solar panels.

Major Steps

0. Planning
   • [x] measure the roof
   • [x] assemble the bill of materials
   • [x] order the materials (Jul 12)
     • [x] solar equipment, related to #13
     • [x] metal roofing (Jul 23, 3-4 week lead time)
1. Remove the solar array
   • [x] run conduit to SW roof (Jul 21)
   • [x] install combiner box and run wire to SW roof (Jul 22)
   • [x] set up rails on SW roof to receive panels (Jul 23)
   • [x] Remove the solar array (Jul 24-25)
2. Tearoff
   • [x] get construction dumpster (Jul 30)
   • [x] mount safety anchor
   • [x] Tear off shingles and underlayment (Jul 31)
3. Repair / Upgrade decking
   • [x] raise skylight curbs to 5-1/2" Remove skylights (Aug 1)
   • [x] replace plywood, as needed (Aug 4)
   • [x] nail schedule to IRC 2021 (6" in field, Aug 6)
4. Install underlayment, 50 yr warranty
   • Grace Ice & Water Shield HT 3'x75', 10 rolls @ $235 4 mo. UV
     • side laps 3.5", end laps 6", roller the laps
   • [x] Sharkskin Ultra SA, 5 rolls @ $319, 12 mo. UV (Aug 9)
5. [x] Install fascia wrap (Sep 7)
6. [x] Install gutters (Sep 9)
   • Gutter 1: install end cap (on the ground)
     • silicone sealant, install cap, drill 2 holes per side and rivet, sealant inside seams
     • splice: 2 beads of sealant 3" from center, mate with gutter, drill 3 holes per side and rivet
     • install gutter on roof, pancake screws on 12" center
   • Gutter 2+: install 2 beads of sealant 3" from end, position in splice leaving 1/8" gap
     • drill 3 holes per side and rivet on sealant seam.
     • sealant on inside seam
   • Downspout Outlets
     • determine position, mark outline, drill hole with stepper bit, snip out hole
     • sealant around perimeter, install outlet, drill 3 holes per side and rivet
   • Straps: 24" spacing
     • drill hole in strap and gutter, rivet strap at front, pancake screw at back
7. [x] Install gutter downspouts (Sep 10 & 11)
8. Install starter trim
   • [x] joggle cleats along the eaves (Sep 10)
   • [x] install 8" strip of Ice & Water (200') along eaves, at 2" from edge (Sep 10)
   • [x] receiver trim along rake/gable, 1" from ridge, flush to eave, fasten 12" OC (Sep 11)
   • [ ] rake/gable trim cleats, fasten 12" OC
9. Install metal panels
   • [x] square up the roof (3-4-5 📐), snap true lines at 3-9' intervals
   • [x] on each panel, fold the bottom tabs 180° and install backer rod
   • [ ] install the panels on the roof, one screw at ridge
   • install flashing around skylights
   • [ ] install gable trim, 6" overlap at seams, rivet to receiver trip @ 12" OC
10. ridge cap
    • [ ] install z-bar closures
    • [ ] seal closures with butyl tape (3/16 x 7/8) and acrylic sealant
    • [ ] install ridge cap
11. Reinstall the solar panels
    • [ ] Seattle City Light, modify Interconnect agreement
    • [x] WA L&I: Electrical Permit (Jul 17)
      • [ ] inspection

References

• Metal Construction Association
  • Metal Roof Installation Manual
• National Roofing Contractors Association
• Mueller Manuals
• Thermal expansion of steel: .080" / 10' / 100ºF temperature change
• Sound Building Supply (Kent)
• Taylor Metal (Auburn)
• Western States Metal Roofing (Spokane)

[msimerson]

July 30th, 1 PM

July 31, 1 PM

[msimerson]

August 7