Author Topic: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair  (Read 10466 times)

Sphinx

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I have a metal roof on my 150 yr. old brick house in a small town in rural Ontario.  It was installed in 2004. I bought this place when I took early retirement in 2003. I had a home inspection, and knew what was involved before I bought. I had a budget, and most of the other renovations have gone very well. I love old houses, with large porches, sun-rooms, firelplaces, and big gardens -- all of which, this house has.  I very much enjoy living here, and am near family. They like to come here and visit. I lead a simple, frugal, happy life.

 Back to the roof -- although I like metal roofs in general, my experience was not the best.  My roof does not leak, and stands up to heavy winds.  It came through a terrible wind storm completely unscathed, when most of the houses with shingles in my neighbourhood had damage.The sound of the rain does not bother me at all.  My problem is that I bought an expensive stone-coated metal roof from Duraloc.  I justified the extra expense, thinking it would last 50 years, as per the warranty,  ( company had been in business for 75 yrs. and I admired the roof they put on a home near my parents place, in another city --researched online, and found no complaints at the time -- many now ! )and the stone coating looked beautiful, but was also supposed to guard against hail, and it prevented the snow from sliding off all at once.  For 7 years I was happy, but did not know I had a problem.  These roofs all had defective stone coating, which comes off, especially on the south side of the house, because the stones are translucent, and burn off in the sun.  One is left with a roof with large brown patches that look like rust. This is the brown primer underneath.  Duraloc was bought out by Allmet, in 2006, who did not take care of the warranty.  That was supposed to be the old Duraloc, which became a numbered Ont. company, 2 years after I bought my roof. They went bankrupt, and now the 50 yr. warranties are worthless.  No one seems to know what to do. The contractor who installed it, and sold it to me, did a good job installing it, and he is not liable. He suggested replacing the roof. I cannot afford that, and hope that some kind of metal paint will work, but so far I have not found much help. Everyone says it will not stay on, and it will be expensive.  I wish I had never tried a new product which had not been properly tested in the market, but I was naive -- never renovated an old house before, and in future would use the standing seam, baked on painted type of roof Mr. MM has installed on his home.

Can anyone offer any suggestions ?  I have talked with other people online who have this problem roof, and they either decided to cut their losses, and sell the house, or just let the stone come off, and look terrible.  No one seems to have a good re-coating solution.  Since my roof does not leak, I am living with an ugly roof at present. Eventually I think the silver galvanized metal will show, and need some kind of coating to protect it.  I was advised by the paint Dept. at Sherwin Williams, near me, that they were not interested in supplying paint unless I had it sandblasted first.  This could damage other parts of my house, would be very expensive, and would remove most of the protective silver coloured metal layer. Another painter suggested pressure washing, then applying an elastomeric paint.  The paint store that supplied that, also did not want to promise it would stay on very long, maybe not even 2 years. Elastomeric coating is very expensive. My problem is compounded by the fact that I have a large roof on the house, and also had a carriage house/garage done too.  It is not a small roof that is easy to replace.

  These roofs were installed in many parts of the United States, as well as Ontario.  Although some people tried class action lawsuits, they could not do anything after Duraloc declared they were bankrupt. I learned that these roofing warranties, whether they are 50 yr. or 20 yr. don't mean much, and they are mainly marketing tools.  Never again will I pay any attention when a salesperson starts talking about warranties. 

 I would appreciate any help or advice that you care to offer.  Thanks .

Greg

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #1 on: April 06, 2014, 02:37:56 PM »
First, sorry it didn't last.  As a designer and builder I steer folks away from this kind of stuff, when they'll listen.  I work in the rainy PNW of the USA, so I don't even like paint.  Water is expensive to fight and it will always win.  I have a metal roof but am wary of painted metal so I used bare "zincalum" finished steel.  It's thicker anyway.  Also, no skylights, just not sure they won't leak.  Anyway...

In your case the roof is functionally fine but looks bad, if I understand correctly.  I would find a painter willing to coat the one side and make do.

After calling your insurance agent of course.  This could be covered somehow by your homeowners.  Worth checking into.

Sphinx

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #2 on: April 06, 2014, 03:33:36 PM »
Thanks Greg. It sounds like you provide a very good service to your clients.

 I honestly had not thought of my home insurance.  I will contact them, and see what they say.  I suspect they only cover damage like hail or fallen trees, but it is worth a try.

I will talk to a painter to get an estimate for pressure washing, then applying metal primer, and a good metal paint to one section that is the worst on the South side of the house.  My roof has different levels, so I will try a smaller section first to see if the paint will last a few years.  The design of the panels is attractive, so it might work, especially since the roof is viewed from a distance.  I need to find some way to make this roof work for at least 20 or 30 years so that I do not lose a great deal of the money invested.  I also do not want to go through all the disruption that comes with the installation of a new roof.

Some of my neighbours bought shingles with a forty yr. guarantee, and after 8 years there are some problems -- guess what ?  the company is no longer in business, and they are on their own too.  Roofing is a very problematic business for consumers.  It really is buyer beware.

Some of the big old brick houses in my historic neigbourhood have old steel roofs that are 75 to 100 years old.  They are treated with tar every 10 yrs. or so, and seem to be fine.  They do not have the galvanized covering which mine has, and which protects it, but makes it " slippery" and hard achieve good paint adhesion.  Perhaps there is a primer that would help overcome this problem.  I am not sure if tar would work on mine, and that would be black, whereas, the roof is a different colour, so the north side, where the stones still look ok would be a different colour.  I think I will have to try paint eventually, but right now, am just letting the stones come off like most people who got burned, and stuck with this junk.

Has anyone else been down a similar road ?  I would like to hear from you.

Thanks.

Thegoblinchief

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #3 on: April 06, 2014, 06:55:40 PM »
No experience with the roofs, but galvanized metal can be painted with proper prep:

http://www.kilz.com/primer/v/index.jsp?vgnextoid=8a25c9dc4812d310VgnVCM100000176310acRCRD

Is any of this within your DIY wheelhouse? The last thing you want to do is fix a sunk cost by paying a second contractor.

Sphinx

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #4 on: April 06, 2014, 11:03:32 PM »
Thanks.  I will keep notes on that metal primer.  It will help when I talk to a painter.  No, I can't do it myself.  I am a senior now, and some things are beyond me. I can still garden though !

strider3700

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #5 on: April 07, 2014, 11:45:05 AM »
I'm not sure about your roof  but I coated the outside of my stucco with gravel/glass embedded house with an elastomeric coating.   It sucked to put on because the gravel kept coming loose and it was not inexpensive(way cheaper then an entire metal roof though).  It however has held up really well to 2 years of harsh abuse in baking sunlight.   

paddedhat

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #6 on: April 08, 2014, 09:55:09 PM »
Sorry I don't have more advice for you. I hope others are paying attention though. I spent thirty years in the trades as a builder and electrician. I can assure you that the warranty BS is far from limited to roofs, it's pretty much any residential product, from most manufacturers. There is a reason why you can gently remove a piece of siding from a house, examine  every inch of it and find zero information as to who manufactured it. The same goes for may windows and other products, If it isn't the non-transferable warranty (which pretty much eliminates 80% of the companies obligation in most cases) it's the hope that you will lose the paperwork, that you will be unable to identify the company, or that they can beat you with their lawyer written weasel language, and claim "installer error" as a way to avoid backing their product.  My favorite is fairly decent window company that clearly states that the flanges of their windows shall be attached to the framing with "1-3/4" aluminum roofing nails". It's easier finding lips on a chicken than that nail, Hum, why would they specify a product that doesn't exist??? Sorry if this sounds a bit cynical, but very few companies have any intention of standing behind their products in this game.

Flaneur

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #7 on: April 09, 2014, 12:16:05 PM »
My favorite is fairly decent window company that clearly states that the flanges of their windows shall be attached to the framing with "1-3/4" aluminum roofing nails". It's easier finding lips on a chicken than that nail, Hum, why would they specify a product that doesn't exist??? Sorry if this sounds a bit cynical, but very few companies have any intention of standing behind their products in this game.

1.75" aluminum nails do exist and are available at Lowe's, Home Depot, etc.

paddedhat

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #8 on: April 09, 2014, 03:25:33 PM »
My favorite is fairly decent window company that clearly states that the flanges of their windows shall be attached to the framing with "1-3/4" aluminum roofing nails". It's easier finding lips on a chicken than that nail, Hum, why would they specify a product that doesn't exist??? Sorry if this sounds a bit cynical, but very few companies have any intention of standing behind their products in this game.

1.75" aluminum nails do exist and are available at Lowe's, Home Depot, etc.


Not in my market area, and BTW, nice job of missing the point. Specifically, if you do force the manufacturer to actually assign a rep. to address your warranty issue, they are taught to attempt to avoid wasting time on a site visit, and frequently, IMHE, attempt to dismiss the complaint as "installer error" before they even bother to take a look.  I have had issues when a product was totally unusable, and clearly defective, and the rep. attempted to blow the situation off, via a phone comment of, "well in my experience this is typically an installation issue, and I'm sure that's what I'll find if I come out" The only reason I had any satisfaction with several manufacturers is because of the pressure my suppliers applied.

Sphinx

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #9 on: April 15, 2014, 01:10:44 AM »
Flaneur,  I really appreciate all the valuable information you have given us.

You are right on the money about the kind of responses customers who bought a Duraloc stone coated roof got -- it was almost always the installation that somehow went wrong -- or the material was not stored correctly in some warehouse, or it was climate and environmental issues.  Once people stuck with this roof started communicating on the internet the manufacturers lost most, if not all of their credibility, in my opinion.  They charged $400.00 just to come out and look at the problem, then the pro-rated, limited  " 50 yr. warranty "  only covered you for replacement and/or re-coating, which was expensive -- thousands of dollars in many cases -- this did not seem to last very long according to many who tried it, and they just lost more money.  One man said they sprayed his skylights with coating, and he could not get it off, but it did not stick to his roof !  I decided not to have anything more to do with them, even before they went bankrupt. 

 I have decided to let the stone come off, then try to find a good painter, with experience painting metal roofs, who will pressure wash, prime, and paint it -- maybe with elastomeric coating, or a metal paint. I will also start with a large section on the roof at the back of my house, as a test area.

 As long as the roof does not leak, I will have to just make the best of it, and live with an ugly roof on a beautiful, historic, old home.

  I am annoyed that my installer sold me this junk. When I asked for an estimate, he brought different samples, and unfortunately for me, the stone coated metal was the most attractive. ( Mike Holmes even had some on one of his shows, but it was made by a different manufacturer I think.) The installer got a good commission no doubt, and he is not responsible either. When I questioned the use of new technology he told me not to worry there was a 50 yr. warranty, and he was sure I would not have to touch that roof for 50 years.  Right. He now buys his steel roofing from a completely different place. Why wasn't he more careful about what he sold ?  Probably the high commission, in my opinion.

  I would never want to build a new home, and have to choose materials. This scenario could happen over and over again. It is bad enough doing the occasional renovation. I try to get several personal references from friends anymore. I never listen to sales people, and I do a great deal of research online.  I do have a good general contractor who does smaller jobs, and he did not want to recommend any roofer -- I wonder why ?  Sarcasm intended. 


luigi49

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Re: Metal Roof -- A Life Lesson onWorthless Warranties -- Coating Repair
« Reply #10 on: April 16, 2014, 02:52:06 PM »
Sorry I don't have more advice for you. I hope others are paying attention though. I spent thirty years in the trades as a builder and electrician. I can assure you that the warranty BS is far from limited to roofs, it's pretty much any residential product, from most manufacturers. There is a reason why you can gently remove a piece of siding from a house, examine  every inch of it and find zero information as to who manufactured it. The same goes for may windows and other products, If it isn't the non-transferable warranty (which pretty much eliminates 80% of the companies obligation in most cases) it's the hope that you will lose the paperwork, that you will be unable to identify the company, or that they can beat you with their lawyer written weasel language, and claim "installer error" as a way to avoid backing their product.  My favorite is fairly decent window company that clearly states that the flanges of their windows shall be attached to the framing with "1-3/4" aluminum roofing nails". It's easier finding lips on a chicken than that nail, Hum, why would they specify a product that doesn't exist??? Sorry if this sounds a bit cynical, but very few companies have any intention of standing behind their products in this game.

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