Roof membrane issues/roof not correctly installed

[jbrook2524]

We have a 2021 390RK that we purchase new in 2020. We have towed the trailer approximately 30k miles. Upon arriving in Phonex AZ last year in July we noticed the first 10 feet of the roof was wrapped around the forward AC unit. It cost 10k to get the roof replaced. We did not contact GD as I have no proof that I did not damage the rook somehow.
Since that time, we have noted 55 trailers going down the road with the roof bubbled up, of those roughly 25% of the trailers are Grand Design Reflection and Solitude fifth wheels.
I am wondering if anyone else has experienced this issue.
If you have not, I would recommend that you inspect your rig for this issue.

 

[Hoopy Frood]

We used to see that a lot about 5-10 years ago, have only seen a couple in the last few years.

 

[huntr70]

We have a 2021 390RK that we purchase new in 2020. We have towed the trailer approximately 30k miles. Upon arriving in Phonex AZ last year in July we noticed the first 10 feet of the roof was wrapped around the forward AC unit. It cost 10k to get the roof replaced. We did not contact GD as I have no proof that I did not damage the rook somehow.
Since that time, we have noted 55 trailers going down the road with the roof bubbled up, of those roughly 25% of the trailers are Grand Design Reflection and Solitude fifth wheels.
I am wondering if anyone else has experienced this issue.
If you have not, I would recommend that you inspect your rig for this issue.

I would recommend everyone check their roof and all seams/sealant several times a year.

Roofs don't just blow up instantly, there are tell tale signs well before it happens.

I saw one trailer this past weekend with a bubble on the front as it went by. By the looks of the truck/trailer combo, the owner doesn't do much maintenance....

 

[dryfly]

I would recommend everyone check their roof and all seams/sealant several times a year.

Roofs don't just blow up instantly, there are tell tale signs well before it happens.

I saw one trailer this past weekend with a bubble on the front as it went by. By the looks of the truck/trailer combo, the owner doesn't do much maintenance....

In your opinion is this a result of poor adhesive, not enough adhesive, bad adhesive application techniques? Maybe all the above?

 

[RRtoRV]

I believe I am in the same boat right now, and 2500 miles from home. I noticed the sealant along the front cap was cracked all the way across the front. I used a whole tube of dicor to fill it in. 4hrs of driving later and the crack reappeared. So now I put down three layers of alphabond. 4hrs of driving and the Alphabond had peeled back. I saw a video that indicates air is getting underneath, coming up the 5th wheel hitch. This video had them laying down a second trim edge to cut off the air flow and adding dicor to seal the work. So now I need to remove everything I did so I can get to that edge with the trim piece. Ugh!

 

[huntr70]

In your opinion is this a result of poor adhesive, not enough adhesive, bad adhesive application techniques? Maybe all the above?

If it starts pulling away from the front cap, it is usually a short install, meaning there isn't enough rubber under the strip/cap to hold it.

Sometimes air comes up through the pinbox and under the membrane also (depends on construction) and can cause it to pull loose.

Don't see a lot of it, but it happens.

 

[huntr70]

I believe I am in the same boat right now, and 2500 miles from home. I noticed the sealant along the front cap was cracked all the way across the front. I used a whole tube of dicor to fill it in. 4hrs of driving later and the crack reappeared. So now I put down three layers of alphabond. 4hrs of driving and the Alphabond had peeled back. I saw a video that indicates air is getting underneath, coming up the 5th wheel hitch. This video had them laying down a second trim edge to cut off the air flow and adding dicor to seal the work. So now I need to remove everything I did so I can get to that edge with the trim piece. Ugh!

Yes, a good fix is to add a second trim strip across to hold it down. Better solution than a new roof!

 

[kb0zke]

Sounds like this is more of an issue for fifth wheels than for travel trailers?

 

[Riverbug]

Yes, a good fix is to add a second trim strip across to hold it down. Better solution than a new roof!

Wonder if a person couldn't cut the membrane back just a bit and use Eternabond to seal the over the top of the membrane and down to the sheathing going under the trim (front and sides) and ideally front cap. Reapply the trim, calk everything, and have a good seal. And can't help myself, always have to suggest marine adhesive caulking instead of the self leveling crud.

 

[huntr70]

Sounds like this is more of an issue for fifth wheels than for travel trailers?

The trailer I saw this past weekend was a bumper pull trailer...

 

[dryfly]

If it starts pulling away from the front cap, it is usually a short install, meaning there isn't enough rubber under the strip/cap to hold it.

That saved 1-2" of roofing material sure ends up costing the customer. I think if I were buying a new trailer today I'd go ahead and add an extra trim piece across the roof, if nothing more than prevention.

 

[LanerC]

Yes, a good fix is to add a second trim strip across to hold it down. Better solution than a new roof!

Where would I get the 2nd trim piece? Building supply? What would I ask for?

 

[huntr70]

Where would I get the 2nd trim piece? Building supply? What would I ask for?

It could be as simple as any metal strip that you can screw down. You just want the extra piece holding down the material.

Otherwise, a dealer would have the screw strip.

 

[LanerC]

It could be as simple as any metal strip that you can screw down. You just want the extra piece holding down the material.

Otherwise, a dealer would have the screw strip.

Got it, Thanks!

 

[goducks14]

That saved 1-2" of roofing material sure ends up costing the customer. I think if I were buying a new trailer today I'd go ahead and add an extra trim piece across the roof, if nothing more than prevention.

If it was glued down right the length would be that much of a factor.

 

[RRtoRV]

I picked up a trim piece at an RV store. Got two tubes of Dicor but really need 4. When I pulled up all the old sealant it was clear to see the cap screwed through the membrane and into the wood. One screw every 6” and no sealant between the cap and membrane to hold it in place.
I have my piece in place and we’ll see how it holds up.

 

[Riverbug]

If it was glued down right the length would be that much of a factor.

We have a comedian in the house!

 

[Corky918]

We just took delivery on a Reflection 270BN, and while on our 1st camping weekend, I climbed the ladder to look at the roof. I noticed that there are a couple of edge areas on the member where the member is not adhering, and bubbling up. I plan to address this, and a couple of minor interior trim issues with out dealer on Monday.

 

[Taj2800]

Good Luck

We just took delivery on a Reflection 270BN, and while on our 1st camping weekend, I climbed the ladder to look at the roof. I noticed that there are a couple of edge areas on the member where the member is not adhering, and bubbling up. I plan to address this, and a couple of minor interior trim issues with out dealer on Monday.

I took pictures of my brand new RV, followed all the right steps, contacted grand design, had the dealer document it on my contract, etc. I was told by all parties that it’s normal.

 

[Laura K]

We have a 2021 310GKR fifth wheel camper. Last summer traveling through southern Utah and Arizona the daytime temps were 115+. When we arrived in California at Sequoia NP (3,000 miles from home), we observed that our roof membrane had come loose near the front of the camper and was torn around the front A/C unit. The rip was causing the A/C unit to blow air under the membrane causing a big bubble on the roof. We had a mobile service do a repair in Visalia CA the following week.

We concluded that the adhesive used to bond the TPO membrane had either failed under the extreme temperatures, or there was an insufficient amount of the adhesive used to bond the membrane to the OSB roof deck. Once the membrane adhesive failed, the suction pressures from the air moving over the roof surface while in transit lifted the membrane up (and down), eventually tearing the membrane around the frame of the front A/C unit. The repeated lifting and lowering (flapping) of the membrane eventually worked to crack and loosen the seal along the front cap where the membrane terminates and is attached to the camper frame with fasteners.

Our $1,600 repair consisted of cutting the membrane across the width of the camper, peeling back the membrane, re-applying new adhesive, and re-securing the membrane. The cut and the cap joint were sealed using a felt-backed peel and stick rubberized-asphalt strip and covered with a pourable flexible epoxy-based coating. We know that this repair is not recommended; however, we have had no issues in the last year with the performance of the repair.

We inquired with GD about the issue, but they told us that our problem was caused by us not properly maintaining the seal along the front cap.

Laura & Rob