Breezeway - Roof

Date Started: May 2004
Date Completed: June 2004

Photo of the completed roof. From the ground this appears to be a flat roof, but as you can see in this photo, this isn't the case. It's actually an extremely flattened "W." The water drains down the two aluminum troughs into a hidden pipe in the ceiling and is routed out to the back side where it drains into the alley.

Photo Gallery:

Before
Demolition
Construction

Before Photos
(Click on photos to enlarge)

The visible roofing material is grey/white asphalt roll roofing. Underneath that was an older layer of black asphalt roll roofing, followed by the original tin roof. (Looking west, toward Main House, on top of roof)

On the right side, some of the black asphalt roll roofing is visible. (Looking east, toward Summer Kitchen/Servants Quarters, on top of roof)

Demolition Photos
(Click on photos to enlarge)

Both layers of roll roofing removed. The original tin roof is visible. Surprisingly, the old tin roof was in fairly decent condition. The worse part was the drain troughs. Most of the bottom of the trough was completely rusted out. (Looking east, toward Summer Kitchen/Servants Quarters, on top of roof)

Another shot of the original tin roof. (Looking west, toward Main House, on top of roof)

A shot of the worse part of the original tin roof.

Beginning to remove the original tin roof, exposing the wide plank decking.

More of the original tin roof removed. The extensive rot of the decking is pretty evident. As more of the tin was removed, the roof structure became less stable. It seemed to be the only thing really holding everything together.

A shot from below.

After all the decking was removed. A shot of the old trusses. These were in really bad shape and were being supported here and there 2x4s and scrap lumber.

Me, beginning the removal of the trusses.

Roof completely removed.

Roof completely removed.

Construction Photos
(Click on photos to enlarge)

All the parts cut and ready to start constructing the new trusses. I used one of the old trusses, that was in fairly decent condition, as a template to transfer the proper angles to the new design. In my opinion, the old design just wasn't correct. Originally, the two angled pieces were supported by a brace nailed into the side of them. Over time these braces failed causing the center to sag, lowering the pitch of the roof. I decided to add a solid "beam" that spanned the entire distance and have the angled part sit on top of that.

The first truss/header attached to the Main House above the kitchen door. Since the original Breezeway had been added after the Main House was built, the builder just attached it to the existing lap siding. We decided to make it more stable and removed the old siding so that the new structure could be attached directly to the wall sheeting.

After removing the lap siding from the upper part of the Summer Kitchen/Servants Quarters, I discovered some heavy water damage to the wall. This all had to be repaired before the truss/header could be attached. The details on this projects will go on the Summer Kitchen/Servants Quarters Exterior West Wall page, when it's complete.

The repaired wall and the other truss header installed.

The temporary roof bracing. Since the walls had sagged so bad in the middle, we decided to install temporary level braces to construct the roof on so that the walls could be rebuilt afterward. It seems a little backward, but we didn't want to have to demolish the entire Breezeway and try to rebuild it all in the short time that was allotted. We figured that the roof was the most important part, and we could then remove each section of wall as needed to be rebuilt.

Another shot of the temporary bracing and the string guidelines.

All the new trusses in place. I believe we actually doubled the number of trusses that were in the original design.

Another shot of the new trusses. It's amazing how much difference, eye-sore-wise, just a little bit of work can make.

A shot from the front of the Breezeway, facing north.

A shot from the back of the Breezeway, facing south.

Some of the OSB installed. The channels have been left for the drainage system to fit into.

A shot of the trusses before the OSB was installed showing the wedges that create the inward pitch on the outer part of the roof.

All OSB installed and the drainage system in place. The original drainage troughs were part of the tin roof. I decided to use aluminum, so that it wouldn't rust. I bought some "k" style eaves troughs and flattened them out, leaving the small indention on the one side where the curved part is. This worked out perfectly to create a "lip" that fit over the outer section of the roof, and created a channel to keep the water from giong over it. You can see what i mean in the third image down from this one.

A shot from the inside, showing the interior drainage pipe.

A shot from the inside, showing the interior drainage pipe and where it exits out the back wall.

The flashing added. Also, this is a good view of how the flattened eaves troughs worked out..

A detailed shot of the flashing.

The roll of rubber membrane roofing material.

The roll of rubber roofing material, unrolled. It was one solid piece, 15 foot X 25 foot.

The rubber roof installed. I carefully measured and then divided the huge sheet into the 3 sections necessary to cover the roof. To lay the roof, adhesive had to be applied to the OSB and the rubber. Once the glue had dried to a certain "tackiness", the rubber was laid into place and smoothed out. This was a very daunting process because once the rubber made contact with the glue on the OSB, there wasn't much moving you could do to get it straight. if it went on crooked, you had pull it off and to start all over.