Roofing contractors offer tips when trying to improve attic airflow to help the A/C system and mistakes to avoid

Here’s a common scenario roofing contractors say they encounter after finishing an attic inspection and discussing their findings with homeowners. “I recently called the HVAC contractor because the air conditioning system isn’t cooling my house like it should. During the service call, the HVAC contractor suggested adding a power fan to boost the airflow in the attic. The vents I had were just not enough.”

There’s no doubt proper attic ventilation can impact the effectiveness of the air conditioning system. Removing the built-up heat inside the attic that radiates from the sun baking the roof is essential. Otherwise, that heat can transfer into the living space which increases the burden on the AC system.

“I try to preach to homeowners the benefits of an updated attic ventilation system: comfort, reduced cycling on big ticket items -- like the AC system -- lower utility bills,” says Clayton Putman, commercial project manager, Elite Roofing, Denver, CO. “My biggest selling point is comfort and reduced AC usage.”

But here are some common mistakes roofing contractors see in the field as a result of someone trying to help the air conditioning system. In some cases, these mistakes are more problematic than the struggling air conditioning.

More Vents is Not Always Better

While the attic may indeed need more vents, be sure it’s more of the same kind of vents, the same category of vents. Because too often we see mixed exhaust vents on the same roof above a common attic. And what started out as a good idea – give the hot attic more airflow – turns into a problem resulting in inefficient airflow and possible weather infiltration. Here’s why.

There are five types or categories of attic exhaust vents: ridge vents installed at the peak of the roof, gable louvers installed in the gable end of the house, roof-top box vents or roof louvers, roof-top wind turbines and power attic fans either gable-mount or roof-mount. Manufacturers of those vents recommend never mixing or combining any two types on the same roof above a common attic because it results in short-circuiting the system. The 2021 International Residential Building Code says to follow the manufacturers’ installation guidelines. The organization representing the asphalt shingle manufacturers, Asphalt Roofing Manufacturers Association, says do not mix exhaust vent types. For good reason.

Air follows the path of least resistance. Always. It’s looking for the closest opening and easiest path it can take. When two different types of attic exhaust vents are used on the same roof, one of them becomes the intake vent which then reduces the flow of air to the upper region of the attic. Significant portions of the attic below are under ventilated as a result. Furthermore, and much more problematic potentially, the exhaust vent that is suddenly working as an intake vent could be pulling in whatever the air is carrying that very moment – rain, snow, debris, etc.

Adding a power fan to the roof, for example, to give a boost to the wind turbines already in place is a bad idea. No matter how hot the attic is. It would be better to add more wind turbines or switch exclusively to the power fan(s).

Mixed Exhaust Vent Problems

“About 5 years ago, I had a seasoned roofer with me that just started working for our company,” recalls roofing consultant Jerry Becker, Roof Life of Oregon, Tigard, OR. “We walked up to this apartment complex and I noticed that there was a power fan alongside can vents (box vents) and very little intake ventilation. I placed a friendly bet with him stating that I know what the plywood already looks like underneath without looking at it.  He argued with me and said, ‘This roof has plenty of ventilation, look at all the vents up top and it even has a fan!’  So, I told him that the ply wood next to the fan and the closest can vents and up to the ridge is going to be perfect, but as soon as you drop down about a foot from the power fan the plywood will be as black as night. 

“We go inside the attic and what do you think we found? Black microbial growth on the lower section of the roof.  It was so black that it was wet.  It is important not to mix exhaust vent types. It’s bad enough when you do it on a single dwelling home, but that same mistake in a multi-family home is deadly. Think of all the moisture that is created by all the families -- The washer/dryer, dishwasher, sinks, showers, and ourselves!”

Inefficient airflow not only can damage the roof deck, but it can also prematurely age the asphalt shingles. “I see examples of this all the time,” says Trevor Atwell, owner, Atwell Exterior Services LLC, Greenville, NC. “Premature aging of roofing materials, buckled sheathing and signs of rotten wood all due to the moisture and heat being trapped.”

We see it often with ridge vents and a power fan just below the ridge vent or box vents with ridge vents; sometimes all three. We call it the Ventilation Trifecta,” says Tom Picha, vice president, All in 1 Home Improvements, Oswego, IL. “More is good in some cases. Not all.”

“In the winter when freezing rain turns into fine ice particles, I observed several times the lower exhaust vents on the roof becoming intake vents instead of exhaust as designed and drawing in ice particles and snow,” says Steve DuCharme, owner, Innovative Builders Roofing & Construction, Oklahoma City, OK.

“I recall an attic several years ago that had ridge vent and two power fans. They installed two because they were told one wouldn't pull enough heat out,” says Paul Vosen, president, Degenhardt Home Improvement, Madison, WI. “House had no overhangs and the attic floor was insulated with a good vapor barrier. I was there in the rain and both fans were running. The attic was so tight that the power fans were pulling rain in through the ridge vent. Never have I seen that before. Nor have I seen it since, but I never forgot it.”

The most common exhaust mixture our seminar attendees tell us they see is gable end louvers combined with something else. Often the homeowner demands that the roofing contractor leave the gable end vent in place despite the fact a ridge vent is being installed as an exhaust vent improvement. The homeowner’s reasoning: The gable louver adds a decorative touch to the home’s exterior. Solution: Do what Ron Bastian does.

“I’ve noticed snow and wind driven rain coming in a gable end vent which was combined with a ridge vent” says Bastian, owner and president, Bastian Roofing Inc., Richfield, WI.  “We closed up the gable end vent from inside the attic and this cured the problem I was called out for.”  By closing the gable vent from inside the attic short-circuiting is eliminated and the homeowner can still enjoy the cosmetics from the exterior.

“We have witnessed numerous issues related to short-circuiting,” says Shawn Bellis, owner, EPIC Exteriors, Overland Park, KS. “We’ve seen fine wind-driven mid-west snow sucked into the exhaust vents – gable vents mixed with ridge vents for example.”

Check the Intake Vents First

Anytime a homeowner believes that the attic is too hot, or the upper floor of the house is too hot and attic ventilation is suspected as part of the problem, roofing contractors recommend checking two things in this order: the intake vents, then the exhaust vents.

Unfortunately, the most overlooked aspect of the attic ventilation system is the intake vents in the soffit, eaves or low on the roof. No amount of exhaust vents on the roof can overcome the lack of proper intake ventilation, because attic ventilation is a “balanced system” of 50% intake and 50% exhaust.

To remove hot air in the summer and moisture in the winter (the average family of four generates 2-4 gallons of water vapor daily from everyday activities such as cooking, cleaning, showering and breathing) from an attic there must be incoming cooler, dryer air into the attic. Together, intake and exhaust vents form a balanced attic ventilation system that also helps to fight ice dams in snow climates by keeping the roof deck temperature even so the snow and ice can melt evenly.

Lack of intake ventilation drives most of the callbacks that we track through our Customer Service. Exhaust vents tend to draw the contractors’ attention. Intake vents tend to cause the trouble. Check the following:

• Are there intake vents at all?
• Are there enough for the square footage of the attic space?
• Is anything inside the attic blocking the intake vents from working (attic insulation, items stored inside the attic, etc.?)
• Have the intake vents been painted over thus reducing their airflow capability?

“Attic ventilation is a two-step process. Proper air exchange inside the attic needs both steps to function properly, says Jeff Barnett, vice president, Barnett Roofing & Siding, Inc., Canton, MI.”

“Intake and exhaust are both needed because they work together as a system, and exhaust is ineffective without supporting help from the intake,” says Putman.

If a non-motorized exhaust vent (ridge vents, wind turbines, roof louvers and gable louvers) is starving for intake airflow it can actually pull air from itself (in testing we’ve seen a ridge vent ingest air from its back side) or from a nearby exhaust vent (a wind turbine or box vent will gladly take air from the wind turbine a few feet down the roofline if intake air from the soffit is not happening). If an exhaust vent is suddenly ingesting air, it could also suddenly be ingesting anything the air is carrying along for the ride: rain, debris, dust, and snow all entering the attic. That’s not what exhaust vents should be doing. Motorized exhaust vents (roof-mount and gable-mount power fans) that are lacking the needed intake air can experience premature motor burnout and pull air from the conditioned living space. Neither one of those situations is desirable.

How Much is Needed?

The amount of attic ventilation needed is based on the attic’s square footage (length x width, floor of the attic). Half of the ventilation should be intake (50%); half exhaust (50%). There are many calculation tools available from various manufacturers (online and smart phone apps) to help figure out how many vents are needed.

If the attic ventilation system is not perfectly balanced with 50% intake and 50% exhaust it’s better to have more intake. Excess intake airflow converts to exhaust on the leeward side of the house. An attic cannot have too much intake airflow. However, if there is more exhaust than intake, that’s a potential red flag described earlier in this article.

What is too Hot?

It’s not uncommon for a homeowner to tell a roofing contractor, “My attic is too hot.” But what is “too hot?” What should the attic temperature be in the warmer months if the balanced attic ventilation system has been calculated, designed, and installed correctly?

Our Customer Service team field calls every summer from unreasonable homeowners complaining that their attic ventilation system is not working right because their attic is too hot, or the top floor of their house is too warm. An attic with balanced ventilation can be expected to have a temperature 15-20 degrees higher than the outdoor temperature peak of day. If it’s 100 degrees in Texas at 5 pm, the attic can be 115-120 degrees. Anything higher than that, we’d want to explore the attic insulation R-level, unusual heat sources, and double-check the attic ventilation system. But please understand, 115-120 degrees is no picnic. Attics are hot. The attic ventilation reduces the heat, but it does not eliminate it.

Article Courtesy of Paul Scelsi of Air Vent Inc:

Paul Scelsi is marketing communications manager at Air Vent Inc. and leader of its Attic Ventilation: Ask the Expert™ seminars (airvent.com). He hosts the podcast, “Airing it out with Air Vent,” and he’s the chairman of the Asphalt Roofing Manufacturers Association Ventilation Task Force. He is the author of the book, Grab and Hold Their Attention: Creating and Delivering Presentations that Move Your Audience to Action.

It’s still too fresh. Several weeks into the New Year is not enough time to put proper perspective on the year 2020 was, and what its lasting implications will be. Without a doubt, the last 12 months will be remembered as a watershed moment for the world, and in roofing. 

The year started with so much promise: record attendance at regional and international trade shows; surging sales revenue in both residential and commercial sectors; and a bevy of new innovations in technology designed to improve efficiency while on the roof, and company management while contractors are off it. 

The COVID-19 pandemic not only slowed that momentum, it brought the roofing industry to a virtual halt — seemingly overnight — until essential-worker status came into play. Even then, contractors and the manufacturers and distributors that serve them needed to adapt quickly to a whole new world where selling, managing workforce, and meeting customer’s health-and-safety expectations all needed redefining. 

As Roofing Contractor itself evolved during the crisis, our mission to help the roofing industry transition into this new era endures. Again with the expertise from Clear Seas Research — the survey and research arm of RC’s parent company, BNP Media — RC circulated our annual survey to roofing contractors around the country last fall. 

The survey set out to measure the pulse of an industry deemed essential in the face of the worst health crisis in more than a century, yet still challenged for survival amid a lingering economic crisis. 

Our key findings are shared below in our annual State of the Industry Report, sponsored by Cotney Attorneys & Consultants. We encourage everyone to learn more with their experts in our exclusive State of the Industry webinar Feb. 18.  

Residential Resiliency

Residential roofing continues to stay strong despite the pandemic and the economic recession it caused. Of those respondents who identified as primarily residential, the median revenue in 2019 was $500,000 to $999,000. A total of 32% had revenue between $250,000 and $999,999.

As a testament to this resiliency, 49% of residential respondents said they expect their 2020 annual sales to increase compared to 2019. Of them, 13% said they expect it to “greatly increase.” This could be attributed to the fact that, due to the pandemic, people were unable to go on vacations and had to work from home. In doing so, they had more time to notice problems with their roofs and sought the help of contractors.

When considering sales for 2021, three-fourths (75%) expect an increase compared to 2020. This optimism is fueled in part by the potential for business to shift toward normalcy with the distribution of the COVID vaccine. For others, it's likely due to 2020 being an unprecedented year that caused major drops in revenue, meaning 2021 can only be better.

However, considering 85% of residential roofers believe their total sales volumes will increase over the next three years, it’s more likely that the roofing industry expects to rebound from the past year and continue to grow from there.

“The way we look at it is you always must adjust to the times. We were fortunate enough to make it through 2008 and it’s looking optimistic that we will get through this COVID-19 situation stronger than ever,” said Cory Varao, general manager of Fraser Construction Company in Mashpee, Mass. “We are constantly learning about new products, new ways to market and making general policy changes to help move the company forward. I think this is one of the keys to success and I look forward to adapting in the future.”

Roof replacements remained the main source of revenue for residential roofing contractors at 31%, compared to repairs and new construction (both at 13%). Drilling into this further shows steep-slope asphalt shingles continue to be the top revenue generator. On average, shingles accounted for 28% of the contractors’ revenue. Around 43% said they saw increases in steep slope sales from 2019 to 2020, while 65% expect those sales to grow in 2021.

When looking ahead to the future, however, residential contractors anticipate that metal roofing will experience the most growth in sales. In 2020, 18% of revenue came from metal roofing for residential roofers. More than half of respondents said they expect metal roofing to grow from 2019 to 2020, and 68% anticipate metal sales to increase in 2021.

As for the types of metal roofs, residential contractors are more likely to install metal shingles, tiles or slate than their commercial counterparts, though architectural standing seam continues to be the most popular metal system.

“Metal roofing, once relegated to barns and sheds, has seen an increase in popularity in recent years,” writes Brian Haraf, vice president of Metal Sales Manufacturing Corporation. “Customers may have some sticker shock when comparing metal to the pricing of traditional roofing, but the benefits far outweigh the costs.”

Following metal roofing and steep-slope asphalt roofing, residential contractors anticipate single-ply roofing to grow in 2021 (56%), followed closely by polymer/synthetic roofing asphalt (55%) and low-slope asphalt (54%). The area residential contractors expect sales to increase the least is spray polyurethane foam (37%), though the survey only gathered a small sample size of contractors that use it.

Challenges in Residential Roofing

There are some hurdles residential contractors will need to clear to see sales and revenue grow. In last year’s report, the lack of a qualified workforce topped the list of challenges contractors expected to face in 2020. Thanks in part to the pandemic, other concerns are keeping residential contractors awake at night.

The most common challenge residential respondents expect to face in 2021 is lowball pricing and bidding wars (54%), followed by increases in building material costs (49%). The aforementioned lack of qualified workers is of concern to 45% of residential contractors. Bryce Curtis, director of Yellowhammer Roofing in Alabama, said “Chuck-in-a-Truck” roofers that bid low weren’t as prevalent in 2020 due to the pandemic, but they’re likely to make a comeback.

“What hurts the roofing industry are your competitors. We would rather have a licensed, insured competitor beat us out 10 times out of 10 than somebody that rolls up in there that does roofing in the spring, flooring during the fall and cabinets in the winter,” Curtis said. 

The need for qualified workers caused an increase in the use of subcontractors to complete field labor by 17% in 2020. Despite this, residential contractors say that 59% of their jobs are completed by full-time workers versus 29% by subcontractors.

“We have amazing team members that are crucial to our success, but finding them among the less effective employees has been a challenge,” said Johnny Marvin, co-owner of Striker Roofing in Texas. “We’re trying to bring on as many people as we possibly can.”

An increase in labor costs isn’t helping matters either. The majority of residential contractors who responded say they have less than 10 employees in their business, but all respondents reported their labor costs jumped by an average of 16% in 2020. 

To try and find good help, residential contractors rely mostly on employee referrals (73%). Paying employees well and providing bonuses are the main methods they use for retention, followed by offering benefits.

When training the employees they do hire and retain, direct training is the preferred method of residential roofing contractors, with 85% saying they train in-house and on the job. Despite this, only 45% of residential contractors have a formal training program. Another 7% say they don’t offer training.

Unlike their commercial counterparts, residential contractors aren’t turning to other sources for training. Just under a quarter (24%) utilize training provided by manufacturers, while 17% use training from industry associations.

When it comes to safety training, 31% of residential contractors hold weekly safety meetings, while 38% prefer it to be a monthly issue. Around 66% of respondents say they supply all safety equipment to workers, while another quarter only provide some of it.

Commercial Conditions

Last year started very strong for commercial roofing contractors in dozens of markets around the country. Roughly half of survey respondents (45%) indicated sales were up over 2019, and only 34% anticipated slight decreases in sales due to the pandemic.

Single ply roofing was the dominant product preference with 91% of respondents. Among those contractors, 38% reported using TPO, followed by EPDM (30%) and PVC (18%). Metal was the second most popular roofing system category at 77%, followed by coatings (68%), low slope asphalt (59%) and steep slope asphalt (50%).

More than half of the roofers using metal said sales remained the same in 2020 and only 18% said sales increased greatly. Coatings appeared to grow the most, as 42% of contractors said sales increased in 2020. 

While some relied on existing backlogs and accelerated project timelines because buildings were empty, other roofing contractors characterized their financial performance as strong and encouraging. Davco Roofing & Sheet Metal Inc., in Charlotte, N.C., added two dedicated business development positions and a marketing manager who are focused on opening doors and increasing revenue.

“Although we were crippled by the global pandemic, we were able to maintain growth while increasing overall profit margins because we were able to be more selective about the work that we targeted,” said President Daniel Davis. 

The positive outlook wasn’t isolated. A strong majority of commercial roofers (68%) said they expected sales to increase again this year, with 11% of respondents anticipating sales to increase greatly. Just 14% of contractors felt sales would slightly decrease in 2021, and 7% expected great losses. 

Of those expecting sales increases, more than half said it would be in single-ply systems, and 53% anticipated a spike in metal jobs.

In terms of challenges — outside of the pandemic — commercial contractors bucked a trend. Safety enforcement for employees and government regulations were out of the top five of perceived workforce issues, at 20% or less.

Instead, contractors were concerned most with the lack of qualified, skilled labor (61%), and lowball bidding (48%). Increased costs of building materials, the overall weak economy, and insurance and healthcare costs rounded out the top five.

Storms and Supply Struggles

As previously mentioned, an increase in building material costs is one of the top issues commercial and residential contractors expect to face, with nearly half of respondents expecting it to be a factor in 2021. Gleaning from the experiences of 2020, it’s understandable. Lockdowns around the globe caused a ripple effect that slowed product manufacturing and distribution, which coupled with a record-breaking storm season, hit contractors hard right during peak season. 

“The supply and demand issues during peak season were particularly challenging this year. We understand and feel the effects of that with our contractors,” said Scott Schumacher, vice president of strategic marketing for Owens Corning Roofing. “Our approach will always be to communicate with contractors honestly and realistically, so they can do the same for their customers.

“Entering 2021, we do not anticipate repeating lost production time due to the pandemic.”

In a virtual town hall hosted by the National Roofing Contractors Association, Asphalt Roofing Manufacturers Association (ARMA) Vice President Reed Hitchcock said as of October, shingle manufacturers reported that they were running at full capacity to help resupply contractors.

“I wish I had the crystal ball on this one,” said Hitchcock. “In talking to our members, there is some anticipated demand slowdown coming with the fourth quarter and the first quarter coming up.”

Single-ply roofing took a hit during the pandemic, according to the Single Ply Roofing Industry, while the Roof Coatings Manufacturers Association (RCMA) reported production of coatings was at an all-time high.

“We always find that the coatings actually can extend the life of the roof, and I think that because of COVID — financial costs on the residential and commercial side — I think owners are looking at more opportunities to save long term,” said RCMA Executive Director Dan Quinonez.

Proactive communication between contractors, distributors and manufacturers proved key in managing product availability, said Mike Jost, chief operating officer at ABC Supply Co.

“The nearly 800 locations within our network have always worked closely together, but it’s been especially advantageous to help contractors get the materials they need,” said Jost. “If one branch doesn’t have the product, we’re able to lean on others to move material around.”

The supply shortage and the level of concern regarding it is largely due to the pandemic, but the blame can also be placed on an unprecedented 2020 storm season.

The Atlantic hurricane season became the most active on record and the fifth costliest season. A total of 31 depressions were recorded, all but one of which became a named storm. Twelve of the named storms made landfall in the U.S., breaking the record of nine recorded in 1916. In total, the hurricane season caused an estimated $51 billion in damage.

2020 was the fifth consecutive above-average season since 2016, and if the last few years are any indication, contractors should brace themselves for yet another heavy storm season in 2021.

Louisiana was among the hardest hit areas by hurricanes. By the time Hurricane Zeta struck Louisiana in late October, it was the fifth hurricane to tear apart buildings in the state. Even contractors who were not working in the hurricane-swept areas were feeling the squeeze on labor and supplies.

“Contractors from all over the country are coming to Louisiana and down to the coast to work, so material has been extremely hard to come by,” said Mike Warren, director of operations for Roof Crafters in Hammond, La.

Though the work proved to be difficult due to jobsite delays and supply issues, it was also plentiful, giving many roofing contractors a boost in what was otherwise going to be a tough year.

During this record-breaking hurricane season, the Midwest experienced a derecho — a straight-line windstorm — in August, with winds hitting 140 mph. The storm caused an estimated $11 billion in damages, flattening entire fields of crops and ripping apart roofs and buildings of every size.

Cedar Rapids, Iowa took the brunt of the storm, causing $7.5 billion in damages from the winds and tornadoes. When snowstorms hit the area in October, contractors were left scrambling to help people recover before winter truly set in, reporting labor shortages and supply line struggles. 

Christina Bible, director of operations for Options Exteriors in Minnesota, said they had to ship shingles from South Dakota to use in Iowa. But the silver lining, Bible says, is that between the derecho and supply shortages, multiple customers are now looking into the viability of metal.

“There has been some interest in homeowners transitioning from asphalt roofs to metal roofs,” she said. “The type of devastation down there was just so great the shingles didn’t even matter, it was actually whole roofs being blown off, but we have been doing some more metal roofs.”

Intense weather wasn’t the only hazard roofing contractors had to deal with in 2020. Wildfires across the West Coast affected thousands of families and caused billions in damage. California alone saw $12 billion in damage, leading many roofing contractors to consider more durable options for the future.

“As we witness the horrible destruction wildfires have and are causing, the more we can do as an industry and community to help homeowners protect themselves against these increasing threats, the better,” said Renee Ramey, Metal Roofing Alliance executive director.

Business Climate 

If acquisitions are any measure of a prosperous business climate, then roofing is starting off 2021 in positive fashion. Several major moves were formally announced around the New Year:

• Multinational building materials manufacturer LafargeHolcim acquiring Firestone Building Products for $3.4 billion.
• Beacon sold off its interior product business, consisting of 81 branch locations to American Securities Inc. for $850 million.
• Innovative Chemical Products (the ICP Group) announced the acquisition of Leeson Polyurethanes, a leading U.K.-based manufacturer of polyurethane adhesives and coatings used in a variety of sectors and markets.

The climate proved good for contractor acquisitions as well. Tecta America — which celebrated its 20th anniversary in 2020 — continued its growth with a handful of additions throughout the year. Company leaders said the pandemic hasn’t slowed down their acquisition strategy, which is more about finding the right company that fits their model, rather than timing. 

“It’s part of who we are, part of our culture, and when we buy companies we buy the best ones out there,” said President and CEO Dave Reginelli. “We’re not looking for turnarounds, we’re looking for solid companies with strong performance with the same features we care about.” 

As in any given year, assessing the state of the roofing industry in 2021 will depend on several factors — known and currently unknown. However, it’s clear that this year will be different for three specific reasons regardless of market, business size or service specialty. 

COVID-19 Vaccinations: The rollout of multiple COVID-19 vaccines at the end of 2020 was slow and cumbersome, a problem President Joe Biden’s administration pledges to fix — and quickly. They’ll have to if there’s any chance to return to normalcy as infections and death totals surge nationwide. 

New Leadership: Vaccinations are just the beginning. The Biden administration already proposed another broad pandemic relief package, and promised a major emphasis on infrastructure and clean energy. While those present opportunities for roofers, the impact on business regulations after four years of a federal scale back remains to be seen. 

Wicked Weather: Predicting long-term weather patterns for any particular region of the country is futile. But given the strength and volatility of recent storm seasons, there’s no reason to believe roofing contractors should expect anything less in 2021. 

It’s still too fresh. Several weeks into the New Year is not enough time to put proper perspective on the year 2020 was, and what its lasting implications will be. Without a doubt, the last 12 months will be remembered as a watershed moment for the world, and in roofing. 

The year started with so much promise: record attendance at regional and international trade shows; surging sales revenue in both residential and commercial sectors; and a bevy of new innovations in technology designed to improve efficiency while on the roof, and company management while contractors are off it. 

The COVID-19 pandemic not only slowed that momentum, it brought the roofing industry to a virtual halt — seemingly overnight — until essential-worker status came into play. Even then, contractors and the manufacturers and distributors that serve them needed to adapt quickly to a whole new world where selling, managing workforce, and meeting customer’s health-and-safety expectations all needed redefining. 

As Roofing Contractor itself evolved during the crisis, our mission to help the roofing industry transition into this new era endures. Again with the expertise from Clear Seas Research — the survey and research arm of RC’s parent company, BNP Media — RC circulated our annual survey to roofing contractors around the country last fall. 

The survey set out to measure the pulse of an industry deemed essential in the face of the worst health crisis in more than a century, yet still challenged for survival amid a lingering economic crisis. 

Our key findings are shared below in our annual State of the Industry Report, sponsored by Cotney Attorneys & Consultants. We encourage everyone to learn more with their experts in our exclusive State of the Industry webinar Feb. 18.  

Residential Resiliency

Residential roofing continues to stay strong despite the pandemic and the economic recession it caused. Of those respondents who identified as primarily residential, the median revenue in 2019 was $500,000 to $999,000. A total of 32% had revenue between $250,000 and $999,999.

As a testament to this resiliency, 49% of residential respondents said they expect their 2020 annual sales to increase compared to 2019. Of them, 13% said they expect it to “greatly increase.” This could be attributed to the fact that, due to the pandemic, people were unable to go on vacations and had to work from home. In doing so, they had more time to notice problems with their roofs and sought the help of contractors.

When considering sales for 2021, three-fourths (75%) expect an increase compared to 2020. This optimism is fueled in part by the potential for business to shift toward normalcy with the distribution of the COVID vaccine. For others, it's likely due to 2020 being an unprecedented year that caused major drops in revenue, meaning 2021 can only be better.

However, considering 85% of residential roofers believe their total sales volumes will increase over the next three years, it’s more likely that the roofing industry expects to rebound from the past year and continue to grow from there.

“The way we look at it is you always must adjust to the times. We were fortunate enough to make it through 2008 and it’s looking optimistic that we will get through this COVID-19 situation stronger than ever,” said Cory Varao, general manager of Fraser Construction Company in Mashpee, Mass. “We are constantly learning about new products, new ways to market and making general policy changes to help move the company forward. I think this is one of the keys to success and I look forward to adapting in the future.”

Roof replacements remained the main source of revenue for residential roofing contractors at 31%, compared to repairs and new construction (both at 13%). Drilling into this further shows steep-slope asphalt shingles continue to be the top revenue generator. On average, shingles accounted for 28% of the contractors’ revenue. Around 43% said they saw increases in steep slope sales from 2019 to 2020, while 65% expect those sales to grow in 2021.

When looking ahead to the future, however, residential contractors anticipate that metal roofing will experience the most growth in sales. In 2020, 18% of revenue came from metal roofing for residential roofers. More than half of respondents said they expect metal roofing to grow from 2019 to 2020, and 68% anticipate metal sales to increase in 2021.

As for the types of metal roofs, residential contractors are more likely to install metal shingles, tiles or slate than their commercial counterparts, though architectural standing seam continues to be the most popular metal system.

“Metal roofing, once relegated to barns and sheds, has seen an increase in popularity in recent years,” writes Brian Haraf, vice president of Metal Sales Manufacturing Corporation. “Customers may have some sticker shock when comparing metal to the pricing of traditional roofing, but the benefits far outweigh the costs.”

Following metal roofing and steep-slope asphalt roofing, residential contractors anticipate single-ply roofing to grow in 2021 (56%), followed closely by polymer/synthetic roofing asphalt (55%) and low-slope asphalt (54%). The area residential contractors expect sales to increase the least is spray polyurethane foam (37%), though the survey only gathered a small sample size of contractors that use it.

Challenges in Residential Roofing

There are some hurdles residential contractors will need to clear to see sales and revenue grow. In last year’s report, the lack of a qualified workforce topped the list of challenges contractors expected to face in 2020. Thanks in part to the pandemic, other concerns are keeping residential contractors awake at night.

The most common challenge residential respondents expect to face in 2021 is lowball pricing and bidding wars (54%), followed by increases in building material costs (49%). The aforementioned lack of qualified workers is of concern to 45% of residential contractors. Bryce Curtis, director of Yellowhammer Roofing in Alabama, said “Chuck-in-a-Truck” roofers that bid low weren’t as prevalent in 2020 due to the pandemic, but they’re likely to make a comeback.

“What hurts the roofing industry are your competitors. We would rather have a licensed, insured competitor beat us out 10 times out of 10 than somebody that rolls up in there that does roofing in the spring, flooring during the fall and cabinets in the winter,” Curtis said. 

The need for qualified workers caused an increase in the use of subcontractors to complete field labor by 17% in 2020. Despite this, residential contractors say that 59% of their jobs are completed by full-time workers versus 29% by subcontractors.

“We have amazing team members that are crucial to our success, but finding them among the less effective employees has been a challenge,” said Johnny Marvin, co-owner of Striker Roofing in Texas. “We’re trying to bring on as many people as we possibly can.”

An increase in labor costs isn’t helping matters either. The majority of residential contractors who responded say they have less than 10 employees in their business, but all respondents reported their labor costs jumped by an average of 16% in 2020. 

To try and find good help, residential contractors rely mostly on employee referrals (73%). Paying employees well and providing bonuses are the main methods they use for retention, followed by offering benefits.

When training the employees they do hire and retain, direct training is the preferred method of residential roofing contractors, with 85% saying they train in-house and on the job. Despite this, only 45% of residential contractors have a formal training program. Another 7% say they don’t offer training.

Unlike their commercial counterparts, residential contractors aren’t turning to other sources for training. Just under a quarter (24%) utilize training provided by manufacturers, while 17% use training from industry associations.

When it comes to safety training, 31% of residential contractors hold weekly safety meetings, while 38% prefer it to be a monthly issue. Around 66% of respondents say they supply all safety equipment to workers, while another quarter only provide some of it.

Commercial Conditions

Last year started very strong for commercial roofing contractors in dozens of markets around the country. Roughly half of survey respondents (45%) indicated sales were up over 2019, and only 34% anticipated slight decreases in sales due to the pandemic.

Single ply roofing was the dominant product preference with 91% of respondents. Among those contractors, 38% reported using TPO, followed by EPDM (30%) and PVC (18%). Metal was the second most popular roofing system category at 77%, followed by coatings (68%), low slope asphalt (59%) and steep slope asphalt (50%).

More than half of the roofers using metal said sales remained the same in 2020 and only 18% said sales increased greatly. Coatings appeared to grow the most, as 42% of contractors said sales increased in 2020. 

While some relied on existing backlogs and accelerated project timelines because buildings were empty, other roofing contractors characterized their financial performance as strong and encouraging. Davco Roofing & Sheet Metal Inc., in Charlotte, N.C., added two dedicated business development positions and a marketing manager who are focused on opening doors and increasing revenue.

“Although we were crippled by the global pandemic, we were able to maintain growth while increasing overall profit margins because we were able to be more selective about the work that we targeted,” said President Daniel Davis. 

The positive outlook wasn’t isolated. A strong majority of commercial roofers (68%) said they expected sales to increase again this year, with 11% of respondents anticipating sales to increase greatly. Just 14% of contractors felt sales would slightly decrease in 2021, and 7% expected great losses. 

Of those expecting sales increases, more than half said it would be in single-ply systems, and 53% anticipated a spike in metal jobs.

In terms of challenges — outside of the pandemic — commercial contractors bucked a trend. Safety enforcement for employees and government regulations were out of the top five of perceived workforce issues, at 20% or less.

Instead, contractors were concerned most with the lack of qualified, skilled labor (61%), and lowball bidding (48%). Increased costs of building materials, the overall weak economy, and insurance and healthcare costs rounded out the top five. 

Storms and Supply Struggles

As previously mentioned, an increase in building material costs is one of the top issues commercial and residential contractors expect to face, with nearly half of respondents expecting it to be a factor in 2021. Gleaning from the experiences of 2020, it’s understandable. Lockdowns around the globe caused a ripple effect that slowed product manufacturing and distribution, which coupled with a record-breaking storm season, hit contractors hard right during peak season. 

“The supply and demand issues during peak season were particularly challenging this year. We understand and feel the effects of that with our contractors,” said Scott Schumacher, vice president of strategic marketing for Owens Corning Roofing. “Our approach will always be to communicate with contractors honestly and realistically, so they can do the same for their customers.

“Entering 2021, we do not anticipate repeating lost production time due to the pandemic.”

In a virtual town hall hosted by the National Roofing Contractors Association, Asphalt Roofing Manufacturers Association (ARMA) Vice President Reed Hitchcock said as of October, shingle manufacturers reported that they were running at full capacity to help resupply contractors.

“I wish I had the crystal ball on this one,” said Hitchcock. “In talking to our members, there is some anticipated demand slowdown coming with the fourth quarter and the first quarter coming up.”

Single-ply roofing took a hit during the pandemic, according to the Single Ply Roofing Industry, while the Roof Coatings Manufacturers Association (RCMA) reported production of coatings was at an all-time high.

“We always find that the coatings actually can extend the life of the roof, and I think that because of COVID — financial costs on the residential and commercial side — I think owners are looking at more opportunities to save long term,” said RCMA Executive Director Dan Quinonez.

Proactive communication between contractors, distributors and manufacturers proved key in managing product availability, said Mike Jost, chief operating officer at ABC Supply Co.

“The nearly 800 locations within our network have always worked closely together, but it’s been especially advantageous to help contractors get the materials they need,” said Jost. “If one branch doesn’t have the product, we’re able to lean on others to move material around.”

The supply shortage and the level of concern regarding it is largely due to the pandemic, but the blame can also be placed on an unprecedented 2020 storm season.

The Atlantic hurricane season became the most active on record and the fifth costliest season. A total of 31 depressions were recorded, all but one of which became a named storm. Twelve of the named storms made landfall in the U.S., breaking the record of nine recorded in 1916. In total, the hurricane season caused an estimated $51 billion in damage.

2020 was the fifth consecutive above-average season since 2016, and if the last few years are any indication, contractors should brace themselves for yet another heavy storm season in 2021.

Louisiana was among the hardest hit areas by hurricanes. By the time Hurricane Zeta struck Louisiana in late October, it was the fifth hurricane to tear apart buildings in the state. Even contractors who were not working in the hurricane-swept areas were feeling the squeeze on labor and supplies.

“Contractors from all over the country are coming to Louisiana and down to the coast to work, so material has been extremely hard to come by,” said Mike Warren, director of operations for Roof Crafters in Hammond, La.

Though the work proved to be difficult due to jobsite delays and supply issues, it was also plentiful, giving many roofing contractors a boost in what was otherwise going to be a tough year.

During this record-breaking hurricane season, the Midwest experienced a derecho — a straight-line windstorm — in August, with winds hitting 140 mph. The storm caused an estimated $11 billion in damages, flattening entire fields of crops and ripping apart roofs and buildings of every size.

Cedar Rapids, Iowa took the brunt of the storm, causing $7.5 billion in damages from the winds and tornadoes. When snowstorms hit the area in October, contractors were left scrambling to help people recover before winter truly set in, reporting labor shortages and supply line struggles. 

Christina Bible, director of operations for Options Exteriors in Minnesota, said they had to ship shingles from South Dakota to use in Iowa. But the silver lining, Bible says, is that between the derecho and supply shortages, multiple customers are now looking into the viability of metal.

“There has been some interest in homeowners transitioning from asphalt roofs to metal roofs,” she said. “The type of devastation down there was just so great the shingles didn’t even matter, it was actually whole roofs being blown off, but we have been doing some more metal roofs.”

Intense weather wasn’t the only hazard roofing contractors had to deal with in 2020. Wildfires across the West Coast affected thousands of families and caused billions in damage. California alone saw $12 billion in damage, leading many roofing contractors to consider more durable options for the future.

“As we witness the horrible destruction wildfires have and are causing, the more we can do as an industry and community to help homeowners protect themselves against these increasing threats, the better,” said Renee Ramey, Metal Roofing Alliance executive director.

Business Climate 

If acquisitions are any measure of a prosperous business climate, then roofing is starting off 2021 in positive fashion. Several major moves were formally announced around the New Year:

• Multinational building materials manufacturer LafargeHolcim acquiring Firestone Building Products for $3.4 billion.
• Beacon sold off its interior product business, consisting of 81 branch locations to American Securities Inc. for $850 million.
• Innovative Chemical Products (the ICP Group) announced the acquisition of Leeson Polyurethanes, a leading U.K.-based manufacturer of polyurethane adhesives and coatings used in a variety of sectors and markets.

The climate proved good for contractor acquisitions as well. Tecta America — which celebrated its 20th anniversary in 2020 — continued its growth with a handful of additions throughout the year. Company leaders said the pandemic hasn’t slowed down their acquisition strategy, which is more about finding the right company that fits their model, rather than timing. 

“It’s part of who we are, part of our culture, and when we buy companies we buy the best ones out there,” said President and CEO Dave Reginelli. “We’re not looking for turnarounds, we’re looking for solid companies with strong performance with the same features we care about.” 

As in any given year, assessing the state of the roofing industry in 2021 will depend on several factors — known and currently unknown. However, it’s clear that this year will be different for three specific reasons regardless of market, business size or service specialty. 

COVID-19 Vaccinations: The rollout of multiple COVID-19 vaccines at the end of 2020 was slow and cumbersome, a problem President Joe Biden’s administration pledges to fix — and quickly. They’ll have to if there’s any chance to return to normalcy as infections and death totals surge nationwide. 

New Leadership: Vaccinations are just the beginning. The Biden administration already proposed another broad pandemic relief package, and promised a major emphasis on infrastructure and clean energy. While those present opportunities for roofers, the impact on business regulations after four years of a federal scale back remains to be seen. 

Wicked Weather: Predicting long-term weather patterns for any particular region of the country is futile. But given the strength and volatility of recent storm seasons, there’s no reason to believe roofing contractors should expect anything less in 2021. 

ARTICLE COURTESY OF ROOFING CONTRACTOR'S MAGAZINE

Protecting First Responders with Vinyl Rib Roofing in Lincoln City, Oregon

By Melissa Lee, Marketing Communications Manager at Duro-Last, Inc.

Lincoln City sits on the central coast of Oregon and is known for having over seven miles of pristine beaches that welcome thousands of vacationers every year. Incorporated in March 1965 as a result of uniting the neighboring communities of Delake, Oceanlake, Taft, Cutler City, and Nelscott, Lincoln City is home to an estimated 9,000 residents. At the heart of this coastal community is the small but mighty North Lincoln Fire and Rescue District #1, staffed almost entirely by volunteer firefighters and a dedicated team of 16 full-time administrative personnel.

North Lincoln Fire and Rescue District #1 is comprised of six stations that provide emergency support to Lincoln City and its surrounding communities. The Bob Everest – 1400 Station is one of the larger facilities in the district, housing Engine 1407, Ladder 1455, Rescue 1438, two water rescue response vehicles, and Reserve Engine 1405.

In 2018, North Lincoln Fire and Rescue appealed to the community for support with Measure 21-183, which provided funding for both equipment and badly needed upgrades to the Bob Everest station. In addition to the local funding request, which was ultimately approved, the district was also able to secure an Oregon Infrastructure Authority Grant, which provided for seismic upgrades to the facility.

Emerick Construction Company of Tualatin, Oregon, was awarded the general contractor role for the project, which included the addition of office space to allow administrative staff to be housed in one location, an enclosed space to house firefighters’ gear, reconfiguring crew quarters with new dorms and bathrooms, repairing kitchen and living areas, and a variety of other upgrades including the roofing system. Portland, Oregon, architect firm Mackenzie drew up plans for the existing 13,900 sq.ft. facility, specifying shingles and approximately 10,000 sq.ft. of 24 gauge standing seam metal panels for the roof.

Through an open bidding process, Nail It Roofing Company of Oregon City, Oregon, was awarded the roofing system portion of the project through Emerick Construction Company. Upon review of the drawings, the Nail It Roofing team knew that the standing seam metal was not going to be a good solution for the 1-1/2:12 low-pitch portions of the roof. Working closely with the architect and general contractor, they evaluated a different solution more suitable for the high winds and precipitation common in Oregon coastal communities.

While a variety of products were reviewed, the Nail It Roofing team proposed the use of the Duro-Last® Vinyl Rib roofing system. Featuring a PVC membrane and separate vinyl ribs that are heat welded to the installed membrane, this system provides an aesthetically pleasing watertight solution where traditional standing seam roofs aren’t practical.

“The architect envisioned the standing seam roof on the lower sloped portions of the project, so we had to find a solution that matched that vision as closely as possible while knowing that it would perform well in the long run,” explained Nail It Roofing Company president Rodrigo Quintanilla. “It took some back-and-forth to make sure everyone was comfortable with the change, but the Duro-Last Vinyl Rib system was ultimately approved and incorporated into the plans.”

Once the Nail It Roofing team received the green light to move forward with the new plans, they were able to begin installation almost immediately. With attic insulation already in place, they installed vapor barrier and 1/4” DensDeck® Prime cover board over the 5/8” plywood deck before adhering the dark gray Duro-Last 50 mil membrane. Dark gray vinyl ribs were then added every 18 inches, giving the appearance of a standing seam metal roof.

With an average crew of six, Nail It Roofing completed the membrane portion of the roofing system in approximately four days. “It actually took us a little longer than it normally would for a project this size,” said Quintanilla. By the time their team was able to install the membrane, the weather had turned cold. As with any coastal community during the winter months, precipitation and ice became a bit of a challenge. “There were days that we had to scrape down the ice from the previous night’s rain before we could begin installation for the day,” he continued. “It got a little labor intensive at points, but the material itself was wonderful to work with, especially under those circumstances.”

Despite the challenges that the Nail It Roofing team faced, they were happy with the installation. “We are extremely happy that we were able to work with the general contractor and architect to modify the plans for the vinyl rib system,” Quintanilla said. “The color options and support that Duro-Last offered were the ideal solution to everyone’s wants and needs.”

Once installation was complete, Nail It Roofing Company provided North Lincoln Fire and Rescue District #1 with a 20-Year NDL Warranty for the Duro-Last Vinyl Rib system. “From the feedback that we have received, it’s safe to say that everyone was very happy with the outcome. The roof looks great, the vinyl rib system complements the dark shingles well, and it still provides the clean aesthetic typically found with traditional standing seam roofs. Not only that, but we were able to deliver a solution that offers the district long-term peace of mind with a warranty to back it up.”

Courtesy of Western Roofing Insulation and Siding

Record-Setting Reroof

Massive Multifamily Complex Reroofed After Hailstorm in Denver, Colorado 

In 2016, a joint partnership of property developers purchased The Breakers Resort apartment complex in Denver, Colorado, for a record-shattering $350 million, the largest multifamily acquisition in Denver’s history. Reimagined as Tava Waters, the luxury residential complex underwent extensive refurbishments and beautification measures to freshen up the 20-year-old property. This included painting the interior and exterior of the units and buildings, adding new amenities, and revamping the community pool. Popularity amongst Denver residents skyrocketed following the residential facelift, and people flocked to the coveted apartments.

The refurbishments went smoothly overall, but the Tava Waters’ roofs would prove to be a bit tricky, as Denver can be privy to some devastating weather events. A particularly nasty hailstorm in July 2019 incurred some notable hail damage to the Tava Waters roofs across its 143 buildings. When it came time to choose a contractor to repair the damaged roofs, Tava Waters’ ownership already knew who they could rely on. Aspen Group of Englewood, Colorado, was familiar with the sprawling property, as they were contracted to paint the exterior of over 1,500 units after the historic acquisition and have consistently been brought back for various repairs and maintenance. Tava Waters’ leadership trusted Aspen Group to know and understand the massive amount of moving parts that this community required to get the job done right.

Founded in 2012, Aspen Group has quickly risen to be known as one of the premier commercial and multifamily general contractors in Colorado. The company’s niche is exterior reconstruction with a heavy emphasis on roofing. Proud of its reputation for overachieving in the service department, Aspen Group goes out of its way to deliver a superior product to its customers. Aspen Group worked closely with the insurance adjusters to establish the scope of work, and it ended up being the largest hail claim that any of the contractor’s vendors or clients has ever been a part of.

From the beginning, Aspen Group and Tava Waters’ ownership agreed that a complete GAF roofing system would be the best option for this massive project. As a GAF Master Elite® Contractor, Aspen Group is a member of a prestigious factory certification program that provides ongoing training to roofing contractors and assures customers that their roofs will be completed with the utmost expertise.

The project called for an incredible 11,000 squares, including shingles, hip and ridge caps, starter strip shingles, self-adhering underlayment, and vents. GAF’s Timberline® HDZ™ Shingles were used on the roofs and provide stylish beauty alongside unmatched protection and durability. By using GAF’s proprietary color blending and enhanced shadow effect, the architecturally stylish shingles emulate a genuine wood-shake look. Timberline HDZ Shingles use GAF’s innovative LayerLock™ Technology and Dura Grip™ Advanced Sealant, which provides resilience, strength, and exceptional wind-uplift performance. Aspen Group also installed GAF Pro-Start® Eave/Rake Starter Strips, which are made with a high-quality, properly positioned adhesive applied at the factory to help prevent shingle blow-offs at the eave and rake areas of the roof. GAF Seal-A-Ridge® ridge cap shingles were also used, which help protect Tava Waters’ residents against leaks at the high-stress areas of the roof, the hips and ridges, while also complementing the overall look of the surrounding Timberline HDZ Shingles.

GAF’s WeatherWatch®, a mineral-surfaced leak barrier, was installed on the vulnerable areas of the roof. It self-seals around fasteners and helps protect against wind-driven rain and ice dam infiltration. Finally, GAF Master Flow vents were installed to help remove excess heat and moisture from the attic, which helps protect the roof system against premature deterioration. The Tava Waters roof system is protected by GAF’s Silver Pledge™ Limited Warranty, one of the best in the industry, including a limited WindProven™ Warranty with no max wind speed limitation.

The project was slated to begin in March 2020, but the COVID-19 pandemic put a wrench in the plans and the reroof was put on hold. When Aspen Group was able to get up on the roofs in July 2020, they were tasked with completing the repairs under the original timeline, and they are set to be fully completed in November this year. It was a hefty task, but clear communication, unparalleled professionalism, and high-quality products have made the project go smoothly. Averaging 1,000 squares per week, Aspen Group is ahead of schedule to complete the reroof on time. This repair schedule also includes over 100,000 linear feet of gutter replacement.

“With so much uncertainty about our world going on at that time, we weren’t sure how the project was going to unfold,” said Scott Ryan, a partner at Aspen Group. “Thankfully, with impeccable communication, our incredibly skilled crew, and top-of-the-line GAF products, we have been able to stay on track to meet our project completion deadline and get the job done right.”

Not only was this roof repair project a challenge for Aspen Group because of the sheer size of the Tava Waters community, but scheduling issues and uncertainty regarding the global pandemic made the process particularly tedious. However, by relying on the tenets of professionalism that Aspen Group is founded upon, as well as high-quality, reliable GAF roof components, the large-scale exterior project will be completed as planned.

Article Courtesy of Marcus Dodson at Western Roofing Magazine