Today I proceeded to fix my A/C leak and was surprised at the cause. When I removed the A/C I found three holes in the TPO under it. They were caused by sheet metal screws protruding through the A/C pan about 1/4". All the parts of the A/C were secured to the pan with sheet metal screws, and all of them (I did not count, but there must have been at least 20 of them) protruding through the pan by 1/4 to 3/8 inches.
The three holes:
The A/C is designed to ride on the foam opening gasket and two pieces of support foam, one in front and one in back. The back support gasket had come off and allowed the screws to penetrate the TPO.
Picture showing missing piece of foam:
Front spacer and gasket:
Picture of protruding screws does not show them well, but take it from me, they are sharp and nasty:
The gasket kit I bought and the 1X3 wood collar I put around the opening:
I put down 1X3 wood spacers to carry the foam spacers. The wood collar and the wood spacers were set in adhesive sealant and covered with eternabond tape. This raises the A/C high enough that the offending screws will not touch the TPO roof:
New gasket and foam spacers applied to A/C:
Set the A/C back on opening, tighten down gasket with 4 bolts from inside, re-install interior unit and the temporary fix is complete.
I say temporary because the TPO and underlayment around the A/C has come unglued and a real roof repair is in order. But that will have to wait until next spring because I am taking this TC to Colorado in a couple of weeks come *ell or high water.
For those with inquiring minds, no beer was consumed during this job. We had it finished by 9 am. Now this afternoon is another story.
I have the following questions:
Do all roof a/c units have protruding screws on the bottom?
Why would a manufacturer install an a/c unit with protruding screws and make no provision for protecting the TPO roof?
I would think that if all air conditioners were installed like this there would be a lot more roof failures, so I am thinking mine is one of a kind.
The three holes:
The A/C is designed to ride on the foam opening gasket and two pieces of support foam, one in front and one in back. The back support gasket had come off and allowed the screws to penetrate the TPO.
Picture showing missing piece of foam:
Front spacer and gasket:
Picture of protruding screws does not show them well, but take it from me, they are sharp and nasty:
The gasket kit I bought and the 1X3 wood collar I put around the opening:
I put down 1X3 wood spacers to carry the foam spacers. The wood collar and the wood spacers were set in adhesive sealant and covered with eternabond tape. This raises the A/C high enough that the offending screws will not touch the TPO roof:
New gasket and foam spacers applied to A/C:
Set the A/C back on opening, tighten down gasket with 4 bolts from inside, re-install interior unit and the temporary fix is complete.
I say temporary because the TPO and underlayment around the A/C has come unglued and a real roof repair is in order. But that will have to wait until next spring because I am taking this TC to Colorado in a couple of weeks come *ell or high water.
For those with inquiring minds, no beer was consumed during this job. We had it finished by 9 am. Now this afternoon is another story.
I have the following questions:
Do all roof a/c units have protruding screws on the bottom?
Why would a manufacturer install an a/c unit with protruding screws and make no provision for protecting the TPO roof?
I would think that if all air conditioners were installed like this there would be a lot more roof failures, so I am thinking mine is one of a kind.
