Tuff Shed

I am unhappy with my recent (May 6, 2020) TUFF SHED Pro Studio roofing installation. The nailing is defective and will likely lead to future problems. I did not realize the wrong nail size was used until after the installation when I noticed that nails were not penetrating the roof deck as they should have. Also, there was no cap flashing at the ridge and there were three nail heads left exposed. I had to have a custom cap flashing made by a local metal shop because TUFF SHED does not provide cap flashing at the top of their monoslope roofs. Without cap flashing rainwater can enter between the shingles and the underlayment. Cap flashing is an industry standard not followed by TUFF SHED.

TUFF SHED shingle roofing is typically installed over 7/16" OSB using 3/4" long roofing nails. This is seen in virtually all TUFF SHED models, even the Premier Pro Studio which comes with GAF Timberline architectural shingles. The nail length is not in TUFF SHED's advertised specifications so customers are unaware. The problem is, 3/4" nails are not long enough to go through Timberline shingles and fully penetrate the OSB deck. Full penetration of the deck is required by roofing shingle manufacturer instructions and by Building Codes. Much of the nail points remain within the thickness of the deck. In fact, if the nails are not overdriven, 3/4" nail points cannot penetrate the deck at all. Do the math: thickness of shingles at nailing strip plus thickness of deck is almost 3/4", making it impossible for the nail shank to penetrate the roof deck. Also, where roof nails enter the roof framing, the 3/4" nails do not meet the 3/4" embedment requirement of Code and manufacturer instructions, due to the thickness of the shingles.

These short nails are junk. They have little grip compared to properly sized 1-1/4" roofing nails and will pop up over time, lifting and damaging shingles and creating roof leaks. Just GOOGLE "shingle roof nail length" and you will see countless technical articles and illustrations warning of the problem with short nails. Many articles say avoid roofers who use 3/4" nails, calling these roofers "storm chasers" and "fly by night" operators. What is the point of having "lifetime architectural shingles" if the nailing is deficient and will detrimentally affect the long term performance of the roof?

It is no wonder I see complaints by TUFF SHED customers of shingles falling off or nails popping though within only a few years. Nails have been overdriven, damaging the shingle matrix, and the nails do not fully penetrate the roof deck. When asked why they use 3/4" nails, local TUFF SHED rep's say customers do not want the aesthetic of nails penetrating the roof deck and creating head hazards. I do not accept that excuse. My shed roof deck is well above head height and I fully expected the roof to meet industry standards and the Los Angeles Building Code. TUFF SHED's "What to Expect" document advises customers to expect to see nails pentrating the roof deck in order to meet Building Code requirements. I expected to see nails penetrating. When I didn't see that, I became concerned and asked my local technical rep why. He said they are coming through, just hard to see. I had to get up on a stepladder and look hard to see even a few nail points that made it through the chips at the bottom of the OSB.

In my installation most nail points are hidden within the deck and the few nail heads that do show are protruding only about 1/8". That leaves part of the nail points still in the deck which will likely, due to expansion and contraction of the deck, cause many of the nails to move up over time, lifting and popping through the shingles. Also, these short nails have few rings which gives them little grip within the deck material. They pull out easily. The fact that any nail points are visible at all means the 3/4" nails were overdriven, violating the shingle manufacturers instructions and voiding any shingle warranty.

TUFF SHED's local rep response is that TUFF SHED will repair roof damage due to defects during its 10-year limited warranty period. They offer no remediation other than "warranty service" for any issues that develop. Their technical rep asked me if I would like them to come and drive in some longer nails. There would be two problems with that: 1) driving in longer nails would not solve the problem of the existing short nails, which would still pop up, and 2) lifting the shingles to modify nails would destroy the manufacturer shingle seal, creating its own long term performance issues. Only a total roof replacement would solve the problem.

I do not want to have to always be inspecting the roof and dealing with repeated call backs in future years, as many TUFF SHED customers have had to do. For a Premium Pro Studio model I expected a reliable roof on day one that is properly installed in compliance with industry standards and local Building Code. I did not get that. I got what every other unsuspecting TUFF SHED customer gets, a substandard roof installation.

3/4" roof nails for shingles on 7/16" OSB or 1/2" plywood should be outlawed. They are the mark of roofers who do not know what they are doing or deliberately do not follow shingle manufacturer instructions. For a few more dollars, longer nails could be used in compliance with industry standards and many future shingle problems could be avoided. I would have readily paid the cost of longer nails.

By registering this complaint, I am alerting other TUFF SHED customers to the TUFF SHED short nail defect. Beware! For me, I am uncertain what the resolution should be. On the one hand, I would like an immediate replacement of the entire roof, with all short nails removed and the replacement roof installed per Code with correctly sized nails. On the other hand, I don't know if I could trust TUFF SHED to do a professional tear off and second install, since they didn't do it right the first time. A better option might be to accept a refund that would cover the cost of a replacement roof and let me choose my own contractor at the time of my choosing.

I purchased my shed from Tuff Shed located in Pacoima, CA. The door that was delivered with the Shed was warped and locking the shed up is difficult. I have made 6 calls to Tuff Shed within the past week and have received 0 call backs. Sales rep. Gave me his card with personal cellphone number. I was told at time of purchase. to contact the sales rep. Anytime if I had any problems or complaints. THIS WAS A LIE...