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Overlap
Overlap a type of repair where new plywood is installed over the old one. This is done when removing the old roof covering causes the plywood or OSB to get damaged and pieces come off with the membrane. To level the surface and avoid height differences, we install a 3/16 inch ( 5 mm ) plywood layer on top. Performed only during TPO/PVC replacement
Removal
- Removing roof components and membrane. If there are any elements mounted on the plywood sheet or a membrane is laid over it, they must be removed before starting work.
- Inspecting damaged plywood: Check for moisture, brittleness, rot, or crumbling. Assess the extent of the damage and determine if replacement is necessary.
Preparation
- Trimming the sheet: Lay down the full plywood sheet, aligning it with one edge. Secure it with screws. Then use a chalk line to mark the cut, set the saw blade to the plywood thickness, and cut in place. If laying out the entire sheet isn’t possible on the roof, pre-cut the plywood to the required length on the ground.
- Cut openings in advance that won’t be accessible after installation — like those for refrigerator vents, antennas, and plumbing vent pipes.
- Cut down plumbing vent pipes flush with the surface so they don’t interfere with membrane installation or mesh application.
- Remove any nails or staples from the area where the new plywood will go. Clean the surface of dirt and dust before applying foam. An air blower may help.
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- Tip: You can ask Home Depot to pre-cut the plywood for convenience.
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Installation