Roof Replacement Case Study: 1922 Hopedale, MA Home
Project Overview
This case study highlights how Master Roof Inc. evaluated and replaced the roofing system on a historic home built in 1922 in Hopedale, Massachusetts. While the original roof structure was well preserved, several construction methods used at the time were not compatible with modern asphalt shingles. A full roof replacement—including new plywood sheathing—was recommended to ensure long-term performance and protection.
Materials
Asphalt Shingles: GAF Timberline HDZ Pewter Grey
Roof Deck: 35 sheets of plywood
Ice Shield: GAF WeatherWatch
Underlayment: GAF Tiger Paw
Roof Size: 10 sq shingles
Vents: 4 GAF Intake vents
The Homeowner’s Situation
The homeowner contacted MasterRoof after years of dealing with patch repairs and ongoing roof concerns. Given the age of the home, the goal was not just to stop leaks, but to determine whether the existing roof system could properly support modern roofing materials.
Inspection Findings
- Aging and Failing Shingles
The inspection revealed worn-out shingles with missing granules, cracking, curling, and lifting. Previous patch repairs were visible across multiple areas of the roof, a clear indication that the roofing system had reached the end of its service life.
- Original Ledger Board Decking
The attic inspection showed that the original ledger board roof decking was dry, clean, and structurally sound - an impressive finding for a home built in 1922. However, the spacing between the ledger boards was designed for older roofing materials and is not compatible with modern asphalt shingles. Modern shingles require continuous solid decking to ensure proper fastening, wind resistance, and warranty compliance.
- Ventilation and Roof Penetrations
The home relied on older ventilation methods such as gable and square vents. While these worked historically, they do not provide optimal airflow for today’s roofing systems. Several roof penetrations, including pipe boots and unused satellite mounts, also showed signs of failure.
Flashing and Water Protection
As part of the roof replacement, MasterRoof installed a complete, modern flashing system designed to protect the most vulnerable areas of the roof. All step flashing at roof-to-wall intersections was replaced, which required temporarily removing sections of siding to ensure the flashing and ice & water barrier were installed correctly and extended up the wall.
At the chimney, MasterRoof installed a multi-layer flashing system following manufacturer specifications. This included an ice and water membrane applied around the chimney and extended up the masonry, individual aluminum step flashing integrated with each shingle, reinforced lead flashing at critical corners, and a properly installed lead counterflashing. This layered approach creates redundant protection and ensures long-term resistance to water intrusion - far beyond what older flashing systems provide.
Why Roof Replacement Was the Right Choice?
Although the original roof structure was in good condition, the roof system as a whole was no longer functioning properly. The combination of aged shingles, outdated decking configuration, and repeated patch repairs made long-term reliability impossible.
Replacing the ledger boards with plywood sheathing allowed MasterRoof to create a solid, continuous roof deck that meets modern installation standards and ensures the new roofing system performs as intended.
Solution
MasterRoof recommended a full roof replacement that included:
- Removal of existing shingles and patch repairs
- Replacement of ledger board decking with plywood sheathing
- Installation of new underlayment and ice & water protection
- Corrected flashing details
- Improved ventilation strategy
- Installation of new asphalt shingles
Frequently Asked Questions
Can older homes support modern roofing materials?
Yes, but older construction methods often require updates to meet today’s roofing standards.
Why was the ledger board decking replaced if it was still in good condition?
While the ledger boards were structurally sound, the spacing between them is not compatible with modern asphalt shingles. Plywood sheathing provides the solid surface required for proper installation.
Is replacing roof decking common in historic homes?
Yes. Many historic homes require decking upgrades during roof replacement.
Why are patch repairs not a long-term solution?
Patch repairs address symptoms, not the underlying system failure.
Repair Gallery
Other Roofing Projects in Hopedale & Surrounding Towns
At Master Roof, we offer exceptional residential roofing services across Hopedale including roof replacement, repairs, attic ventilation, chimney flashing, skylight installations, roof maintenance, and assessments. Here are some other Master Roof projects in the area.
