Coronado Ranch, Gilbert: 34-Square Tile Underlayment Replacement in 3 Days

The homeowner called us mid-June 2026 after finding a coffee-colored ring on the guest room ceiling. The house was built in 2004. Nobody had touched the roof. Below is the full walk-through of what we found and what we did about it.

What the lift-and-look showed

• Original 30-pound felt, dry and powdery to the touch
• Long tears at the batten screw rows across the west elevation
• Two pipe boots split down the collar (UV kill)
• Valley metal was original 26 gauge galvanized, still serviceable
• 3 tiles cracked at the rake, 4 slipped at the hip

The scope we quoted

1. Full tear-off of tile, felt, and battens on all elevations
2. Deck inspection with 6 sheets of CDX budgeted for spot repair
3. TileSeal HT synthetic underlayment, mechanically fastened
4. New 26 gauge painted valley metal and drip edge
5. New lead pipe boots on all 4 penetrations
6. Re-lay existing Westlake Royal tile with 5 percent breakage allowance
7. New mortar at ridge and hips with weep provisions

How the three days went

Day 1: tear-off and dry-in

6-person crew on site at 5:30 am. Tear-off complete by 11. We staged tile on the driveway on plywood over lawn. Deck was 90 percent sound, replaced 2 sheets at the north eave where a rodent had chewed a soffit vent open. Full synthetic underlayment down by end of day, house was dry before the monsoon cell that rolled in at 7 pm.

Day 2: flashings and hips

New valley metal, drip edge, pipe boots, and wall flashings. Hip and ridge battens set with corrosion-resistant screws. Started re-laying tile on the low-slope hip.

Day 3: tile re-lay and cleanup

Full tile re-lay, mortar bed at ridge and hips, mag sweep for nails and screws, drone photos for the homeowner's records. Off site by 3 pm.

What it ran

Contract was $22,800. Change order for deck came in at $640. Total delivered $23,440. Full 25 year underlayment warranty from the manufacturer, 10 year workmanship from us.

What we would do differently

Nothing structural. Next time we will pre-order two extra bundles of Westlake Royal replacement tile from the supplier because we ended up 8 tiles short and had to send a truck for them on day 3.