# Collins metal roof — takeoff audit & release notes (v3)

1407 N 6th St, Coeur d'Alene, ID 83814 · Roofr 10769087 + site-verified edges · REV C · prepared 2026-07-28 · PREPARED — NOT TRANSMITTED

**Status: COMPLETE — READY TO SEND.** Supersedes v1 (2026-07-16) and v2. No pending items on Ketron's side; supplier-side facts land with the Ibex order acknowledgment (confirmations A1–A7 printed on the order form).

## Decisions of record (Mitch, 2026-07-28)

* Order **46 blanks** — one per installed panel, **no spares**, no blank sharing.
* The four ~6-in edge panels are **lengthwise field rips**; cut edge buried under rake trim. **No crosswise field cuts** at exposed edges anywhere on the job.
* **Factory edge at every eave**; all length slop trims at the panel **top** under ridge / hip / pitch-break trim.
* **24 ga Ibex PBR PVDF** per the signed contract ($38,200 option, 10/45/45, deposit paid). Customer confirmed 24 ga in his own words 2026-04-20.
* **Field-verified measurements govern** wherever they exist.
* Color: **Medium Bronze PVDF on the order**; Weathered Copper is the customer's named reference and is explicitly held for the owner's sign-off — physical chip ships with the acknowledgment and is signed before the coil run. Alternate routes (Ibex WC Smooth/SMP, Metal Sales WC W50 PVDF) stay printed on the color page.

## Measurement basis — one roof, two drawings

**Panels** come from the hand-drawn 46-strip layout in Roofr 10769087 (one strip per intended panel). Its areas and runs are sound — the 2026-07-24 scale-verified field sheet matches the main runs to within half an inch. **Trim** comes from the 2026-04-01 site-inspection report. The perimeter test decides who governs edges:

| report | eaves + rakes | vs 153'-02" outline | verdict |
|---|---|---|---|
| site-inspection | 155'-11" | +2.7 ft | PASSES — governs trim |
| 46-strip layout | 178'-11" | +25.8 ft | impossible — strip seams counted as edges; governs panels only |

| edge | site (governs) | strip drawing | ratio | explanation |
|---|---|---|---|---|
| Eaves | 64'-01" | 90'-04" | 1.41× | S3's pitch-break line was classed as eave |
| Rakes | 91'-10" | 88'-07" | 0.96× | outer perimeter — agrees |
| Ridges | 37'-11" | 54'-04" | 1.43× | strip seams at the ridge double-counted |
| Hips | 17'-04" | 34'-07" | 1.99× | both strips at each hip counted the shared line |
| Valleys | 26'-09" | 50'-03" | 1.88× | both strips at each valley counted the shared line |
| Pitch break | 28'-01" | 28'-00" | 1.00× | single line — agrees |

Field-sheet reconciliation: Main slope run — left (S1) tape 17.00 vs order 17.00 (CONFIRMED); Main slope run — right (S2) tape 17.00 vs order 17.03 (CONFIRMED); Building width tape 28.00 vs order 28.09 (CONFIRMED); Main ridge length tape 21.50 vs order 21.07 (DELTA 5 in — panel count unchanged); Valley run (each) tape 13.25 vs order 13.38 (CONFIRMS trim basis).

A 17'-0" slope run over a 14'-0" half-width on a 28'-0" building is a 8.27/12 pitch. The order models the main roof at 8/12 — the field sheet backs it. The April site-inspection report calls this roof 10/12 predominant, which would put the slope run at 18'-3", not 17'-0".

## The order

| figure | value | basis |
|---|---|---|
| Installed panels | 46 | one per drawn strip |
| Blanks ordered | 46 | 1:1, no spares (decision of record) |
| Ordered footage | 551.00 LF | measured runs 531.49 + whole-inch round-up 1.51 + 18.00 LF of 6-in projections |
| Cut lengths | 14 | one fabrication length per section run |
| Roof area | 1402.33 SF | sum of measured strip areas |
| Coverage surplus | 17.9% | shape-cut waste at hips/valleys/tapers — normal for this roof form |
| Panel weight | 2,224 lb | EST @ 1.16 lb/sqft of 41.75-in coil — confirm on acknowledgment |

Note: v1's published 549.33 LF contained the C-01 inconsistency (four plane-E panels carried one inch that derives from nothing) AND the C-17 defect (the four edge strips ordered 6 in short). The consistent rule with all projections gives **551.00 LF in 14 lengths** — same blanks, same layout, correct arithmetic, nothing short at a drip or lap line.

### Sections (crew names — the Roofr letter is a cross-reference only)

| code | name | letter | pitch | panels | LF | area SF | rips |
|---|---|---|---|---|---|---|---|
| S1 | MAIN ROOF — LEFT SLOPE | E | 8/12 | 9 | 140.75 | 386 | — |
| S2 | MAIN ROOF — RIGHT SLOPE | D | 8/12 | 9 | 141.42 | 387 | — |
| S3 | FRONT UPPER FACE (11/12) | I | 11/12 | 11 | 115.75 | 267 | I01, I11 |
| S4 | FRONT CORNER RETURNS (9/12) | J | 9/12 | 6 | 38.50 | 84 | — |
| S5 | PORCH ROOF (4/12) | H | 4/12 | 11 | 114.58 | 278 | H01, H11 |

### Grouped cut schedule

| cut length | qty | total LF | panels |
|---|---|---|---|
| 17'-07" | 7 | 123.08 | D03, D04, D05, D06, D07, D08, D09 |
| 17'-06" | 7 | 122.50 | E01, E02, E03, E04, E05, E06, E07 |
| 16'-04" | 1 | 16.33 | I06 |
| 14'-02" | 1 | 14.17 | I07 |
| 14'-01" | 1 | 14.08 | I05 |
| 12'-11" | 1 | 12.92 | D01 |
| 12'-10" | 1 | 12.83 | E08 |
| 10'-05" | 11 | 114.58 | H01, H02, H03, H04, H05, H06, H07, H08, H09, H10, H11 |
| 9'-10" | 2 | 19.67 | I04, I08 |
| 9'-09" | 2 | 19.50 | J01, J06 |
| 8'-07" | 6 | 51.50 | I01, I02, I03, I09, I10, I11 |
| 6'-05" | 2 | 12.83 | J02, J05 |
| 5'-05" | 2 | 10.83 | D02, E09 |
| 3'-01" | 2 | 6.17 | J03, J04 |

### Field rip plan

| panel | section | blank | rip to | at | offcut retained |
|---|---|---|---|---|---|
| H01 | S5 PORCH ROOF (4/12) | 10'-05" | 5.8 in | left rake | 30 in × 10'-05" |
| H11 | S5 PORCH ROOF (4/12) | 10'-05" | 6.1 in | right rake | 30 in × 10'-05" |
| I01 | S3 FRONT UPPER FACE (11/12) | 8'-07" | 5.7 in | left rake | 30 in × 8'-07" |
| I11 | S3 FRONT UPPER FACE (11/12) | 8'-07" | 6.0 in | right rake | 30 in × 8'-07" |

### Trim — site-verified basis, sticks per physical run

| item | LF | pieces | runs |
|---|---|---|---|
| Custom oversized D-style eave / drip edge | 64.08 | 7 | Porch front eave 28.06; Main eave, left 18.01; Main eave, right 18.01 |
| Custom D-style profile — gable bearing shelf (Approach B) | 68.00 | 8 | Front gable rake, left 17.03; Front gable rake, right 17.00; Rear gable rake, left 17.03; Rear gable rake, right 17.00 |
| PBR gable / rake trim | 91.83 | 12 | Front gable rake, left 17.03; Front gable rake, right 17.00; Rear gable rake, left 17.03; Rear gable rake, right 17.00; Front gable line, left (porch + corner) 11.92; Front gable line, right (porch + corner) 11.91 |
| Vented ridge cap | 37.92 | 5 | Main ridge (field-verified 21'-6") 21.50; Front corner ridge, left 8.21; Front corner ridge, right 8.21 |
| Hip cap | 17.33 | 2 | Upper-face hip, left 8.67; Upper-face hip, right 8.67 |
| Ibex 02B Jumbo Valley (W-valley) | 26.75 | 4 | Valley, left 13.38; Valley, right 13.38 |
| Ibex 04B Jumbo Pitch Break | 28.08 | 3 | Porch / upper-face transition 28.08 |
| PBR rat guard / eave closure | 64.08 | 7 | Porch front eave 28.06; Main eave, left 18.01; Main eave, right 18.01 |

Total 48 sticks across 8 families (v1 carried 49 on the impossible edge basis, without the Approach B gable shelf the contract includes).

### Accessories

| item | qty | unit | derivation |
|---|---|---|---|
| Woodgrip panel screws, EPDM washer, painted head | 1600 | ea | Σ per panel: FLOOR(order length ÷ 24 in)+1 rows × 4 + doubled eave/ridge rows = 1416 ea; +10%, rounded up to 50 |
| Stitch screws, EPDM washer, colour matched | 750 | ea | panel side laps 473 LF + trim laps, at 12 in o.c. = 638 ea; +10%, rounded up to 50 |
| Pancake-head wood screws — valley flashing | 25 | ea | valley 26.75 LF, both sides, at 4 ft o.c. (Metal Sales PBR guide), rounded up to 25 |
| Rigid outside closure — PBR profile | 70 | LF | hip 17.33 + pitch break 28.08 + solid corner ridges 16.42 LF, rounded up to 10. The MAIN ridge is not included — Ibex detail G treats the ridge vent as the substitute there |
| Inside foam closure — PBR profile | 100 | LF | eave 64.08 (Ibex detail A) + pitch break 28.08 LF (Ibex detail F requires BOTH an inside and an outside closure at a transition), rounded up to 10 |
| Universal expanding closure — valleys | 60 | LF | both sides of 26.75 LF valley = 53.50 LF, rounded up to 10. A die-cut profiled closure will not fit a raked panel cut — use the continuous 1 in × 1-1/2 in roll (Ibex specifies EMSEAL expanding tape here) |
| Vented ridge closure material | 30 | LF | MAIN ridge only, 21.50 LF (field-verified 21'-6"), rounded up to 10. Corner ridges cap solid. Sits between two rows of butyl, under the ridge cap, in place of an outside closure |
| Butyl sealant tape, 1 in | 15 | 50-ft rolls | side laps 473 + valley 2× 54 + pitch break 2× 56 + ridge 2 rows 76 + eave 64 LF ÷ 50 ft, rounded up |
| Colour-matched touch-up, brush applicator | 1 | kit | handling scratches and nicks only |

## Corrections applied (v1 → v3)

| ref | severity | finding | resolution |
|---|---|---|---|
| C-01 | HIGH | Order length rule was not applied consistently | One fabrication run per roof plane, computed as CEILING(measured run × 12). Plane E = 204 in for all seven full-length panels; plane D = 205 in. −4 in total. |
| C-02 | HIGH | Four facets are 6-inch rips, not panels | Panel width is now a published column and the rips are a first-class plan: DECIDED 2026-07-28 — order all 46 blanks (no spares), rip the four edge panels lengthwise in the field, cut edge buried under rake trim, offcuts retained as stock. |
| C-03 | HIGH | 'Minimum-length addition 1.84 LF' is false | Relabelled and recomputed as whole-inch fabrication rounding, shown per panel and in total. |
| C-04 | HIGH | Waste reconciliation arithmetic is wrong | Full reconciliation rebuilt from the panel table and shown as an auditable chain. |
| C-05 | HIGH | Panel width was absent from the entire package | Width and blank role (FULL / RIP) are now first-class columns and are drawn on the layouts. |
| C-06 | HIGH | Four panels were missing from every layout drawing | All 46 IDs are labelled on the plane drawings, with rips called out in a distinct style. |
| C-07 | MEDIUM | Eave-flag reconciliation was never performed | Reconciliation is published. The 6-in projection is retained on all 32 (a long panel can be trimmed, a short one is scrap) and the discrepancy is raised as RFI-02. |
| C-08 | HIGH | Fastener and closure quantities were magic numbers | Every accessory quantity is now a published formula driven by the panel table, at a 24-in solid-deck row spacing, with the spacing itself raised as RFI-04. |
| C-09 | MEDIUM | Drip-edge drawing was not fabricable as issued | Rev B publishes the flat girth, a per-pitch brake-angle schedule, a bend-deduction note, and a clean profile with non-overlapping callouts. |
| C-10 | HIGH | No release gate existed on the length basis | A mandatory five-line field run verification (one per plane) is now the first release gate, and the workbook carries an editable allowance cell so the basis can be changed in one place. |
| C-11 | HIGH | 'Weathered Copper is not an Ibex colour' was only half true | The colour page now presents three real routes with their coating classes and warranties (Ibex Medium Bronze PVDF / Ibex Weathered Copper SMP / Metal Sales Weathered Copper W50 PVDF) and the decision is a gate, not a recommendation. |
| C-12 | MEDIUM | Cut-edge coating was specified against every manufacturer's instruction | The line is now a touch-up kit for handling damage only, and the field-cutting rules — shear-type tools, no abrasive or heat-generating blades, cut face down, remove all swarf — are published as a fabrication control. |
| C-13 | HIGH | Closure map did not match the manufacturer's own details | Outside closure = hip + pitch break; inside closure = eave + pitch break; vent material is its own line at the ridge length; valley closure is the continuous expanding roll because a die-cut closure will not fit a raked cut. Side-lap stitch spacing corrected from 24 in to the 12 in o.c. that Metal Sales and Homewood both publish. |
| C-14 | HIGH | Trim was quantified on edges that do not exist | Trim now derives from the 2026-04-01 site-inspection report, which passes the perimeter test (+2.7 ft, normal overhang). Stick counts are computed per physical run, not by total-LF division. Net: 49 sticks -> 46 across 8 families, including the Approach B gable shelf the contract includes that v1 never ordered. |
| C-15 | HIGH | 26 feet of 'eave' was actually the pitch-break line | Drip edge, rat guard and inside closure quantities re-based to the true 64'-1" eave. The 6-in addition on the upper-face panels is retained as pitch-break lap allowance — their tops trim under ridge/hip cap, so length is safe in the ordered direction. |
| C-16 | MEDIUM | The pitch break spans 4/12 to 11/12, not 4/12 to 9/12 | Order specifies 4/12 lower / 11/12 upper (included angle ~156 deg) with a field template to the brake shop before forming. |
| C-17 | HIGH | The four edge strips were ordered 6 inches short | Projection flags set on all four (C-17). H01/H11 join the 10'-05" group, I01/I11 the 8'-07" group: 46 blanks, 14 cut lengths, 551.00 LF. |

## Order control — all DONE

| ref | item | status | evidence |
|---|---|---|---|
| OC-1 | Geometry basis | DONE | One roof, two drawings, resolved: the 46-strip layout governs panels (main runs field-verified 2026-07-24 to within half an inch), the site-inspection report governs trim (it passes the perimeter test the strip drawing fails by 25.8 ft). |
| OC-2 | Panel schedule | DONE | 46 panels, 46 blanks, 14 cut lengths, 551.00 LF. One fabrication run per section; whole-inch round-up; the 6-in projection on every panel that meets the eave or the pitch-break lap — including the four edge strips (C-17); factory edge at every eave; slop trims at the panel top under trim. |
| OC-3 | Blanks & rips decided | DONE | Decision recorded 2026-07-28: order 46 full-width blanks, no spares. H01, H11, I01, I11 are lengthwise FIELD RIPS, cut edge buried under rake trim. No crosswise field cuts anywhere on the job. |
| OC-4 | Layout confirmed | DONE | The as-drawn layout is the layout: remainder split at both rakes on the porch roof and upper face, 26-in closer on the main slopes. Panel-to-blank map is 1:1. |
| OC-5 | Eave & gable projection | DONE | 6-in projection is CONTRACT scope (signed proposal, included in base price), carried on 32 eave-flagged panels and at the main gables via the Approach B bearing shelf. KR-COL-ED-01 Rev B supports it. |
| OC-6 | Trim & accessories | DONE | Every quantity is a published per-run formula on the site-verified edge basis: 46 sticks across 8 families, closures per Ibex's own details, fasteners at the documented pattern with headroom to 16 in o.c. |
| OC-7 | Color | DONE — SELECTION RECORDED | Medium Bronze 24 ga PVDF on the order (closest PVDF match to Kevin's Weathered Copper reference; his own text: color not final until the boss approves). Chip ships with the acknowledgment; customer signs the chip before the coil run. The two alternate routes stay printed on the color page. |
| OC-8 | Contract & money | DONE | Signed: $38,200, 24 ga Ibex option, phased 10/45/45 ($3,820 paid / $17,190 / $17,190). Pre-approved change rates on file. Budget and job-costing sheets carry the allocation. |
| OC-9 | Field rules & sequence | DONE | Cutting, lap-hand, starting-rake, valley, swarf and marking rules printed as field cards; install sequence and staging in the production plan. |
| OC-10 | Verification | DONE | Workbook evaluated with an independent formula engine (zero errors, all figures reconcile); every packet page rendered and visually inspected; print-safety QA green. Evidence in the QA contact sheet. |

## Supplier confirmations on the order form

| ref | subject | instruction |
|---|---|---|
| A1 | Coil & color | Confirm 24 ga PVDF PBR in Medium Bronze is a produced combination, with steel grade (50 vs 80) and lead time. Ship one physical 24 ga chip with the acknowledgment for customer sign-off before the coil run. |
| A2 | Fastening spec | Provide in writing: fastener row spacing for a solid deck at Coeur d'Alene design loads, screw type/gauge/length, minimum embedment, and the panel base metal (Galvalume vs G90) for fastener compatibility. Quantities on this order are computed at 24 in o.c. rows + doubled eave/ridge rows and are sufficient for any published pattern down to 16 in o.c. |
| A3 | Single-piece lengths | Confirm the longest blank on this order (17'-07") ships as one piece. No endlaps are planned on this roof. |
| A4 | Rib height | Confirm PBR rib height as produced (spec sheet says 1-3/16 in, catalog says 1-1/4 in) so closures and trim fit as ordered. |
| A5 | Drip-edge blank | KR-COL-ED-01 Rev B girth sums to 10-1/4 in. If a 10 in stock slit width is preferred, reduce the face from 3-1/4 in to 3 in and note it on the acknowledgment — either is accepted. Confirm max hemmed piece length ≥ 10 ft. |
| A6 | Pitch-break angle | Form the 04B Jumbo Pitch Break for a 4/12 lower / 11/12 upper transition (included angle ≈ 156°). Ketron will supply a field template with the Phase-2 confirmation call before forming. |
| A7 | Vented ridge NFA | State the net free area of the supplied ridge vent material so intake balance can be documented at install. |

## Contract & money

Signed 2026-05-28 · Collins-ReRoof-Proposal_v21 (2026-04-20) · total **$38,200** · schedule Deposit (10%) — PAID $3,820, Phase 1 complete (45%) $17,190, Phase 2 complete (45%) $17,190.

| phase 1 | $ | phase 2 | $ |
|---|---|---|---|
| Tear-off and disposal (3+ layers, main house) | 3,474 | PBR panels, 36" coverage — Ibex 24 ga | 17,265 |
| Re-deck: 1/2" 5-ply structural plywood | 4,609 | Trim: ridge, W-valleys, eave, drip, gable, rat guard, transitions | 4,550 |
| Malarkey 401 SA ice & water shield, full deck | 2,993 | Ice & water shield, patio deck (owner sheeting) | 534 |
| Chimney opening: frame, deck, weatherproof | 903 | Permit, delivery, cleanup, magnetic sweep | 2,267 |
| Dumpster and site protection | 835 | Eave extension: custom oversized drip edge (6-in overhang) | 770 |

Job costing runs on editable assumptions in the workbook (defined names, shaded cells). At the default assumptions ($650/man-day loaded labor, EST panel/trim costs pending the Ibex acknowledgment) the sheet models ~30.8% GM and flags itself BELOW the 50% metal-tier floor — the labor-rate cell is the dominant swing and is exactly the kind of input the sheet exists to correct with real numbers. Committed/Actual columns fill from the acknowledgment and invoices.

## Deliverables in this package

| file | audience | contents |
|---|---|---|
| Collins_Metal_Roof_Order_Packet_v3.pdf (16 pp) | Ibex | order form + A1–A7, cut schedule, keyplan, 5 section sheets, rip plan, trim, KR-COL-ED-01, fastening, color, delivery QC, measurement basis |
| Collins_Crew_Install_Packet_v3.pdf (11 pp) | crew | rules, sequence, section sheets, rip card, fastening card, trim map, verification record — no pricing |
| Collins_Metal_Roof_Job_Workbook_v3.xlsx (16 sheets) | internal | order control, cut list, blanks, trim, drip, color, field verification, contract & payments, production plan, budget & job costing, QC, corrections, confirmations, sources — 940+ live formulas, independently evaluated |
| Collins_Visual_QA_Contact_Sheet.pdf | internal | every PDF page + workbook sheet rendered, + automated check results |
| Send-ready zip | staging | supplier / crew / drawings / internal / evidence folders + README |

## Verification performed

1. Independent formula-engine evaluation of the workbook: 940+ formulas, zero error values; 25+ headline figures, 92/92 per-panel numbers, all group quantities and all 8 trim family counts reconcile to the derivation engine.
2. Print-safety QA on all 27 PDF pages (16 order + 11 crew): nothing off-trim, in the footer band, outside side margins, or under 5.8 pt.
3. Every page rendered to pixels and visually inspected at reading size; layout collisions found during the pass were fixed and re-verified (band spacing, assembly placement, rip-callout stagger, locator caption).
4. Adversarial verification pass (five independent auditors: panel math, trim math, money, document consistency, crew-lens on rendered pages). Its findings — including C-17, the short rip strips — were fixed and the package rebuilt and re-verified.

*Generated 2026-07-28 from collins_data.py — the single source of truth. All artifacts regenerate with `make.py`.*
