Concerned that your roof has hidden damage that might cause problems once the crew begins working? Wondering if roofing costs can really change once the project has already started?
Working on roofs is tricky because even if your roofer explained how much work needs to be done, they still might run into unexpected problems while working on your roof.
At RoofSmart, we understand how frustrating it can be when you feel like your roofer keeps increasing the cost of the project after you thought you agreed on a price. To avoid this frustration, we make sure that every customer is aware that unexpected problems might come up during the project.
For example, if we see evidence of a potential leak, we’ll warn them that the crew might find rotting wood that needs to be replaced when they start tearing off the roof.
This article features insights from Omar Moran, our Production Manager, who helps guide customers through the change order process.
In this article, you’ll learn why roofing projects can uncover unexpected problems, what kinds of surprise repairs are most common, and what it could cost you.
We’ll also explain how RoofSmart handles these surprises, so you’re never caught off guard—financially or otherwise.
Why Do Roofing Projects Sometimes Cost More Than Expected?
Roofing contractors do their best to include all the necessary steps and total cost for your roofing project in the proposal, but sometimes unexpected things happen once the roof work begins.
So, if your roofing contractor uncovers damage or another issue on your roof that needs to be fixed to continue, they’ll let you know about it and create a change order. A change order is a notice of additional work that’s being added to the contract for your roofing project.
This will increase the cost of the project, but the amount depends on how much work needs to be done. It could be as low as an extra few hundred dollars or even up to $15,000 to fix major issues.
A change order is used to document the new work that needs to be done and how much it will cost so that you and your roofing contractor are on the same page. It helps prevent miscommunication and holds your roofer accountable for charging the right amount.
What Unexpected Work Happens During a Roof Replacement in Seattle?
Roofs are tricky because they can sometimes conceal damage or other issues until you start tearing the roof apart. So, even if your roof looks normal, your roofer might end up finding damage when they start your project.
Here are some common examples of unexpected roof issues that require a change order that Omar sees all the time:
1.) Multiple layers of roofing: Sometimes it’s really obvious when your roof has multiple layers, but a skilled roofer can hide it really well. Modern building codes don’t allow multiple layers of roofing, so if your roofer notices this, they’ll have to remove it.
There might be two layers over the entire roof, or it could be just a small section. The bigger the section is, the more it will cost to remove it.
2.) Rotting plywood: Sometimes, when your roofer scrapes the shingles of your roof, they notice that the wooden roof decking underneath is rotting. This is a very common problem in the Greater Seattle area due to the constant rain. It isn’t always visible during the roof inspection because the water damage can be hidden underneath the shingles.
Rotting wood loses its strength and durability and cannot support the weight of your new roof. If your roofer discovers rotting plywood, they’ll need to replace it to make sure that your roof can protect your home for as long as possible.
This also applies to any other kind of wood material used in your home, such as trusses, fascia, or soffit. Damage to these areas can also be hidden within the roof or painted over.
3.) Incorrect roof decking: Building codes have changed a lot over the years, so your roof decking might be out of date. Current building codes have specific regulations about what kind of roof decking you can have. If your roofer notices that you don’t have the right roof deck for the type of roof material you want, they’ll have to install new roof decking.
For example, some older homes have skip sheathing (boards that are spaced out so that every other row is empty) on the roof instead of plywood. If you want an asphalt shingle roof or metal, then you need to have OSB or plywood roof decking to meet current building codes.
Here’s an example of what skip sheathing looks like:
Skip sheathing is only allowed with wood shake roofs, which is a less common roof type because it is so expensive.
4.) Adding ventilation: A lot of homes in the Seattle area have attic ventilation that is out of date and doesn’t work well. Ventilation isn’t always considered when people think about roofing, but having poor attic ventilation can cost you lots of money in repairs.
Some roofs only need a few small changes, but others might need their entire attic ventilation system redone.
How Much Do Unexpected Roofing Repairs Cost?
Depending on the amount of extra work that needs to be done, the cost of a change order will change.
Omar says that for a small job like adding a few vents or replacing a few plywood boards, it might only be an extra $150 to $500. But if you need to redo your attic ventilation or replace a lot of trusses or framing on your roof, then it might cost around $5,000 to $15,000.
What Happens If RoofSmart Finds a Problem During Installation?
At RoofSmart, we do thorough inspections of the roof and surrounding areas to make sure that we can catch issues before the roof work begins. But if our crews notice an issue while they’re working, we will reach out to you to let you know.
For example, the most common issue we discover is rotting wood. Here’s what it might look like:
We’ll go over the issue with you and how much it should cost to fix it. Not everything is easy to tell at an early stage exactly how long it will take or what will be involved until it’s all uncovered.
“That being said, we want to make sure that we keep the project going as fast as we can”, says Omar. “The Seattle area has unpredictable weather sometimes, and we don’t want to leave your roof vulnerable to the rain.”
So, we will keep moving forward to make sure that your roof is protected so that you don’t get further damage to your roof.
We want to make sure that we come to a fair agreement about the work we’ve done by showing you pictures of the damage and discussing the cost. The change orders will be added to your final invoice so that you can see the total cost.
This change order process is typical for most roofers. If you’re worried that your roofer isn’t being truthful, ask for documentation of the extra damage they worked on. The easiest way for your roofer to show this is by taking pictures or video of everything during the entire roofing process.
What’s Next? Learn How Much a Roof Really Costs in Seattle
At the end of the day, unexpected roofing costs can catch any homeowner off guard, especially when hidden damage or outdated materials are only discovered once work begins. That’s why it’s so important to understand what a “change order” is and how it protects you from miscommunication or surprise charges.
If you’re planning for a roof replacement, knowing what might go wrong is only part of the equation. The next step is understanding what your roof should cost under normal circumstances before surprises come into play.
Read our article "How Much Does a Roof Cost in 2025? Prices for Seattle Homeowners"
to learn what you can expect to spend and the factors that impact new roof costs, so you can budget with confidence.
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