Out of Sight, Out of Mind

During a visit to a manufacturing plant two months ago, the plant manager proudly proclaimed his company performs weekly, monthly and semi-annual maintenance on every piece of equipment in the plant. Equipment requiring daily maintenance had an acquisition cost over $750,000, while two compressors costing $480,000 apiece required semi-annual maintenance inspections.

When visiting a major corporation recently, I had to park a block away because the parking lot was being repaired. The maintenance engineer explained that it was important for them to create a positive image for their employees, visitors and potential clients, and so it was necessary to demonstrate their commitment to maintaining the plant.

Why is this same standard and mind set not applied to the roof? A recent meeting with a company representative might explain the reason, "If the roof doesn't leak, I figure it's performing satisfactory." The reason given by a plant manager might further justify why roofs are often neglected, "I have a ten year warranty on 80 percent of my roofs and that is my protection. Why should I need roof maintenance or inspections when I paid extra for the warranties?"

While both reasons may apply ideally, they are not practical in the real world. Production equipment is serviced as often as daily, and air conditioning equipment maintained monthly, but the roof is not receiving the same attention. This is short sighted, considering it ultimately protects the equipment below that is so faithfully maintained.

Investment for reroofing is an expensive proposition and it needs the same care to serve its full estimated life, as promised by the manufacturer at time of installation. Today, the average cost for roof recover is $4.00 per square foot and 20-30 percent higher for tear-off and reroofing. The thought of a 100,000 square foot project costing half a million dollars sends shock waves through many a plant manager. Because the roof does not directly produce product and revenues, it is often pushed back in the priority schedule until a major problem occurs.

Roofing is one of very few industries providing owners with warranties as long as 10, 15 and 20 years. Because of the length of liability extended by manufacturer's warranties, many covenants or exclusions apply. Today, every roofing warranty contains an exclusion stating if preventive maintenance is not performed, the warranty is null and void. Warranties often give people a false sense of security more than a source of protection.

The roof is exposed to the elements like the parking lot, HVAC equipment, lighting fixtures and building surfaces. Why then should it not receive the same treatment and attention? Even though the roof is out of sight, a company can be greatly affected by interruptions in the production schedule or shipment of goods attributable to roof problems.

As roof consultants, we can provide information for repairs, recommendations and budgeting, but we can't force management to treat this investment as they do others. We can educate maintenance personnel on preventive maintenance techniques, but can't force them to conduct inspections after change of seasons, severe weather, or heavy foot traffic. Proper follow up and action are the cure to these ills.

Since people become lulled to sleep by the misperception roofs are self preserved and need minimal attention, they are seldom observed, thus "out of sight, out of mind." A roof is an investment just like plant equipment, and should be given the same care and maintenance.