The Dallas Independent School District (DISD) has utilized Alpha sprayed polyurethane (SPF) roof systems since the 1980s. Alpha SPF roof systems are high performing roof systems if installed properly and are very resistant to hail damage (hail damage is significant in the Dallas area). However, DISD, due to their low bid award procurement system, have had some poor performing roof systems installed by contractors who did not utilize performing materials and processes. The Alpha SPF roof system is now being questioned by designers who are not aware of their high performance and wanted to tear-off one of the oldest SPF roofing systems after a hail storm. This case study is on one of DISD roofs which were studied to determine the actual and potential service period based on actual performance. It was concluded that the roof is capable of lasting another 15 more years with a simple recoat (resulting in 38 years of performance at a fraction of the cost of a traditional modified roof).
The performance of the Alpha Sprayed Polyurethane Foam (SPF) roofing system is perceived as not an economical option when compared to a 20-year modified roofing system. The Dallas Independent School District (DISD) is replacing the existing Alpha SPF roof systems with new roof systems rather than recoating the existing systems at a cost that is 100% more than the recoating costs. The DISD is in a heavy hail area, and the proven hail resistance of the Alpha SPF roof system is an additional benefit for DISD who is self-insured. The Casa View Elementary School roof system was installed with a Neogard Permathane roof system in 1987. This roof was hail tested with ten drops from 17 feet 9 inches of 1-3/4-inch steel ball (9 out of 10 passed) and three drops from 17 feet 9 inches with a 3-inch diameter steel ball (1 out of 3 passed). The analysis of the passing and failing core samples show that the thickness of the top and base Alpha SPF coating is one of the major differences in a roof passing or failing the FM-SH hail test. The current potential cost savings of purchasing a 61,000 square feet Alpha SPF roof versus modified bitumen roof is approximately $610,000 for DISD. The past hail tests on Alpha SPF roof systems show high customer satisfaction (9.8 out of 10) and an over 40-year service life after a $6.00/SF recoat.
Many problems are caused by owners specifying project technical requirements to expert vendors, then picking the low-price vendor, assuming that all the vendors are providing the same quality of product. Research over the last 20 years has identified that when working with highly technical areas, this practice brings high risk to the owner because the vendors do not have the expertise to understand the requirements. The Alpha sprayed polyurethane foam (SPF) roof system has brought the Dallas Independent School District (DISD) high value but also occasional risk caused by the low-price vendor. The authors are proposing that DISD’s effort to buy the Alpha SPF roof system through the low-price competition will cause DISD risk. A new approach is proposed to DISD: the Alpha SPF roof system only be used as an alternate value added option. This approach assumes that the only way the Alpha SPF system can be procured is if it is in the best interest of the owner due to dominant value. This approach minimizes the risk that DISD has encountered from low-price contractors who have not been able to minimize risk through the use of expertise and experience because their low-price was directly related to practices which are related to a lack of experience and expertise.
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