Introduction

The Alpha Program was originally developed in the mid 1990’s to assist a high performing roofing manufacturer by identifying techniques to differentiate offerings and reduce risk to all parties. This program has shifted into an all-encompassing continuous improvement program, which performs the following: Tracks and monitors the performance of qualified roof installers (contractors) Educates facility owners on the concept of buying based on value (instead of just low price) Educates facility owners on the differences between high performing and low performing contractors and systems Requires that all qualified installers meet performance metrics identified by the PBSRG. These include: Documentation of all roofs installed (over 5000 SF) Yearly survey of all new roofs installed Third party physical inspection of roofs biennially Ensure that 98% of roofs do not leak Ensure that 98% of customers are satisfied Attend an annual Alpha conference The Alpha program has resulted in the documented performance of an SPF roofing system that can last over 20 years - the 'Alpha System'. This system is unlike any other SPF roofing system on the market due to its documented high performance. Click the box below to request a password to a free overview video of the research conducted on sprayed polyurethane foam roofing systems. This presentation can be used to assist building owners in procuring a roof based on value, rather than just lowest price.

Neogard Coatings

Background of the Spray Polyurethane Foam (SPF) Industry

Coated sprayed polyurethane foam (SPF) roofing has been commercially installed since the 1960s. Historically, the SPF system was sold as a "cheaper" roofing system than the conventional "built-up" roofing systems. SPF can be installed cheaper than the traditional systems due to the capability to be installed over an existing waterproofing membrane. The SPF roof system is also monolithic, seamless, lightweight, and is one of the best insulating materials of any roofing material.

A SPF Roofing System is made up of two major components: the Polyurethane Foam and the Coating System. The figure to the right illustrates a SPF Roofing System. The Polyurethane Foam is sprayed onto the roof deck (or can be applied to many existing waterproofing membranes), and acts as the waterproofing agent. However, the foam is sensitive to ultra violet light, and will deteriorate if not protected. The Coating system is sprayed or rolled on top of the foam to protect the foam from deterioration. The three major types of coating system are: Silicone, Acrylic, and Urethane. The Foam is normally sprayed to a thickness of about 1.5 inches. The coating system, which is extremely important in determining how well the overall system will perform, is typically applied to the thickness of a credit card. Use of cheaper and/or thinner systems greatly increases the risk of roof failure by allowing a contractor to install less coating material, use a lower quality product, or use a product that does not have any documented performance

The Alpha Roofing Program

Neogard is a manufacturing company that produces coatings with the highest documented performance over the past twenty years. They have used quality raw materials to produce a urethane coating for sprayed polyurethane foam roof systems that has documented performance of over 25 years. Neogard began to see the roofing marketplace exhibit a commodity mentality in the 1980s. It became harder for them to compete as their competitors were issuing warranties with twice the service period with less coating material and no documented performance information. Neogard realized that to stay profitable and maintain its high performance, they would have to find a new way to sell their products. In 1995, Neogard approached the PBSRG with the objective of designing a delivery system that could deliver high value to intelligent building owners. By maintaining high quality, Neogard could become more efficient, minimize their risk, and make owners happy, which would maximize their profits.

The main objectives of the Alpha Program are to:

1. Track and monitor the performance of the roofing system to make sure the product and contractors perform.
2. Educate clients on making decisions based on performance information (rather than marketing information, low price, or extended warranties).

To achieve the objective of ensuring product performance, a continuous improvement program was created to monitor the performance of the products and system installers. Although Neogard its product could perform, they did not have any documented proof that would differentiate them from their competitors.


Alpha Program Requirements

The participating manufacturers and contractors realized that the nonparticipating (less performing manufacturers and contractors) would also use the performance information to represent the capability of their products and installations. They would claim that their performance was the "same" as the Alpha vendors. However, the Alpha participants realized that in order to reduce their own risk of nonperformance, to continuously improve, and to service their customers in a manner that would lead to repeat business, a structure of performance information was necessary. The program has the following requirements:

1. Only qualified contractors can install an Alpha Roof System.
2. Contractors must pass all of the qualifications to be eligible to install the system. This includes having their roofs inspected by a certified inspector every other year, maintaining 98% customer satisfaction, and 98% of roofs that do not leak. (Click here for detailed requirements).
3. Qualified contractors must attend an annual educational meeting.
4. Qualified contractors must maintain their level of customer satisfaction every year and agree to have their information posted on the website.
5. An Alpha Roofing System will receive a 15-year Joint and Several Warranty from the Manufacturer. This warranty contains minimal exclusions unlike many other warranties in the industry (see next section for information about roofing warranties)

By using a high performing product (documented to last over 25 years), and by requiring high performing contractors to install the product, the Alpha Program greatly reduces the risk to a building client. Although many other contractors and manufacturers claim to have the same level of performance, none have been able to prove their performance using simple performance measurements. The difference between the Alpha Program and other systems is that one is based on proven/documented performance, and the other is based on marketing information. However, it is up to the client to pick which is best for their situation.


The Truth Behind A Roofing Warranty

Many clients believe that the longer the roof warranty is, the better the product. Clients must understand that warranties are prepared by lawyers of the roofing manufacturers to protect the roofing manufacturer. Warranties are not written to protect the building client!!! A warranty is carefully written to include language to make the warranty void if damage occurs. This is achieved through warranty exclusions. For example, a 25-year warranty can be void if the manufacturer finds water on the roof!

Clients that are looking to minimize risk, must NOT buy a roof based on the length of warranty. Vendors that attempt to sell you a longer warranty are only trying to market you. Clients that are interested in minimizing their risk should disregard the stated length of warranty, and should focus on how well the product actually performs (force the vendor to provide you with 15 roofs that are at least half the age of the warranty they are trying to sell you. Then call the clients to see if the roof leaks and if they are satisfied). Most vendors will not be able to provide you with this information. Documented performance should always have more value than a number on a piece of paper. Be careful, there are some warranties claiming to be long-term warranties (25-30 year warranty period), but after reading the exclusions, they are in fact only 5 year warranties (that require inspections and repairs every 5 years to extend the warranty). This is just another tool that manufacturers use to market their products.


Publications

The PBSRG has published several articles on SPF and Alpha Roofing Systems. To purchase these publications, please contact the PBSRG or visit our Publications section.