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w.llw j. /u.S Postal Service QCrJoo U56 NO 85-3275 V1985 C.1 NBS-PUB- NBSIR 85-3275

U.S. Postal Service Roofing

Practices

Reference

NBS

PUBLICATIONS

Walter J. Rossiter, Jr. #

William C. Cullen**

Robert G. Mathey*

*U.S. DEPARTMENT OF COMMERCE

National Bureau of Standards

National Engineering Laboratory

Center for Building Technology

Gaithersburg, MD 20899

**William C. Cullen Associates

Potomac, MD 20854

November 1985

•QC

100

. U56

85-3275

1985

Prepared for: U.S. Postal Service

Design Management Division

Real Estate and Buildings Department

Washington, DC 20260-6415



NBSIR 85-3275

U.S. POSTAL SERVICE ROOFING

PRACTICES

RESEARCH informatics CENTER Oc

Walter J. Rossiter, Jr.* William C. Cullen**

Robert G. Mathey*

•U.S. DEPARTMENT OF COMMERCE

National Bureau of Standards

National Engineering Laboratory

Center for Building Technology

Gaithersburg, MD 20899

••William C. Cullen Associates

Potomac, MD 20854

November 1985

Prepared for: U.S. Postal Service

Design Management Division

Real Estate and Buildings Department

Washington, DC 20260-6415

U.S. DEPARTMENT OF COMMERCE, Malcolm Baldrige, Secretary

NATIONAL BUREAU OF STANDARDS. Ernest Ambler, Dinctor

Table of Contents

Page

ABSTRACT iv

LIST OF FIGURES v

ACRONYMS USED IN REPORT vi

1. INTRODUCTION 1

1.1 Background 1 1.2 Objective 2 1.3 Scope 2

2. OVERVIEW OF USPS ORGANIZATION REGARDING ROOFING 3

3. REVIEW OF USPS ROOFING PRACTICES 8

3.1 Approach 8

3.2 Design, Materials, and Construction Practices 9

3.3 Inspection, Maintenance, and Repair Practices 26

4. DISCUSSION 41

4.1 Advantages and Limitations of USPS Design, Materials, and

Construction Practices 41

4.2 Advantages and Limitations of USPS Inspection, Maintenance,

and Repair Practices 46

5. SUMMARY 51

6. REFERENCES 53

7. ACKNOWLEDGMENTS 54

Appendix A. Results of Questionnaire on Design, Materials and

Construction A-l

Appendix B. Results of Questionnaire on Inspection, Maintenance, and

Repair B-l

Appendix C. USPS Roof Inspection Forms C-l

iii
ABSTRACT

This report reviews the roofing practices of the U.S. Postal Service (USPS).

The USPS has direct responsibility for the design, construction, and maintenance

of about 100 million ft^ of roofing. In addition, it leases buildings having

approximately an equal amount of roof area. The approach taken was to obtain

information on USPS roofing practices which could be used as a data base for

judging strengths, weaknesses, and identifying problems. The primary sources

of data were: discussions with USPS personnel; discussions with individuals

who provide roofing services to USPS; review of USPS roofing documents; results

of the distribution of questionnaires to USPS staff; and the determination of

training requirements for those involved with roofing.

The review was divided between two major phases of USPS roofing construction

practice. One part involved design, materials, and construction, and the other

involved inspection, maintenance, and repair. The primary topics addressed

with regard to the review on design and construction were general design considerations, training, responsibility, material selection, and quality control

during construction. With regard to maintenance and repair, the review included

general considerations, frequency of inspections, responsibility, training,

maintenance guidelines and manuals, repairs and when they are conducted, and

inspection and maintenance records. The advantages and limitations of the

USPS roofing practices were given, and will form the basis of recommendations

for improving USPS roofing practices.

Key words: construction; design; low-sloped roofing; maintenance; material

selection; repair; review; roofs

iv
List of Figures

Page

Figure 1. Main USPS Organizations Involved with Roofing 4

Figure 2. Interactions of Building Management and Engineering Offices

with Other Offices of the USPS 7

v
This report contains a the Roofing Industry,

presented here for the

Acronym

A/E

ARMA

BMEO

BUR

FM

FREBO

MSC

MTSC

NBS

NRCA

RIEI

UL

USPS

Acronyms Used in Report

number of acronyms used by the U.S. Postal Service and

The expressions represented by these acronyms are convenience of the reader.

Expression

Architect /Engineer

Asphalt Roofing Manufacturers Association

Building Management and Engineering Office

Built-Up Roofing

Factory Mutual

Field Real Estate and Building Office

Management Sectional Center

Maintenance Technical Support Center

National Bureau of Standards

National Roofing Contractors Association

Roofing Industry Educational Institute

Underwriters Laboratories

U.S. Postal Service

vi
1 . INTRODUCTION

1.1 Background

The United States Postal Service (USPS) is among the Nation's largest

users of buildings with an inventory of about 34,000. Although USPS leases

about 85% of the buildings, the majority are relatively small with the area

being less than 10,000 ft^. The total roof area of the buildings used by

USPS is estimated to be about 200 million ft^. However, because USPS owns

the majority of its larger buildings, it assumes responsibility for design,

construction, and maintenance for about one half of the total roof area of the

buildings used. Moreover, in the case of some leased buildings, USPS has

indirect responsibility for roof maintenance and repair.

It is difficult to estimate accurately USPS roofing costs for new

construction, repair, and replacement, since roofing costs are often combined

with those connected with general construction, and repair and maintenance.

Roofing industry figures for the United States generally indicate that the

annual cost of new roofing construction is about equal to the cost of roof

repair and reroofing. Over the last few years, about $15 million dollars

has been spent annually on direct repair and replacement of USPS roofing. If

USPS follows the general trend found in the private sector of the roofing

industry, another $15 million dollars may be spent on its new roofing

construction each year.

The USPS buildings are located throughout the United States. As may be

expected, roof design and maintenance practices differ widely depending on the

area, climatic conditions, and local design procedures and materials perference.

The complexity of understanding and predicting roofing performance is further

1
complicated by the many different types of available materials and the variety

of application practices.

The USPS requested the National Bureau of Standards (NBS) to provide

technical support to obtain quality assurance in its roofing. In providing

this support, the following two major tasks were carried out: 1) review of

USPS roofing practices, and 2) review of roof management programs currently

used by organizations in both the public and private sectors. The information

obtained from these two tasks will provide the basis for recommendations for a

roof management program applicable to the needs of USPS. This report, one in

a series of three reports, addresses USPS roofing practices and provides a

discussion and summary of these practices.

1.2 Objective

The objective of this report is to review USPS roofing practices regarding

design, construction, maintenance, and repair, and to give the advantages

and limitations of the practices.

1.3 Scope

This report is limited to a review of USPS roofing practices. Comparisons

with roof management programs conducted by other organizations having many

buildings located in various parts of the United States will be the subject to

the final report.

2
2. OVERVIEW OF USPS ORGANIZATION REGARDING ROOFING

The primary objective of the USPS is the collection and distribution

of mail for the United States. Facilities are constructed and maintained with

this objective in mind. As a consequence, USPS has numerous buildings located

in all areas of the United States and its territories ranging in size from a

few hundred square feet to over one half million square feet. The organizational

structure of the USPS reflects this wide distribution of the buildings and

the variability in size. The main units with regard to roof performance

within the USPS organization are: Headquarters, Regions, Districts, Management

Sectional Centers, and Post Offices. This breakdown in organization is shown

in figure 1 along with the practices regarding building design, construction,

and maintenance generally carried out within each of the major units. As

indicated in figure 1, the design and construction activities are generally

separated from the maintenance activities. In addition, major design and

construction activities are not carried out at levels below the Regional Offices

and Field Real Estate and Building Offices (FREBO). Roofing is only one aspect

regarding building design, construction, and maintenance. The units involved

with buildings, as would be expected, have responsibility for the total facility.

An overview of the responsibilities of each of the major units is given as

follows.

1. HEADQUARTERS — located in Washington, DC.

a. Design Management Division — The Design Management Division is part

of the Administrative Group at USPS headquarters. It is responsible

for the design of facility projects which cost $5 million dollars

or more. Thus, roofing in such projects is controlled by the

Headquarters Project Manager. In addition. Headquarters provides

managerial policy to the Regional Offices. Guidelines regarding

construction practice including roofing are generally not provided.

3
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USPS

ORGANIZATIONS

INVOLVED

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Figure

1.

Main

USPS

Organizations

Involved

with

Roofing
b. Construction Management Division — This unit has responsibility

for the construction of facilities designed at the Headquarters

level. Among the activities included here are bidding, scheduling,

monitoring of progress, completion and acceptance of the facility.

Also, change orders regarding alterations to the original design

and specification which are initiated during construction are handled by the construction management unit.

c. Maintenance Management —This unit is part of an operational group

at headquarters and provides policy direction regarding maintenance of facilities. The Maintenance Management Office has

connected with it the Maintenance Technical Support Center

(MTSC) which provides technical assistance, maintenance handbooks,

and technical training.

2. REGIONS — There are five regions distributed in the northeastern,

eastern, central, southern, and western sectors of the United States.

a. Design and Construction — This unit generally has responsibility

for facility projects costing less than $5 million. A major

responsibility is the setting of administrative policy for

the regions. The regions have a certain amount of autonomy

from headquarters regarding construction practices. Each

region may provide general guidelines for its own use. The operational procedures of the regions may vary from one

to another depending upon regional preference. This is

particularly true for new roofing design and construction.

For example, the Eastern Regional Design and Construction

Branch does mostly new design for the Eastern Region. FREBOs

(see next paragraph) connected with the Eastern Region do repair

and renovation. In contrast, in the Southern Region, all roofing

design and construction is the responsibility of the FREBOs

connected to the region. None is done by the regional office.

b. Field Real Estate and Building Offices (FREBOs ) — There are 15

located across the United States. They are responsible for new design and construction including roofing where the costs do not

exceed $5 million, in cases where the Regions do not handle this

responsibility. In addition, they provide for major repair,

renovation, and replacement of existing roofing. Such work is

normally initiated at the request of the Building Management and

Engineering Offices (BMEOs) and submitted through the District

Offices.

c. Regional Maintenance Management Divisions — Overall responsibility

and policy management for the USPS building maintenance program

regarding repair and alteration is provided by the Regional

Maintenance Management Offices. In addition, some technical

assistance and guidance is provided to the Building Management

and Engineering Offices (BMEOs) and Management Sectional Centers

(MSCs) through the district offices.

5
3. DISTRICTS — USPS has 43 Districts located across the United States.

The District Offices have responsibility for the building maintenance

program in each of its MSCs (see item 4 below) and for administrative

duties including operational, financial, and scheduling decisions

regarding maintenance.

a. Building Management and Engineering Offices (BMEOs) — Each district

office has connected with it a BMEO. The BMEOs are key units

in the maintenance of USPS facilities including roofing. Maintenance related functions under the responsibility of the BMEOs

include the coordination and assistance of other USPS organizations, the recommendation of priorities of needed repairs and

alterations, identification of responsibility for conducting

repair, submittal of plans for approval and funding, the initiation of repair work, and the monitoring of progress for ongoing

repair activities. Repair and maintenance of USPS facilities may

be done either in-house or by contract. With regard to roofing,

the BMEOs conduct in-depth inspections on a regularly scheduled

basis, which in many circumstances is every 2-3 years. In

general, repair work costing less than $5000 can be initiated

directly by the BMEO. If the cost exceeds that amount, the BMEO

requests the FREBO to provide for the completion of the repair.

Figure 2 depicts the interactions of the BMEO with the other

USPS organizations [1].

4. MANAGEMENT SECTIONAL CENTERS (MSCs) — There are over 200 MSCs.

They are responsible for the maintenance of all buildings including

roofs, and the equipment in the building. Regarding roofs, the MSCs

have maintenance officers who are responsible for establishing preventive maintenance programs included routine inspections which, for

the most part, are on an annual schedule. For minor repairs, the MSC

can issue work orders and have repair work completed. When more extensive repair is needed, the MSCs make requests of the BMEOs.

5. POST OFFICES — For any individual Post Office, the postmaster has

responsibility for the maintenance of the facility. Large post

offices may have assigned maintenance employees who would, among

other duties, provide for routine roof inspection and maintenance.

It is at the Post Office level that leaks in roofs are normally

first discovered. When such occurrences happen, requests for assistance

are made to the upper organizations to have repair work initiated.

Postmasters have a small amount of discretionary funding which they

may use for minor roof repair. However, since such funding is also

used for mail handling needs, it is not likely to be spent on roof

repair.

6
7

Figure

2.

Interactions

of

the

Building

Management

and

Engineering

Offices

with

Other

Offices

of

the

USPS.
3. REVIEW OF USPS ROOFING PRACTICES

3.1 Approach

This phase of the study was conducted to review existing USPS roofing

practices and activities in order to identify their strengths, weaknesses, and

problems so that recommendations may be made to improve existing practices and

activities. A two-fold approach was taken to conduct the review. First, NBS

research staff briefly looked at USPS roofing practices and activities to

become acquainted with its roofing operations. Preliminary discussions were

held with USPS personnel, primarily at USPS Headquarters, covering the design,

construction, and maintenance areas to obtain an overview of the USPS organizational structure regarding roofing. Next, tasks were proposed for conducting

a more in-depth review of the USPS roofing practices and activites.

In planning the conduct of the study, it was recognized that four elements

are essential to assuring the quality of successful roofing performance: sound

design, suitable materials, good workmanship, and good maintenance. Thus, the

review addressed obtaining information about these elements with regard to USPS

roofing practices and activities.

Preliminary discussions with USPS headquarters personnel revealed that,

with regard to facilities including roofing, the USPS building operations are

divided into two major areas (Figure 1). One area centers on design and

construction, while the other concerns maintenance and repair. This division

was considered during formulation of the work plan. Some project activities

primarily considered design and construction, while others were oriented towards

maintenance and repair.

The major project tasks undertaken during the study to obtain information

and to review USPS roofing activities and practices were to:

8
o Hold discussions with USPS personnel having responsibilities for roofing.

The discussions were held with both headquarters and field personnel.

o Hold discussions with individuals who provide the USPS with roofing

assistance including architects/engineers (A/Es), and roofing

specialists.

o Review typical contract and maintenance documents used by USPS for

roofing construction, and maintenance.

o Develop two questionnaires concerning USPS roofing practices and

activities for distribution to USPS; one questionnaire concerned design,

materials, and construction; the other dealt with maintenance and repair.

m

o Determine training requirements for USPS roofing personnel.

3.2 Design, Materials, and Construction Practices

This section of the report presents the review of the USPS roofing activities

and practices concerning design, materials, and construction. It is based

primarily on the review and analysis of information obtained from a questionnaire on that subject. Information obtained in discussions with USPS personnel

and others who work under contract to USPS was used to complement the results

obtained from the questionnaire. For the most part, information obtained in the

discussions with USPS personnel was consistent with that determined from the

review of the completed questionnaires.

The questionnaire for design, materials, and construction, along with

typical responses, is given in Appendix A. Since most of the questions were

multiple choice and respondents could mark more than one answer for some

9
questions, the average response often totals greater than 100 percent. This

questionnaire, which contained 78 questions, was sent to individuals at USPS

headquarters, and regional and field offices across the United States. Fifteen

organizational units responded. In many cases, those responding were contacted

by phone to discuss some of the results and USPS roofing practices in general.

In some cases, those responding were visited by NBS staff. The results of the

questionnaire, complemented by discussions with USPS personnel, form the basis

of the trends regarding USPS roofing design, materials, and construction

practices which follow.

3.2.1 Roofing Performance

Those contacted during the study were strongly of the opinion that roofing

performance constituted one of the major facilities problems within the USPS

system. Most staff also indicated that USPS roofing has improved in recent

years because of an increased awareness by USPS of the benefits of having

better roofs and the actions which have been taken towards that aim. Nonetheless,

although many roofs are providing satisfactory service, discussions pointed

out many examples of premature failure and replacement of roofing only a few

years after construction. In at least one case, the story was told of a large

roof which was partially re-roofed, but before completion of the total job,

sections of the new roofing were leaking. In general, because of the concern

that USPS roofing was experiencing an unacceptably high incidence of problems

with resulting high costs, USPS field personnel encouraged the taking of steps

to improve the roofing activities and practices.

Answers to questions concerning roofing performance and problems covered a

wide range of topics commonly associated with problem roofing. A wide range

10
of problems was often mentioned resulting from such causes as poor design and

workmanship including construction under adverse weather conditions, improper

material selection, and inadequate slope to provide drainage. Specific system

problems such as poor flashing details, blisters, splits, alligatoring, and

exposed felts with built-up roofing were given as typical examples.

Regarding the performance of roofing systems in general, many responses

indicated that the most critical parameter was proper application. The

experience of some individuals indicated that most roofing systems specified by

USPS will perform satisfactorily if properly installed. These same individuals

continued to state that most roofs will experience problems where poor workmanship is involved. This response was not surprising. In fact, it was typical

of concerns expressed in 1979 by Federal government agencies having large

inventories of roofs [2]. In a report issued by the Federal Construction

Council, inadequate workmanship during roofing installation was singled-out

as a major cause of poor performance of Federal government roofs.

Both built-up roofing and single-ply roofing was equally noted as having

provided satisfactory performance. On the other hand, when discussing unsatisfactory performance, most comments pointed to built-up roofing. Only a few

respondents indicated poor performance from single-ply membranes. This response

may be partially influenced by the fact that, over the years, USPS has used

considerably more built-up membranes than single-ply membranes. It is only in

recent years that the use of single-ply membranes has increased for USPS

facilities.

11
3.2.2 General Design and Construction

By and large, the design of roofing systems as well as the preparation of

specifications is accomplished by an architectural firm or roofing specialist

under contract to the USPS. Less frequently, these task responsibilities are

assigned to USPS personnel. With the exception of headquarters, there is

no uniformity related to the design and specification phases as the practices

varied somewhat among the organizations contacted.

Headquarters, in having responsibility for construction totaling in excess

of $5 million including the roof costs, awards a contract to an A/E firm for

total design of the facility in question. This firm has a wide latitude in

its selection of the roofing system. The USPS does not have guide specifications for roofing but provides the A/E with general design guidelines. These

guidelines address considerations such as: a minimum slope of 1/4 inch per

foot; a maximum thermal U-value of 0.05 Btu/h«f t2«°F; materials; roof top

equipment; walkways; and warranties. The A/E proposes three roofing-system

designs and conducts a life cycle cost (LCC) analysis of the proposals. The

LCC analysis provides the justification for which of the three proposed systems

is selected. Key factors in the LCC analysis are initial material and

installation costs, energy savings, and maintenance costs.

As a matter of recent USPS headquarters practice, the A/E is required to

engage the assistance of a roofing specialist. The responsibilities of the

specialist are to: review and critique the contract documents; participate in

the pre-job conference; review roofing contractors' submittals; provide fulltime on-job inspection during installation; and where applicable in cases of

major renovation, provide a field evaluation of existing roofing. When a

project is still in the design phase, the three parties, A/E, roofing specialist.

12
and USPS project manager, will discuss and review the comments made by the

roofing specialist concerning the A/E’s design. Steps to be taken for

appropriate revision of the design will be planned. The A/E firm will execute

the revisions.

With regard to roofing practices conducted by the regional offices,

design and construction practices may vary widely between regions and FREBOs.

Some design is conducted in-house, although most is done using the services of

an A/E firm or roofing specialist. This may depend upon the office. For

example, in the case of one FREBO, essentially all roofing design is

conducted in-house. Only major new construction is designed under contract to

an A/E firm. In contrast, 5 FREBO offices do no design work in house. For the

most part when an A/E firm is under contract, design and material selection

is left to the A/E. The USPS project manager reviews and approves the A/E's

design. Some general guidelines on preferred systems may be given to the A/E

firm by the USPS project manager before design is begun. Such guidance may

promote the use of a built-up membrane system over single-plies, or vice versa.

When design work is done for USPS under contract, the A/E may be selected

based on merit for the specific job. This is often the case with new construction. A/E firms are also placed under term contract so that they are available

as needed, particularly for repairs, renovations, and re-roofing. Limitations

on the contracts of the term A/Es are imposed. Generally, the contracts have

a 1-year duration with options for repeated 1-year renewals which cannot exceed

a total contract term of three years.

Roofing specialists are sometimes used at the regional and field levels

for both new and re-roofing. This is not a matter of USPS policy, but a matter

of preference of the particular USPS regional office or FREBO. In many cases,

13
roofing specialists are not used but the A/E firms are instructed by USPS

project managers to obtain the assistance of roofing specialists if they

consider that such help is needed to design the roof in question.

Recently, some FREBO offices, particularly those in the Southern Region,

have initiated a practice of providing contracts to term A/Es who specialize

in roofing design and construction. These roofing specialists are selected in

lieu of general A/Es to provide evaluation of existing roof, design recommendations on repair, renovation, and reroofing, and inspection and testing (as

required) of roofing installation.

The reason why some FREBO offices use roofing specialists for their roof

design and construction activities, and other FREBO offices do not, appears

to be philosophical. Those engaged in the practice believe that general A/E

firms are not adequately knowledgeable in roof design and therefore specialists

are needed. Those offices that do not use roofing specialists have the viewpoint that trained designers are professionals capable of generally handling

all aspects of building design including roofing. Thus, it is reasoned,

specialized assistance in the form of roof specialists is not needed for normal

design and construction. Another reason often given is that the A/E under

contract may need to design repair work for many areas of the building, and

not just the roof. Thus, the A/E cannot necessarily be a roofing specialist

in these cases.

This divergent opinion between various FREBOs was reflected in the

questionnaire responses. All the responding offices reported satisfaction with

the A/E firms used for design and specification of roofing systems. However,

the opinion was about evenly divided on whether the A/E firms under contract to

14
USPS were adequately knowledgeable in roofing technology. Half the respondents

answered that the A/E firms were seldom knowledgeable.

In discussing the use of roofing specialists for roof design and construction

with FREBO offices which have taken up the practice, much enthusiasm was

expressed at its success. Indications were that no major problems have arisen

to date with roofs designed and constructed under the practice. Unfortunately,

the oldest program of this type has only been in place at one FREBO for about 4

years. Thus, it is difficult to draw conclusions as to its long term success.

Nevertheless, the trends based on the limited experience point towards significant

reduction in premature failures of new roofs.

One area of concern with the use of roofing specialists for design and

construction expressed by some FREBO personnel is that it is imperative that

qualified individuals are selected. Uniform criteria have not been established

for their selection, although each FREBO engaged in the practice has its own

guidelines. For example, one FREBO indicated that the A/E firm must be able to

demonstrate specialization in roofing with a minimum number of years of

experience.

With regard to the field offices, the majority of the roofing projects

undertaken according to the questionnaire respondents involved new and reroofing

jobs in a cost in the range of $5,000 to $50,000. The new job projects had a

slight edge over reroofing which included tear-off of existing membranes.

Recovering, repair, and routine maintenance accounted for little effort. Some

of the FREBO offices indicated that they are not involved in repair and maintenance applications. Routine repair and maintenance with costs less than

$5000 are handled by the BMEOs.

15
Almost 50 percent of the FREBO units seldom contact other USPS units

regarding roofing problems or information. Forty percent of the units responding indicated that contact is made in cases when design is involved or serious

roofing problems and failures are experienced. Questions relating to material

selection, application procedures, and maintenance considerations seldom precipitated office to office communications. Periodic meetings are held with

selected personnel from the various FREBOs to discuss general engineering and

facility problems. Roofing may be a subject at some of these meetings.

3.2.3 Guide Specifications and Other Documents

The majority of the questionnaire respondents reported that the

USPS had guide specifications available for both new roofing and reroofing.

About 40 percent were of the opinion that such documents were not available.

For those who responded affirmatively, there was general agreement among the

respondents that the documents available were inadequate for the needs. In

discussions with field personnel on this subject, it was generally indicated

that USPS did not have guide specifications. The "Facility Design Orientation"

package issued to A/Es by headquarters for its construction projects specifically

states that USPS has no guide specifications. General requirements for slope

and U-value are included in all USPS design. Some field offices have packages

for distribution to A/Es. For example, a design checklist including roofing

considerations was obtained from the USPS Eastern Regional Office. Regarding

roofs, it contained 8 items including the slope and U-value requirements. It

is difficult to assume that such a checklist would be considered as a design

specification by the questionnaire respondents. Nevertheless, the possibility

cannot be ruled out. If it were the case, it may be rationalized as to why

16
the document would be considered inadequate as a guide specification since it

is limited to general design guidelines.

USPS Headquarters has prepared "short form specifications” for use by field

real estate and buildings, and maintenance personnel to implement small repair

and improvement of construction contracts. The intent is to avoid having

field personnel writing new specifications for each small project they

encounter. With regard to roofing, the "short form specifications" are for:

replacement of a BUR membrane with a new BUR membrane; recovering an existing

BUR membrane with a single-ply membrane; recovering a BUR membrane with another

BUR membrane; and others for repair or replacment of roof accessories such as

metal flashings, drains, gutters, and scuppers.

These "short form specifications" were reviewed during this study. A

notable observation was that they require updating due to recent changes which

have taken place regarding roofing materials use and availability. Another

concern was the manner in which these specifications addressed the allowed

recovering of existing membranes which may contain unacceptable amounts of

moisture. The finding that the "short form specifications" was out-of-date

was not surprising. A general criticism often voiced at the use of form

specifications is that they require considerable attention to keep them current.

In fact, many USPS personnel raised concerns regarding the need for updating

during this study when asked whether they thought the use of master specifications would be beneficial to USPS roofing practice.

The National Roofing Contractors Associations (NRCA) "Roofing and

Waterproofing Manual" was the most frequently cited industry document used to

assist in roof design, especially with respect to design details for flashings

at perimeter walls, penetrations, and the like. Manufacturers' specifications

17
were also used in a large number of cases. Other documents such as Underwriters

Laboratory (UL) and Factory Mutual (PM) bulletins and other releases were used

to a lesser extent. The Roofing Industry Educational Institute (RIEI) documents

were also cited to a lesser extent. Nevertheless, apparently those who attend

RIEI courses use the manuals and information- provided. In cases where the

FREBO offices are using roofing specialists for design work, no documents were

cited. The FREBO offices rely on the advice of the roofing specialists who

use the documents of their choice.

3.2.4 Education and Training

A wide difference of opinion is apparent regarding the question whether

USPS personnel keep abreast of the current state-of-the-art of roofing technology

with respect to design and material selection. Fifty percent of the questionnaire respondents replied affirmatively, while the other 50 percent responded

negatively.

This response was not totally surprising considering that the roofing

industry has changed drastically in the last few years. Nonetheless, the

majority of units indicated that training and educational opportunities in

roofing are available for selected staff members. The questionnaire results

indicated that less than 25 percent of the staff in any office attend training

courses annually and 10 percent take that no training related to roofing.

Reluctance to take time away from the work at the office for needed training

was a reason often given for lacking of continuing education.

Industry courses such as RIEI and in-house seminars provide the major

information sources for keeping the staff current with roofing design, materials,

and technology. Very often in-house seminars are conducted by material

18
vendors at the USPS facility. An attraction of vendors seminars is that they

are usually put on without direct expense to the USPS. Questions can, of

course, be raised about the objectivity of vendors seminars. One FREBO

indicated that it tries to have many broad-based seminars from vendors

so that bias may be minimized. In a few cases, roofing specialists are used

to provide in-house training.

3.2.5 Responsibility

Eighty percent of the offices responding to the questionnaire indicated

that no individual staff member was designated as having office responsibility

for design, construction, repair, and maintenance of roofing. In many cases,

the reason given was that flexibility in staff responsibility was desired, and

thus all project managers were assigned roofing responsibility at one time or

another. The project manager has the ultimate responsibility that a given

roof is designed and constructed acceptably. Further, there were wide

differences of opinion expressed (ranging from none to all) when responding to

the question of how many project managers have roof design and construction

responsibilities. In some offices, where roofing specialists are used under

term contract, one individual in the office is given the responsibility of

coordinating the roofing jobs with the specialist.

3.2.6 Roof Slope

The questionnaire respondents indicated almost unaminously that all design

documents for new roofs include a provision for a minimum slope of 1/4 inch

v per foot. This was not surprising since USPS., as a matter of current policy,

requires such slope. In cases of roofs on existing buildings, inadequate drain

age due to lack of sufficient slope is an often-cited problem with USPS roofing

* 19
3.2.7 Material Selection

In the case of roofs designed by headquarters, material selection is left

to the A/E firm working in conjunction with the roof specialist. The A/E must

propose 3 systems and make a life-cycle cost analysis on which one of the three

systems is selected.

With the field offices, the discussions indicated that material selection is

left to the A/E firm or roofing specialist in the majority of both new and reroofing projects. Alternative systems are proposed for major renovations.

Frequently, USPS field staff provide input into the selection process. This was

often done by informing the A/Es of materials and systems that are or are not

acceptable to the office.

It appears from the discussions that USPS uses all types of roofing

materials and systems for its buildings. As more than one USPS individual

indicated, "if it is possible to purchase the material, we have it on some of

our roofs somewhere.” Exact distributions of the types of materials and systems

used were not ascertained during the study. Local preferences in some FREBO

offices exert a large influence on the materials selected for roofing. Over

80 percent of the questionnaire respondents answered that they preferred one

or two roofing systems over others. Some FREBOs are using only single-ply

materials; while others are using only BUR. In at least one case of a regional

office, there was a strong preference for spray-in-place polyurethane foam.

Many field personnel and most respondents to the questionnaire were of the

opinion that membrane materials were selected on a basis of performance or on

% history in service. As an example, one FREBO project manager indicated in

discussions that many phone calls to previous users are made, along with some

site visits, to check the performance of new materials for which the FREBO has

20
little experience. It was reported that the FREBO would not use the new material

if the reports on performance were not satisfactory. Discussions with field

personnel also indicated that the preference of the A/E or roofing specialist

with input from USPS personnel also influence material selection.

The questionnaire respondents indicated that membrane material cost and

availability provide little basis for the selection of materials. This response

concerning material cost was not unexpected, since the USPS has a requirement

that life cycle costs be considered for new roofing, and major repairs and

renovations. In general, USPS personnel feel that the mechanism for materials

selection is adequate.

Although the respondents feel that the materials selected for specific

projects are adequate most of the time, there is a wide range of opinions as

to whether or not quantitative or even qualitative comparisons between materials

are made. ASTM standards industrial or manufacturers specifications are most

often used for material specification. Many of the questionnaire respondents

felt that USPS roofing specifications were seldom adequate to define roofing

materials.

Those USPS personnel who keep abreast of materials and their performance

use information sources such as seminars and formal training courses, technical

bulletins, and manufacturers' literature. Although the majority of the

questionnaire responses pointed toward expertise in the materials selection

area, there was the prevalent opinion that considerable improvement is needed

to keep abreast of materials and their performance. Little feedback from inservice performance of materials on the roof occurs. When feedback is received

it comes on a one-to-one basis from maintenance people confronted with specific

problems. As one FREBO project manager indicated, feedback is seldom obtained

21
until a "request for services" is received from the BMEO to repair a roof which

the office previously designed. Records of material performance are seldom

kept and field testing of materials is seldom used to evaluate new materials.

Research, either laboratory or field evaluation, is rarely supported by the

offices. When it is supported, reports are normally not prepared, and consequently, little use is made of the research by USPS Headquarters or other

USPS organizations.

3.2.8 Application

In discussions with many field personnel, poor workmanship during roofing

application was considered a major problem with respect to roof performance

in the USPS. This was confirmed in the questionnaire responses to questions

concerning roofing performance. For example, respondents often indicated that

all roofing systems used by USPS will perform satisfactorily if they are applied

properly. The majority (70%) of respondents to the question on workmanship

indicated that it is satisfactory. Nevertheless, it appears to be significant

that about 30% of the respondents indicated that the workmanship is seldom

adequate.

Private sector roofing contractors are always used to install USPS roofing.

These contractors are selected by an open bid process either for the specific

job or on a term contract basis. In discussions, USPS field personnel expressed

concern that the open bid process results in some roofs being applied by contractors who are not qualified. This concern was echoed in conversations with

roofing specialists who provide roofing service to USPS. A number of individuals

stated that local labor obtained in small towns was normally more reliable

than that obtained in large cities.

22
Factors considered in the selection of contractors include past experience,

training, and costs. Uniform criteria for contractor selection are not available

for the entire USPS system. Certain offices have assembled criteria for their

own use, but these may not be used beyond those offices. In these cases, the

offices are satisfied that their selection criteria are adequate.

In cases where the work provided by term contractors is not adequate,

the contract can be terminated. This has reportedly happended in some instances.

In other cases of unsatisfactory performance, the term contractor will not

be given additional work, and the contract would not be renewed.

The discussions with USPS personnel found some contrasting opinion concerning

contract requirements that the roofing contractor be "approved" by the material

manufacturer. Some individuals indicated that such contract requirements could

not be used, while others stated they were doing so. In light of this mixed

finding, it is interesting to note that the "short form specification" for

recovering a BUR system with a single-ply membrane requires, as a contract

submittal, that the contractor is approved by the material manufacturer.

3.2.9 Quality Control During Construction

A prejob conference among the various parties involved in the roofing projects

is a recommended USPS practice. For the most part, USPS staff members are

represented at the prejob conference.

The use of full time inspection during construction to help assure adequate

workmanship varies widely depending upon the operational procedure of the local

office. Headquarters provides such inspection for its projects through roofing

specialists. In this case, the specialists are hired by the A/E using guidelines

prepared by USPS headquarters. Likewise, some field offices have similar

23
requirements for inspection for all new roofing, reroofing, and major renovation

\ regardless of the costs. In other cases, the field offices may provide fulltime inspection on projects where costs exceed a certain dollar amount, for

example, $50,000. Full-time, continuous inspection was seldom used by some

offices as a normal practice. The field offices usually use a "term"

roofing specialist for the inspection. However, at least one FREBO has the

roofing contractors hire the inspector for each job as part of the construction

contract. The FREBO has to approve the selected inspector who has responsibility

to the FREBO.

BMEO staff will occasionally visit a job site where re-roofing is underway,

particularly if it is known that inspection is not being provided by the A/E

or FREBO. The BMEO inspection is usually not pre-planned for all roofs,

and is also a one time occurrence for a given roof. Additionally, the roof is

usually conveniently located near the BMEO office.

In cases where field offices do not provide full time inspection as a

routine practice, the opinion was often expressed that the assurance of adequate

workmanship is the responsibility of the project A/E under contract to the USPS.

The A/E should assure that inspection is provided on whatever frequency is

adequate to have the construction carried out satisfactorily. The inspection

may be done by the A/E or by a consultant. In some cases, USPS personnel will

do periodic inspections.

Roof test cuts are not used as a routine procedure to evaluate quality of

workmanship during construction of USPS roofs. However, representatives of

one FREBO office stated that USPS should define acceptable requirements for

membrane properties and allowable application tolerances as determined from

test cuts. Their reasoning was that USPS needs to know precisely when the

24
installation is either "in-spec" or "out-of-spec" for purposes of determining

liability should questions 'of acceptable practice arise.

Communication between the A/E firms and roofing contractors involved in

USPS roofing appears to be satisfactory. It is the general consensus that

responsible project officers are quite successful in holding the roofing contractor accountable for correcting deficiencies traceable to unacceptable

workmanship. However one FREBO office suggested that specific criteria

defining unacceptable workmanship need to be better defined so that the

contractors responsibility is clearly defined. As an example, the size and

percent of voids in the interply layers of asphalt in built-up roofing was

given.

Quality audits (final inspections) of the completed roofs are generally

conducted by USPS personnel, A/Es and consultants, and representatives of the

material manufacturer. Nevertheless, the questionnaire respondents indicated

that there are cases where quality audits are seldom conducted. Furthermore,

it was generally the consensus that record keeping on the design and

construction of roofs requires improvement to assure completeness. The FREBO

offices keep warranty records, but the roof file is generally turned over to

the BMEO.

3.3 Inspection, Maintenance, and Repair Practices

The review of the USPS roofing activities and practices regarding inspection,

maintenance, and repair is presented in this section of the report. As with

the previous section, the information presented is primarily based on a review

and analysis of questionnaire results. The results are complemented with

25
information obtained in discussions with USPS personnel or individuals performing

roofing work under contract to USPS.

Appendix B presents the questionnaire for inspection, maintenance, and

repair, as well as bar graphs of the responses. Most of the questions were

multiple choice, and in some cases, the respondents selected more than one

answer. Thus, the average response often exceeds 100 percent. This questionnaire contained 51 questions. It was sent to the Building Maintenance Engineering

Offices (BMEOs) and Regional Offices. Thirty-nine units out of 48 responded.

The trends in the USPS roofing practices regarding inspection, maintenance,

and repair are based on the results of the questionnaires complemented by the

information obtained from discussions with USPS personnel and others.

3.3.1 Problems Encountered During Inspections

Those who inspect roofs are obviously in the position to observe common

problems experienced by them. In general, based on the experience of the

BMEOs, the USPS problems are typical of the U.S. roofing industry in general.

The defect most often experienced during USPS inspections involves flashing

which has historically been a weak link in low-sloped roofing systems. Most of

the membrane problems reported are associated with built-up roofing. This

response is interpreted to reflect that, until recently, the USPS was using

primarily built-up roofs. With regard to built-up roofs, the inspectors

indicated that the major problems were blistering, splitting, and exposed

felts. These problems are typical with built-up roofing in general and it is

not surprising that the inspectors find such problems with USPS roofing.

Another frequently encountered problem, which deals with design, is lack of

proper drainage of the roof due to inadequate slope. Problems with single-ply

26
roofing such as gravel displacement and defective seams were also indicated.

Problems with foamed in-place roofing were also reported.

It was reported numerous times that clogged drains and debris on the roofs

were encountered during inspections by BMEO staff. Such observations indicate

that periodic routine inspections are not being conducted to the extent

desirable. These observations are also consistent with the often-expressed

BMEO opinion that local preventive maintenance and inspection for roofs is

inadequate.

Inadequate workmanship during roofing installation was also considered to

be a common problem experienced by those conducting the inspections. Several

respondents qualified the level of workmanship as being "poor" or the labor

being "unskilled." There was also a strong response implying that inadequate

workmanship was allowed due to inadequate inspection during the application of

the roofing. Among the defects attributed to inadequate workmanship, flashing

was cited as the most common. Others included improper installation of felts,

membranes, insulation, bitumen, aggregate, ballast, caulking, and drains. In

addition, the improper storage of materials at the job and installation of wet

materials were reported in a number of cases.

3.3.2 General Considerations Regarding Maintenance and Inspection

In the vast majority (>95%) of cases, inspections of USPS roofs are carried

out by USPS personnel and mainly those having maintenance responsibilities.

Consultants or architects are sometimes used for this purpose. Indepth roof

inspections by BMEO personnel are held in conjunction with inspections of

other areas of the building. Generally, the inspections are planned events as

opposed to inspecting after leaks or other problems are reported. Nevertheless,

27
the BMEOs respond to requests for local assistance when a xoof is leaking and

corrections are not possible at the local level. About half the questionnaire

repondents indicated that roofs are inspected only after leaks or other problems

were reported. Routine preventive maintenance inspections are the responsibility

of the maintenance officers at the MSC level.

The majority of BMEO staff conducting roofing inspections are likely to

seek and use outside assistance with difficult and unusual problems. For the

most part, this assistance is provided by USPS FREBOs, contract A/Es, or

roofing specialists. The USPS MTSC is seldom used, although MTSC provides

assistance in investigating specific roofing problems and making recommendations

for their solution.

Within the BMEO offices, each staff member may inspect from 10 roofs to 40

roofs a year. In a few cases, in some offices, staff inspect more than 80

roofs per year. About two thirds of the inspections result in repair work,

with the remaining one third involving roof replacement.

3.3.3 Frequency of Inspection

For the most part, indepth roof inspections are conducted once every two

to three years by the majority of the BMEO offices. About one quarter of

these offices report yearly or twice yearly inspections, while about 10 percent

inspect once every three years. The BMEO offices work on an inspection schedule

which considers the age and size of the building. The roofs are normally

inspected during the inspection of the building. Older buildings (greater

than 15 years) having large roof area (greater than about 15,000 square feet)

may be Inspected once every one or two years. Newer (less than 10 years old)

and small buildings may be inspected about once every 4 or 5 years. Buildings

28
with intermediate ages are generally inspected in a 3 or 4 year interval by a

BMEO office. USPS had a requirement that roofs be inspected routinely every 6

months under the direction of the maintenance offices on the local level.

However, for normal circumstances, the current USPS directive now requires

routine inspection of roofs annually. It is also recommended that more frequent

inspections be carried out for buildings located in extreme climates or for

those having a history of roofing problems. Directives also provide that roofs

be inspected after storms or other climatic events which may damage them.

Based on the results of discussions with USPS personnel and the

questionnaire results, there appear to be some problems with having the local

inspections conducted as USPS requires. As previously indicated, the BMEO

inspectors frequently find clogged drains and debris on roofs. Such routine

maintenance defects should be found and corrected during the local inspections.

Reasons why the local inspections are not alway conducted were not ascertained

during the study. Some suggested reasons were the availability of personnel

and the reluctance of some local maintenance staff to climb on roofs. In

spite of the opinion that local preventive maintenance and inspection is often

inadequate, the BMEO personnel generally consider that its own frequency of

inspection is quite satisfactory. It is realized that more frequent inspections

by the BMEO are difficult to conduct because of limited personnel in the BMEO

offices. Thus, local maintenance must be relied upon for the routine

inspections.

3.3.4 Responsibility

In general, the BMEO offices responded that they do not have a key staff

member with primary responsibility for roof maintenance and repair activities.

29
On the other hand, they generally felt that those making the inspections were

adequately knowledgeable to do so. In many offices, a number of individuals

have had training with roof inspection techniques and the use of non-destructive

evaluation (NDE) methods of detecting moisture in roofing systems. Nevertheless,

in a minority of cases, necessary expertise on the part of the inspectors was

considered to be lacking. In addition, about two-thirds of the BMEO respondents

to the questionnaire felt that their offices were not adequately knowledgeable

about the non-conventional systems, notably single-ply membranes and

polyurethane foam.

3.3.5 Training

Training is provided to the inspectors but that less than a quarter of

them attend training courses annually. The majority of those having training

receive it from the MTSC. Until recently, MTSC provided 4-day courses about 8

or 9 times a year at various postal locations around the country. Two days

were devoted to inspection techniques for built-up roofing and two days were

spent on the use of nuclear equipment for conducting moisture surveys. The

inspection technique course included practical sessions which occur on the

roof.

Since most BMEO inspectors receive their training from the MTSC, it is

apparent why they should feel that they are not adequately knowledgeable

regarding non-conventional systems. MTSC courses in the past have not included

non-conventional systems in the curriculum. The course on built-up roofing

and moisture surveys is now planned to be replaced with a 40-hour course on

inspection, maintenance, and techniques for in-house repairs. The new course

will consider all types of roofing problems experienced, and how to fix specific

30
problems. Course attendees are expected to include not only the BMEO personnel

but also local maintenance people who have responsibility for specific buildings,

or a group of buildings in an area. Training on the use of nuclear NDE techniques will be discontinued by the MTSC, but the Regions can provide for such

training if desired.

Vendor seminars as well as industry-sponsored courses are also sources of

training for the BMEO staff. However, use of such sources was considerably

less than that for the MTSC course. The RIEI and the NRCA are the most-used

industry courses. It is noted that USPS recently sponsored an RIEI course for

USPS personnel.

The majority of the questionnaire respondents feel that they do not

adequately keen abreast of the current state-of-the-art of roofing technology.

In-house courses and vendor seminars are the two most common means of remaining

current.

3.3.6 Timing of Repairs

The inspection procedures often reveal deficiencies which require

attention ranging from minor maintenance to major repairs and occasionally

recovering or replacement. Regardless of the magnitude of the defects, good

roofing practice dictates that repairs be made as soon as practicable to avoid

worsening of the defect (if minor), or extensive water damage to the roof,

other building components, or the building contents. USPS maintenance directives

provide that repair work be done in the most expedient and economical method

which can be accomplished, whether in-house or by contract. In general, USPS

practice does not provide for "on-the-spot" repairs by the inspector. Furthermore, except in a few cases, materials and tools for making "on-the-spot"

31
repairs were generally not part of the inspectors* equipment. In general,

repair work, even that of a minor nature, is done by roof contractors, although

USPS building maintenance staff may do some from time to time. In many cases,

these are term contractors who are available under contract for one year with

the option to be renewed two options twice. The mechanism is available to

provide for emergency repairs within one day in the case of roof leaks. However,

in discussions with some roofing specialists, they have been critical that

such emergency repairs are not carried out soon in many cases. These individuals

were also critical that the term contractors were not always fully qualified.

If the repair work is to be done through normal channels , many weeks may

pass between the roof inspection and initiation of needed repairs. More than

two^thirds of those responding to the questionnaire indicated that repairs were

accomplished more than two months after defects were first observed in the roof.

Roofing specialists who provide assistance to USPS under contract suggested that

steps should be taken to expedite roofing repairs. Often water damage to the

roofing and building components occurs before leaks are fixed. One roofing

specialist gave an example where base flashings of a large facility were badly

deteriorated and leaking. More than 15 months had passed between his inspection of the roof and the time when the bid package to repair the base flashing

was let. During that time, the flashings continued to leak. These roofing

specialists gave recommendations to NBS staff that USPS should take steps to

ensure that repairs are carried out expediently.

32
3.3.7 Guidelines, Manuals, and Bulletins

Communication was found to be somewhat lacking with regard to the question

of availability of guidelines, manuals, and bulletins. USPS has available

documents dealing with roof inspection and maintenance. Two examples are

Maintenance Handbook #1, "Operation and Maintenance or Real Property,” Guide

No. P-20 on "Drains, Roof, Gutter, Etc," and Maintenance Handbook MS-6," Repair

and Alteration Surveys," Chapter 2 on "Roofs." Most respondents to the

questionnaire indicated that guidelines and manuals were available to assist

USPS roof inspections. However, 15 percent of the respondents replied that

manuals were not available. In addition, a number of individuals who indicated

that USPS has documents available referred to industry publications and not

the USPS maintenance handbooks.

For cases where respondents indicated that manuals were available, about

three-quarters of them believed that the manuals were inadequate. Guide No.

P-20 gives the USPS guidelines for local inspection including walking the roof,

checking key items, and removing trash and debris. These guidelines are also

given in Maintenance Bulletin MMO-1-85. Chapter 2 of Maintenance Handbook

MS-6 gives guidelines for conducting repair and alteration inspections of builtup roofs. In reviewing the MS-6 document, it could be seen why many USPS

personnel consider it to be inadequate. First, it only concerns built-up

roofing. Attention is not given to single-ply or other types of low-sloped

roofing. Second, it needs updating regarding technological advances in roofing

technology. Examples of areas of concern include newer systems, bitumens,

% felts, "resaturation", venting, and the listing of reference publications.

Third, reference photos to assist the uninitiated local inspector regarding

typical BUR defects are not incorporated. MS-6 was last revised in 1979.

33
Regarding maintenance bulletins, mixed opinions, divided almost 50-50 in

the questionnaire, were expressed as to whether or not the USPS provided timely

bulletins about specific aspects of inspection and repair procedures. This

response may be another indication of communication problems regarding roofing

inspection practices. The question may be asked why some individuals are not

aware of bulletins from the MTSC. The MTSC provides bulletins to the local

offices regarding generic roofing problems. It also distributes summaries of

maintenance and repair information that is taught at industry courses such as

RIEI. Conversation with one individual at the local level indicated that MTSC

bulletins were received. In this case, the individual found the bulletin to

be of assistance, although he admitted having little direct interaction with

the MTSC.

Private sector documents such as the NRCA Roofing and Waterproofing Manual,

the ARMA/NRCA Maintenance Manual, and the RIEI maintenance publication were

commonly used as reference materials. Nevertheless, a few respondents to the

questionnaire indicated that they use no industry reference documents regarding

inspection and maintenance.

3.3.8 Repairs

When inspections reveal that extensive treatment is required, the inspector

provides recommendations as to the course of action to be taken. Under such

circumstances, the BMEO will request the services of the FREBO to initiate design

of the repair or replacement roof. Thus, the design of the remedial work, as

indicated in the questionnaire responses, is normally provided by an A/E firm

or roofing specialist under contract to USPS, since the FREBOs generally contract

34
for their assistance. Some portion of the repair work may also be provided by

design personnel at a FREBO.

It should be remembered that, in general, BMEO staff personnel are not

designers; thus, they provide recommendations for repair, not design. The

BMEOs have dollar limitations and, in general, if a BMEO recommendation for

repair costs more than $5000, the work will be assigned to a FREBO. However,

in discussions at one BMEO office, it was indicated that the BMEO can provide

repair work up to $25,000 without assistance of a FREBO. It was stated that,

if the BMEO feels it has the capability, it will prepare the scope of work and

write the specification, and have a procurement office put the job out to bid.

Normally a USPS "short form specification" is used to assist development of the

specification. In cases where the BMEO does not have the experience to write

the specification, FREBO services will be obtained.

Once design responsibility is placed, the inspector initiating the repair

is unlikely to be consulted by the designer. Nevertheless, there are cases

where the designer and inspector discuss the repair. Also, the A/E or roofing

specialist responsible for design in extensive repairs and renovations almost

always makes an on-site roof visit.

3.3.9 Criteria for Repair Versus Replacement

Only 55 percent of the questionnaire respondents felt that USPS has available

criteria for condition assessment and for making a decision whether or not a

roof should be repaired or replaced. The majority of these felt that the

criteria were adequate. The remaining 45 percent responded that such criteria

were not available.

35
The mixed response to this question was hot surprising since in many cases,

it is difficult to judge when to repair or replace an existing roof. The USPS

does not have available a written set of criteria including cost analysis on

condition assessment and treatment. It is believed that those who responded

affirmatively to this question were relying on their personal experiences as to

how they judge roof condition. These experiences were interpreted as criteria,

which is not inconsistent with overall industry views. In practice, many roofing

technologists have their own procedures for subjectively judging quality.

Often the costs of maintaining and repairing the existing roof are compared to

the costs of replacement, and are heavily considered in the final decision.

In dicussing this question with one individual who indicated that criteria

were not available, it was indicated that "rules of thumb" in some cases influence

decisions. For example, one rule mentioned was that if a roof is at least 15

years old and considered to be in bad condition, it is re-roofed and not repaired.

3.3.10 Non-Destructive Evaluation

The use of non-destructive evaluation (NDE) methods for assisting the

assessment of roofing condition depends upon the individuals involved. In some

cases, it is never used, while in others it is always employed. In still others,

its use may be considered based on the situation and roof condition. For

example, an inspector may have an NDE inspection conducted after a visual

inspection has been completed.

The nuclear backscatter technique is by far the most common method. Most

often, the NDE inspections are done by USPS personnel. These findings are

to be expected since, up to recently, USPS practice provided that each BMEO

office had a nuclear instrument. Moreover, the MTSC, as previously mentioned,

36
used to conduct a two-day seminar on the use of the nuclear instrument.

Presently, the course has been canceled and decisions to use nuclear backscatter

or other methods will be left to the Regional Offices. It was found in one

series of discussions that a BMEO office was purchasing a capacitance meter.

In general, those using NDE techniques feel that they are adequately trained,

and that the results of the NDE inspections are reliable. It is noted that

the availability of inspectors trained in the use of nuclear backscatter does

not preclude the use of consultants providing other NDE services such as

thermography or capacitance.

The use of NDE techniques has been beneficial. In discussing this subject

with USPS personnel, many examples were given where only selected areas of

roofs, found to be unacceptably wet, were replaced, while the dry portions

were left in place. The result was, as to be expected, considerable cost

savings in the repair of the roofing. It is noted that those who conduct

routine roof inspections at the MSC level are directed to request an NDE

evaluation of the roof if it is known to be leaking, or suspected of being wet.

3.3.11 Inspection and Maintenance Records

For the most part, inspection and maintenance records are kept by the BMEO

offices for the roofs for which they have responsibility. Nevertheless, some

respondents to the questionnaire indicated that records are frequently kept

but not alyways. In general, records are usually kept in files in the BMEO

office; in some cases, a computerized data base management system is used.

Most individuals believe that the record keeping is adequate, but there is a

minority opinion which stated that record keeping was not. As an example, it

37
was reported that a bonded roof was undergoing extensive repair, but the bond

on the roof could not be found.

With regard to the use of computerized record keeping, the BMEO offices have

recently begun a system to identify the maintenance work needed at individual

facilities including roofing, and to track the progress of the work from

beginning to end. Estimated costs for all projects are also included in the

record. Besides addressing individual roofs, this system will allow a BMEO to

follow the number of roof repair or replacement jobs under way and their total

costs. It will also allow the BMEOs to know which roofs are continually having

problems, including the costs of repair in those cases. Nevertheless, the

records are quite limited and do not include information on the roof construction such as age and components, nor is specific information given regarding

the nature or cause of the problem.

The lack of information regarding roof construction in the computerized

record system means that the records cannot be used to identify materials and

systems for which performance has been less than satisfactory. Also, the types

of specific problems experienced by USPS roofing resulting in repair and replacement cannot be analyzed. At present, using the conventional file system of

record keeping, many BMEO offices seldom use the records to identify poorly

performing systems. Moreover, it is felt by the BMEO respondents that maintenance records are hardly ever used in the preparation of guidelines or alert

bulletins regarding specific aspects of roof materials and system performance.

Maintenance records are, for the most part, not used to recommend research to

% improve USPS roofing performance.

38
3.3.12 Inspection Forms

The USPS has available two forms for use during roof inspections

(Appendix C) . One is for use by maintenance personnel within the Management

Sectional Centers (MSCs) who conduct routine inspections on an annual basis.

This form provides an overview of steps to be taken in inspecting a roof and a

list of deficiencies to be looked for regarding built-up roofing. It also

instructs that action be taken to correct the deficiencies. A cover memo

accompanying the form states that those using it should be familiar with the

inspection of roofs. Discussions with some roofing specialists under contract

to USPS have raised some questions as to whether or not those using this form

are, in all cases, adequately familiar with roof inspections. A major criticism

voiced is that the individual using the form observes a defect in the roofing

which is taken to be a major problem, and thus reports that a new roof is

needed. However, the defect discovered in the roofing may only require repair

to be fixed and not total. roof replacement. Review of the form by NBS staff

indicated that it does not provide sufficient detail for use by inspectors who

are only partially knowledgeable.

The second form available to USPS personnel for roof inspections is a

detailed checklist for use by BMEO staff when conducting in-depth inspections.

USPS maintenance guidelines indicate that those using the detailed checklist

have an good knowledge of roof construction and repair. The checklist contains

over 70 items to be observed during the inspection. These items deal with the

general condition of the interior and exterior of the building, the roof

condition, its surface, the membrane, pitch pans, flashings, copings, parapet

walls, penetrations, terminations, and expansion joints. One purpose of the

checklist is to assist the BMEO in requesting the services of the FREBO for

39
major repair and renovation. In the case of both forms, the references to

membrane inspeciton are pertinent primarily to built-up membranes and do not

include direct reference to single-ply roofing membranes or other types of

low-sloped roofs.

During the course of the study, some of the completed in-depth inspection

forms were examined by NBS staff. It was found that the forms were generally

being used as checklists, as intended, to note defects found in the roofs.

Usually only items founded to be deficient were marked. In many cases the

information requested at the beginning of the form regarding roof construction

was not completed. Additionally, some maintenance individuals are not as yet

using the form, which has been available for over a year. In reviewing the

form, the thought was discussed that it may be cumbersome to use' in having

listed over 70 items. The question was raised as to whether a computerized

data base system for noting the results of the roofing inspection might be more

efficient. Such a system would need to be developed. The system should have

the capability of being used on the roof.

40
4. DISCUSSION

This section presents the advantages and limitations of the USPS roofing

practices regarding design, materials, and construction, as well as inspection,

maintenance, and repair. It is based on the review of these practices given

in sections 3.2 and 3.3. The advantages and limitations .are given with

respect to USPS current roofing practices and activities which are generally

considered to be in line with industry accepted practice.

4.1 Advantages and Limitations of USPS Design, Materials, and Construction

Practices

4.1.1 Roofing Performance

A) Advantages

o Many roofs are providing satisfactory in-service.

o Both built-up and single-ply membranes have performed satisfactorily,

o USPS field personnel would welcome steps taken to improve USPS roofing.

B) Limitations

o Roofing is a major facility problem; problems are typical of those

found in the industry for low-sloped roofing.

o Many premature failures and replacements of roofing occur a few years

after construction.

o Many problems are attributed to improper workmanship during roof

application.

4.1.2 General Design and Construction

A) Advantages

o Headquarters has a uniform policy regarding roof design under its

direction.

41
o Headquarters requires the use of roofing specialists for design,

review, and inspection during application.

o Some field offices are using roofing specialists for design and

inspection during construction; the practice has been successful

over the limited time it- has been in place; it is being used

for both new and re-roofing construction.

B) Limitations

.» . o Field offices have, in general, no uniform procedures regarding roofing

practice; in many cases, the design of the roof is assigned by

contract to an A/E firm which is only given general guidance on preferred systems.

o In many field offices, the A/E is selected on the basis that the firm

can handle many facets of building design and repair, and is not a specialist regarding roofing.

o Criteria are not available to aid in the selection of roofing specialists.

o Field offices infrequently contact other USPS units regarding roofing.

4.1.3 Guide Specifications and Other Documents

A) Advantages

o USPS headquarters has prepared "short form specifications" to assist

field personnel in small repair and the improvement of construction

contracts.

o Many offices are using the NRCA "Roofing and Waterproofing Manual"

to assist in roof design, particularly with the details; other industry

documents from organizations such as RIEI, FM, and UL are also

used.

B) Limitations

o The "short form specifications" are in need of updating and revisions.

o USPS has no guide specifications for roofing, particularly for use in cases where general A/E firms are being used for roof design.

o Some guidelines are available; however, the documents are generally

considered to be inadequate.

o Not all USPS offices use industry documents such as the NRCA "Roofing

and Waterproofing Manual" to assist design.

42
4.1.4

Education and Training

A) Advantages

o Training opportunities are made available for USPS staff involved with

roofing; training may be in-house or through industry seminars.

o Many USPS personnel believe that they have sufficient training to

keep abreast of current technology changes.

B) Limitations

o Many USPS staff have difficulty in keeping abreast of changes in roofing

technology.

o A minority of USPS staff take no training related to roofing.

o Many in-house seminars are conducted by material vendors which can raise questions concerning the objectivity of the information supplied.

4.1.5 Responsibility

A) Advantages

o In some offices where roofing specialists are used to assist design

and construction, a USPS staff member has responsibility for

coordinating roofing

B) Limitations

o In the majority of offices, no individual staff member has responsibility

for roofing; all project managers will handle roofing jobs at one time

or another.

o Design, material selection, application, and maintenance responsibilities

are not clearly assigned.

4.1.6 Roof Slope

A) Advantages

o USPS designers are keenly aware of the necessity of proper slope for

adequate drainage.

o USPS has a design requirement for minimum slope of 1/4 inch per foot.

B) Limitations

o Many existing roofs have poor drainage due to the inadequate slope.

43
4.1.7 Material Selection

A) Advantages

o Headquarters requires A/Es to use roofing specialists to assist in

material selection.

o For some field offices, FREBOs are also using roofing specialists

to assist in material selection.

o Life cycle cost (LCC) analyses are used for headquarter projects and

field projects involving major renovation.

o ASTM specifications, as well as other industry documents, are used

to specify materials.

B) Limitations

o Little guidance is given to designers regarding material selection;

this has particular importance in cases where roofing specialists

are not involved with projects.

o Although field offices may in some cases give advice to designers on preferred systems, it is usually in regard to the choice of one type (e.g., BUR or single-ply) over another; advice concerning the

limitations in use of materials is seldom given.

o USPS field personnel have difficulty in keeping abreast of new materials

their use, and their performance.

o USPS field personnel receive little feedback on the performance

of materials in roofs for which they have had design

responsibility.

o Records of materials performance are seldom kept and field testing

of new materials is seldom conducted.

4.1.8 Application

A) Advantages

o In the majority of roofing applications, workmanship is generally

satisfactory.

o Contractors are selected in many cases with consideration of factors

such as past experience, training, and costs; manufacturers approval

of the contractor for given materials may be used as one criterion

for selection.

o The contracts of term contractors who provide unsatisfactory workmanship

may be terminated.

44
B) Limitations

o Although in the majority of cases workmanship is considered satisfactory,

poor workmanship is regarded by many USPS offices as a serious problem

for many roofing applications.

o USPS does not have criteria or guidelines for the selection of contractors, although some offices have assembled their own criteria.

4.1.9 Quality Control During Construction

A) Advantages

o Pre-job conferences with USPS staff present is a general roofing

practice.

o Headquarters provides for full time inspection of major roof constructions using roofing specialists.

o Some field offices are providing for full time inspection using

qualified roofing specialists.

o USPS project officers generally hold contractors responsible for

correcting problems considered due to poor workmanship.

o Final inspections for acceptance of USPS roofs are generally conducted

with USPS personnel present.

B) Limitations

o Full time inspection during construction is seldom practiced by some field offices.

o In some cases, inspection is left to the A/E to be provided on whatever

frequency considered necessary to assure satisfactory installation.

o Record keeping regarding roof construction needs considerable

improvement.

o Criteria are not available that define acceptable construction including

tolerences.

45
4.2

Advantages and Limitations of USPS Inspection, Maintenance and Repair

Practices

4.2.1 Problems Encountered During Inspections

A) Advantages

o Problems encountered by USPS inspectors are not specific to USPS roofs.

B) Limitations

o A common problem encountered is clogged drains and debris on roofs

which is indicative that periodic routine inspections are not

being conducted to the extent desirable.

o Poor workmanship during roofing application is often cited

by BMEO inspectors as a common USPS roofing problem.

4.2.2

General Considerations Regarding Maintenance and Inspection

A) Advantages

o Inspection of USPS roofing occurs as a planned event, and not as a reaction to a reported problem.

o The BMEO offices seek outside assistance in solving difficult roofing

problems found during inspection.

B) Limitations

o Although roof inspections generally occur as planned events, concern

has been expressed that some roofs are only inspected when problems

such as leaks have been reported by the building occupants.

o Most field units are not aware of the assistance of MTSC to investigate

roofing problems, although the MTSC is available for such help.

4.2.3

Frequency of Inspection

A) Advantages

o General directive requires that, in general, routine inspection of

roofs be conducted annually by local maintenance staff.

o Directives provide that roofs in severe climatics or having a history

of problems be inspected at least more than once a year) and that

roofs should also be inspected after storms which may cause damage.

46
B) Limitations

o Indepth inspection of roofs by BMEO staff occurs generally only once every two to three years.

o BMEO in depth inspections frequently find problems with clogged drains

and debris on roofs which are indicative that some local routine

inspections are not providing needed housekeeping.

4.2.4 Responsibility

A) Advantages

o BMEO staff who inspect roofs are generally knowledgeable concerning

roof inspection techniques.

B) Limitations

o BMEO offices do not have in general a key staff member who has

responsibility for coordination of roof maintenance and repair

activities.

o BMEO staff are often not adequately knowledgeable concerning

inspection techniques for the newer roofing systems, notably

single-ply membranes and polyurethane foam.

4.2.5 Training

A) Advantages

o MTSC provides for the development and delivery of training courses

for USPS inspectors.

o MTSC is redesigning and broadening the curriculum of its roof

inspection course to address inspection, maintenance, and in-house

repair techniques for all types of roofing systems; the course will be designed for local maintenance staff as well as BMEO staff.

o USPS inspectors attend industry courses given by organizations such

as RIEI and NRCA.

B) Limitations

o Many of BMEO staff take no roofing training annually; consequently

they have difficulty in keeping abreast of changes in roofing materials

and systems technology.

47
o Until recently, the MTSC inspection course addressed only built-up

roofing.

o The MTSC is dropping its course on the use of nuclear meters for

NDE of moisture in roofing; the responsibility for training

with NDE techniques is being given to the Regions.

4.2.6 Timing of Repairs

A) Advantages

o USPS directives provide that repairs be made expediently.

o Emergency repairs by roofing contractors can be expedited through

the BMEO offices in cases of emergency.

B) Limitations

o In many cases , necessary and timely emergency repairs are not carried

out.

o Many roof repairs done through normal channels take 2 months or more

to be accomplished during which time water damage occurs to the"

building.

4.2.7 Guidelines , Manuals , and Bulletins

A) Advantages

o USPS provides maintenance manuals.

o MTSC distributes maintenance bulletins regarding generic roofing

problems.

o Some BMEO staff use industry maintenance documents such as those

prepared by NRCA, AKMA, and RIEI.

B) Limitations

o USPS maintenance manuals for roofing are limited and out of date.

o Many BMEO staff are not aware that MTSC provides maintenance bulletins.

o A few BMEO staff make no use of roofing industry documents or maintenance.

48
4.2.8

Repairs

A) Advantages

o Major repairs (in excess of $5000) are generally placed under the

direction of a FREBO which is staffed with trained designers.

o The A/E, roofing specialist, or FREBO project manager responsible

for the major repair generally makes an on-site visit.

B) Limitations

o The BMEO can provide for major repair work if it considers that it

has the capability; this may be a subjective judgement; often in these

cases the "short form specifications" are used which are not considered

adequate.

4.2.9 Criteria for Repair Versus Replacement

A) Advantages

o None

B) Limitations

o Criteria are not available for condition assessment and deciding

whether to repair or replace a roof; judgments are often made

based on personal experiences.

4.2.10 Non-Destructive Evaluation

A) Advantages

o USPS has encouraged the use of NDE techniques; each BMEO office

has a nuclear backscatter meter; staff at the BMEOs were trained

in its use.

o The use of NDE has resulted in cases where only selected wet areas

of roofing have been replaced at considerable cost savings; dry

portions of the roofs were left in place.

B) Limitations

o Some BMEO staff reported that they never use NDE techniques in

evaluating roofing.

49
4.2.11 Inspection and Maintenance Records

A) Advantages

o The BMEOs have initiated a computerized system for identifying

needed repairs and tracking the progress of the repairs.

B) Limitations

o Although the BMEOs keep records of roof maintenance and repairs, the

records are not always kept as they should be.

o The computerized record keeping for roof repairs does not include

information on the type of roof, its age, and the nature of the

problem.

o Existing records are not used to provide alert bulletins regarding

roofing performance.

4.2.12 Inspection Forms

A) Advantages

o USPS has a checklist for those who inspect roofs either on a routine

basis or indepth.

B) Limitations

o It is assumed that those using the forms are familiar with roof

inspections; the checklists do not provide sufficient information

if the inspector is not fully familiar with roofs.

o The inspection forms deal primarily with built-up roofing; updating is

needed.

o Not all BMEO staff are using the indepth checklist.

50
5. SUMMARY

This report reviewed the roofing practices of the U.S. Postal Service

(USPS). The USPS has direct responsibility for the design, construction, and

maintenance of about 100 million ft^ of roofing. In addition, it leases

buildings having approximately an equal amount of roof area. USPS buildings

range in size from quite small to very large and are located across the United

States. The USPS is multi-level organization including Headquarters, Regional

Offices, District Offices, Management Sectional Centers, and Post Offices.

This organizational structure effects the manner in which USPS conducts its

roofing activities and was considered in the review.

The general approach taken during the study was to obtain information on

USPS roofing activities and practices which could be used for judging strengths,

weaknesses, and identifying problems. The primary sources of data were:

discussions with USPS personnel; discussions with those who provide roofing

services to USPS; review of typical USPS roofing documents; results of the

distribution of questionnaires to USPS staff; and the determination of training

requirements for those involved with roofing.

The review focused on two major phases of USPS roofing construction practice.

One involved design, materials, and construction, and the other concerned

inspection, maintenance, and repair. The division in the review of USPS roofing

practices was consistent with the distribution which exist between design and

construction groups, and maintenance and repair groups in the USPS organizational

structure. The primary topics addressed with regard to the review on design

and construction included general design considerations, education and training,

responsibility, material selection, and quality control during construction.

With regard to maintenance and repair, the review included general considerations.

51
frequently of inspections, responsibility, training, maintenace guidelines and

manuals, repairs and when they are conducted, and inspection and maintenance

records.

Based on the results of the review of each of the selected topics, the

advantages and limitations of the USPS roofing practices were given. The

listed advantages and limitations will form, in part, the basis of recommendations of steps to be taken to improve USPS roofing practices.

52
6. REFERENCES

1. "Repair and Alteration of Real Property,” Maintenance Handbook, MS-7,

U.S. Postal Service (June 30, 1979), Exhibit 1-1.

2. "Low-Slope Roofing Problems," Transactions of the Federal Construction

Council for 1979-80, Federal Construction Council, Washington, D.C.

,

pp. 21-27.

53
7 . ACKNOWLEDGMENTS

This study was sponsored by the United States Postal Service (USPS),

Design Management Division, Real Estate and Buildings Department. The authors

acknowledge with thanks the assistance of Mr. Warren L. Walker, Project

Manager, who provided technical liaison between NBS and USPS. Thanks are also

extended to Mr. William D. Hayen, Maintenance Management Officer, MTSC,

and Mr. Leon Schroeder, Facility Systems Branch, Technical Training Center,

for their discussions regarding USPS maintenance and training practices.

Appreciation is also expressed to Mr. Edwin W. Barnard, Jr., Sverdrup and Parcel,

Jacksonville, Florida, for his assistance in describing his experiences with

USPS roofing activities and in taking one of the authors to a number of roofs.

Finally, the assistance of those USPS staff who took their time to meet with

NBS researchers during the study or who completed the questionnaires regarding

roofing practices is also gratefully acknowledged.

54
APPENDIX A. RESULTS OF QUESTIONNAIRE ON DESIGN, MATERIALS, AND CONSTRUCTION

This appendix presents the results of the questionnaire on design, materials,

and construction. The questionnaire contained 78 questions for which the

majority could be answered as a multiple choice selection. Questions 2, 3, 4,

6, 31, 33, 52, 53, 54, 58, 65, and 66 required written answers.

This questionnaire was sent to each of the USPS Regional (5) and FREBO offices

(15), as well as to Headquarters (2). Fifteen completed questionnaires were

returned to NBS.

The results are summarized in bar graphs of the percent response versus the

multiple choice answer. The question accompanies each bar graph. Since the

respondents selected more than one choice for some questions, the average

response often totals more than 100 percent. The results are given for only

those questions which had multiple choice answers. The information obtained as answer to those questions requiring written responses was used in the summary

of USPS activities given in the main body of the report.

A-l
1. For roofing construction! In which your office hoc Involvement, who

generally designs the roofing systen and develops the spaelf lest Ions:

a* DSPS personnel

ho architect or consultant under contract

c. OSFS personnel with assistance of an architect or consultant

d. other

PERCENT RESPONSE QUESTION 1

A • C 0 RESPONSE

i

I

3. Please indicate the approximate number of roofing Jobs ui eaeh staff member of your office each year:

\ So leas than 10 d. between 40 and 60

be between 10 and 20 e. greater then 60

e. between 20 and 40

tn by

7. To what extent does your office Interact with other OS PS offices regarding

roofing:

a. mover d. moat of the time

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 7

A • C 0 I RESPONSE

•. for what reasons does your office interact with other DSPS offices regsrdlm

roofing:

a. roofing failures or problems

b. design considerations

c. Information on materials selection

d. Information on roofing application

a. maintenance considerations

f. ether

PERCENT RESPONSE QUESTION 8

"tA—

•

1 —— tC

- — nr

D

- — t—1—1 t I P RESPONSE

A-2
t. Dmi DSPS howa gulda apnea oval labia for:

«. now roof Inf

b. ro-roof Inf

PERCENT RESPONSE QUESTION 9

10. If DSPS gulda apaca art arallabln do you find thca adequate:

a. yea

b. . so

PERCENT RESPONSE QUESTION 10

11 • Are any of tha docuaaaca llatad below uaad to aaalat la roofing doalgn:

a. RICA Roofing Manual

b. Dept. of Dafanaa gulda apaea and aanuala

e. ARMA/WRCA Malntananea and rapalr annual

d. UL and PH guldaa

a. othar

PERCENT RESPONSE QUESTION 11

12. For roofing datalla aueh aa for penetrations, eapansion Joints, and graval stops, which of tha following docuaants ara usad:

a. HRCA Roofing

b. aanufaeturara lltaracura

e. USPS Guide Spacs

d. othar

PERCENT RESPONSE QUESTION 12

A C C RESPONSE

A3
13.

De«s your office uke use of documents which deal with specific aspects

of roof performance and problems such design alerts and bulletins Issued

by the following organisations:

a. KXCA or MRCA d. MCI

b. ARMA e. OoO

c. USPS (HT5C) f. other

14.

Does your office provide the opportunity for training and educational

courses from the following:

a. t!Cl

b. WftCA Co AIA/CS2

d. DSPS (HTSC)

e. University short courses

f. ocher ____________ ___________ go a© training provided PERCENT RESPONSE QUESTION 13 PERCENT RESPONSE QUESTION 14

IS. What percent of the staff who have roofing responsibilities attend training courses annually:

a. lees than 23

b. between 23 and 30

c. between 30 and 73

d. more than 73

PERCENT RESPONSE QUESTION 15

16.

Do you find that A/E firms under contract to DSPS are adequately knowledgeable In roofing technology:

a. mover d. most of the time

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 16

T

1 " * i " " * "

I A • C 0 I RESPONSE

A4
17. 0* yeu f 1 *4 chat your office can adequately keep abraaat of changes

and advances In roofing technology:

18. By what oechanlso do deelgnere In your offlee keep abreast of change* and advances In roofing technology:

b. ltfhouse (USFS) eeolnars

industry seminars

Industry educational eourees

vendor sealnars

other

PERCENT RESPONSE QUESTION 17 PERCENT RESPONSE QUESTION 18

It. Does your office have a key staff sober who has designated responsibility

for roofing: 20. Row oany of the project oanagers In your office have responsibility for roof design and construction:

b. a. none c. oost

b. few d. all

E

y

tb

PERCENT RESPONSE QUESTION 19 PERCENT RESPONSE QUESTION 20

RESPONSE RESPONSE
21 e Dmi your off let ictk assistance for solutions to roof problem* from

consul toots and othor roofing experts:

•o asT«r d. moat of tho time

b. soldo* o. always

6 • of ton

22.

ftefore Initiating roof eons cruet Ion, Is your office represented In a "pro-Job conference” with those Involved In the design and construction;

a. never d. nose of the tine

b. soldo* o. always

Co often

PERCENT RESPONSE QUESTION 21

A C D I RESPONSE

23.

Is adequate elope (normally 1/4 inch per foot) for drainage Included In roof design:

a. never d. most of the time

b. seldom e. elways

c. often

24.

In mojor repair end re-rooflng applications, does the designer (your offics

or s contract kJ E) conduct a roof lnapectloo prior to design:

a. never d. most of the time

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 23 PERCENT RESPONSE QUESTION 24

At\ — —1 CO* , 1

Response

A5
25. Dmi fovr of f lev uoo oo*-de»cruct 1 ve methods of evaluation (HDE) Co •ealst lo the determination of the roof condition and the prooonco of eeiscure before deciding whether cho roof should ho repaired or replaced:

a. aavar d. moat of the else

b. aeldom «• always

c. of tan

PERCENT RESPONSE QUESTION 25

26. Xn your experience, do you find that roofs which you have deeifned and constructed have received adequate maintenance after completion of the construction:

a. never d. nose of the tine

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 26

A C D I RESPONSE

2?. What ipproilaiti p«rc.nta(t of tha roof in, project, undartakan by your •fflc. ar* Id r.apoo.. to . rapuaat to aolaa in laMdlatl roof prsblaa

(i.l.. ooraally 1 Ink):

a. It., thin 2} c. batman SO and 75

b. batman 25 and 50 d. aora than 75

PERCENT RESPONSE QUESTION 27

RESPONSE

28. Does your office receive feedback from those responsible for roofing maintenance and repair concerning the le-aervice performance of roofing designed by your office:

e. never d. most of the time

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 28

A • C D I 8C9POHII

A7
29. Does your office keep records of the In-service performance of roofs for which it bad design responsibility:

®c never do most of the time

bo seldom e. always

c. often

PERCENT RESPONSE QUESTION 29

32. For re-roofing applications in which your office has Involvement, who generally selects the membrane material:

a. OSPS personnel

b. architect or consultant under contract

c. USPS personnel with assistance of an architect or consultant

d. other

PERCENT RESPONSE QUESTION 32

30. For new roofing constructions in which your office has Involvement, who generally seleets the membrane material:

a. OSPS personnel

b. architect or consultant under contract

c« USPS personnel with assistance of an architect or consultant

d. other _

i
Art qualitative comparisons of dlffsrsnt materials carried out as

t ha basis for materials selection:

a. never d. most of the time

b. seldom •• always

c . often

36. Are any of the Aoemaeota listed below used In the specif lcatlor. of materials:

a. A5TH standards

b. Federal specifications

e. Industry specifications

d. Foreign standards

o« other

PERCENT RESPONSE QUESTION 35 PERCENT RESPONSE QUESTION 36

If USPS material specif lest ions are oeed, are they coneldei

a. oarer d. most of the time

b. seldom a. always

c. often

PERCENT RESPONSE QUESTION 37

A C D I USKRSB

38. On what basis are meobrane materials normally selected:

s* performance considerations of the roof in question

b. past history of successful perfomance on other USPS roofs

c. materials availability

d. materials eost

e. architect's preference

f. other

PERCENT RESPONSE QUESTION 38
39. Dock your offle« favor one or two typos of roofing tyeteaa over others:

i. yes Please Indicate: _______ b. ao

40.

By what aechanlea does your off lee keep ebreast of new aaterlals offered

for aeabrane roofing:

a. Industry sealnars

b. Industry trade publications

c. industry training courses

d. OSPS bulletins and circulars

e. vendors' salesaanshlp and workshops

f. other

41.

By what aeans does your office reaain aware of the perforaance of aeabrane aaterlals and roof systeas In service:

a. industry sealnars

b. Industry trade publications

c. Industry training courses

d. USPS bulletins and circulars

e. vendors' salesaanshlp and workshops

f. other

42.

Do you eoaelder that those individuals hawing responsibility for aaterlals selection are adequately knowledgeable in roofing notarial and systcc

perforaance:

a. never d. nose of the tine

b. eeldoa e. always

c. often

PERCENT RESPONSE QUESTION 41

T1 * L-f, ^ * * \ * A • C D I P BKSPONSE A • C D B BBSPONSK

A- 10
O. Do ye* consider that cha mechanise lor keeping abreast of o«v roof lag malarial* la adequate:

a. ye* b. mo

PERCENT RESPONSE QUESTION 43

44.

Doss your off let receive feedback concerning materials perf romance for roofs for whleh It had design responsibility:

a. never d. most of the time

b. aeldoa e. always

c. often

A • C D I RESPONSE

45.

If your office receives feedback on materials performance, by what aeans

la the feedback received:

a. first hand experience

b. roof consultant or A/E who participated In the design

c. USPS maintenance personnel

d. vendor who supplied material to USPS

e. other

46.

Does your office keep records of the performance of materials which it Incorporated In roof designs and constructions:

a. never d. moat of the tlM

b. aeldoa e. always

c. often

PERCENT RESPONSE QUESTION 45

c RESPONSE RESPONSE

A- 11
47. If records ore kept concerning ln-servlce materials performance, in whs: fora ere they assembled: N

a. project managers notebook or files on lndlvldusl projects

bo central file In the office

e. dots processing file using computers

d. other „

40. Are date on materials and systems performance In-service analyzed by your office to Improve design criteria for future roofing projects:

a. never d. most of the time

b. seldom e. always

c. often

49. Does your office conduct field teats of new materials and syatems before accepting them for geoeral nee la all roofing projecte:

a. never d. most of the time

b. seldom e. aloeye

c. often

50. Does your office support research to further the understanding of roofir.g materials and systems with the aim of Improving performance and upgrading design criteria:

a. never d. most of the time

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 49

T * ' 1 ‘

1

' 1 1 1 ' ' 1 A • C D I ESPOUSE

PERCENT RESPONSE QUESTION 50

A C D I ESPOUSE

A- 12
SI. 1/ research and field cates are supported by your office, whet be cooes

of the results:

e. so report le prepared

b. e report is prepared but used by Che offiee only

«. e report Is prepared end sent to headquarters for distribution to USPS roofing personnel

d. e report le published lo the technical literature

e. other

PERCENT RESPONSE QUESTION 51

35o Are private roofing contractors used for the construction of USPS roofing:

a. often

b. kic of the tine

c. always

PERCENT RESPONSE QUESTION 55

54. Are USPS personnel used for roofing constructions:

a. never for new roofing

b. never for re-roofing

c. occasionally for new roofing

d. occasionally for ninor repai ra/nalntenance

e. occasionally for systen application on snail Jobs

f. * eeldoa for new roofing

g. seldom for re-roofing

PERCENT RESPONSE QUESTION 56

f I I T i l l A • C 0 B P G Response

57. How are roofing contractors selected:

a. open bid for the Job In question

b. open bid for a tern contract

e. sole-source contractor

d. other

PERCENT RESPONSE QUESTION 5?

tisroRsi

A- 13
59.

Docs USPS Kcvc available • see of uniform criteria to assise the selection

of roofing contractors:

60.

If a set of criteria for concraccor selection la available, do you consider that It la adequate:

a. yea b. •• never d» most of the time

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 59 PERCENT RESPONSE QUESTION 60

61.

If a set of criteria for contractor selection la available, shat factors are considered In the criteria

a. pest experience

b. cralnlng/knovledge

c. contractor costs

d. contractor availability

e. other ^

PERCENT RESPONSE QUESTION 61

A • C D I •ESPOUSE

62.

Do you consider that roofing contractors under contract to USPS provide adequate workmanship:

a. never d. moat of the tine

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 62

RESPONSE

A- 14
Hi »r. ttKidni cMiridon aalaccad bacaua* thty art 'approved* by aattrlali aau/aciaraa far application of proprietary aaabrana ayatama:

a. amr d. aoat of tha tloa

b. ooldoa a. aloaya

C. often

PERCENT RESPONSE QUESTION 63

64. Do you believe choc roofing contractors under contract to DSPS art adequately knowledgeable regarding Industry organisations (e.g., KKCA

,

ASTM, RICH that provide Information on roofing performance:

a. never d. most of the tine

b. seldom e. always

e. often

PERCENT RESPONSE QUESTION 64

67. are quality audita (Inspections) of completed roofs conducted to determine

whether the construction la satisfactory:

a. never d. moat of the time

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 67

66. Who conducts the quality audit (Inspections ) of the completed roofs:

a. DSPS peroonoel

b. A/C or roofing consultant

c. material manufacturer's rapraaantatlva

d. othar

A » C D tCSPOMC

A- 15
69.

Art roofing *eutt* for amaolnatlon of tht completed roof taken •• part

of the quality audit proctdurt: . aavtr d. not t of tht tint . ttldoo a. always

c. oftae

70.

Dots your offlet find that contractors apply tht roof systtn according

to spaclflcatlon: . aavtr d. oost of the tint N . stldoo a. always

c. ofttn

PERCENT RESPONSE QUESTION 69 PERCENT RESPONSE QUESTION 70

71.

Dots your offlet find that roofing contractors have good cooounlcatlon

with tht A/E or othtr Individuals rtaponslblt for tht roof daslgn:

a. aavar d. oost of tht tloa

6c stldoo a. always

c. ofttn

72.

Dots your offlet find that for now construction or axtanslvc renovation,

tbt roofing construction Is adtquattly coordinated with other trades: . never d. oost of the tloa . soldoo a. always

c. often

PERCENT RESPONSE QUESTION 71

A • C D I isroRst

PERCENT RESPONSE QUESTION 72

1 L.-C -C -f < U \ U/( | A • C D I Response

A- 16
7). Dm* y ovr offlci find that roofing aatsrlals are properly stored mi allowed to become wet) ond handled on the Job alta:

a. wear d. ooat of tha tioc

b. eeldoa a. always

c. aftan

PERCENT RESPONSE QUESTION 73

75. la vbat farm ara tha eaaatructloo racorda kept:

a. job file

b. cancrallaad file on roofing; sot computerised

c. computer lied data file

d. ether

PERCENT RESPONSE QUESTION 75

A C D RESPONSE

74. Ara conacructlon record* (e.g. ( datec, veacher, materials, specs, asphalt teaperatures , amount of roofing spiled) kept for each job

.for which your office has responsibility:

a. never d. aosc of the claa

b. seldoa a. always

c. often

PERCENT RESPONSE QUESTION 74

A C D RESPONSE

76. Do you feel that tha construction records which sra kept sre complete

a. never d. aost of the tlae

b. aaldoa a. always

c. often

PERCENT RESPONSE QUESTION 76

A I C 0 RESPONSE

A- 17
77, Xf your office bcllmi choc i roof Inc contractor la responsible for a deficiency in the newly completed roof construction, doea your office

atteapt to bold the rooflnf contractor accountable for repair of the deficiency:

a. never d. aoat of the tiae

b. aeldoa e. always

c • of ten

79. With regard to previous questions, bow often la your office successful In bolding the roofing contractor accountable for repair of the deficiency

So never d. aoat of the tlae

bo aeldoa e o always

c. often

PERCENT RESPONSE QUESTION 77

A • C D I tlSFORSI

PERCENT RESPONSE QUESTION 78

A • C D I aespoiisi

A- 18
APPENDIX B. RESULTS OF QUESTIONNAIRE ON INSPECTION, MAINTENANCE, AND REPAIR

This appendix presents the results of the questionnaire on inspection, maintenance,

and repair. The questionnaire contained 51 questions for which the majority

could be answered as a multiple choice selection. Questions 2, 3, 8, 35, 48,

50 and 51 required written answers.

This questionnaire was sent to the USPS (43) Building Management and Engineering

Offices (BMEOs), and (5) Regional Offices. Thirty-nine units responded.

As in the case of appendix A, the results are presented as bar graphs of the

percent response versus the multiple choice answer. The question accompanies

each bar graph. Since the respondents selected more than one choice for some questions, the average response often totals more than 100 percent. The results

are given for only those questions which had multiple choice answers. Written

answers were considered in presenting the results of USPS roofing activities

given in the body of the report.

B-l
1. Plea** Indicate the approxlaate nuaber of roof Inspectiona undertaken by each staff asnber of your office each year:

a. lea* than 10

h. between 10 and 40

c. between 20 and 40

do between 40 and 80

e. greater that 80

4. For thoee building* which your office ha* roof Inspection responsibility,

on the average what 1* the frequency of Inspection:

•• sore than twice a year

b. twice a year

c. once a year

d. once every 2*3 years

e. less than one* every 3 year*

V< m i found that for aost cases the frequency of roof inspections is 4# Mow oftsn in your experience hsve you found that roofs are oi adequate: Inspected when soaeone reports a roof leak or other problen:

a. never d. aost of the tins a. never d. aost of the tlae

b. seldoa e. slwsy* b. seldoa e. always

c. often c. often

PERCENT RESPONSE QUESTION 5

T * * f * * ' * ‘

1 * f ^

/ L * * < f A • C D I KI3POHSI

PERCENT RESPONSE QUESTION 6

B-2
Mm generally perfoi-M the rowtloa roof Inspections:

0 . UfFS Mint tuner personnel

to. Ocher USFS paraoaoal

c. architect or consultant under contract

d. USFS maintenance poraotmal with aatlataact

af an arcMtact or coneultant

to. ottoar __________

PERCENT RESPONSE QUESTION 7

A B C D I RESPONSE

t. Do tboaa DSPS paraotmal who conduct routine roof inspections alto inspect other arena of the building and equipment:

a. never d. aost of the tlae

to. aeldoo a. always

c. often

PERCENT RESPONSE QUESTION 9

RESPONSE

10. Oms your sfflea hs»s s ksy staff Habtr vboss primary responsibility Is the lnapaction , maintenance, and repair of roofs:

• •yes to. no

PERCENT RESPONSE QUESTION 10

A

RESPONSE

11. In eases where It Is difficult to identify the cause(s) of roof probleos.

does your office seek outside assistance:

a. never d. aost of the tine

to. seldoe e. always

c. often

PERCENT RESPONSE QUESTION 11

B-3
12. Who provides your office with oucsldc assistance in solving roof problcns:

«. OSPS headquarters

be USPS regions

c. usps recBOs

de USPS »*0s

e. USPS KTSC

f. contract A/E or consultant

g . other ^ ____

PERCENT RESPONSE QUESTION 12

RESPONSE

14. Do you believe that your office is adequately knowledgeable In the lnepectlon, Maintenance, repair of eon-conventional roof eyetene auch as single-ply and spray-in-place polyurethane fean:

a. yea b. no

PERCENT RESPONSE QUESTION 14

A —

RESPONSE

13. Do you consider chat those conducting routine roof inspections are adequately knowledgeable:

a. never d. nose of the tine

b. eeldon «. always

c. often

B-4
1 *. Mui preset of your staff who conduct rout loo roof Inspections attend *>° 7°“ find that a*abers of your office can adequately keep abreast of traiainf couraea annually: changes and advances in roofing technology:

a. leoa than 23 •• T** 80

b. between 23 and 30

c. between 30 and 73

d. nor* than 73

PERCENT RESPONSE QUESTION 16 PERCENT RESPONSE QUESTION 17

f ‘ * 1 1 *1 * ‘ * * *’* ‘I ' A • C D

Response

II. ly what mechanise do thoee ataff who eonduet routine roof inspections

keep abreast of changes and advances in roofing technology:

a. in-house (USPS) seminars

b. Industry seminars

c. Industry educational courses

d. vendor seminars

e. other

A • C D I Response

19. In conducting routine roof Inspections, how often does your office make repairs “on the spot”:

a. never d. most of the time

b. seldom e. alvsye

c. often

PERCENT RESPONSE QUESTION 19

A B C D I Response

B-5
20 . Do those oak inf roof Inspection* have with the* on cha roof adequate

aaterlals and tools for asking “on the spot* repairs:

a. never d. aost of the tlae

b. scldoa e. always

c. often

21.

0a the average, what aaount of tlaa elapses betweeo laapactlon of tha roof and repair of defects vhleh were observed:

a. lass than 1 week

b. between 1 and 2 weeks

c. between 2 and 4 weeks

do between 1 and 2 aonchs

e« acre than 2 aonths

PERCENT RESPONSE QUESTION 20 PERCENT RESPONSE QUESTION 21

22.

Does USPS have guidelines and aavraals available for laapectlon and aalntenanc* of roofs:

23.

Xf Inspection and aalntenanca docuaenta are available, do you find then adequate: please indicate titles:

b. no

PERCENT RESPONSE QUESTION 22

A

RESPONSE

PERCENT RESPONSE QUESTION 23

A >

RESPONSE

B-6
24. are any #f the 4mcuatoti listed below used to assist in roof inspection

sad *e lot ensues:

a. MCA roof Inf manual

b. DoD quid# epees and oanuala

c. ASNC/NItCA maintenance and repair manual

d. othar

Doos USPS headquarters provide maintenance bulladna and guides concerning

•pe’clfic aspects of roof Inspections, maintenance and repair:

a. never d. ooac of the tloa

b. soldo* e. always

c. often

PERCENT RESPONSE QUESTION 24

A » C D ESPOUSE

PERCENT RESPONSE QUESTION 25

26. Do you find that the USPS oalntenanea bulletins and guides concerning roof laapactloo, oalntenanea, and repair are of assistance:

a. never d. oost of the tloe

b. soldo* e. always

c. often

PERCENT RESPONSE QUESTION 26

27, In eases where It was found during the roof inspection that eitensive

repair or replacement was needed, does the inspector provide recomaendet ions on the repair and replacement:

a. never d. most of the tl*e

b. soldo* a. always

c. often

A • C D I Bcspomt

B-7
26. In umi where extensive repair or replacement la needed, otto provides

the design of the remedial word:

a. USTS design personnel (FUBOs)

b. USPS oalncsnance personnel

c • architect or consultant under contract to PSPS design personnel

d. other

PERCENT RESPONSE QUESTION 28

A I C D ESPOUSE

29.

If extensive roof repairs or replacement la needed and the job is designed

by soseone other than the oalntenance Inspector, does the designer meet with and discuss the needed work with the inspector:

! a. never d. most of the tine

be seldoo e. always

Co often

A • C 0 I RESPONSE

30.

Does the A/E responsible for design of extensive repairs or replacement

visit the roof In question:

a. never d. most of the time

b. seldom e. always

c. often

1 ^ ^ 1 ^ ^ “f A • C D B

31.

Does USPS have available a set of criteria to assist In the asscssnent of the roof condition and In making a decision on whether the roof should be repaired or replaced:

a. yes b. no

PERCENT RESPONSE QUESTION 31

RESPONSE RESPONSE
JJ. tf tKe answer to the previous question was >«’, do you find that the critsrla or* odoqusts In aost coses of use:

e. a*v«r d. aost of Che tlae

h. seldoa e. always

C. of ISO

PERCENT RESPONSE QUESTION 32

i .--.i l( M' n i r r {

r | A C 0 I SPOUSE

33 . An non-daacruetiva aachoda of .valuation (NDE) auch at theraography or nuelaar uaad during roof lnapactlom for datactlon of oolalura In tha ayacaa:

a. navor 4. aoat of the tlaa

b. aaldos a. always

c. of can

PERCENT RESPONSE QUESTION 33

33. Who conducts the NDE Inspections:

s. USPS aslntenence personnel

ha DSPS design personnel

C. A/E or consultant who sepdellses

la roofing

d. firm which specialises In use of NDE sschods

e. other ^

„

36. Do you consider that those conducting NDE Inspections srs sdsquscsly

trained:

b. no

PERCENT RESPONSE QUESTION 35

A B C D I Response

b

R

u

h

PERCENT RESPONSE QUESTION 36

B-9
36 • Do you find that tho results of NDE Inspections sre rsllsbls: 37. If U5?S personnel conduct NDE Inspections, sre adequate written guidelines

available to esslst the use of the equipment:

e. yes b. no

e. never d. aott of the tine

ho seldoa e. elwsys

c. often

PERCENT RESPONSE QUESTION 37 PERCENT RESPONSE QUESTION 38

A S C D E IISPONSI

39. Does USPS heve svsllsble trslned teens whose expertise Is the Inspection

of roofs Including NDE aethods:

s. yes b. no

40. Does your office keep Inspection end aslntensnce records (Including decs*

end work required end accomplished) for the roofs for which it hss responsibility:

e. never d. nose of the tine

b. seldom e. elwsys . . c. often

PERCENT RESPONSE QUESTION 39 PERCENT RESPONSE QUESTION 40

B-10
*1. itov are t he uiattiunci records kept:

• . In 111* of maintenance onglnoorlnf

0 . In • central file In ch« office

c. at USPS regional office or el headquarters

d. ether .

PERCENT RESPONSE QUESTION 41

42. Are maintenance records kept using a computerized data base manageoent

system:

a. never d. most of the time

b. seldom e. always

c. often

PERCENT RESPONSE QUESTION 42

43. Dm you consider that the maintenance records are adequate:

a. never d. moat of the time

b. seldom o. always

c. often

PERCENT RESPONSE QUESTION 43

44. Dome your office analyse the maintenance records in order to Identify materials and systems for which the performance Is less than satisfactory

s. never d. most of the time

b. seldom a. always

c. often

PERCENT RESPONSE QUESTION 44

B-ll
45. Art maintenance records analysed to proper* guidelines or elert Pullet ins for other USPS personnel regarding sons specific aspects of roofing materials end systems performance:

Sc never d. nest of the time

P. seldom «. always

e. often

PERCENT RESPONSE QUESTION 45

( ( < l * S (

S S..I 1 t * { * .4 \ I < { tit -y- A B C D B RESPONSE

47. la your experience , have you found that the design of oev and replacement USPS roofing constructions ha* Peso satisfactory:

a. never d. most of the time

P. seldom *• always

c. often

PERCENT RESPONSE QUESTION 47
APPENDIX C. USPS ROOF INSPECTION FORMS

Two forms which the USPS has available for use during roof inspections are

1. Maintenance Check List (MMO-1-85)

2. Roof Inspection Report (MMO-109-83)

This appendix presents copies of these forms.

C-l
Maintenance Technical Support Center MM0-109-83

U.S. POSTAL SERVICE

ROOF INSPECTION REPORT

mojen N*aota

A. riNAMCE. NO. 8. sub-locatiw ml C. ZIP asunziia cm. STATE

L FACILITY NAME

X MAINTENANCE IIBILITYmi AfiENCY

It TEAM WILT I. HOOP AfiE A LEASE EXPIN OATE

X PQSTMASTER/MAMACER rrj M. IMPECTION OATE

X HECSMCWCO ACTION QREPAIR LOCAL)

At^T

Q XEPAIR CQMTRACTQR)

•I. I EC2. AOaWAMt TTPt SECTION 2 0MJOEAR 3URTY REQUIRED

a. number or «.ys ra. BALLAST TYPE a. status op nor sjamamtee/vm is. date or last major kpaih or

MPECTIW AREA (LASS

rr

ACTION

BY WORK

ITEM NX

ICCESBARV CORRECTIVE ACTIW

OATE

or MPAIR

1 . SETTLEMENT WALLS AM) FOUOATKM X PLUMS

WALLS AM) COWERS t MOISTUV/BITIBCN

STAINS

4. OMOONS

| X PASCU AM) SOPPITS

1 S. WALL FINISWS

7. OVCWUNEX'CBMICEXTDGIMC

a. WTTOU/DOMM SPOUTS X EXPAMIOA/CONTROL JOINTS

10.

It.

i

IB. OAAW

IX DISCOLORED CEIL ME OR

CZILINC TILE

IX PEEL INS PAINT

IX <KAO(INB/SPAU.INE

IX

n.

IX * J .

, F46.1 •CET I or B

C-2
Maintenance Technical Support Center HM0-109 -<53

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Maintenance Technical Support Center MMO- 1^>-83

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C-5
Maintenance Technical Support Center MMO- 109-63

MKCTICM MCA CLAW

nr

ACTION

or

•OAK

ITEM

NO. mxMMrr connective action DATE

or pair

ft. WOW LOWING SIWACE

POSTED

m. mar tears xoms :

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C-6
Maintenance Technical Support Center MMOU. S. POSTAL SERVICE

ROOF INSPECTION REPORT

INSTRUCTIONS

1. FILL IN ALL ITEMS IN SECTION Is

2. COMPLETE ALL ITEMS IN SECTION 2 (BE SPECIFIC)

A1. DECK TYPE - WOOD DECK, STEEL DECK, ETC.

B1. INSULATION - FIBER BOARD, FOAM, FIBERGLASS , ETC.

Cl. MEMBRANE TYPE - BIT UMENOUS BUILT-UP, SINGLE PLY, SPRAY IN PLACE

FOAM, ETC.

D2. MASTIC TYPE - COAL TAR PITCH, ASPHALT, ELASTOMERIC, ETC.

E2. NUMBER OF PLYS - FOR SINGLE PLY ROOFING STATE TICKNESS OF PLY

AND TYPE OF PLY I.E., RAG, ASBESTOS, FIBERGLASS, ETC.

F2. BALLAST TYPE - RIVER ROCK, CINDERS, ETC.

G2. STATUS OF ROOF GUARANTEE /BOND - IF A GUARANTEE OR BOND IS IN

AFFECT PROVIDE EXPIRATION DATE. IN THE REMARKS SECTION PROVIDE

PERTINENT INFORMATION.

H2. DATE OF LAST MAJOR REPAIR OR REPLACEMENT - PROVIDE DATES. IF THE

ROOF HAS HAD MAJOR REPAIRS OR REPLACEMENT WITHIN THE LAST 3

YEARS PROVIDE P/A NUMBER IS REMARKS SECTION.

3. COMPLETE SECTION 3 OF THE INSPECTION, ITEM BY ITEM.

A. FOR EACH INSPECTION AREA, IDENTIFY THE FOLLOWING CLASS OF

PROJECT MOST CLOSELY DESCRIBING THE WORK NEEDED TO CORRECT

CONDITIONS FOUND. ENTER THE APPROPRIATE LETTER FOLLOWED BY A

NUMBER, INDICATING THE RECOMMENDED TIME PERIOD FOR ACCOMPLISHMENT (1 - FISCAL YEAR, 2 - NEXT FISCAL YEAR, ETC. UP TO 5 FOR

5 YEARS FROM DATE OF REPORT).

CLASS A - WORK NECESSARY TO CORRECT CONDITIONS WHICH CONSTITUTE

IMMINENT HAZARD TO LIFE OR HEALTH, OR AN IMMINENT

HAZARD TO PROPERTY OR CONTINUITY OF POSTAL OPERATIONS.

CLASS B - WORK NECESSARY TO PREVENT ACCELERATED DETERIORATION OF

THE ROOF OR BUILDING.

CLASS C - WORK THAT WILL RESULT IN IMPROVED BUILDING OPERATING

EFFICIENCY AND HAVING ECONOMIC BENEFIT MEETING THE

CRITERIA IN PUBLICATIONS 190 AND 191. THIS CLASS CODE

SHOULD BE USED FOR REPAIRS NOT URGENT ENOUGH TO BE IN

CLASS B.

( ) - CHECK MARK, CONDITION SATISFACTORY. NO WORK REQUIRED.

C-7
Maintenance Technical Support Center MM0-109-83

B. FOR EACH WORK ITEM INDICATE THE ACTION OFFICE - L - LOCAL

AUTHORITY; D - REQUIRES APPROVAL AT THE DISTRICT; R - REQUIRES

APPROVAL AT REGION.

C. ASSIGN EACH WORK ITEM A NUMBER. THE FIRST TWO DIGITS SHALL BE THE

FISCAL YEAR OF THE INSPECTION, I.E. 83-1, 83-2, 83-3* ETC.

C-8
U.S. POSTAL SERVICE

MRINTENANCE CHECK LIST

LN F IF ICR r ION

?i ft A r-M NUMBER TYRE

2 B L D G 0 0 1 M

•TSTEM/LOCATION

Rn-MrHng Tnatwrt'.lnn

EQUIPMENT TYPE Ronf-AII TvdpaM0DEL/8ERIES 0RI61NAL ISSUANCE DATE

SUB- EQUIPMENT/APE A DATE LAST REVISED REVISION NO. APPROVEO ST (INITIALS)

PART OR COMPONENTITEM

NO.* INSTRUCTIONS(COMPLY WITH ALL CURRENT 9APETY PRECAUTIONS)

FREQUENCY

Safety

Procedure

Preparation

Building Wall

Top Floors

Tools-Equipment

Roof Perimeter

Expansion

JointsControl Joints

Roof

Penetrations

Roof Drains

Roof Mat

T.

2.

3.

4.

5.

6.

7.

8 .

9.

10 .

Repairs 11 .

Comply with all applicable safety rules and

regulations

Review material on Roofs-Inspection and

Maintenance. Use copy of reduced size roof

plan.

Observe condition of outside building walls.

Observe condition of ceilings, walls, etc., on all top floors. Look for Indications of

leaks, damage, etc.

Check out required tools and equipment

.

Examine all items for safety condition

(ladders, rope, etc.).

Walk entire outer edge of roof. Check roof

edges, parapet wall, flashings, etc., for

bad caulking, open Joints, expansion cracks,

damage, etc.

Walk entire length of expansion and control

Joints. Check each side closely for damage

and condition.

Check all roof penetrations for damage or problems (air ducts, fans, support steel,

etc.). Not vent pipes.

Check each drain for proper drainage,

tightness, trash build-up, etc., check roof

mat around drain.

Walk roof in not more than 20' wide paths.

Check roof condition for 10' on either side.

Note any damage, exposed roof felts, blisters,

loss of flood coat or aggregate, soft spots,

boils or alllgatoring of bitumen, etc.

All spots requiring repair will be marked by

spray paint. Area will be noted on roof print

and identified by location and number. Use

the number to show the problem and necessary

repairs. Issue work order and show when work

was completed.

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PS FORM a rj rj rj DEC 1982 4777 C-9 PAGE OF PAGES
U.S. POSTAL SERVICE

MAINTENANCE CHECK LIST

B

1L3LKI f lFICflTTSTT

I«HnTM nuj NUMBER

1

ttpe

M

8Y9TEM/LQCATI0N EQUIPMENT TTPE M00EL/9ER1ES 0RI6INAL ISSUANCE OATE

SUB*EQUIPMENT/APEA OATE LAST REVISED REVISION NO. APPROVED BT (INITIALS)

PART OR

COMPONENT

ITEM

NO. INSTRUCTIONS

(COMPLY WITH ALL CURRENT SAPETT PRECAUTIONS)

No time allowance. Safety is included in all

items.

30 minutes per inspection for review.

2 minutes per 100 lineal foot.

2 minutes per 1,000 square foot (office).

1 minute per 1,000 square foot (workroom).

10 minutes standard.

1 minute per 20 lineal foot.

1 minute per 20 lineal foot.

.5 minute each.

.5 minute each.

1 minute per 1,000 square foot of roof.

30 minutes per standard plus 1 minute per 1,000

square foot roof area.

Repairs. Note : Actual repairs are charged to

corrective maintenance.

T.T. s approximately 100,000 square feet

per day.

If required roof repairs indicate that water

is entering the Built-Up Roof or you have reason

to believe the roof insulation is wet, contact

your regional Maintenance Management office and

request a roof moisture survey.

FREQUENCY

T.

2 .

3.

4 .

5.

6 .

7.

8 .

9.

10 .

11 .

PS FORM . n n n

DEC 1982 * / / / C-10 PAGE OF PAGES
HPS-1 14A mv. 2-«o> U.». OEPT. or COMM. BIBLIOGRAPHIC DATA

SHEET (See instructions)

1. PUBLICATION OR

REPORT NO. NBSIR—85/3275

2. Performing Organ. Report No 3. Publication Date

DECEMBER 1985

4. TITLE AND SUBTITLE

U.S. Postal Service Roofing Practices

5. AUTHOR(S)

Walter J. Rossiter, Jr., William C. Cullen, Robert G. Mathey

6. PERFORMING ORGANIZATION (If joint or other than NBS. see instructions)

NATIONAL BUREAU OF STANDARDS

DEPARTMENT OF COMMERCE

WASHINGTON. D.C. 20234

7. Contract/Grant No.

8.

Type of Report & Period Covered

9.

SPONSORING ORGANIZATION NAME AND COMPLETE ADDRESS (Street. City. State, ZIP)

U.S. Postal Service

Design Management Division

Real Estate and Building Department

Washington, D.C. 20260-6415

10.

SUPPLEMENTARY NOTES

]] Document describes a computer program; SF-185, FIPS Software Summary, is attached.

11.

ABSTRACT (A 200-word or less factual summary of most significant information. If document includes a significant

bibliography or literature survey, mention it here) This report reviews the roofing practices of the U.S. Postal Service (USPS). The

USPS has direct responsibility for the design, construction, and maintenance of about

100 million ft^ of roofing. In addition, it leases buildings having approximately

an equal amount of roof area. The approach taken was to obtain information on USPS

roofing practices which could be used as a data base for judging strengths, weaknesses,

and identifying problems. The primary sources of data were: discussions with USPS

personnel; discussions with individuals who provide roofing services to USPS; review

of USPS roofing documents; results of the distribution of questionnaires to USPS staff;

and the determination of training requirements for those involved with roofing.

The review was divided between two major phases of USPS roofing construction

practice. One part involved design, materials, and construction, and the other involved

inspection, maintenance, and repair. The primary topics addressed with regard to the

review on design and construction were general design considerations, training,

responsibility, material selection, and quality control during construction. With

regard to maintenance and repair, the review included general considerations, frequency

of inspections, responsibility, training, maintenance guidelines and manuals, repairs

and when they are conducted, and inspection and maintenance records. The advantages

and limitations of the USPS roofing practices were given, and will form the basis of recommendations for improving USPS roofing practices.

12.

KEY WORDS (Six to twelve entries; alphabetical order; capitalize only proper names; and separate key words by semicolons)

construction, design, lew-sloped roofing, maintenance, material selection, repair,

review, roofs

13.

AVAILABILITY

| | Unlimited

fin For Official Distribution. Do Not Release to NTIS

1 I Order From Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. QOrder From National Technical Information Service (NTIS), Springfield. VA. 22161

14. NO. OF

PRINTED PAGES

15. Price

uSCOMM-OC »0.1 -p»0


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