John Kenney, CPRC, CEO, Cotney Consulting Group
Quality control in construction, especially in roofing, is often misunderstood or overlooked. Unfortunately, it can become a formality – reduced to paperwork that project managers frequently delegate without much direct involvement. However, the true essence of quality control extends far beyond a checklist or a signature on a form. It’s about delivering a final product that meets and exceeds the client’s standards, complies with building codes and reflects the contractor’s commitment to excellence.
The success of a roofing project lies in implementing robust quality control processes that involve every team member. From the project manager down to the field crew – a top-to-bottom commitment to quality is essential. Let’s explore the nuances of quality control and understand its importance through real-life case studies and best practices in roofing projects.
While documentation is vital for verifying that proper quality procedures are followed, it alone cannot transform subpar work into quality craftsmanship. Quality control in roofing projects should focus on three primary objectives: meeting the client’s standards, adhering to local building codes and fulfilling the contractor’s internal quality expectations. These standards extend to various aspects of the roof installation, including its functionality, durability and
suitability for the intended purpose.
For roofing contractors, this means ensuring that the materials and equipment installed meet the required quality specifications. A paper trail alone will not suffice; a comprehensive approach encompassing every project step is necessary. The project manager must actively oversee quality control, setting clear expectations and ensuring the team understands the standards they need to achieve.
One of the critical aspects of quality control is fostering pride in workmanship among workers. Poor quality in construction often results from a lack of pride in the work being installed. Whether it’s improperly installed membrane or shingles, uneven surfaces or poorly fitted flashing, signs of poor quality often indicate a deeper issue with the team’s mindset. Quality craftsmanship stems from a sense of ownership and pride in one’s work, regardless of whether the final installation is visible or hidden.
A valuable lesson comes from a foreman known for their dedication to doing the job right. On a particular project, the client was more concerned with early completion than structural integrity and aesthetics, prompting the project manager to advise the foreman to take shortcuts on the finishing. The foreman, however, insisted on delivering the best quality possible. “There is only one way to do a project,” he said, “and that is to do it right.” This approach is the
hallmark of quality control – every task should be performed with pride and attention to detail, irrespective of how visible the final product will be.
Roofing projects present unique quality control challenges compared to other construction types. Each roofing project has varying materials, specifications and conditions. Factors such as extreme weather, site accessibility and changing personnel can affect the quality of work. To maintain high standards, contractors must be proactive in their quality control efforts.
■ Changing Environmental Conditions: Unlike factory production, where conditions are controlled, roofing projects are subject to variable weather, site conditions and temperature fluctuations. Quality control must adapt to these changes, requiring the roofing crew to be vigilant and flexible.
■ Diverse Teams: With workers and subcontractors often changing from one project to the next, maintaining consistency in workmanship becomes challenging. Each new team member must be thoroughly briefed on the project’s quality expectations and provided with the necessary training.
Quality control begins at the top and the project manager is pivotal in establishing a quality-focused culture. The project manager must provide clear guidance on quality requirements and set the tone for the team. During site visits, the project manager should assess completed work and ongoing tasks to ensure compliance with the quality plan.
Delegating quality control tasks is essential but does not absolve the project manager of ultimate responsibility. Each team member, from supervisors to field workers, must understand their role in ensuring quality. Foreman and crew members should take ownership of their sections, overseeing the materials and workmanship.
A quality plan should be developed at the project’s outset, detailing the processes and requirements for each phase. It is a roadmap outlining inspection points, checklists and responsibilities. While the quality plan is a crucial document, it should be concise – often no more than a few pages – and accompanied by relevant specifications, inspection forms and backup documentation. The quality plan must empower the contractor to control quality, minimizing unnecessary delays caused by awaiting client approvals. It should clearly define who is responsible for each quality check and under what circumstances work can proceed without direct client inspection.
The effectiveness of quality documentation hinges on its simplicity and relevance. The documentation process should not be burdensome or overly time-consuming. Foreman and crew members must understand that filling out a checklist is not a substitute for a thorough inspection. Documentation is about recording the quality process, not just ticking boxes.
Standardized forms and templates should be adapted to each project rather than merely carried over from previous jobs. Additionally, the documentation should align with client expectations, as agreed upon at the project’s start, to prevent the need for revisions later.
Non-conformance reports (NCRs) are essential tools for addressing quality issues. While contractors may be hesitant to issue NCRs for fear of blame, these reports highlight problems, identify corrective actions and prevent future occurrences. Addressing mistakes openly allows for cost tracking, a better understanding of the issue’s impact and timely resolution.
In some cases, non-conforming work may need to be removed and reinstalled. Although it may be a difficult decision, this course of action often sends a powerful message: promoting a quality culture and ensuring that future work meets the required standards is frequently cheaper than going to litigation and trying to resolve.
Quality control isn’t just about workmanship; it also extends to the materials used. Roofing contractors must verify that materials meet project specifications and tolerances. Materials should be inspected upon delivery and any defects or non-compliance must be documented and communicated to suppliers. Establishing clear protocols for handling defective materials ensures they do not inadvertently get used in the project.
Achieving quality in roofing projects requires skilled craftsmen and knowledgeable supervisory staff. Investing in training programs for workers, supervisors and project managers is crucial. Providing ongoing education about quality standards and best practices strengthens the team’s ability to deliver high-quality roofing installations consistently.
Subcontractors also play a critical role in quality control. Contractors must ensure subcontractors understand the project’s quality requirements and monitor their work to ensure compliance. When issues arise, non-conformance reports help track and resolve problems while fostering open communication with subcontractors.
Quality control in roofing projects is more than a set of procedures or paperwork – it is a mindset and a culture. It requires a commitment from every project team level, led by the project manager, to produce a product that meets and exceeds client expectations. By implementing a comprehensive quality plan, conducting regular inspections, documenting processes and addressing issues transparently, roofing contractors can uphold their reputation for excellence.
Ultimately, quality control is about delivering a final product that stands the test of time, providing functionality, durability and client satisfaction. Roofing contractors can ensure success and profitability in every project they undertake by taking pride in their work, fostering a culture of quality and being proactive in addressing challenges.
John Kenney, CPRC has over 50 years of experience in the roofing industry. He started his career by working as a roofing apprentice at a family business in the Northeast and worked his way up to operating multiple Top 100 Roofing Contractors. As CEO, John is intimately familiar with all aspects of roofing production, estimating and operations. If you would like further information on this or another subject, you can contact John at jkenney@cotneyconsulting.com.
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