Reserve studies are just estimates. In these times of inflation and high construction costs you would be prudent to get an more accurate estimate for roof replacement. Then approach the board and decide if there is enough reserves to cover it when it is deemed necessary. Depending on the roofing material, guessing flat roof with tar and asfault, you may be approaching its end of life.
Technically, the reserves should be funded to pay for replacement per the reserve study without a special assessment.
Have you been using the same reserve study people? Maybe it is time to use someone new and ask for a full in person (level 1??) review and do not provide them with anything from past review companies. Reserve study folks tend to base things on past reviews. Easier for them.
Sounds like you actually have a well run association. Nothing wrong with pointing out some areas that need a bit more $.
Final thought. Yes, annual budgets are net zero. You are actually supposed to collect and spend and not make a profit nor incur a loss. In practice some years you may go over budget just because. Trees need more trimming, pool equipment gets abused or doesn’t last as long as expected. I’m looking at you pool pumps and filter cleanings!!
Termite tenting is often overlooked and may not be in reserve study. Some think this should be covered in operating account. Several thousand dollar cost, I think should be reserved for.
Nothing wrong with beefing up the reserves. Not only roof, but spa refinishing is getting expensive. So, it sounds prudent to up the assessments a bit earmarked specifically for reserves. People tend to be more compliant if they feel they are getting a benefit.
I didn’t mean moving up dues every year. That pisses people off. Do a one time increase. Not huge but back it up with data ;). Better to keep assessments same (politically) for several years.