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TPO Roofing Systems – Everything You Need to Know

Avoid confusion with overwhelming roofing choices. Understanding the attributes and advantages of a TPO roofing system will help you make your commercial roofing selection with confidence.

newimageroofingatlanta.com gathered essential information on TPO roofing systems, their benefits, installation, potential issues, and how they are manufactured.

What is TPO?

TPO is Thermoplastic Olefin. It is a single-ply roofing membrane used to cover flat and low-slope roofs. TPO roofing systems are made from blending polypropylene and ethylene-propylene rubber reinforced with polyester or fiberglass. The result is a flexible, durable, and energy-efficient roofing material used in residential and commercial applications. Consider the following TPO roofing system advantages:

Durability – TPO roofing systems are well-known for their durability. They can endure extreme weather conditions like:

High winds
Heavy rain
Hail

TPO is resistant to UV radiation and ozone, helping prevent premature degradation while extending your roof’s life.

Energy Efficiency – TPO roofing systems are highly reflective. This allows them to reflect a significant amount of sunlight and heat away from the building. This reflective property leads to lower cooling costs in the summer months, making TPO roofs environmentally friendly and cost-effective.

Cost-Effective – TPO roofing systems are affordable when compared to other roofing materials, like:

PVC
EPDM

They offer a cost-effective solution for initial installation and long-term maintenance. Additionally, their energy efficiency can lead to significant savings on utility bills, further contributing to their cost-effectiveness.

Easy Installation – TPO roofing systems are lightweight and easy to install. This reduces labor costs and installation time, making them a practical choice for new construction and roof replacement projects.

Environmentally Friendly – TPO roofing systems are recyclable, offering a significant advantage for those looking to reduce their environmental footprint. At the end of their lifespan, TPO membranes can be fully recycled into other products, reducing waste in landfills.

Versatility – TPO roofing membranes come in 3 thicknesses (45mil (15 year warranty), 60mil (20 year warranty), and 80mil (30 year warranty) and 3 colors (white, gray, and tan), allowing for customization to suit the aesthetic needs of your structure. This versatility and ability to handle hot and cold climates, makes TPO roofing systems suitable for many applications.

TPO Installation and Maintenance

Installing a TPO roofing system should be done by qualified professionals. Proper installation is critical to ensuring the roof’s longevity and performance. The installation process is typically mechanically attached (screws and iso or TPO plates), fully adhered (glue or low rise foam), or ballasted (held down with gravel or rock). It’s essential to ensure seam integrity and make sure the membrane is securely fastened to prevent leaks.

Regular maintenance is crucial to extend a TPO roofing system’s lifespan. Inspections should be conducted at least twice a year, with additional checks after severe weather events. Maintenance tasks often include cleaning the roof surface, inspecting seams and flashings, and repairing any punctures or tears promptly.

Potential Issues and Solutions

While TPO roofing systems are extremely durable, they are not entirely immune to issues. Some common problems that may arise include the following:

Punctures and Tears – Sharp objects, excessive foot traffic, or falling debris can puncture or tear a TPO membrane. These issues should be repaired promptly to prevent water infiltration.

Seam Failures – Regular seam inspections are essential to catch and repair any developing issues (weather related, foot traffic, ponding water, etc.).

Read more about roof maintenance plans at newimageroofingatlanta.com/residential-roofing-maintenance-plans-protecting-your-investment/

How is TPO Manufactured

Thermoplastic Olefin (TPO) roofing membranes are manufactured through a process combining multiple materials to create a flexible, durable, and thermoplastic roofing material. This process involves the following key steps:

Raw Material Selection – TPO membrane production begins with the selection of raw materials. A TPO membrane’s primary components are polypropylene and ethylene-propylene rubber. These materials are selected for their flexibility, durability, and resistance to environmental factors.

Polymer Blending – Raw materials (polypropylene and ethylene-propylene rubber) are blended together in predefined ratios to achieve TPO membrane’s desired characteristics. The blending process ensures the polymer’s uniform distribution, creating a homogenous mixture.

Reinforcement – To enhance TPO’s strength and dimensional stability, a reinforcement layer is added. This reinforcement layer is typically made of polyester or fiberglass fabric. It is embedded within the polymer blend during the manufacturing process.

Extrusion – The blended TPO compound is extruded through a die, forming a continuous sheet of TPO membrane. The thickness of the membrane can be controlled during the extrusion process by adjusting the die’s settings.

Calendering – After extrusion, the TPO membrane may go through a calendering process. This involves passing the membrane through a set of heated rollers, smoothing out the surface and adjusting the thickness to precise and consistent specifications.

Lamination (Optional) – Some TPO membranes undergo a lamination process, where an additional layer of TPO material is added to one side of the membrane. This enhances UV resistance and weatherability.

Cooling – The extruded and calendared TPO membrane is cooled to solidify the material and prepare it for further processing.

Cutting and Rolling – Once the TPO membrane has cooled and solidified, it is cut into predefined rolls. These rolls are then packaged and prepared for distribution to roofing contractors and manufacturers.

Quality Control – Throughout the manufacturing process, quality control measures ensure the TPO membrane meets specific industry standards and performance criteria. This includes testing for thickness uniformity, tensile strength, flexibility, and other desired properties.

Customization – Manufacturers can customize TPO membranes by adding colorants or pigments to achieve the desired color. Customization options allow the TPO roofing membranes to match the aesthetic requirements of multiple roofing projects.

Packaging – The finished TPO membrane rolls are packaged, labeled, and prepared for shipment to distributors or roofing contractors.

TPO roofing membranes are designed to offer excellent weather resistance, UV stability, flexibility, and ease of installation. Their thermoplastic nature means they can be heat-welded together during installation to create strong seams, which further enhance their waterproofing capabilities. Additionally, TPO roofing systems are known for their energy-efficient and reflective properties, making them the roofing industry’s “Gold Standard” for residential and commercial roofing applications.

Visit this YouTube channel for more information and valuable tips about this and other roofing systems.

TPO Roofing Membrane

In this article, you discovered essential information on TPO, its advantages, installation, problems, and manufacturing.

Your decision to install a TPO roofing membrane can provide decades of protection and energy savings for your residential or commercial structure.

Failure to fully evaluate and consider the pros and cons of the roofing systems available for your structure may leave you with an inappropriate roof.

Sources:
energystar.gov/products/cool_roofs_emissivity
epa.gov/sites/default/files/2017-05/documents/reducing_urban_heat_islands_ch_4.pdf
tporoofing.org/tpo-roofing-systems/
ibhs.org/guidance/ricowi-roof-guide-single-ply-membrane/

New Image Roofing Atlanta

2020 Howell Mill Rd NW Suite 232
Atlanta, GA 30318
(404) 680-0041

September 25, 2023/by Hayley Mace

EPDM Roofing Systems – Everything You Need to Know

Commercial Roofing

Avoid installing the wrong roofing system on your commercial building. Knowing the benefits of an EPDM roofing system and how one protects your structure will help you determine which commercial roofing system is best for your needs.

newimageroofingatlanta.com gathered essential information on EPDM roofing systems, their compelling benefits, and how they are manufactured.

What is EPDM?

EPDM (Ethylene Propylene Diene Monomer) is a synthetic rubber material commonly used in multiple applications, including roofing systems. This material is renowned for its excellent durability, weather resistance, and versatility. EPDM roofing membranes are widely used in the construction industry to install flat or low-slope roofs on industrial, commercial, and residential buildings. Consider the following benefits of EPDM roofing:

Exceptional Durability – One of the primary reasons for selecting an EPDM roofing system is its exceptional durability. EPDM is a synthetic rubber membrane that can withstand a range of environmental stressors, including:

Exposure to UV rays
Extreme temperatures
Inclement weather conditions

EPDM roofs have a proven track record of longevity. They can last anywhere from 20 to 30 years or more with proper maintenance, making them a durable, reliable, and cost-effective roofing solution.

Superior Weather Resistance – EPDM roofing systems are renowned for their ability to withstand a range of severe weather conditions. They are highly resistant to damage from rain, snow, hail, and ice. EPDM membranes are designed to expand and contract with temperature fluctuations, ensuring they remain intact and effective over time. This weather resistance provides unparalleled peace of mind to property owners, knowing that their roofs can stand up to the elements.

Energy Efficiency – EPDM roofs are excellent at reflecting sunlight and heat away from the structure, contributing to significant energy savings. EPDM roofing’s reflective nature helps reduce the cooling load on the building during hot summer months, leading to lower energy bills. EPDM roofing materials are often completely recyclable, further promoting environmental sustainability and reducing your carbon footprint (associated with cooling systems).

Low Maintenance Requirements – Maintaining an EPDM roofing system is straightforward, and its low maintenance requirements are another significant advantage. Routine inspections and occasional cleaning are typically all that’s required to keep your EPDM roof in excellent condition. EPDM’s resistance to mold and algae growth helps maintain its pristine appearance and structural integrity, reducing the need for frequent repairs or replacements.

Cost-Effective Installation – EPDM roofing systems are known for their cost-effective installation. They are lightweight and can be installed quickly, which leads to reduced labor costs. Additionally, EPDM membranes come in large rolls, allowing for seamless installation with minimal seams or joints, reducing the risk of leaks over time. This efficiency in installation can save property owners substantial time and money.

Eco-Friendly Alternative – EPDM roofing systems are an eco-friendly roofing option. EPDM membranes are typically composed of recyclable materials and can be fully repurposed at the end of their useful life. This sustainable aspect aligns with the growing demand for environmentally responsible construction practices.

Note: EPDM roofs also contribute to energy efficiency, reducing the carbon footprint of the building and helping property owners reduce their environmental impact.

Versatility and Adaptability – EPDM roofing systems are incredibly versatile and adaptable to multiple architectural styles and roof designs. They can be installed on flat roofs, low-slope roofs, or even steep-slope roofs. EPDM roofing materials are available in different thicknesses and can be fully adhered, mechanically fastened, or ballasted, depending on your project’s specific needs. This versatility makes EPDM a suitable choice for both new construction and roof replacement projects.

See if an EPDM roofing system is appropriate for your structure by requesting a free roof inspection.

How is EPDM Manufactured?

To fully understand how EPDM offers so many incredible benefits, here’s an overview of how EPDM roofing membranes are manufactured:

Raw Materials – EPDM is made from a combination of several raw materials, including:

Ethylene
Propylene
Diene monomers

These materials are derived from petrochemical sources. The specific formulations and additives may vary depending on the manufacturer and the intended application.

Polymerization – The manufacturing process begins with the polymerization of the raw materials. This process chemically bonds the ethylene, propylene, and diene monomers to create the EPDM polymer. The polymerization is typically done using catalysts and heat.

Vulcanization – After the EPDM polymer is formed, it needs to be vulcanized to achieve its desired physical properties. Vulcanization is a polymer cross-linking process that increases strength, durability, and heat resistance. This is typically achieved by adding sulfur and using heat or chemical accelerators.

Processing – The vulcanized EPDM rubber is processed into the desired form, which is often in large sheets or rolls. During this stage, multiple additives may be mixed in to enhance specific properties, like UV resistance, flexibility, and/or flame resistance.

Sheet Formation – The EPDM rubber is then processed into sheets or rolls at a desired thickness. These sheets are typically available in various widths and lengths to suit different roofing applications.

Curing – The EPDM sheets may go through a curing process to ensure that they are fully set and ready for use. This process typically involves applying heat to further improve their physical properties.

Reinforcement – Some EPDM roofing membranes may have reinforcement layers incorporated into them. These reinforcement layers, often made of polyester or fiberglass, are embedded within the EPDM sheets (creating a composite) to provide additional strength and stability.

Final Quality Control – Before the EPDM roofing material is packaged and shipped to customers, it undergoes multiple rigorous quality control checks to ensure that it meets industry standards and specifications. This includes checking for defects, thickness consistency, and quality.

Once the EPDM roofing material is manufactured and quality-controlled, it is ready for distribution and installation on roofs. EPDM roofing systems are known for their ease of installation, as the sheets can be adhered to the roof substrate using various methods, like adhesive, ballast, or mechanical fasteners.

Visit and subscribe to this commercial and residential roofing contractor’s YouTube channel for short informational videos on multiple roofing topics.

EPDM Roofing Systems

In this article, you discovered what EPDM is, its multiple benefits, and how it is manufactured for roofing systems.

Understanding what EPDM is, its valuable benefits, and its extreme versatility will contribute to making informed decisions when installing or replacing your roofing system.

Failure to educate yourself about different roofing systems can lead to an inadequate or problematic roof being installed on your structure with costly consequences.

Sources:
energystar.gov/products/building_products/roof_products/other_types_roofing_that_can_save_energy
gccds.msstate.edu/research/altconstruction/roof/roof.pdf
vtechworks.lib.vt.edu/bitstream/handle/10919/109460/polymers-14-01308.pdf?sequence=1&isAllowed=y
mulehide.com/en-us/News-Events/Blog/why-choose-epdm