Should You Install a TPO Roof in 2016?

Business and homeowners who are looking to replace their old roofs will have to balance between a number of factors, such as cost, expected service life, durability, and energy-efficiency when comparing different roofing products.

This dilemma remains particularly stark in the flat roofing market, where the competition between PVC and TPO single ply membranes is going strong, with no clear winner in site.

However, there are some important trends in the TPO roofing market that can help you figure out whether this is the right material for you.


Estimated 1500 s.f. Flat Roof Costs in US Average Flat Roof Costs in US
Rubber Roof
Rubber
$7065
TPO Roof
TPO
$7455
PVC Roof
PVC
$8055

See costs in your area Start Here - Enter Your Zip Code



No Recent Updates or Revisions of ASTM Standards (very technical)

One of the major issues with TPO roofs has been premature aging and seam failures due to prolonged exposure to intense heat. Membrane failures were particularly frequent in the states that experience the most heat and UV radiation all year round. These failures sparked serious concerns from MRCA and NRCA / NRCC, both of which issued advisories back in 2010 and 2011 urging roofing contractors to be aware of these issues and take extra precaution when installing TPO roofs.

Moreover, MRCA called a panel of TPO manufacturers to take a closer look and discuss these issues. Since TPO was documented to be experiencing major issues, it would be expected that both organizations would continue to periodically issue updates for roofing contractors. However there have been no updates since the dates of the initial advisories and discussions (about 5 years).

Here is a “printout” of MRCA TPO Advisory – we added it sicne it has magically dissappeared off MRCA / NRCA / Roofing Contractor Magazine and other prominent roofing publication websites.



ASTM International was also closely involved, and worked on testing the membrane, as well as revising and improving standards for TPO formulations. The last revision of ASTM D6878 TPO standard, dates back to 2011, at which point the organization stated that further tests and research will be conducted and more updates will follow. However, it has been over 5 years, and ASTM has not issued any updates.

In a nutshell, the latest revision of ASTM standard (Revision D6878-11a) required the top ply (weathering surface) of a TPO membrane to be increased by 25% from 12 mil to 15 mil (15 mil = 0.015″).

A typical TPO roof installed today is 60 mil in thickness, thus even by new standards, the weathering surface of the membrane is still only 1/4 of total thickness. However, in the standard’s review article by RCI, the conclusion is that 15 mill is sufficient, and 25% thickness increase provides exponential (not linear) growth on increased membrane life – source.

Do note however, that this report was written by two Carlisle Syntec employees, which is a major manufacturer of TPO in the US, and therefore is “somewhat subjective”.

Other “post-ASTM-revision” concerns that we have are: when will the new standard be applied in the manufacturing process, and how will it affect the cost of TPO roofing?


Estimated 1500 s.f. Flat Roof Costs in US Average Flat Roof Costs in US
Rubber Roof
Rubber
$7065
TPO Roof
TPO
$7455
PVC Roof
PVC
$8055

See costs in your area Start Here - Enter Your Zip Code



1) How do you know if the material installed on your roof was manufactured after “D6878-11a” was issued and meets that standard? Many suppliers are sitting on excessive inventory of “old” materials, and will want to get rid of them as fast as possible.

2) Contractors will want to buy seemingly inexpensive materials, without any concern for which generation it is. Most contractors do not even know anything about these standards.

3) The cost of TPO that meets D6878-11a revision will increase drastically. Manufacturers will have to use significantly more expensive raw materials in the top ply. The bottom ply has no UV or weathering stabilizers, as it is not exposed, and therefore is much cheaper per 1 mil to produce. Hence the bottom ply is so much thicker than the top ply (cost cutting and maximizing profits). How will this affect the final cost to consumer?

Lack of information from TPO manufactures

TPO roofing manufactures have not posted any new information on their websites about TPO performance, simply ignoring the issue. The only company that addresses durability and performance of TPO in detail and provides assurance of their product’s quality is Versico ( a private label for Carlisle). The company provides in depth educational information on TPO for their clients ( source ), which is in sharp contrast to the minimal information found on other manufacturer’s sites.



Recently, GAF put out a comparison study of their TPO products vs other manufacturers, which was supposedly conducted by an independent laboratory. Surprise, surprise GAF’ TPO products significantly outperformed the others. We will review this study in greater detail in a separate post.

Finally, a Google search on “TPO roofing” and related keywords returns no posts in the last 12 months that would address the issue and shed light on whether TPO membranes have been performing well. You do however get many generic articles extolling the benefits of TPO as a durable, inexpensive and energy efficient material.

Savvy consumers should wonder whether this overall silence means that the problems have been addressed, or that they are being swept under the rug, because TPO roofing is such a lucrative and profitable business.

Growing Popularity of TPO roofing membranes

 

 

The competition

It is important to note that TPO continues to grow in popularity both for commercial and residential applications. Currently, it is the fastest growing segment in the commercial roofing industry. There are two factors that account for this:

1. Increased demand for energy efficient materials. An increasing number of consumers are realizing that they can save a significant amount on their energy bills and help the environment by installing cool roofs that are Energy Star Rated.

TPO is designed as a white, solar reflective membrane and is Energy Star rated, rightfully attracting consumers. Its direct competitor, PVC membrane, is also an Energy Star rated, white cool roof, but costs significantly more.

2. Relatively cheap cost compared to its direct competitor, PVC membrane (TPO costs about 25-30% less).

Naturally, more consumers who are looking to save money or have a limited budget will chose TPO over PVC (a more expensive, but time-proven single ply roofing system), since both roofing membranes offer very similar features and benefits.

PVC vs TPO Roofing

PVC membranes have a proven track record of performance for over 30 years, with no recent revisions in the membrane’s formulation. At the same time, lack of information on problems with TPO also contributes to the fact that most consumers cannot distinguish between the two products, and go for the cheaper option.

In the interest of full disclosure and transparency, PVC membranes did have several serious failures in its early days in the 80’s when US manufacturer TROCAL produced an unreinforced sheet that would freeze and glassify in severely cold temperatures, and could shutter on impact (falling branch, tool, etc).

According to several former Trocal managers, the shattering problem mostly affected the PVC membrane imported from Germany – not the sheet produced by Trocal in US. Trocal contained the shattering issues before it was bought by John’s Manville. The buyer took care of all the outstanding warranties. No other major PVC failures have been recorded. Many TROCAL roofs are still in service and are completely watertight.

Showcase of recent TPO roofing projects across the US

Commercial Facility, Leominster, MA

TPO

Boys and Girls Club, Fitchburg, MA

TPO 3

Apogee Instruments, Inc. Utah

TPO

UFCU Disch–Falk Field, University of Texas at Austin

TPO

Exeter Hospital, Exeter, NH

TPO

Do Your Homework

If you are interested in a TPO roof, it is imperative that you get the best product and a reputable contractor who specializes in installation of TPO. Especially if you live in a state that experiences high temperatures, take the time to talk to different roofers and ask what has been their experience with TPO: repairs, problems, material failures, etc.

Also, contact different TPO manufacturers and do research on their websites. Overall, it is best to get a TPO product from a manufacturer that has been in the business for at least 15 years. Doing your homework will enable you to save money and get a quality roof that will serve you well for many years to come.


Estimated 1500 s.f. Flat Roof Costs in US Average Flat Roof Costs in US
Rubber Roof
Rubber
$7065
TPO Roof
TPO
$7455
PVC Roof
PVC
$8055

See costs in your area Start Here - Enter Your Zip Code



14 thoughts on “Should You Install a TPO Roof in 2016?

  1. Dan K

    I ran across this website I am looking at getting a roof replaced on an old court house in albany ga. I am getting bids from several roofing contractors who is biding using tpo. I was reading here that their has been problems with tpo in hot climates. how old is this website and has any improvements been made to tpo to correct these issues. What brand of tpo is the best to use.

    Reply
    1. Leo - Roofer

      Hi Dan,

      This is excellent question. Here is how what’s going on with TPO in hot climates.

      In 2010 there was an advisory (warning) from Midwest Roofing Contractors Association (MRCA), about TPO failures, and a big stink followed this advisory, with several big manufacturers leaving the association and threatening to sue. In the end, MRCA removed the original advisory, but there are numerous copies saved around the web.

      To answer your question is short – there has been a major overhaul of ASTM standard for TPO roofing, dealing with heat, weathering, and thickness (loss). The problem that we see is how do you know which version of material you get? Also this “NEW” material is better than old only on paper, and there is no testing done with it, as it’s too new.

      You can take contractor’s word for it, but 99% of contractors do not even know anything about this issue, and will most likely use older material which s typically on sale at roofing supply.

      My suggestion, if you are unsure, and this is a big risk to take, you may want to look at proven alternatives such as PVC, or if your roof has slope, you may consider EPDM rubber. Cost wise, these are not far apart.

      Check out our TPO vs Rubber guide.

      Good luck.

      Reply
  2. Addison Clark

    It is reliable, cost effective, energy efficient roofing material for ideal roof and the main benefits of TPO Roofing system is that it is very easy to install.

    Reply
  3. fred

    I’m having 28 squares of .60 mil TPO installed today on the low slope roof of a 100 year old commercial building. After reading about the concerns with old material, I had the roofer show me the rolls before installing. The Firestone rolls were date coded, late 2013 so I know I’m getting material manufactured after the standard changed. I plan on coating the roof with an elastomeric coating for TPO every 5 years to hopefully extend the life.

    Reply
    1. Leo - Roofer

      Hi Fred,

      I strongly recommend that you do not coat this new roof until warranty expires. If there are any issues with it, you will lose warranty (both labor and material) and the coating will make it IMPOSSIBLE to perform any repairs. Stay away from coatings for 15 years or all together. Every coating job on flat roof that i’ve seen was peeling and leaking.

      Yo have to let the roof “be tested” for now for at least 1 year, to see if there are any installation problems. If you put coating on, you won’t be able to fix the roof and your roofer will walk away.

      The roof should do its job properly without any coatings anyways.

      Good luck with your roof. Leo.

      Reply
  4. Rob

    In 2010 the Midwest Roofing Contractors Association finished a 7 year study and found that TPO is the most stable of all the single ply’s out there. If you live in a high heat area, you might want to look at GAF manufacturer’s Extreme TPO. Extreme TPO is the best formulation of TPO out there and doesn’t give off toxic chlorine gas when being welded, like PVC does. PVC get’s dirty faster than TPO, and PVC grows mold quite a bit easier than TPO.

    Reply
  5. Craig

    Hi Leo

    Planning on replacing a leaking tar and chip flat roof here in Southern Ontario. Single story, 60×60 roof. My concern is that our weather here varies over the year from -40c to +40c, or in other words, 40 below to 120 above.
    Cost is always an issue of course but I would rather spend the money and get a good roof than have to redo it in 10 years.
    Any suggestions?

    Reply
  6. george lubinski

    Hello. I want to re-roof an extension of my home. It is a flat roof of approximately 750 sf. I have hear good and bad things about TPO. Pro’s like it last for many, many years, many 30; never leaks, etc.
    Cons- Be careful when you walk on TPO, not very good with hear.
    I live in Albuquerque, New Mexico where the hottest days in the summer could reach 98-100 degrees, very little humidity.
    Please give me your recommendations, thank you
    George

    Reply
    1. ruby

      I live in Albuquerque too considering a TPO roof. What did you get? Results? Which roofing compnay did you use?

      Reply
      1. TPO Roofer

        Ruby,

        There was industry chatter (Midwest Roofing Contractors Association issued an Advisory) that TPO membranes do not stand well to heat.

        You may consider a time proven PVC material instead (such as IB Roof or Sarnafil)

        Let me know what you decide to do.

        Reply
  7. Bob

    We are in need of a replacement roof on our flat garage & breezeway. Roofing company proposed White TPO 60 gauge (carlisle-syntec) and a mechanically fasten 1/2″ high density polyiscyanurate board over old roof (about 40 yrs. old) We are in the Toronto Ontario area and wonder if this would be a good replacement.

    Reply
  8. Casey Smith

    Hi, Help! I am struggling to find any recent articles on TPO improvements in recent years. We have a flattish roof on an old house (and located in the back of house as an addition). The tin roof is continuing to fail here and we are being told it has a lot to do with the low pitch. I have been reccomended TPO by 2 different roofers to solve our problem. Any recent advice? Thanks so much!

    Reply
    1. TPO Roofer

      Casey,

      It’s hard to find articles on improvements to TPO because they are not being published and if they do go out, it’s heavily censored by TPO manufacturers (in my opinion) … Even Roofing Contractors Associations (Midwest RCA or MRCA) are “encouraged” to remove an negative press about TPO

      Since you have a sloped roof (albeit slightly), I don’t see a problem of using TPO there.

      BUT if you are not 100% comfortable with using TPO, i recommend using PVC instead – it is a much more “proven” system, in my opinion, and installs EXACTLY the same as TPO – so your roofers should have no problem doing PVC instead of TPO

      Good luck

      Reply

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