TPO Roofing and Repairs

If you manage a commercial building or own a large flat-roofed property, you’ve probably heard about TPO roofing. TPO, or Thermoplastic Polyolefin, is a single-ply membrane roofing material commonly used on low-slope or flat roofs. Known for its durability and energy efficiency, TPO roofing is a popular choice among building owners and contractors.

However, like all roofing materials, TPO systems can develop issues over time. Understanding the pros and cons, common problems, and repair options can help you protect your investment and extend the life of your roof.

At Hardesty Roofing, we’ve been repairing and maintaining TPO roofs across Richmond, Charlottesville, the Tri-Cities, Northern Neck, and Tidewater since 1990. If you think your TPO roof may need attention, we’re here to help.

What Makes TPO Roofing a Popular Choice?

TPO roofing systems offer many advantages. First and foremost, they are cost-effective. TPO costs less than PVC or EPDM roofing but still offers solid performance and protection.

Another benefit is energy efficiency. TPO membranes are typically white or light-colored, reflecting sunlight and reducing the heat load on a building. As a result, your HVAC system doesn’t have to work as hard, which can lower utility bills.

TPO also has strong resistance to UV rays, punctures, and chemicals. It performs well in a variety of climates, and it has a reputation for being environmentally friendly, as many TPO systems are recyclable.

Installation is relatively straightforward, especially on large commercial roofs. Because of its flexibility, it works well on buildings with various roof shapes and penetrations.

The Drawbacks of TPO Roofing

Although TPO has many benefits, no roofing system is perfect. One downside is that TPO membranes vary in quality, depending on the manufacturer. Some lower-cost versions may degrade faster or be more prone to cracking over time.

Additionally, TPO roofs can be sensitive to heat welding mistakes during installation. If seams are not properly welded, the membrane may peel or split, which eventually leads to leaks.

Over time, exposure to standing water, extreme temperatures, or foot traffic can wear down the surface. Regular maintenance is required to catch issues early and avoid major repairs.

Common TPO Roofing Problems

Even the best-installed TPO roofs may develop issues as they age. Identifying these early can prevent costly water damage and protect your building’s interior.

Seam Failures

Seams are the most vulnerable part of any TPO roof. Since TPO is a single-ply system, we join sheets together using heat-welded seams. Over time, these seams can fail due to poor installation, aging materials, or the building's movement. When seams open up, water can enter and soak into the insulation or decking below.

To fix this, technicians re-weld the seams using hot-air equipment or apply specialized seam tapes or adhesives.

Punctures and Tears

Flat roofs get more foot traffic, HVAC equipment, and debris. These can lead to punctures or small tears in the TPO membrane. If left unaddressed, water will eventually seep through the layers and cause structural problems.

We can typically patch smaller punctures with compatible TPO materials and perform heat-seal repairs to achieve a watertight finish.

Ponding Water

Flat and low-slope roofs often struggle with drainage. If water remains on the surface for more than 48 hours after a rainstorm, it can stress the membrane and cause premature wear.

The fix might involve improving drainage, adding tapered insulation, or resurfacing low spots to eliminate pooling.

UV Degradation

Although TPO resists sunlight by design, extended exposure to harsh UV rays can cause the surface to become brittle. This is more likely to happen on older roofs or those with lower-quality materials.

Repairs may include adding a coating, replacing degraded sections, or installing a reflective top layer to improve longevity.

Flashing Failures

TPO roofs often include flashing around HVAC units, vents, and skylights. Improper flashing or damage over time can create entry points for water. Have your roofing contractor inspect these areas carefully during every service visit.

Repairs typically involve removing the failed flashing and replacing it with new materials that are heat-welded or sealed to the existing membrane.

How TPO Roof Repairs Work

The first step in any repair process is a thorough inspection. At Hardesty Roofing, we begin by identifying the exact source of the leak or damage. Sometimes water enters in one spot but travels along the membrane before becoming visible inside the building.

Once we identify the issue, we use tools specifically designed for TPO systems to complete the repair. That may include hot-air welders, patches, seam rollers, and adhesives. All repairs are performed with compatible materials to ensure long-term success.

If the roof is in otherwise good condition, isolated repairs can extend its service life by several years. However, if problems are widespread, it might be time to consider a larger restoration or full replacement.

When Repairs Are Not Enough

TPO roofs generally last 15 to 25 years, depending on material quality and maintenance. If your roof is nearing the end of its lifespan and showing signs of age, regular repairs may no longer be sufficient.

You may notice multiple seam failures, large areas of discoloration, or ponding water in several places. These are signs that the system is nearing failure. At this point, a replacement may be more cost-effective than continuing to patch.

The good news is that we can often complete a TPO roof replacement without tearing off the entire existing system. In many cases, a new membrane can be installed over the existing roof using a recovery board or insulation layer.

How Hardesty Roofing Can Help

With over 30 years of experience, Hardesty Roofing is your trusted partner for TPO roof repair and maintenance. We collaborate with leading manufacturers to ensure that the materials we use are durable, reliable, and fully compatible with your existing system.

Our team is trained in commercial flat roofing systems and understands the unique challenges that come with TPO. Whether your property is a warehouse, office, institutional facility, or retail location, we have the tools and knowledge to get the job done right.

We serve clients across Richmond, Charlottesville, the Tri-Cities, Northern Neck, and Tidewater with fast response times and expert service. From small puncture repairs to complete membrane replacements, we provide honest evaluations and dependable results.

Schedule a TPO Roof Inspection Today

If your TPO roof is leaking, aging, or showing signs of wear, now is the time to act. Hardesty Roofing offers professional inspection and repair services that can restore performance and extend the life of your roof.

Contact us today to schedule a TPO roof evaluation. We will provide a clear report of our findings, explain your options, and recommend the best course of action. With the right care, your TPO roof can continue to protect your building for many years to come.