TPO Roofing Material: A Comprehensive Guide for Homeowners

TPO roofing is a popular choice for both residential and commercial buildings, especially those with flat or low-slope roofs. It’s resistant to tears, mold, and heat, but it doesn’t last as long as some other roofing options. Below, l cover the basics of the TPO roofing material, its pros and cons, costs, and more so homeowners can make an informed decision for their house and budget.

What is TPO Roofing?

TPO, which stands for thermoplastic polyolefin, is a white, reflective, single-ply roofing membrane that is made of polypropylene and ethylene-propylene rubber. It’s popular for homes that have flat or low-slope roofs thanks to its durability, flexibility, and energy efficiency. 

TPO roofing is typically available in thicknesses ranging from 45 mils to 90 mils (.045″ to .09″), with rolls coming in widths of six to 20 feet. The rolls can weigh between 400 and 430 pounds.

Two major benefits of TPO roofing are its ability to reflect ultraviolet (UV) rays, which helps reduce cooling costs, and its thermal emittance ratings. As a result, the material is often used in building projects seeking Leadership in Energy and Environmental Design (LEED) certification.

The History of TPO Roofing

TPO roofing has come a long way since its inception. It was first introduced in the early 1990s as an alternative to more traditional roofing materials, such as polyvinyl chloride (PVC) and ethylene propylene diene monomer (EPDM). As environmental concerns increased and energy efficiency became more important, TPO gained traction as an eco-friendly option due to its recyclable nature and energy-efficient properties.

TPO vs. EPDM Roofing

TPO and EPDM are the two most popular single-ply membrane roofing options. While both materials have their merits, there are some key differences to consider.

EPDM, known for its longevity and durability, has been a popular roofing choice for about 60 years. It typically has a darker color and is installed using fasteners to secure it to the roof decking. EPDM roofs tend to last between 30 and 40 years.

TPO has been in use for about 20 years. It offers higher UV resistance than EPDM and comes in lighter colors that reflect heat, helping to keep building interiors cooler. Roofers usually install TPO with hot air welding, but other roof sealants can be used instead, providing more flexibility in installation methods. However, it doesn’t last quite as long as EPDM — TPO has an average life span of only 20 to 30 years.

Pros and Cons of TPO Roofing

Before deciding on TPO roofing, homeowners should weigh its advantages and disadvantages.

Here’s a look at some of the advantages TPO has over other roofing materials:

• Flexible and strong: TPO is a highly flexible roofing material, which makes it resistant to tears, punctures, and punctures. When its seams are welded properly, it’s much stronger than EPDM.
• Energy-efficient: A cool roofing material, TPO is very resistant to UV rays and heat, reflects sunlight, and it often exceeds ENERGY STAR standards for energy efficiency.
• Environmentally friendly: This roofing material doesn’t contain chlorine and is completely recyclable. 
• Year-round installation: As long as the conditions are dry, TPO can be installed at any time of the year.
• Chemical-resistant: TPO roofs are known for their exceptional resistance to chemical exposure, including acids and oils. This makes them particularly suitable for commercial applications.
• Durable: TPO can handle extreme temperature fluctuations without cracking or becoming brittle.

However, the roofing material has some downsides that need to be noted:

• Shorter life span. TPO roofs only last between 20 and 30 years, compared to 30 to 40 years for EPDM. PVC roofs also tend to have a 20 to 30-year life span, but high-quality PVC membranes can last over 35 years.
• Less fire-resistant: While TPO does have some fire-resistant qualities, it’s not as resistant as PVC roofing. Some adhesives used for TPO can also be flammable. Adding a thick insulation layer between the roof and substrate can improve the roof’s overall fire resistance.
• Installation concerns: Welded TPO should be installed by a professional and experienced welder. Not all roofing companies have the required equipment or experience, and suboptimal installation processes can lead to seam failures.

The technology behind TPO roofing is continually evolving. Recent advancements have focused on improving the longevity and durability of these membranes.

TPO Roofing Cost

While TPO is generally more cost-effective than some other roofing options, the total expense can vary based on several factors, including the roof size, manufacturer, installation processes, roll size, and location.

According to Angi, TPO roofing material costs between $4.50 and $16 per square foot. Installation expenses can range from $3 to $7 per square foot, depending on the condition of the roof and insulation needs.

When choosing a roofing material, homeowners should also think about long-term costs. Thanks to its energy-efficient properties, TPO roofing can significantly lower cooling costs, especially in warmer climates. Over time, these savings can offset the initial investment, making TPO a cost-effective option in the long run.

TPO Roofing Installation Process

I recommend working with a professional roofing contractor for TPO. The job requires specialized tools, welding experience, and overall knowledge about the material to create a watertight seal. Most homeowners don’t have this experience. Installation mistakes can lead to costly repairs. In addition, TPO rolls are heavy, weighing between 400 and 430 pounds, and they can require specific equipment to move safely.

However, if you have the welding experience or you’d like to learn about the installation process, here’s a look at the steps:

1. Prepare the roof: Clean and dry the existing roof surface thoroughly. Moisture can lead to mold and degradation over time. You can leave old shingles or roofing materials in place if they’re not damaged.
2. Install insulation: Apply a layer of rigid polyiso foam insulation, typically 0.5 to 1 inch thick. Cut the insulation to fit around vents, pipes, and other roof protrusions.
3. Set TPO sheets: With the TPO roll perfectly square to one of your roof corners, begin rolling it over the insulation. Overlap subsequent edges with about a foot of material and secure trailing edges with fasteners every 8 to 12 inches.
4. Heat weld seams: Use a specialized heat welding tool to join adjacent panels, creating a watertight seal. Seal any vent edges.
5. Apply TPO to side walls: If the roof has protruding walls, apply TPO to these using resin-based adhesive. Seal all remaining panel overlaps with the heat welder.

(T&G Roofing – Los Angeles)

Homeowners should seek contractors with extensive experience in TPO roofing, verified references, and appropriate licensing and insurance. My recommendation is Champion Roofing.

TPO usually comes in white, but other colors are available if you’d prefer a different shade. This roofing material can also be painted, but homeowners will have to use specialized products designed for TPO roofing, such as single-coat elastomeric paint.

TPO Roofing Maintenance and Repairs

Proper maintenance can significantly extend the life of a TPO roof and prevent costly repairs.

To maintain your roof and its reflective properties, clean it regularly to remove debris. You can use a low-power pressure washer (under 2,000 PSI) and a gentle household cleaner. You should also inspect it twice a year and after storms for signs of damage or wear.

In the event of minor damage, you can generally repair the roof yourself if you have a small heat welder. Clean the area, apply a rounded TPO patch, and then use the welder to fuse the patch edges to the existing roof layer. If you don’t have a small heat welder, specialized adhesive and silicone caulk can work.

If you notice large tears or issues with the seams or flashing, you’re likely going to have to call a professional.

Final Thoughts About TPO Roofing

TPO roofing offers a blend of durability, energy efficiency, and cost-effectiveness for homeowners with flat or low-slope roofs. Its reflective properties and resistance to UV rays make it an excellent choice for energy-conscious homeowners, while its relatively simple installation process and longevity provide good value for money.

Today's Homeowner’s Roofing Methodology

Arranging for a home repair of this scale is going to be a fairly involved project. If you haven’t conducted renovations like this – either via a contractor or on your own – then it can be a bit overwhelming. At Today's Homeowner, we pride ourselves on being able to take all of the guesswork out of the equation for you.

We’ve thoroughly evaluated each roofing type to make your selection process easier. Through exhaustive research into hundreds of different roofing providers throughout the United States and analyses of thousands of individual homeowner experiences, we’ve broken our roof rating system down into the following categories.

All roofs receive an aggregate rating between (0.0) and (1.0). This rating is comprised of six key evaluation criteria, which we’ve outlined below. The rating between (0.0) and (1.0) will correspond to a secondary rating out of five stars, which is displayed more visibly in our articles across this category.

• Durability (.40): With roofs being constantly exposed to the elements, different materials’ relative durability is a key metric that must be considered. If you’re planning on conducting such an extensive upgrade to your home, then your roof’s expected lifespan should be among your primary concerns. We’ve weighed the relative effectiveness of all roofing materials, from asphalt shingles to corrugated metal roofing from different manufacturers in order to determine the most long-lasting options.
• Cost (.25):The nationwide average cost for replacing a 1,500-square-foot roof falls between $6,500 and $16,000. Across the board, you should expect to pay between $4 and $11 per square foot of roofing material. This range will account for your location, material choice and availability, ease of access to and installation of your roof, and far more.
• Contractor Availability (.13): Different roofing contractors in different locales will have varied service offerings. For example, not all roofers are equipped with the requisite skillset and knowledge to install metal roofing. Depending on the kind of roof you want to have installed, your contractor options may be somewhat limited.
• Warranty Offerings (.12): Aside from workmanship warranties, many roofing manufacturers will offer warranties for the panels themselves. Structural failure should be covered by any manufacturing firm for at least 10 years after the installation has been completed, at the panel or shingle’s full value. We grade each roofing type by standard warranty offerings to ensure that you’re covered in this case.
• Ease of Future Maintenance and Upgrades (.05): You should always have contingency plans after any home upgrade. Maintenance is inevitable, no matter the material you use. Whether you’re installing solar panels on a functional existing roof, or are simply replacing a defective panel or shingle, certain materials will be easier to work with than others. Typically, less durable materials will score higher in this category due to their better pliability and workability.
• Customization Options (.05): Any exterior and visible home upgrade is going to have an aesthetic element, aside from functionality. A roof replacement should be an upgrade to the curb appeal of your home. Different types of roofing materials will have varying numbers of style and color options, which factor into our rating.