Thermoplastic Polyolefin (TPO) roofing systems have become a popular choice for commercial and residential buildings due to their affordability, energy efficiency, and ease of installation. However, despite their advantages, TPO roofs are not without challenges. If you’re considering this type of roofing or already have one installed, understanding the most frequent TPO roofing issues and how to prevent them is essential for maintaining a long-lasting, trouble-free roof.

At DT Roofing, we’ve worked with countless property owners in Stephenville, TX who have either encountered or narrowly avoided major TPO roofing problems. With the region’s variable weather patterns and intense UV exposure, it’s critical to recognize these issues early on and take preventive action.

Poor Installation Can Shorten the Lifespan of TPO Roofs

The number one issue we see with TPO roofs is improper installation. TPO roofing membranes must be installed by skilled professionals who understand the nuances of the material. Inadequate seam welding is a particularly common issue—when seams aren’t heat-welded properly, they can come apart under stress from wind, water, or thermal expansion. This leads to leaks that may not be visible right away but can result in significant internal water damage over time.

Another frequent installation issue is poor insulation attachment. If insulation boards under the membrane are not securely fastened or correctly aligned, the roofing system becomes vulnerable to uplift in high winds and will perform poorly in terms of energy efficiency. Make sure your roofing contractor is experienced with TPO systems and follows manufacturer guidelines during installation.

Shrinking and Tearing from UV and Weather Exposure

TPO membranes are designed to be UV-resistant, but over time and under extreme sun exposure, they can begin to shrink or become brittle. Shrinkage causes tension at roof penetrations, seams, and edges, which increases the risk of cracking and tears. In areas like Stephenville, where hot summers are common, this issue tends to occur more quickly if the roof lacks sufficient protection or maintenance.

Tearing can also happen as a result of debris impact during storms or even from frequent foot traffic on the roof. To avoid these problems, regular inspections and protective walk pads in high-traffic areas are crucial. Additionally, using a membrane with a thicker gauge can enhance durability and resist damage more effectively.

Ponding Water Accelerates Roof Deterioration

Flat or low-slope roofs are particularly vulnerable to water pooling if the drainage system isn’t functioning properly. With TPO roofs, prolonged exposure to standing water weakens the membrane and can lead to mold, algae growth, or even penetration of the roof surface. This compromises insulation and increases the chance of leaks.

To prevent this, ensure that your roof has the correct slope and that drains and scuppers are regularly cleaned. A roofing professional can also install tapered insulation systems that direct water toward drainage points, further reducing the risk of ponding.

Flashing Failures Around Roof Penetrations

Flashing is a key component of any roofing system, and with TPO roofs, the quality of the flashing work is especially important. Poorly flashed vents, HVAC units, or skylights can quickly become entry points for water. These areas require precise detailing and reinforced membranes to withstand temperature fluctuations and movement.

Over time, even properly installed flashing can degrade, so annual inspections are essential to catch and repair minor issues before they escalate. A qualified roofer can reseal or replace deteriorated flashing as needed to maintain the roof’s integrity.

Incompatible Repairs and Patches

When issues arise, it’s tempting to use whatever materials are available to make a quick fix. But incompatible repair products can do more harm than good. TPO roofing systems are made to work with specific adhesives, patches, and sealants that match the membrane’s chemical properties. Using the wrong materials can cause adhesion problems or even accelerate membrane breakdown.

Always work with a contractor who is certified to repair TPO systems using manufacturer-approved products. They will understand which methods are appropriate and can ensure your warranty remains intact.

Manufacturer Quality Matters

Not all TPO products are created equal. Some manufacturers use formulas that are more resistant to UV degradation and weathering, while others may prioritize cost over longevity. Choosing a high-quality TPO membrane is just as important as proper installation.

We’ve seen the difference firsthand through our work with trusted brands like CertainTeed and Owens Corning Platinum Preferred Contractors, whose products consistently outperform lower-grade alternatives in Texas’s demanding climate. Investing in a quality system from the beginning pays off in reduced maintenance and longer service life.

Routine Maintenance Is Non-Negotiable

TPO roofs are often marketed as “low maintenance,” but that doesn’t mean “no maintenance.” Routine inspections—especially after storms—are crucial for catching small problems early. A comprehensive maintenance plan includes removing debris, checking seams, testing drainage, and inspecting flashing.

In Stephenville, TX, where severe weather events are not uncommon, roof inspections at least twice a year (preferably spring and fall) can prevent many of the most common problems. It’s always better to address a minor seam issue now than deal with ceiling stains or structural damage later.

TPO roofing systems can offer excellent performance, energy savings, and cost-effectiveness—but only when installed and maintained correctly. By working with knowledgeable professionals and staying proactive with care, you can avoid the most frequent issues and keep your roof in top condition for years to come.

 

Read also our blog: Common Roofing Mistakes That Could Cost You