Seam Failures in TPO Roofing: Causes and Prevention

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Seam Failures in TPO Roofing: Causes and Prevention

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What to do if Your TPO Roofing System Has Seam Failures

Flat roofing systems like thermoplastic polyolefin (TPO) have to be kept in good condition or it can lead to problems very quickly. Unlike pitched roofs there's a greater chance of ponding water and drainage issues. These both can both steam from the same problem - seam failures. Seam failures are one of the most common TPO roofing problems, but it can be repaired and maintenance can prevent it from happening again.

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Why Seams Fail on TPO Roofs

TPO seams fail because they aren't fully adhered. The material is heat welded, however it can still come apart. There can be a few reasons why this occurs. Common causes for seam failures include:

Some of the most common issues we come across include:

Improper Installation – As with other common roofing problems, poor installation is a main culprit for seam failures in TPO roofing membranes. Roofing contractors without experience in the material may mishandle the TPO installation, particularly the heat welding.
Harsh Weather – Storms with heavy winds and hard rain can put too much stress on the seams for them to handle.
Extreme Environments – Roofing exposed to extreme temperatures, humidity levels, rainfall, or winds on a regular basis is more prone to seam failures.
Prolonged Exposure to UV Rays – Constant sun exposure can break down materials over time. Most TPO materials deflect UV radiation because they contain UV stabilizers within the membrane.
Foot Traffic – Flat roofs with rooftop equipment that requires regular servicing may experience seam failures due to frequent foot traffic.

Most Common Problems That Occur When TPO Membranes Have Seam Failures

There are a few serious reported problems that can easily occur if there are seam failures:

The Roofing Won't Drain Properly – When seams allow moisture to come through, water accumulates on the roof and can damage the roofing material.
Leaks and Water Damage – If water damage becomes severe, it can lead to structural issues that compromise other parts of the home or building.
Reduced Energy Efficiency – Gaps in failed seams allow heat and cold to seep through, making temperature regulation more difficult. Additionally, TPO roofing with seam failures reflects fewer heat-producing UV rays.

Repairing TPO Roofing Membranes With Seam Failures

The good news for building owners is that a roofer that knows what it's doing can make the necessary repairs and fix the damage.

Have a Professional Roofing Contractor Inspect the Roof

A roofer who is familiar with this type of roofing material can determine what's behind the seam failures so that the cause can be fixed and the problem is less likely to occur again. The inspection should also look beyond the roof surface to identify any potential underlying damage.

Address the Cause and Repair the Roof

The repair process should encompass two things: addressing the factors that caused the problem and repairing any damage. To repair the seams custom patches will need to be cut and heat welded into place over them. It's extremely important to have the patches installed by a professional who has experience with TPO membrane roofing.

Make Regular Inspections Part of the Maintenance

To avoid significant damage from seam failures TPO roofs need regular inspections to spot problems quickly. If you live in an area with temperate weather and there's less to no foot traffic on the roof, then annual inspections should be enough. For those in areas with inclement weather and/or a lot of foot traffic, semi-annual or quarterly inspections may be needed.

We're One of the Highest Rated
Roofers in Austin for a Reason

At LOA, we believe success is defined by customer satisfaction. We're proud to say we have some of the happiest clients in the roofing industry! You can find hundreds of 5-star reviews like the ones below online.

"I got three inspections and decided to use LOA Construction for a new roof. LOA’s Dan Harvey worked with my insurance inspector to make sure all the hail/wind damage was accounted for, gave us a good choice of shingle colors, and was great at communicating. The workers did quality work, found and repaired rotted wood and cleaned up. Highly recommend!"

— Brian McFarlin, 5-Star Google Review

"Brandon at LOA construction made replacement of our roof very easy. He was the only roofing contractor that I could find that would work directly with our insurance company. They showed up on time and made the whole process very easy. And we have a great looking high quality roof! I Would definitely recommend them to anyone looking for a new roof. Give them a call if you need a roof or think you might have wind or hail damage. I had several other bids that were higher cost and didn't think our insurance would cover it. Our insurance did cover it, I think they were just unwilling to work with the insurance company. Not Brandon, not only was he will to work with our insurance he met with the adjuster and made the whole thing a breeze. Thanks again LOA and Brandon!!!!"

— Mike A., 5-Star Google Review

LOA Construction has exceeded my expectations again. This is the second roof installation with them and I couldn't be happier. Specifically, Tyler Griffiths is professional, attentive, and made the entire process of working with my insurance company effortless. My tenant sent a glowing account of their experience as well. Knowing it was a rental, they still diligently protected all property and plants. They were on time every time and went out of their way to not inconvenience the residents. LOA Construction has integrity and takes pride in their work. I couldn't recommend them more.

— Sheri Moran

"Worked with Zac and his team. Zac did an outstanding job working with the insurance company to ensure all damage was covered. Roof and gutters installed each were on time and all work was top of the line. This is a company that really does put the customer first. With out question I would recommend loa construction and roofing."

— Tony Smith, 5-Star Google Review

From the very start, I knew I was in good hands. The professionalism was top-notch, but most important, was the caring attitude of the project manager, Dan Harvey, the roofing supervisor, Ambrocio, and the roofing crew. They made sure every detail was covered. They are definitely an asset to LOA Construction. I highly recommend them. Dennis and Suzy S

— Dennis Sanger

Andrew was very great at getting myself and my wife all the information and getting us started from start to completion. His workers were friendly and professional. If ever I had to contact him, he was quick to respond back. We are very happy with the finished product. Yes, I would and have recommended him and his company to get their work by LOA Construction and Austin. Andrew made sure my wife would be satisfied with whatever roof she liked. Can't thank you enough Andrew and LOA Construction.

— Paul Coleman

As a first time home owner with no experience in how to make claims and start the process of getting a new roof I was scared to the point of avoiding what needed to get done after the bad hail storm. August Walker did an amazing job walking me through each step along the way. He answered all my questions and calmed my concerns. They inspected my roof and drove from Austin to Belton just to be there with the ins inspector, and followed up with me in person after the roof was installed. He also made a special trip back to drop off samples! I’m grateful to August and LOA construction for being highly professional and friendly!

— Angela Baker

From start to finish Lee and his team took great care of us. He made us feel comfortable during the process and answered any and all questions we had. I would definitely them recommend to anyone.

— Taneisha Jones

Arthur Harris and his team with LOA Construction did an excellent job on our roof. They finished it in one day. Arthur was very good in explaining all the information to us.

— Crystal Hill

Will, has been so awesome and easy to work with he gets everything we want done the way we want it and also keeps us updated as we are over the road truck drivers !!! Hands down to LOA Construction for their great service and great customer service !!!

— Tanya Dudkiewicz

Dan Harvey is Very Knowledgeable and directed me straight to the products that will save us money in the next 3 years the savings on energy costs alone will pay for the installation itself. I highly recommend LOA Construction and Dan Harvey! Actual Customer Jefferson Fara

— Jefferson Fara

Mark from LOA roofing was very professional from the git, the initial estimate process, he quickly identified all the issues that needed to be addressed. The company was very prompt, to coordinate the crew, and for a very reasonable price, got my roof repaired without any hassle. They also took care of all the cleaning, so that it all looked like nothing happened. I would recommend Mark from LOA to anyone needing a roof repair, with no kind of hesitation.

— Ale León

Loa Construction provides quality services in installing roof and related repairs. I’ll recommend it to my friends and family.

— Peijie Li

Thanks to Landon Wells of LOA Construction for the beautiful new roof! It was all completed in one day including a meticulous clean up job afterwards. The workers were all polite and professional. Landon made sure everything went smoothly and that all of our questions were answered. I am thrilled with our new roof. I would definitely recommend Landon and LOA Construction to all of my friends and family. Thank you Landon!

— Renee Johnson

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Dedicated to excellence, our Austin roofing company ensures quality in every project. Contact our skilled Central Texas roofers for a same-day, hassle-free inspection. Call +1 (512) 375-3654 to book your free inspection.