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How To Repair a TPO Roofing System

Posted on October 4, 2023

Estimated Reading Time : 5 Min.

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How To Repair a TPO Roofing System

Though TPO roofing membranes are made to resist UV rays, heat, and chemicals, they are not unsusceptible to damage. Many factors can contribute to the durability of a TPO roof, including the quality of installation, harsh weather events including hail, strong winds, and rain, frequency of maintenance, and its age. 

As a building owner or manager, maintaining and repairing your TPO roof is your responsibility. If your TPO roof has been damaged, this guide can help. From tips on how to repair a TPO roof to the average costs, read through the end for everything you need to know. 

What You Need To Know About TPO Roofing Systems

repair tpo roof

TPO, short for thermoplastic polyolefin, is a single ply roofing membrane that is highly durable and resistant to wear and tear, chemical exposure, and UV rays. It is known for its energy efficiency, cost effectiveness, and ease of installation. TPO roofs are composed of a thermoplastic rubber or synthetic layer with an added protective coating, offering strength and longevity.

While TPO roofs are designed to withstand various environmental elements, they are not immune to damage. Over time, TPO roofing systems can develop issues due to prolonged exposure to harsh weather conditions, poor installation, or general wear. It is important for property owners to be aware of the potential damages that can occur on TPO roofs so they can be addressed promptly. Also, frequent damage and poor maintenance can lead to the reduced lifespan of a TPO roofing system

Common Types of TPO Roof Damage

TPO roofs are more commonly susceptible to the following types of damage. It’s important to routinely inspect your TPO roof for these signs: 

1. Punctures and Tears

Punctures and tears in the TPO membrane are relatively common and can result from various factors, including:

Falling Debris: Tree branches, hail, or other objects can puncture the roofing material, causing damage.

Foot Traffic: Frequent maintenance or inspections can lead to accidental damage from foot traffic.

Sharp Objects: Tools or equipment used on the roof can cause punctures or tears if not handled carefully.

2. Blisters

Blisters can form on the TPO roofing membrane, affecting its appearance and structural integrity. Common causes of blisters include:

Inadequate Installation: Poor quality installations can trap air or moisture within the TPO membrane, leading to blister formation.

Adhesive Breakdown: The breakdown of adhesive bonds can create blisters, especially in areas exposed to extreme temperatures.

3. Seam Separation

TPO roofing systems are typically installed with heat welded seams. If these seams come apart or fail to bond correctly during installation, it can lead to leaks and other issues. Seam separation can be caused by:

Improper Installation: Inadequate heat welding during installation can result in seam separation.

Aging: Over time, the heat welded seams may degrade, leading to separation and potential leaks.

4. Weather Damage

While TPO is highly resistant to UV rays and heat, it can still be affected by severe weather conditions. Over time, weather-related damage can occur due to:

Strong Winds: Intense winds can lift and damage the TPO membrane if it’s not properly adhered.

Heavy Rain: Persistent heavy rain can expose weaknesses in the roofing system and lead to leaks.

Hail: Hailstorms can puncture the TPO membrane, causing significant damage.

5. Aging

As with any roofing material, TPO roofing systems will naturally age over time. This aging process can result in a variety of issues, such as:

Membrane Degradation: The TPO membrane can become brittle, less flexible, and more susceptible to damage as it ages.

Loss of Reflectivity: The reflective surface may lose some of its energy efficient properties with age.

6. Neglected Maintenance

A lack of regular maintenance can exacerbate existing damages and lead to new issues. Neglected maintenance can include:

Debris Accumulation: Leaves, branches, and other debris can accumulate on the roof, trapping moisture and reducing drainage efficiency.

Unaddressed Leaks: Ignoring leaks can lead to further damage to the roof’s underlying structure.

Tools and Materials You’ll Need For TPO Roof Repair

If you choose to repair your TPO roofing system yourself, you’ll need a set of tools and materials. Here’s a list to get you started:


  1. Utility knife
  2. Heat gun
  3. TPO membrane patches
  4. TPO seam primer
  5. TPO seam cleaner
  6. TPO seam roller
  7. Roofing adhesive
  8. Seam rollers

How To Repair a TPO Roof

Now that you’ve identified the damage and gathered your tools and materials, it’s time to start the repair process.

1. Clean the Damaged Area

Begin by cleaning the damaged area. Use TPO seam cleaner to remove any dirt, debris, or contaminants. It’s essential to have a clean surface for proper adhesion.

2. Prime the Area

Apply TPO seam primer to the cleaned area. This will help improve the adhesion of the TPO membrane patches and ensure a long lasting repair.

3. Cut and Apply the Patch

Using your utility knife, cut a TPO membrane patch that is slightly larger than the damaged area. Carefully place the patch over the damaged section and press it down firmly.

4. Heat Weld the Seams

Use a heat gun to heat weld the seams of the patch to the existing TPO membrane. Be sure to follow the manufacturer’s recommendations for temperature and duration.

5. Seam Rolling

After heat welding the seams, use a TPO seam roller to ensure proper adhesion and remove any air bubbles or wrinkles.

6. Check for Leaks

After completing the repair, it’s essential to check for leaks. You can do this by spraying water on the repaired area while looking for any signs of the moisture getting through. If you notice any leaks, repeat the repair process.

The Cost To Repair a TPO Roof

Understanding the potential cost of TPO roof repairs is essential so homeowners can budget accordingly and make informed decisions. The cost of TPO roof repairs will vary depending on a variety of factors, including:

  • Size of the Repair Area: The larger the damaged area, the more materials and labor will be required, potentially increasing the overall cost.
  • The Extent of Damage: If the damage is extensive and requires more complex repairs or a complete section replacement, the cost will be higher.
  • Professional Services: Every roofing contractor has varying prices when it comes to TPO roof repairs, so get multiple quotes before you make a decision.  

Maintenance Tips To Keep Your TPO Roof In Top Shape

To keep your TPO roofing system in good condition, regular maintenance is key. Here are some tips to prevent future issues:

  1. Clean your TPO roof at least twice a year to remove debris and dirt.
  2. Inspect your roof after severe weather events to catch damage early.
  3. Keep overhanging tree branches trimmed to prevent falling debris.

By following these maintenance practices, you can extend the life of your TPO roofing system and minimize the need for repairs.


Repairing your TPO roofing system can seem like a daunting task, but with the right tools, materials, and a step by step approach, it’s a manageable DIY project. Identifying damage early, using the correct techniques, and performing regular maintenance can help ensure the longevity and performance of your TPO roofing system.

Remember, your roof plays a vital role in protecting your home or business, so don’t hesitate to address any issues promptly. With this comprehensive guide, you have the knowledge and tools to tackle TPO roof repairs effectively.

Hire Professional Roofers In Tulsa, OK, To Repair Your TPO Roof 

If your TPO roof is damaged due to any of the factors described above, contact the team of professional roofers in Tulsa, OK, to get it repaired. The team at A. Fricker Roofing & Waterproofing is proficient at handling any type of roof repair, including TPO roof repair. Call us today at (918) 402-7167, and consul with one of our professional roofers.