Single-ply roofing systems like TPO, PVC, and EPDM have become a staple in the commercial roofing world. They’re lightweight, durable, energy-efficient, and relatively easy to install. But even the best roofing systems aren’t immune to problems over time. Whether it’s caused by weather, installation errors, or regular wear and tear, understanding how to troubleshoot issues before they become major repairs can save you thousands in the long run.
Here’s what to watch for (and what to do) when your single-ply roof starts showing signs of trouble.
Membrane Shrinkage Can Lead to Costly Failures
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To stay ahead of the issue, monitor the perimeter of your roof and areas around penetrations for signs of pulling or curling. If caught early, your contractor may be able to reinforce the membrane or re-flash affected areas. Left unchecked, though, shrinkage can mean serious repairs—or even full replacement.
Foot Traffic and Debris Can Cause Punctures and Tears
Single-ply roofs are tough, but they’re not invincible. Rooftop foot traffic, service crews, dropped tools, and flying debris during storms can all lead to punctures or cuts in the membrane. Even small punctures can allow moisture to reach the insulation layer below, leading to saturation, mold, and reduced thermal performance.
Keep an eye on areas with heavy foot traffic and consider installing walkway pads near rooftop equipment. After storms or maintenance visits, inspect the membrane for new damage. Small holes can often be patched, but widespread damage may signal larger problems.
Seam Failures Are a Common Leak Source
Seams are critical to the integrity of any single-ply roof. Whether they’re heat-welded (TPO, PVC) or adhered (EPDM), seams are a potential weak spot; especially if not installed properly or subjected to years of UV exposure.
Watch for areas where seams appear bubbled, lifted, or separated. A simple probe test can often detect loosened seams. Address these quickly, as a failed seam can let in water that migrates far beyond the point of entry. For best practices on seam repairs, consult the Single Ply Roofing Industry (SPRI) guidelines.
Ponding Water Can Accelerate Roof Degradation
Flat and low-slope roofs should be designed with proper drainage in mind, but over time, things shift. Settling, insulation compression, and clogged drains can lead to ponding water. Water that remains more than 48 hours after rainfall can damage the membrane, promote algae growth, and increase UV degradation.
If you notice standing water, act quickly. Cleaning out drains may be a simple fix. If ponding is recurring, solutions like tapered insulation or secondary drains may be needed. Don’t wait—long-term ponding can void warranties and compromise your roof’s performance.
Flashing Around Penetrations Is a Frequent Failure Point
Anywhere your roofing system must be sealed around an object – like a vent, HVAC unit, or skylight – is a potential vulnerability. Flashing that cracks, pulls away, or lifts from the membrane can open the door for leaks and interior damage.
Check flashing details regularly. Look for gaps, tears, or dried-out sealant. These areas can often be patched or re-sealed without major cost if caught early. But if several flashings fail at once, or if there’s visible water damage inside, it may point to more systemic issues with the roof’s installation or age.
Protect Your Investment with Regular Inspections
Single-ply roofs are designed to last 20–30 years when maintained properly—but that lifespan depends on regular inspections and timely repairs. Routine maintenance not only extends the life of your roof, it helps you avoid costly surprises when the next storm hits.
Need help? The National Roofing Contractors Association (NRCA) and Choice Roof Contractor Group are excellent resources for finding commercial roofing service providers who have experience with single-ply systems.
