Causes and Prevention for Commercial Roof Punctures and Tears
“They are the most common thing we see on single-ply,” says Erika Figueroa, Service Project Manager, D. C. Taylor Co., Concord, CA, about punctures and tears.
According to Figueroa, the two primary causes are human activity and weather. “Accidents happen,” says Figueroa. When asked how workers on the roof cause damage, she explains: “When they do maintenance, dropping tools or the panels from the AC units, damage from sharp objects, dragging stuff, and not carrying the [equipment/tools] like they should.”
Preventing this type of damage starts with education. Before any work begins, contractors and maintenance personnel should review roof protection guidelines, and signage at roof access points should remind workers to use caution. Installing walkway pads from access points to rooftop equipment can provide an additional layer of protection for the membrane. Keeping a log of everyone who accesses the roof can also hold individuals accountable if damage occurs.
Weather is another major culprit of punctures and tears. “Hail storms are one of the most common causes. Wind too,” says Figueroa. Often, it’s not the storm itself that causes the damage but the debris it sends airborne. “If they have big trees around the facility, one big branch can go through the single-ply all the way to the decking.”
Identifying punctures and tears isn’t always straightforward. “When it’s something small, you may need a detailed roof inspection to spot the damage,” she suggests. Scheduling routine roof inspections before and after seasons known for severe weather can help identify issues early. If you suspect your roof has been damaged following a storm, contact a professional roofing contractor promptly for an inspection. Ensuring the roof is in good condition before severe weather – and confirming no damage occurred afterward – can help prevent more extensive repairs.
When roof repairs are needed, acting quickly is essential. “It needs to be taken care of as soon as possible. The damage can extend beyond the membrane itself – insulation can get wet, decking can get damaged, mold can grow,” she warns. “There are a lot of things that can happen if you let it pass.”
Whether a puncture goes unnoticed or repairs are delayed, a professional commercial roofing contractor can determine the full extent of the damage. “Sometimes there’s a small puncture, but when you get closer to the puncture, you feel the soft [surface]. That’s when you want to investigate if there’s more damage. If there’s wet insulation, how long has that leak has been going on?” notes Figueroa, whose D. C. Taylor Co. service team examines more than 30 roof components during an inspection and can identify a wide range of deficiencies – not just punctures and tears.
If insulation becomes wet, its R-value is compromised, significantly reducing its thermal performance. As a result, you’re not only facing a more extensive repair but also reduced energy efficiency and higher operating costs.
“First, we inspect the damage, prepare the area, and check the underlayment. That’s how you know how big the damage is. If that’s not [damaged], we can just repair the area with a patch,” she explains.
Once the extent of the damage has been determined, the repair area is thoroughly cleaned and prepared to ensure proper adhesion. The specific repair method depends on the roof membrane. For TPO and PVC roofing systems, a new membrane patch is typically heat-welded over the damaged area, although repair methods may vary depending on the age and condition of the existing membrane. For EPDM (thermoset) roof systems, repairs often involve applying primer followed by peel-and-stick seam tape or a compatible patch. When performed correctly, these repairs restore the membrane’s watertight integrity and help extend the roof’s service life.
To help ensure the repair is completed correctly, hire a roofing contractor who is approved by the roof system’s manufacturer. These professionals are trained in proper repair procedures and will use suitable materials. Using incompatible products or improper repair techniques can compromise the roof’s performance and, in some cases, void the manufacturer’s warranty.
Ultimately, Figueroa emphasizes that consistent maintenance is the best defense against damage from punctures and tears. “The main way to prevent [punctures and tears] is roof maintenance,” she recommends. Routine general preventive maintenance of the roof helps identify deficiencies before they become major problems, provides a clearer understanding of the roof’s condition as it ages, and supports its long-term performance.
Need a roof inspection? Suspect there’s tear in your membrane? Contact D. C. Taylor Co. at 319.731.4118 or [email protected] today.
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