Rolling out the facts: Width consideration for thermoplastic roofing rolls

By Dani Sheehan. 

Wide-width products are marketed as more cost-effective and efficient than narrower rolls, but for mechanically attached systems the wider and heavier rolls pose several workforce challenges. 

IB Roof Systems is all about working smarter, not harder. Many manufacturers of wide-width single-ply rolls market that wide-width products have application advantages over narrower rolls because there are fewer seams and installation is quicker. However, in mechanically attached applications, the installation process for wider and heavier rolls can take longer and pose several challenges for installers. 

Jason Stanley, CEO of IB Roof Systems shared that two years ago he was discussing the state of the roofing industry with Colin Murphy at the International Institute of Building Enclosure Consultants (IIBEC). He says, “At that time, I confided in Colin about being at a difficult crossroads. Heavy, wide-width rolls had taken over the industry, and there was a common belief that these rolls reduced a significant amount of labor. Colin laughed at my ignorance, and said, ‘You know it’s not true.’ I said, ‘I know it’s not true, but the industry believes it.’ Colin then stated, ‘I can prove it.’” 

Over the next two years, they investigated these claims, analyzing side-lap attachment spacing and seam welding lengths comparing the use of wide-width rolls versus more traditional, narrower rolls. A recent article published in the IIBEC Interface presents their findings, highlighting the misconceptions surrounding wide-width single ply roofing rolls and challenging the marketing claims made by manufacturers.  

The claim that wider rolls lead to faster installations and fewer seams holds true only for fully adhered and plate-bonded systems and does not fully consider mechanically attached applications. While wider rolls may reduce seam welding, the increased fastening pattern offsets any time-saving advantages. You can find a calculation in the article developed from time trials to allow contractors a way to evaluate lap-attached assemblies based on various roll widths. 

Additionally, there are limitations of wide-width systems when it comes to wind uplift ratings beyond 90 psf. The study presents examples of TPO assemblies achieving such ratings with non-standard deck and fastener types, but the increased material costs associated with these configurations outweighs the benefits of using the wider rolls. 

Finally, the article addresses the practical challenges related to the maneuverability of large rolls onsite, emphasizing the potential risks and labor-intensive processes involved. Despite marketing claims, wider rolls are not inherently more cost-effective in mechanically attached systems, and contractors should carefully consider the practical implications before opting for wide-width rolls.  

Read the full article to gain a comprehensive understanding of the nuanced factors influencing efficiency of thermoplastic roofing installations.