Heat-Welded Seam (Roofing)

Installation - A heat-welded seam is the connection between two membrane sheets that have been fused together with hot air and pressure to create one, continuous waterproof surface.
A detail membrane seam on a TPO roof being heat-welded and rolled by a roofer.

How TPO and PVC Become a Single Waterproof Surface

Heat-welded seams are a defining feature of TPO and PVC roof systems. These membranes are manufactured in separate sheets, so the seams between them must be joined together to create a single waterproof layer across the roof.

Most roof replacement proposals involve heat-welded seams, since TPO and PVC are common membrane choices. While EPDM uses tape or adhesives to join sheets, TPO and PVC fuse them together with heat welding followed by a roller to press the melted sheet edges together. The same process is used to secure membrane detail flashing.

Higher quality welds greatly increase the roof’s ability to keep water out. If the seam was not heated correctly during installation, it may separate over time, producing a cold weld.

Further Reading

TPO vs. PVC
TPO and PVC both use heat-welded seams to create a monolithic, continuous waterproof roof. Comparing the two materials also shows where their installation methods begin to differ.

Common Failure Points for Low-Slope Roofs: Improper Installation
The field of a membrane roof performs as well as its seams. Improper welds can create weak points long before the membrane itself wears out.

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