Achieve the Look of a Metal Roof Using New TPO Colors and Contour Rib
April 30, 2019
The Sure-Weld® TPO Contour Rib profile is a great way to achieve a standing seam metal roof look on sloped roofs or mansards. Sure-Weld TPO membrane and the contour rib profile are now stocked with no minimum order quantities in five special colors in addition to the standard white, gray, and tan options. This makes it even easier to satisfy a building owner’s desire for an aesthetically pleasing standing seam look using TPO.


When using special color TPO and contour rib, an owner will be judging the finished roof on its looks, in addition to its performance. It’s important to ensure proper spacing and alignment, and consider where membrane splices will fall when installing the contour rib profile.


Here are some easy tips to follow on your next contour rib profile job:
  • “Measure twice, cut once”: Similar to the old carpenter’s saying, check your measurements before you start the job. Prior to installing any contour ribs, measure the spacing for the ribs on the roof to ensure they are spaced properly. If possible, try to align the edge of a contour rib with a splice in the membrane to hide seams.
  • Use a jig or pan to make spacing easy: Once the spacing has been determined, lay out a few ribs on the ground and position the automatic welder as if the rib is being welded. Then, measure the space between the edge of the welder and the next rib. This dimension can be used to fabricate a metal pan to ensure proper alignment and spacing of the ribs.
  • The first rib is critical: Always chalk a line to position and install the first rib. Align the edge of the rib with the chalk line and tack-weld it every 6” to ensure it is perfectly straight and stays in place. If done properly, the first rib can act as a guide to align the next rib using the metal spacing pan. Ensure that after tack welding the first rib for positioning purposes, it is fully welded for permanent installation.
  • Use heat to hold contour rib pieces together: To reduce separation of connected contour rib pieces during the welding process, use a hand welder to heat the end of one of the contour ribs after inserting the connector pin, and push the two ends together. This will help eliminate small gaps between contour rib pieces.


  • Sure-Weld TPO special colors and contour ribs can give a building the look of a metal roof, with the fast installation and proven performance of TPO. Refer to the Contour Rib Installation Guide for more great tips to make sure your next Special Color Contour Rib installation is a success.

        Adam Burzynski
        TPO Product Manager
        Product Marketing
        [email protected]
    September 17, 2019
    Solving Unique Challenges with a Hybrid Approach to Insulation

    One of the simplest ways to meet building codes requirements in construction is through the effective use of insulation. There are several types of rooftop insulations available in the marketplace, but two of the most commonly accepted in commercial roofing applications are polyisocyanurate (polyiso) and expanded polystyrene (EPS). Polyiso is a lightweight and cost-effective, closed-cell, rigid foam board insulation that provides energy-efficient solutions for buildings in any region and climate, as well as outstanding return on investment and significant energy savings. EPS is a closed-cell, rigid foam insulation manufactured using expandable polystyrene. It is block-molded for most construction applications and is highly customizable, enabling thicknesses up to 40 inches in a single board. EPS is versatile and durable and can provide significant cost and labor advantages. Both polyiso and EPS provide great benefits and R-value in roof construction projects. However, projects often arise when a hybrid solution to insulation may be the most practical. A hybrid polyiso/EPS solution can help you edge out the competition in a number of scenarios. New Construction with Concrete Decks  A recent innovation introduced by Carlisle is ChannelDry® EPS Insulation. ChannelDry is ideal for new construction projects with structural concrete, lightweight structural concrete, and lightweight insulating concrete roof decks. Using ChannelDry in conjunction with one-way and two-way relief vents allows the installation of the roof system to begin upon structural cure of concrete (typically around 28 days). ChannelDry is compatible with ballasted, mechanically fastened, induction welded, and adhered single-ply roofing systems. The use of ChannelDry creates a problem-solving solution for new construction involving concrete decks, enabling construction to commence immediately upon structural cure. Standing Seam Metal Roofs  With square-, taper-, and profile-cut flute-fill products in custom shapes and sizes, a solution is available for all metal retrofit roofs. Combining EPS to fill the metal roof flutes with a subsequent layer of insulation or coverboard can create an ideal foundation for a retrofit roof. Click here to hear a contractor describe the benefits of this system from a project in Windsor, Ontario, Canada. Tapered Roof Design  A tapered roof is another ideal candidate for a hybrid approach to save time and money. With thicknesses up to 40" and virtually any slope available in a single board, a base layer of tapered EPS insulation can save nearly 30% in product cost alone, with additional savings on installation time when combined with polyiso. Combining polyiso and EPS in commercial roofing applications is an effective solution that can often save you money and labor on a project. Contact your local Carlisle representative to learn more.

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    September 3, 2019
    Roofing with Resilience: A Review of 30-Year EPDM Enhancements

    The history of EPDM roofing runs deep. With over 50 years on the market and billions of square feet produced and installed, Carlisle SynTec’s EPDM has a proven track record as one of the most resilient membranes in the single-ply roofing industry today. As time goes on and the construction industry evolves, more sustainable structures are becoming the norm. Building codes are increasingly robust and are placing a greater emphasis on protecting your building from Mother Nature’s wrath. Your roof system plays a huge part in achieving compliance and serves as the first line of defense against hail, wind, and other damaging elements. This is where EPDM’s sustainability and durability come into to play. Sustainability and resiliency are some of the strongest attributes of Carlisle’s EPDM membranes, and EPDM’s durability allows us to offer a high-end, 30-year Total System Warranty that guarantees long-term performance. Below are the enhancements that Carlisle SynTec requires when upgrading to a 30-year EPDM system: 30-Year EPDM Enhancements The Membrane: The thicker and more durable 90-mil EPDM, 75-mil reinforced EPDM, or 145-mil FleeceBACK® EPDM are required; fully adhered, mechanically fastened, or ballasted designs are available. The thicker membranes will provide greater long-term performance and superior resistance to weathering. Please note, 45-mil and 60-mil membranes are not eligible for 30-year Total System Warranties. The Splices: Membrane splices are one of most important parts of any roofing system and utilizing our Factory-Applied Tape™ means more watertight seams and fewer warranty claims. On a 30-year EPDM system, Carlisle requires membrane with 6”-wide Factory-Applied Tape or 6” SecurTAPE™ to be installed at all seams and end laps. The 6”-wide tape has greater peel and sheer strength and results in a stronger bond. Please note, 3” factory-applied or hand-applied tape on 30-year warranties must be stripped in with Pressure-Sensitive Cured Cover Strip. The Flashing Details: In addition to seams, flashing details are critical to preventing issues where rooftop penetrations are tied in to the field membrane. On 30-year EPDM systems, Carlisle requires specific details to be double-wrapped or covered with two layers of flashing. Below is a list of these details: Key U = Universal (applies to all 30-year systems) A = Adhered Systems Only B = Ballasted Systems Only MF = Mechanically Fastened Systems Only U-2D SecurTAPE Splice Intersection (25-/30-Year Warranties) U-8A.1 Pre-Molded Pressure-Sensitive Pipe Seal with 90-mil Membrane or 25-/30-Year Warranties U-8B.1 Field Fabricated Pipe/Structural Steel Tube Flashing for 25-/30-Year Warranties U-15D.1 Inside Corner Flashing for Projects with 90-mil Membrane or 25-/30-Year Warranties U-15H Outside Corner Flashing for Projects with 90-mil Membrane or 25-/30-Year Warranties A-2 Membrane Splice (25-/30-Year Warranties) B-2 Membrane Splice (25-/30-Year Warranties) MF-2D Membrane Splice (25-/30-Year Warranties) MF-2E SecurTAPE Splice Intersection (25-/30-Year Warranties) ***Please speak with a Carlisle SynTec Design Analyst about additional 30-year requirements in regards to adhesives, coverboards, insulation, fastening density, perimeter securement, and metal edging.***     Ryan Ferguson     EPDM Product Specialist     Product Marketing     [email protected]

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    August 20, 2019
    Making the Choice Between Prefabricated and Shop-fabricated Metal

    When it comes to choosing a fascia or coping, the options for colors, finishes, and profiles are virtually endless. Most times, the color and finish will be dictated by the building owner or designer. Roofers and general contractors, on the other hand, often have much more influence over which profile is used and how it’s sourced. This post breaks down the benefits of prefabricated edge metal (such as Carlisle SecurEdge products) as well as the advantages of shop-fabricated edge metal (made in-house by the roofing contractor or outsourced to a local sheet metal shop). Prefabricated edge metal has a lot to offer, from enhanced performance and code compliance to labor-saving benefits. Below are a few of the advantages of using prefabricated edge metal. Testing and code compliance: All Carlisle SecurEdge products are tested to ANSI/SPRI ES-1 standards as required by International Building Code. ES-1 testing has been mandatory for all low-slope roofs since IBC-2003 and using prefabricated SecurEdge ensures that code requirements can be met. The majority of SecurEdge coping and fascia profiles offered by Carlisle are also approved for use on Factory Mutual-insured buildings or where FM-approved edge flashings are required. Convenience: Using prefabricated SecurEdge products allows contractors to order edge metal and have it shipped directly to the jobsite, with many products available to ship within days. No sheet metal shop is required. On the flip side, roofing contractors who have shops with skilled sheet metal workers can use those resources to work on more complex and profitable sheet metal work, rather than fabricating basic coping and fascia designs. Labor Savings: Unlike traditional gravel stop and drip edge, many SecurEdge profiles have a snap-on design and do not need to be stripped in. This saves considerable labor on the roof and eliminates the need to use primer and cover strip (as is typical with a drip edge or gravel stop). Warranty: All SecurEdge products are covered under the Edge-to-Edge Total Roof System Warranty, offering the building owner protection backed by Carlisle. While prefabricated edge metal offers many advantages over shop-fabricated edge metal, local fabrication has its own benefits, and shop-fabricated metal is still covered in some Carlisle warranted roof systems. Here are a few reasons why shop-fabricated edge metal might be a good fit for a project. Flexibility: While SecurEdge products can be customized, it’s often easier to create complex custom parts locally where the sheet metal fabricator can see what is needed, measure, and fabricate the part. Speed: Many SecurEdge profiles can be shipped in as little as one day; however, if you need something immediately, there’s no substitute for a local sheet metal shop that can fabricate something for installation the same day. Warranty: While SecurEdge will almost always meet warranty requirements, shop-fabricated metal using Carlisle metal flat sheets can also be included in many warranted roof systems for up to 20 years. For more information, visit the edge metal product page on the Carlisle website.      Adam Burzynski     TPO Product Manager     Product Marketing     [email protected]

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