If you are planning a roofing project for your commercial building, you may be deciding between a built-up roof and a TPO roof. Comparing a built-up roof vs TPOÂ can help you understand which system will deliver the best performance for your building, budget, and maintenance preferences. Rhino Commercial Roofers has more than fifty years of family-owned experience serving Tampa and Miami, and we can guide you through your options.
Choosing the right roof affects energy efficiency, durability, and the overall condition of your building. By understanding the differences between built-up roofs and TPO membranes, you can make a choice that will protect your investment for years to come.
What is a Built-Up Roof?
A built-up roof, commonly called BUR, is one of the oldest and most dependable roofing systems for commercial buildings. This type of roof is constructed with several layers of roofing felt, which are alternated with asphalt or tar to create a strong, durable barrier. On top of these layers, a final layer of gravel or stone is added to protect the roof from UV rays, foot traffic, and weather conditions.
Built-up roofing is known for its reliability and long-term performance, making it a preferred choice for property owners who want a proven solution. The multiple layers work together to provide insulation, helping your building stay cooler in the summer and warmer in the winter.
This type of roof can withstand heavy wear, hail, and other environmental challenges, making it well suited for industrial facilities, warehouses, and commercial buildings that experience frequent rooftop activity. The thick construction of a BUR also reduces the likelihood of leaks and damage, offering a long-lasting surface that can protect your building for decades.
What is a TPO Roof?
TPO, or Thermoplastic Olefin, is a modern single-ply roofing membrane that provides a smooth, reflective surface for commercial buildings. This roofing system is lightweight and flexible, which makes it faster to install than built-up roofs and easier to handle during large projects. TPO membranes are joined together with heat-welded seams, creating a watertight surface that helps prevent leaks.
The reflective surface of TPO reduces heat absorption, which can lower cooling costs and improve energy efficiency for your building. Many TPO membranes are manufactured using recyclable materials, adding an environmental advantage. Because TPO is smooth and lightweight, it is ideal for flat or low-slope roofs and is often used on new construction or retrofitted commercial buildings.
While it is less thick than built-up roofing, TPO is durable enough to resist UV rays, punctures, and general wear when installed correctly. This roofing solution offers a balance of energy performance, cost efficiency, and installation speed, making it a popular option for property owners looking to update or replace commercial roofs without extensive disruption.
Durability and Lifespan
When considering the lifespan and durability of a commercial roofing system, built-up roofs are widely recognized for their ability to last twenty to thirty years or more with proper attention and care. The multiple layers of felt, asphalt, and gravel create a strong, thick barrier that protects against punctures, heavy foot traffic, extreme weather, and long-term wear. This makes built-up roofing ideal for buildings that face constant exposure to environmental challenges.
TPO roofs generally have a lifespan of fifteen to twenty years depending on the material quality and installation process. While TPO is resistant to UV rays, heat, and punctures, the seams can be more vulnerable over time, which means careful installation and monitoring are important. The choice between BUR and TPO depends on your building’s use, exposure, and how long you plan to keep the roof.
Built-up roofs perform well under heavy-duty conditions and offer long-term stability, while TPO roofs provide a lighter, energy-efficient option that can still deliver reliable protection when installed and maintained properly. Both systems have advantages depending on your goals and priorities.
Energy Efficiency
TPO roofing is known for its highly reflective surface, which can help lower heat absorption on your building and reduce cooling costs during the warmer months. The smooth membrane makes it easier to clean and maintain its reflective properties over time. Because TPO reflects sunlight, it can keep interior spaces cooler and reduce the strain on air conditioning systems, which can lead to energy savings. Built-up roofing is typically darker and may absorb more heat, which can increase indoor temperatures if left uncoated.
However, applying reflective coatings to a BUR system can improve its energy performance and help it compete with lighter roofing options. Energy efficiency is an important factor if you want to reduce operating costs for your building. While TPO often provides a stronger benefit in this area due to its natural reflective properties, built-up roofing can still perform well when combined with coatings designed to reflect sunlight and maintain temperature control.
Maintenance Needs
Maintenance requirements vary between built-up roofs and TPO systems, and understanding these differences can help you plan for long-term care. Built-up roofs require inspections to make sure the layers remain intact and that the gravel or stone surface has not shifted or worn away.
Repairs can be more involved because multiple layers may need attention, and patching a damaged area often requires more labor and time. TPO roofs, with their single-ply membrane, are easier to repair when small tears or punctures occur. Repairs can be completed quickly, reducing disruption to your building operations.
Seams in TPO membranes should be checked periodically to prevent water infiltration, as seam failure is one of the most common issues in single-ply systems. Both built-up roofing and TPO benefit from regular inspections to extend their lifespan, but the type of maintenance work, materials, and time required differ significantly depending on which system you choose.
Installation and Cost
Installing a built-up roof requires multiple layers of roofing felt and asphalt, a process that can take time and specialized labor to complete properly. This method often increases upfront costs, but it results in a very durable surface that can last for decades under heavy use.
TPO installation, by contrast, is faster and simpler because it involves a single-ply membrane and lighter materials that are easier to handle. The speed and simplicity of TPO installation can reduce labor costs and allow the roofing project to be completed with minimal disruption to your building.
Built-up roofs provide a thick, resilient surface that can withstand harsh weather and heavy traffic, which may justify the higher initial investment. Rhino Commercial Roofers can evaluate your building, provide cost estimates for both systems, and help you select the solution that balances upfront cost, durability, and long-term value.
Appearance and Design
You might be happy to find out that built-up roofing typically has a gravel or stone surface that gives a rugged and textured look. This style is common on warehouses and industrial buildings. TPO roofs are available in light colors, usually white or gray, and provide a smooth, clean surface. They can be customized with coatings or branding to match your building’s aesthetic. If appearance and energy efficiency are priorities, TPO can offer advantages, while built-up roofs excel in traditional durability and heavy-duty performance.
Choosing the Right System for Your Building
When evaluating a built-up roof vs TPO, think about your building’s age, how long you plan to keep the roof, and your budget. Built-up roofs may be a better fit if you want a surface that handles heavy use, extreme weather, and long-term durability. TPO roofs may be more appealing if you want a lighter system with energy efficiency, faster installation, and easier maintenance.
At Rhino Commercial Roofers, our products and services include the installation and repair of both built-up roofs and TPO systems for commercial buildings. We deliver high-quality workmanship that protects your building, reduces future maintenance costs, and maximizes the lifespan of your roof.
