During a recent commercial roof inspection in Claremore, Oklahoma, Ridgeline Roofing & Solar evaluated a large-scale industrial facility featuring a combination of fluted TPO roofing, R-panel metal roofing, and extensive solar panel systems. While the structure is still serviceable, several key issues were identified—many of which stem from improper solar installation and long-term wear.

This project is a perfect example of how complex commercial roofing systems require careful coordination between trades. When that coordination breaks down, leaks and damage often follow.

Solar Panels: When Installation Causes Problems

One of the biggest concerns on this property came from the solar array. Two different installation methods were observed:

• Mechanically fastened brackets, screwed directly into the roof system
• Ballasted (weighted) systems, which sit on the surface without penetration

The mechanically fastened sections are now experiencing active leaks, likely due to improper sealing around penetrations. In contrast, the ballasted system showed significantly fewer issues.

Large crews installing solar panels can unintentionally damage roofing materials, especially on TPO membranes and metal systems. Foot traffic, dropped tools, and poor flashing details all contribute to long-term failure.

TPO Roofing System: Still Functional with Proper Drainage

The TPO sections of the roof are designed with multiple drainage directions and include a tapered insulation system to guide water toward internal drains. While the design is sound, damage from installation traffic and penetrations has created vulnerabilities that need to be addressed before they worsen.

R-Panel Metal Roof: Aging and Fatigue Showing

The facility also includes a 26-gauge R-panel metal roof, which is showing signs of age and structural fatigue:

• Rib creasing and splitting, caused by thermal movement and stress
• Worn neoprene washers on fasteners, allowing water intrusion
• Deteriorating closures, creating gaps at panel transitions
• Minor ridge cap issues, contributing to leak points

These issues are common in older metal systems, especially when combined with added weight and stress from rooftop equipment like solar arrays.

Strategic Repairs Can Prevent Major Costs

The good news is that this roof system does not yet require a full replacement. With the right plan, Ridgeline can:

• Repair and reseal solar penetrations
• Address fastener and closure failures
• Reinforce problem areas on both TPO and metal sections
• Extend the overall lifespan of the roofing system

Choosing an experienced contractor makes all the difference when dealing with multi-system commercial roofs like this one.

Don’t Let Small Issues Turn Into Big Repairs

Whether your building has TPO, metal roofing, or rooftop equipment like solar panels, early detection and proper repair strategies can save thousands in future costs.

Think your roof may have hidden issues from equipment or age? Let’s find out. Contact us today!

Hear Tim’s Thoughts

Video Transcript: "Hey, it's Tim Yates with Ridgeline Roofing and Solar. I am in Claremore, Oklahoma on a steel mill and I'm with Joey and Dave and we're inspected some roofs and it's got, it's a great big building. It's got some solar panels up here. These over on this side are actually the solar panel brackets are screwed into the roof and now they're experiencing some leaks. These over here are just,
the brackets are not, they're weighted down. Definitely the way they do it. It has, this roof over here is a TPO roof. It's got actually two facets and they're both draining. That one's draining north and this one's draining south and this one's draining to these roof drains here and they've even got a little bit of taper. You can kind of see it outlined down the roof a little bit, but they're having a lot of problems up here and I think most of this started when they had the solar panels put on because whoever put them on was just, you know, you've got a lot of problems.
a lot of people up here working and it was really hard on the roof. So, you can see this old R panel. It's a thinner R panel to start with. It's about a 26 gauge. It's got some striations in it. You can see where the movement has caused creases in the ribs.
and exo facto we've got some some roof leaks and you can also see that the closures up here
are rotting out and it's also a place for for water intrusion then you also have
some of these these screws the neoprene's on the screws are
just rotting away here's another example of that hope you can see it
so that's that's usually what happens that the the are that the rib itself creases and it ends up
splitting it out i've tried to fix a couple of them and there's just a bunch so um and then we've got
some ridge cap down on the other end that's that's got a little bit of issue but it's really hard to
come up with a plan if you have to take all this off and i don't think we're at that point yet but
eventually hopefully not soon eventually that'll probably have to happen
anyway we're gonna we're gonna put our estimate in on this and and suggestions and just kind of go from
there if you need any assistance with your residential or commercial roof give us a call thank you"