Hi, I’m Mike Di Pinto, Vice President of Construction Insurance at Ferrari & Associates. Torch roofing is popular for its durability, but it comes with risks that can drive up insurance costs. In my previous articles, we explored why roofing insurance is so expensive and how contractors can reduce their premiums through proactive strategies. In my second article, I emphasized the importance of safety certifications like Red Seal and COR for roofing companies. These certifications are especially critical when dealing with high-risk methods like torch roofing. Now, we’ll focus on torch roofing risks and how it impacts your insurance rates.

What Is Torch Roofing?

Torch roofing, or torch-down roofing, is a method used on flat or low-slope roofs. It uses an open-flame propane torch to melt layers of modified bitumen onto the roof. This creates a waterproof seal that lasts 15–20 years when installed correctly. Torch roofing involves a base sheet to provide a stable foundation for the roof. There is also a cap sheet, which adds waterproofing and durability. Finally, torch roofing involves a granular surface that helps to protect against UV damage and wear.

Torch roofing is known for its durability and effectiveness, but the use of open flames introduces significant risks.

Why Is Torch Roofing Risky?

Torch roofing risks are serious, and torch roofing poses serious hazards both during and after installation:

Understanding Torch Roofing Risks

When it comes to roofing options, torch roofing presents unique advantages, such as effective waterproofing and durability. However, using open flames during installation comes with significant torch roofing risks.

Torch Roofing Risks – Fire Hazards

One of the most significant threats associated with torch roofing is the inherent fire hazards that arise from the use of open flames. During the installation process, the intense heat from the torch can easily ignite surrounding flammable materials, including wooden decks, shingles and insulation. This risk is amplified in areas where dry leaves, debris, or other combustible materials accumulate.

A particularly insidious danger is the potential for hidden smoldering fires. These fires may start unnoticed beneath roofing materials or in nearby insulation, only to flare up days or even weeks later, causing significant structural damage and safety hazards. It’s therefore crucial for roofers to be vigilant and implement appropriate fire prevention measures to mitigate these risks.

Torch Roofing Risks – Injuries

In addition to fire hazards, injuries related to torch roofing pose a serious concern for roofing professionals. Workers are at risk of suffering burns from direct contact with the torch or heated materials. This can occur through accidental spills of hot asphalt or tar, which can result in severe skin injuries. 

The physical demands of torch roofing can also lead to injuries. Roofers may be required to lift heavy materials, climb ladders, or work in awkward positions, increasing the likelihood of falls, strains, or musculoskeletal injuries. Although safety equipment such as flame-resistant clothing, gloves, and eye protection can help mitigate some of these risks, the nature of the work still exposes employees to potential hazards that cannot be entirely avoided.

Torch Roofing Risks – Environmental Concerns

Beyond immediate safety concerns, torch roofing can have environmental repercussions as well. The process of heating materials can release fumes and volatile organic compounds into the air, affecting both the workers on site and the surrounding community. Prolonged exposure to these substances can cause respiratory issues and has raised concerns about long-term health effects.

The Impact of Torch Roofing Risks on Insurance Costs

Torch roofing presents certain inherent risks that can significantly affect insurance premiums. One of the primary contributors to increased costs is liability. As I previous mentioned, with torch roofing’s installation process, the potential for fires is heightened. This can lead to extensive property damage and result in substantial claims. This elevated risk compels insurance providers to raise premiums to account for potential liabilities associated with fire-related incidents.

Additionally, the dangers inherent in torch roofing also translate into higher workers’ compensation costs. The increased likelihood of burns and other injuries during installation raises the frequency and severity of workers’ compensation claims. As a result, premiums for these policies are often elevated to mitigate the financial impact of potential workplace accidents.

Furthermore, historical claims data underlines the overall risk profile of torch roofing. Evidence shows that roofs installed using this method have a higher incidence of severe damage, influencing premiums across the industry. Insurers often examine such historical data to assess risk, ultimately leading to increased insurance costs for contractors and property owners engaged in torch roofing projects. 

Mitigating Torch Roofing Risk

Managing the risks associated with torch roofing is critical for protecting your team, minimizing liability, and reducing insurance costs. Many of the strategies outlined in my second article on lowering roofing insurance premiums apply directly to torch roofing. Let’s explore how these can be adapted to address torch-specific risks while also considering new approaches.

Training and Certification

Proper training is the cornerstone of risk reduction. Thoroughly training workers in torch operation, fire prevention, and emergency response will save your business. Certifications like Red Seal and Certificate of Recognition (COR), discussed in my previous articles, demonstrate your company’s commitment to safety and professionalism. These certifications also reassure insurers that your team meets the highest industry standards, helping to lower your premiums.

Implementing Safety Protocols

Safety protocols play a pivotal role in mitigating fire and injury risks:

Roofers should use fire-resistant materials and ensure all worksites are equipped with fire extinguishers and other emergency tools. Fire watches are also important and roofing teams should conduct fire watches during and after installations to detect and address potential smoldering fires. Equipping workers with flame-resistant clothing, gloves, and eye protection will also minimize injury risks. These measures not only reduce the likelihood of accidents but also build a strong safety record, which can lead to discounts from insurers.

Adopting Alternative Methods to Torch Roofing

According to my roofing friend, one of the most effective ways to eliminate the risks of torch roofing is to switch to safer roofing methods. For instance cold-applied systems eliminate the use of open flames, significantly reducing fire hazards. Self-adhering membranes also provide a safer, equally effective alternative for flat or low-slope roofs. While these methods may require an upfront investment, they often lead to long-term savings by lowering claims and insurance costs.

Many of the strategies discussed in my second article—such as maintaining a clean claims history and investing in ongoing safety training—also apply here. When combined, these steps can help lower your insurance premiums and improve your company’s risk profile.

My roofing friend admits that torch roofing is an effective method of roof repair, but also carries significant risks that can increase claims and insurance costs. By prioritizing safety, investing in certifications, and exploring alternative methods, roofing companies can mitigate these risks and secure better premiums. If your business relies on high-risk methods like torch roofing, adopting proactive risk management strategies can make all the difference.

To learn more about managing roofing risks and insurance costs, check out my previous article on lowering premiums or contact me directly at Ferrari & Associates for expert guidance.