Slips and falls from heights are among the most common causes of construction incidents—and they consistently rank among the costliest workers’ compensation claims. Roofs are the most frequent surface involved. Most flat roofing membranes sold in the United States are thermoplastic, creating slippery and unsafe walking surfaces.
Recognizing the need for research in this area, Triton Inc. partnered with Iowa State to study materials commonly used on commercial and industrial flat and low-slope roofs. The Cedar Rapids-based company manufactures roofing systems for industrial, institutional, and commercial facilities worldwide, with a focus on developing safer technologies.
“It is a known problem that commonly used materials are the most dangerous, but there is little research in this area,” said Dustin Brooks, president of Triton. “When someone replaces a flat roof, they typically use smooth membranes. We are the only manufacturer to provide textured materials, which we believe to be safer. I thought a study would not only benefit us, but our industry as a whole.”
Brooks contacted Dr. Rick Stone, Iowa State’s director of engagement for industrial and manufacturing systems engineering, who then connected him with CIRAS. Stone and Brooks worked with CIRAS project manager Brian Muff to initiate the study. “The process was seamless,” said Brooks. “We never had issues. We love working with CIRAS.”
The 10-month study evaluated walking performance on various roofing materials under a range of weather conditions. Nine materials were tested on commercial and industrial flat and low-slope roof setups.
Human testing was a key component of the study. Stone and his team recreated realistic walking conditions using Triton-provided materials in actual weather scenarios, including waiting for ice and snow events to occur. With multiple safety precautions being taken, participants walked across the surfaces, being closely monitored by videos to track slips and falls.
The study found that material type plays a critical role in reducing slip risk, while factors such as shoe type have minimal influence. Textured thermoplastics significantly outperformed smooth versions, with higher friction leading to fewer slips and falls. These findings could help reduce workplace injuries and lower workers’ compensation claims.
The report recommends adopting textured thermoplastic membranes as a baseline safety standard. “This groundbreaking research will affect the entire industry,” said Brooks. “The study’s impact has been significant for our clients, and we’re seeing increased demand for these materials. Creating awareness will take time, but it will begin a monumental shift in the commercial roofing industry.”
Sales of thermoplastic membranes in the United States are projected to reach $2.7 billion by 2026. Triton estimates that even a modest one percent increase in market share would generate $12 million in revenue. Based on the study’s findings, the company forecasts its market share could increase to 5–10 percent by 2032—representing $135 million to $200 million in annual revenue.
Contact Brian Muff at bmuff@iastate.edu to learn more.