Tar paper staples are the specialized fasteners that bind layers of felt paper to wooden roof sheathing and walls, creating a critical moisture barrier. These small yet essential components are typically made from coated or stainless steel to resist the tar’s corrosive nature and the elements. Selecting the correct staple length and gauge is vital for ensuring a secure, weather-tight seal that protects the structural integrity of a building.
The Role of Tar Paper in Modern Construction
Before examining the fasteners, it helps to understand the material they secure. Tar paper, or asphalt-saturated felt, acts as a secondary water-resistive barrier (WRB) within a wall or roof assembly. It sheds water that penetrates the outer cladding and provides an extra layer of protection against air infiltration and moisture damage. The effectiveness of this barrier relies entirely on proper installation, which starts with the right tar paper staples.
Material and Coating Specifications
Not all staples are suitable for securing tar paper. Manufacturers typically use materials that can withstand the bitumen’s sticky texture and acidic properties. The most common options include:
- Standard Steel: Galvanized or coated with polymer to prevent rust and ensure a tight grip.
- Stainless Steel: Used in high-moisture environments or coastal areas where corrosion resistance is paramount.
- Copper: Employed for specific aesthetic or durability requirements, though less common due to cost.
The coating also matters; a polyethylene or vinyl backing reduces friction during driving and prevents the staple from tearing the fibrous paper.
Size Matters: Length and Diameter
Using the wrong size staple is a common installation error that leads to blow-outs or inadequate coverage. Building codes often specify minimums to ensure performance. Generally, the staple must penetrate through the sheathing and into the framing member to be effective.
| Application | Recommended Length | Typical Use Case |
|---|---|---|
| Roof Deck | 1/2" to 5/8" | Securing felt to rafters or trusses |
| Walls | 3/8" to 1/2" | Attaching paper to wall sheathing |
Opting for a staple that is too short results in a loose fit, while one that is too long risks penetrating interior walls or causing handling difficulties.
Essential Installation Techniques
Proper installation ensures the tar paper lies flat and wrinkle-free, which is crucial for its drainage function. Contractors should follow these best practices:
- Space staples approximately 6 to 12 inches apart along edges and 12 to 18 inches in the field.
- Drive staples flush with the surface; over-driving can tear the material, while under-driving creates tripping hazards.
- Staple perpendicular to the surface to avoid tearing the fibrous material at an angle.
- Overlap seams correctly and secure the overlap to prevent wind-driven rain from lifting the edge.
Modern Alternatives and Innovations
While traditional tar paper staples remain the standard, the construction industry has seen innovations that change the workflow. Synthetic roofing underlays, for instance, often utilize thicker, fabric-like materials that may require wider or coated staples designed for aggressive fastening. Furthermore, some modern membranes are self-adhering, reducing the reliance on mechanical fasteners altogether. However, for traditional asphalt-saturated felt, the physical staple remains the most reliable method of securing the product.
Common Mistakes to Avoid
Even experienced builders can cut corners, leading to long-term waterproofing failures. Avoid these pitfalls when working with tar paper staples:
- Using smooth staples: The rough, jagged edges of cement-coated staples bite into the paper, preventing slippage.
- Ignoring the weather: Driving staples into wet, cold paper makes the material brittle and prone to tearing.
- Improper storage: Storing staples in humid conditions causes them to clump and rust before they even hit the sheathing.
By respecting the material and the method, professionals ensure a tight, durable envelope that stands the test of time.