Best Roofing Staples for Tar Paper: Types Sizes and Installation Tips

Choosing the right roofing staples for tar paper affects durability, wind resistance, and installation speed. This article explains staple types, gauge and crown size recommendations, compatibility with nailers, proper spacing, and troubleshooting common problems to help users make informed decisions. Key factors include staple material, crown width, leg length, and tool compatibility.

Factor	Recommended Options
Material	Stainless Steel or Hot-Dipped Galvanized
Crown Width	7/16″ To 1/2″ For Tar Paper
Leg Length	1/2″ To 7/8″ Depending On Underlayment
Gauge	16–18 Gauge For Durability

Why Choosing The Right Roofing Staples For Tar Paper Matters

Tar paper, or roofing felt, serves as a moisture barrier beneath shingles; improper fasteners can allow blow-offs or water intrusion. Using incorrect staples can corrode, tear the felt, or pull loose under wind uplift.

Professional roofers and DIYers must consider corrosion resistance, holding power, and compatibility with pneumatic staplers or manual staplers. Selection affects long-term roof performance and can influence warranty acceptance by shingle manufacturers.

Types Of Roofing Staples And Their Pros And Cons

Galvanized Steel Staples

Hot-dipped galvanized staples feature a thick zinc coating that resists rust. They are cost-effective and commonly used for tar paper attachment.However, in coastal or high-humidity areas they may still corrode faster than stainless options.

Electro-Galvanized Staples

Electro-galvanized staples have a thinner zinc layer applied via electroplating. They are cheaper but less durable against corrosion than hot-dipped variants.Best used in dry inland climates where long-term exposure to moisture is limited.

Stainless Steel Staples

Stainless steel staples provide the highest corrosion resistance and are ideal for salt-spray environments. They are more expensive but offer superior longevity and reduce the risk of rust staining under certain materials.

Copper-Coated Staples

Copper-coated staples appear in specialty installations where staining or chemical interactions are a concern. They offer good corrosion resistance and compatibility with certain roof metals.They are less common due to higher cost.

Staple Gauge Crown Width And Leg Length Explained

Gauge refers to wire thickness; lower numbers mean thicker wire. For tar paper, 16–18 gauge staples balance holding power and minimizing felt tearing.

Crown width affects distribution of holding force. A standard roofing crown of 7/16″ to 1/2″ prevents staples from pulling through the felt while not interfering with shingle laying.

Leg length must penetrate the felt and secure into the roof deck adequately. Typical leg lengths for tar paper are 1/2″ to 7/8″, depending on sheathing thickness and whether a vapor barrier or other underlayments are present.

Tool Compatibility: Which Staplers Work Best

Air-powered pneumatic staplers are common in professional roofing for speed and consistent depth. They work with collated roofing staples sized for roofing staplers. Ensure the stapler supports the staple crown width and leg length used.

Manual hammer tackers can be used for small jobs but risk inconsistent drive depth and bent staples. Cordless electric staplers provide a middle ground for DIYers, offering portability with reasonable power and depth control.

Recommended Staple Specifications For Tar Paper

For most standard residential roofing with 15 lb or 30 lb tar paper over plywood or OSB, use 16–18 gauge, 7/16″–1/2″ crown, and 1/2″–5/8″ leg length galvanized staples.

In areas with high wind or for heavier underlayment like synthetic felt, increase leg length to 3/4″–7/8″ and consider stainless steel or hot-dipped galvanized staples for added corrosion resistance and holding strength.

Staple Patterns And Spacing For Secure Installation

Proper staple pattern matters for wind uplift and uniform attachment. For tar paper underlayment, staples are typically spaced 6–8 inches along edges and 10–12 inches in the field.

When overlapping felt sheets, place staples at least 1 inch from the overlap edge to prevent tearing. Use a double row along eaves and rakes in high-wind zones for extra security.

Common Installation Mistakes And How To Avoid Them

Overdriving staples can split sheathing or embed staples too deeply, weakening the hold. Adjust stapler depth so crowns sit flush without cutting the felt.

Under-driving leaves staples loose and prone to pull-out. Use consistent pressure or proper pneumatic settings and check sampling every few rows to ensure correct depth placement.

Using too-short legs leads to inadequate deck penetration. Verify leg length considering sheathing thickness, underlayment layers, and whether roof vents or ice-and-water barriers are present.

Corrosion, Staining, And Material Interactions

Metal fasteners can corrode and cause stains or roof failure if incompatible with surrounding materials. Choose galvanic-compatible staples when working near copper or other dissimilar metals.

In coastal or chemically aggressive environments, prefer stainless steel to avoid accelerated corrosion and preserve warranty coverage for roofing products sensitive to staining.

Code And Manufacturer Requirements

Building codes and shingle manufacturers often specify fastening methods. Some shingle warranties void use of staples for final shingle attachment but accept staples for underlayment. Always verify local code and manufacturer instructions before staple selection.

Codes may mandate corrosion-resistant fasteners in certain climate zones. Inspectors commonly look for consistent spacing, penetration, and attachment method during installation reviews.

Cost Considerations And Value Analysis

Galvanized staples balance cost and performance for many projects. Stainless steel increases material cost but reduces long-term maintenance and corrosion risk. Calculate unit price versus potential replacement or repair costs when choosing premium staples.

For large jobs, buy bulk collated staples compatible with existing tools to reduce per-staple cost and maintain consistent performance across the job site.

Troubleshooting Common Problems On The Roof

If felt tears or staples pull out, check staple length and crown width. Switching to a wider crown or longer legs often resolves pull-through issues.

For frequent staple jams, inspect the stapler for worn feeding components and use the correct collated strip type. Damp felt can cause slippage; allow underlayment to dry or schedule work in dry conditions when possible.

Best Practices For Storage And Handling Of Roofing Staples

Store staples in a dry, covered area to prevent corrosion before use. Keep unopened boxes on pallets or shelves off the ground. Once opened, use smaller containers to limit exposure to humidity.

Handle collated strips carefully to avoid bending. Bent staples may jam staplers or misfire, slowing installation and increasing waste.

How To Choose Staples For Specific Scenarios

Coastal Homes

Choose stainless steel staples to resist salt spray and humidity. Longer legs and closer spacing help withstand higher wind loads typical of coastal storms.

Low-Cost Inland Projects

For dry inland areas, hot-dipped galvanized staples provide sufficient protection at a lower cost. Maintain recommended spacing and correct leg length to avoid failures.

Commercial Flat Roofs

Flat roofs with membrane systems often prefer mechanical fasteners compatible with membrane manufacturer specs. For underlayment attachment, use corrosion-resistant staples sized to the underlayment and deck thickness. Always align with membrane fastening guidelines.

Resources For Further Information

Refer to shingle manufacturer installation guides, local building codes, and tool manufacturer stapler specifications for exact requirements. Technical bulletins from roofing associations provide data on wind testing and fastening methods.

Professional roofing contractors and supply houses can offer practical recommendations based on local climate and roof system composition.

Quick Checklist For Purchasing Roofing Staples

• Confirm Material: Stainless steel or hot-dipped galvanized for durability.
• Verify Gauge: 16–18 gauge for tar paper applications.
• Choose Crown Width: 7/16″–1/2″ to prevent pull-through.
• Select Leg Length: 1/2″–7/8″ based on deck thickness.
• Match Tool: Ensure stapler supports selected staples.
• Check Codes: Verify local code and manufacturer requirements.