ThermaLiner™ vs. TBS™: Which Butler Roof Insulation System Is Right for You?

When it comes to insulating a Butler MR-24® roof, builders have two standout options: the ThermaLiner™ system and the TBS™ (Thermal Blanket System). Both are engineered by Butler Manufacturing to boost energy efficiency, meet strict energy codes, and keep interiors comfortable year-round. But each system has its own strengths. If you’re wondering which one fits your next project best, this guide breaks it down—simply, accurately, and from a builder’s point of view.

What Both Systems Have in Common

Both ThermaLiner and TBS are designed to work with Butler’s MR-24 standing seam roof system, known for its weather-tight, long-lasting performance. Each insulation system has been tested in Butler’s Guarded Hot Box to ensure its R-values and U-factors are real—not just theoretical. That means you can trust the numbers you see on paper will hold up in the field.

Both systems help meet today’s tougher energy codes, reduce heating and cooling costs, and contribute to the overall strength and comfort of a metal building. But the way they get there—and the kind of finish they create—are very different.

The TBS™ Insulation System: Fast, Clean, and Efficient

If speed and simplicity are your top priorities, the TBS Insulation System is tough to beat. It’s installed entirely from the top of the roof framing—no need to crawl underneath to hang insulation bands or support straps.

Here’s how it works: a faced insulation blanket is rolled over the purlins, followed by a second layer of unfaced insulation held in place by steel brackets and channels. Because everything stays above the purlins, the vapor barrier (the facing on the insulation) remains intact—no holes, no punctures, no weak spots.

This design keeps installation fast and clean. Crews can insulate a large roof in a fraction of the time it would take using older systems. It’s also safer, since most of the work happens from the top. The system works with standard Z-purlins and Butler’s Truss PurlinXT™, and it’s compatible with Butler’s Sky-Web® fall protection netting for extra safety.

Thermal performance: TBS delivers tested R-values between R-28 and R-34, depending on configuration. That’s more than enough to meet or exceed modern building codes in most climates.

Interior appearance: When the job’s done, the inside of the roof has a smooth, bright white facing between the exposed purlins. It looks clean and professional—ideal for warehouses, manufacturing plants, or agricultural buildings.

In short, TBS is for builders who want a straightforward, fast-installing insulation system that still delivers solid energy savings and a neat finish.

The ThermaLiner™ System: Premium Performance and a Finished Look

If the building’s interior will be visible or needs to look polished, the ThermaLiner Insulation System is the way to go. It’s the higher-end option, but for good reason.

ThermaLiner starts with a steel liner panel fastened to the underside of the roof structure. This forms a sturdy, attractive interior ceiling right away. Once the liner is in place, multiple layers of unfaced insulation are added above it, followed by the MR-24® roof panels on top.

The liner panel isn’t just for looks—it acts as a built-in vapor barrier, protecting the insulation from moisture. Because fixtures like lights, ducts, and sprinklers are mounted below the panel, the vapor seal stays completely intact.

Thermal performance: With uncompressed insulation up to 13 inches thick, ThermaLiner can reach R-values as high as R-38.7 (U-factor 0.026)—the highest of any Butler roof insulation system.

Interior appearance: The finished look is smooth, bright, and architectural. Available in unpainted Galvalume® or painted finishes, the liner panels create a clean metal ceiling that reflects light, improves acoustics, and adds a sense of quality to the space.

ThermaLiner is ideal for offices, schools, retail stores, and athletic facilities—anywhere the underside of the roof will be seen and needs to look finished.

Vapor and Moisture Control

Condensation can be a silent problem in metal buildings, but both systems handle it exceptionally well.

• TBS: The faced insulation acts as the vapor retarder. Because there are no punctures from bracing or banding, the vapor barrier stays continuous—keeping moisture out of the insulation.
• ThermaLiner: The steel liner panel itself forms a tight vapor barrier, and an optional vapor sheet can be added for extreme conditions. It’s the most moisture-resistant setup Butler offers and perfect for buildings with high humidity, like gyms, pools, or food-processing facilities.

Installation Speed and Efficiency

• TBS = Fastest Install: Crews install everything from the top, with minimal materials and steps. There’s no banding, no interior work, and less labor overall.
• ThermaLiner = Quick Enclosure: While it takes an extra step to install liner panels, those panels create an instant enclosed ceiling. They also serve as a sturdy work platform for crews finishing the roof above—handy in bad weather.

In other words, TBS wins for raw speed, while ThermaLiner wins for functionality during construction and long-term finish quality.

Interior Finish: Industrial vs. Architectural

TBS leaves a bright, practical finish: white insulation between steel beams. It looks good in functional spaces where durability and brightness matter more than design.

ThermaLiner, on the other hand, delivers a professional, polished look. The steel liner panels hide the insulation and structure, creating an attractive, easy-to-clean ceiling. For clients who plan to leave the ceiling exposed, this system elevates the entire space.

Thermal Performance Comparison

Which One Should You Choose?

Choose ThermaLiner™ if:

• The building interior will be visible to the public.
• You need the highest R-values and best vapor protection.
• You want a clean, professional ceiling finish that doubles as a vapor barrier.

Choose TBS™ if:

• Speed, simplicity, and cost-efficiency are the main goals.
• The space is industrial, storage, or utility-oriented.
• You want strong energy performance without extra steps or materials.

Both systems are engineered to integrate perfectly with Butler’s MR-24® roof, providing decades of reliable performance and energy savings. Whether your project calls for the clean lines of ThermaLiner or the quick efficiency of TBS, you’ll get a roof that performs as well as it looks.

Wrapping Up

When you pair a Butler MR-24® roof with the right insulation system, you’re building for comfort, efficiency, and longevity.

ThermaLiner and TBS represent two smart ways to get there: one focused on premium performance and aesthetics, the other on speed and simplicity.

Whichever you choose, you’ll be getting a system tested, proven, and backed by Butler’s engineering expertise—and that means a more efficient, longer-lasting building your clients will appreciate for decades to come.

Continued Learning

Learn more about Butler Insulation Systems, the MR-24® Roof System, and how cool roof coatings and insulation together maximize building performance.