Manufacturing of Asphalt Shingles
The manufacturing process of the organic asphalt shingles is a process where an organic felt material (either recycled paper fibers or wood) is reduced to a pulp, formed into sheets which are then dried, cut into strips, and placed on rolls. Fiberglass shingles are made from a fiberglass reinforcing mat. To make the mat, fine glass filaments are chopped and mixed with water to form a pulp, and then is formed into a sheet. Any remaining water is then vacuumed out of the pulp and a binder is added in the shingle making process.
The process of making organic shingles
The process of manufacturing the asphalt shingle is the same for organic or fiberglass shingles. To make the shingle, a roll of either the organic felt or the fiberglass mat is fed into a dry looper. Asphalt is used in the manufacturing, but not in the same state as the asphalt used in asphalt pavement. Prior to using asphalt for making shingles, it must be oxidized. To do this, air must be bubbled through hot asphalt (with the appropriate added catalysts) to cause a chemical reaction. The product is an asphalt that softens at the correct temperatures to produce a good shingle. Following the oxidation process, mineral stabilizers such as finely ground limestone or ash are added to make the asphalt more durable. Interesting fact, Gloeocaspa Magma which is a form of cyanobacteria feeds off of the limestone filler and will form the mold commonly seen on shingles.
Asphalt shingles come in different shapes and sizes
The shingles are then passed through a pre-saturation chamber where it is sprayed with hot asphalt to remove any moisture. Then, it is placed into a tank of hot asphalt to coat the fibers and fill any remaining holes. As the asphalt cools, it is drawn into the felt which ensures greater saturation, weather resistance, and UV protection. Next, a coating of asphalt that has been stabilized with minerals is applied to all surfaces of the mat. Then, a layer of fine mineral particles is applied to only the back surface of the mat and it is put through rollers to ensure the minerals are pushed into the asphalt. By this time, the asphalt has cooled and the sheet can enter the cutting machine. The shingle is cut from the back side into a specified shape and size. The cut asphalt shingles are then stacked into bundles, wrapped, and labeled for sale.
Some remnants are left when tabs are cut on the asphalt shingles. In recent years, these remnants have been recycled for use in making asphalt for roads.
