How Are Asphalt Shingles Made?

Asphalt shingles have been around for a long time, and they’re one of the best choices for both new and existing homes. They offer numerous benefits and possibilities for all design types and budgets. Offering excellent protection against extreme weather conditions, asphalt shingles are inexpensive and easy to install. Understanding how asphalt roofing shingles are created is an important part of making an informed decision on which shingles to choose from.

What is an asphalt shingle?

Asphalt shingles are roofing shingles that are made out of a felt paper or fiberglass base that’s coated with a layer of waterproof asphalt and topped with ceramic granules. Due to their excellent performance, cost-efficiency, and customizability, asphalt shingles are the most popular type of roofing material in the USA today.

Today, the old 3-tab shingles are falling out of fashion and are being steadily replaced by the far more advanced and versatile architectural asphalt shingles. They’re also being made using more modern and eco-friendly roofing technologies that make them easier to recycle, replace, and maintain.

How is an asphalt shingle made?

Asphalt roofing shingles consist of an asphalt core placed between two layers of material that are glued together. Usually composed of ceramic-coated granules, the top layer offers UV protection from the sun’s rays. The bottom layer adds extra strength and stability against environmental factors like wind damage.

Shingle Production Process

Step #1: Fiberglass

Fiberglass mats made of glass fibers of specific diameters and lengths serve as the base that reinforces asphalt roofing shingles. They also provide fire resistance, weather protection, and extend the roof’s life.

The asphalt shingle manufacturing process begins with these fiberglass mats being bound together with binders and stable resins so that the other materials can be layered on top of them.

Step #2: Asphalt

This is the main ingredient of asphalt roofing shingles. Its purpose is to provide water resistance and keep protective granules in place. The asphalt used for this purpose is a final product of oil refining and looks and feels similar to road asphalt.

Unlike its road counterpart, however, shingle asphalt is heavily processed through oxidation to make it tougher and more resistant to the elements. This process includes boosting the asphalt’s viscosity by blowing air through it and mixing in fine mineral powder to increase each layer’s weather and fire resistance properties. It adds thickness and dimension, increasing the durability and fire resistance of the shingles.

Step #3: Granules

Finally, stone or ceramic granules are installed on top of the asphalt layers. These granules give the shingles their reflective qualities, and can also be painted and shaped in a variety of different ways to give the shingles their unique look and style. They can even be made to faithfully mimic other materials such as slate, wood, and more. They provide UV protection and prevent asphalt from cracking and drying out. Infused with copper to prevent algae and streaking. Also gives the roof its color, tone, and texture.

Benefits of Asphalt Shingles

There are a wide variety of benefits to using asphalt shingles for roofing.

• Lower installation costs
• Less maintenance than other types of shingles.
• Durability
• Fire resistance
• Most come with manufacturer warranties.
• Higher wind rating
• Variety of color options

Asphalt Shingle Creation Throughout Time

Asphalt roofing was first introduced in rolls before 1900. Companies began experimenting with various granules to add to their surface by 1897. All of the asphalt roofing consisted of an organic base material, usually cotton rag. Henry Reynolds, a roofer from Michigan, was the first person to cut rolls of asphalt roofing into individual shingles in 1901. By 1915, shingle manufacturers had begun producing pre-cut shingles.

After the National Board of Fire Underwriters started a campaign against wood shingles, manufacturers began using other organic materials for the base. In the 1950s, shingle sizes were standardized, and the first self-sealing asphalt shingles appeared. In 1960, the first asphalt shingles to use a fiberglass mat as a base were developed. By the late 1970s, an estimated 95% of all asphalt shingles used a fiberglass base.

Once the 21st century began, manufacturers started to react to the growing consumer demand for more architecturally intriguing asphalt shingles. These innovations have included new colors, textures, and three-dimensional effects, as well as shingles that imitate other kinds of roofing materials.

How Long Will Asphalt Shingles Last?

Whether you are buying or building a house, you need to know the age, condition, and material requirements of your new roof. Purchasing a new roof is a significant financial commitment, and you want to make sure you know how long the expected lifespan of your new roof is. Factors that determine the life expectancy of asphalt shingles include:

3-Tab Shingles

3-Tab shingles are made of three flat layers of asphalt, fiberglass, and mineral grains. They are affordable, durable, and suitable for sloped roofs. They are ideal for households on a budget and are best suited for temperate areas like the East Coast and Midwest.

Dimensional (Architectural) Shingles

Made of fiberglass with a thin layer of asphalt, dimensional shingles have a 25-year lifespan. They typically come with a 30-year warranty.

Premium Shingles

With a higher profile and longer lifespan, premium shingles are typically more luxurious and installed in high-end homes. They can withstand wind uplift up to 130 MPH, making them useful for areas prone to severe weather. However, they may not be suitable for areas with very cold winters or frequent storms.

Workmanship

The choice of a roofing contractor significantly impacts the lifespan of your asphalt roof. A reputable company with a good track record offers premium service, warranty, materials, and high-quality workmanship. Improper installation techniques can shorten the roof’s lifespan, so investing in high-quality materials and professional installation ensures long-lasting roof durability.

Weather Conditions

Asphalt roofs in warm regions like southern California, Texas, Nevada, New Mexico, or Arizona may deteriorate more quickly due to thermal shock and hail. This may result in premature failure and reduced insurance coverage.

Ventilation

The health of your roof depends on the ventilation of your attic, which helps maintain a comfortable temperature year-round. It reduces heat and moisture buildup and also prevents damage to your property and your roof’s warranty.

Roof Maintenance

Regular roof inspections and servicing are crucial for maintaining the roof’s lifespan and preventing the buildup of debris. Regular maintenance detects and fixes common roofing issues before they cause significant damage.

Are Asphalt Shingles Right For My Home?

Asphalt shingles are a popular choice for homes, offering protection against extreme weather, affordability, and ease of installation. Understanding their production process is beneficial for making an informed decision when investing in a new roof.

Where in Maple Shade, NJ & the rest of the Mid-Atlantic can I hire a quality roofing service?

The experts at Nu Look Home Design are your top choice for new roof installation with precision-crafted asphalt shingles. We offer industry-leading roofing warranties, including a manufacturer warranty, to protect your home’s roof for years to come.

Nu Look Home Design is an in-demand roofing company that operates across Maple Shade and other communities in New Jersey, Virginia, and Maryland. Our hard work and commitment to quality has earned us numerous awards, including 2020 Qualified Remodeler Top 500, and many others.

Get in touch today and experience a higher standard of service that puts your needs front and center, and ensures your long-term satisfaction.