How Are Roofing Shingles Made?
To ensure roofing shingles protect your home and endure the various elements, they undergo a careful manufacturing process. The foundation of asphalt shingles can be organic felt or fiberglass. The shingles are produced by passing the base material through a roofing machine that successfully adds other components. Here’s how roofing shingles are made:
One jumbo roll of either fiberglass or organic felt mat that measures around 6ft in diameter is mounted and fed into a roofing machine. This is done in an accordion style to ensure the device continues operating when one roll is exhausted, and a new one is mounted.
The base material then passes through a presaturation chamber where hot asphalt is sprayed on one side to remove any moisture and make good shingles. It then goes through a saturator tank that contains hot asphalt. The fibers within the mat are coated, and the voids between them filled as it soaks in the asphalt.
The mat is again formed into accordion-like folds. As the asphalt coating cools, it’s drawn into the felt, where an even greater degree of saturation is created.
Both mat surfaces are then applied with asphalt coating, which has been stabilized with powdered minerals. The mat passes through a pair of coating rolls separated by an appropriate distance to ensure the correct amount of coating is applied. Sometimes the saturation and wet looping steps can be skipped with fiberglass because this step is enough to coat and fill the voids between them.
Ceramic-coated mineral granules of the desired color are then applied to the top surface of the asphalt-coated mat. On the back surface, a coating of fine mineral particles like mica talc is applied. The mat then goes through a series of rollers that embed the coating particles in the asphalt and cool it.
Finishing, Cutting, And Packaging
The roofing material strip is then accumulated on a cooling looper to finish cooling. The finished shingle material is then passed through a cutting machine and cut into the desired shape and size. The device also separates and stacks the shingles in bundles. The bundles are then transferred to equipment that wraps them and affixes labels.
Quality control begins at the manufacture of the base material. It has to perform well in the final product and have enough tear resistance and tensile strength to withstand the shingle-making process. In manufacturing, the thickness and uniformity of the coating are monitored. Mineral coating application is monitored to ensure proper embedding of particles and uniform distribution. Finished shingles are inspected to verify correct size, count, weight, and color.