Asphalt shingles
Creating Asphalt Shingles
Creating asphalt shingles is a multi-stage industrial manufacturing process that combines raw materials, engineering controls, and quality testing to produce one of the most widely used residential roofing materials in North America. Asphalt shingles are designed to provide water shedding, UV protection, fire resistance, and long-term durability while remaining cost-effective and easy to install.
This article explains how asphalt shingles are made, from raw material selection to final packaging, and how manufacturing decisions affect roofing performance.
What Are Asphalt Shingles?
Asphalt shingles are roofing materials composed of a fiberglass or organic mat saturated with asphalt and coated with mineral granules. They are primarily used on sloped roofs and are valued for their balance of durability, affordability, and ease of repair.
Asphalt shingles are commonly compared with systems such as Metal Roofing and other Residential Roofing options.
Raw Materials Used in Asphalt Shingles
The performance of asphalt shingles depends heavily on the materials used during production.
Fiberglass Mat
Most modern shingles use a fiberglass base mat, which provides:
Structural strength
Fire resistance
Dimensional stability
Older organic mats (felt-based) are largely obsolete due to lower durability.
Asphalt Coating
Asphalt acts as the waterproofing component. It is refined and modified to:
Resist UV degradation
Remain flexible in cold temperatures
Maintain adhesion in heat
Mineral Granules
Ceramic-coated granules are embedded into the surface to:
Protect against UV exposure
Add color and aesthetic appeal
Improve fire resistance
Adhesives and Sealants
Thermally activated seal strips allow shingles to bond together once installed, improving wind resistance.
Step-by-Step Manufacturing Process
Step 1: Mat Formation
Fiberglass strands are bonded together to form a thin, strong mat that serves as the structural backbone of the shingle.
Step 2: Asphalt Saturation
The mat passes through hot asphalt, which saturates and coats it to create a waterproof barrier.
Step 3: Granule Application
Mineral granules are pressed into the asphalt-coated surface while it is still hot. Excess granules are reclaimed and recycled back into production.
Step 4: Cooling and Cutting
The coated sheet is cooled, stabilized, and cut into standard shingle dimensions, including architectural and 3-tab profiles.
Step 5: Seal Strip Application
Self-sealing adhesive strips are applied to ensure shingles bond properly during installation.
Step 6: Packaging
Finished shingles are bundled, labeled, and prepared for distribution to suppliers and contractors.
Quality Control and Testing
Manufacturers perform extensive testing to ensure shingles meet industry standards:
Wind resistance testing
Fire rating verification
Granule adhesion testing
Tear strength evaluation
Weathering and aging simulations
These standards help ensure compatibility with local building codes and performance expectations outlined in Roof Warranties Explained.
Environmental Considerations
Modern asphalt shingle manufacturing includes sustainability efforts such as:
Recycling scrap materials
Using reflective granules for energy efficiency
Reducing volatile organic compound (VOC) emissions
Some asphalt shingles contribute to Energy-Efficient Roofing Systems when designed with solar-reflective surfaces.
How Manufacturing Affects Roof Performance
The way asphalt shingles are created directly impacts:
Resistance to leaks
Lifespan and aging characteristics
Granule retention
Wind uplift performance
Improper manufacturing or low-quality materials can lead to premature failure, which is often identified during Roof Inspection and Maintenance.
Common Uses of Asphalt Shingles
Asphalt shingles are primarily used for:
Single-family homes
Multi-family residential buildings
Light commercial structures with steep slopes
They are not typically recommended for flat or low-slope roofs, where systems like TPO Roofing or Modified Bitumen Roofing are more appropriate.
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