The manufacturing procedure for the natural asphalt shingle is a method where a natural felt material (a choice between recycled paper fibres or wood fibers) is reduced to a pulp, formed into sheets which are then dried out, cut into strips, and placed on rolls. Fibreglass shingles are produced from a fibreglass strengthening pad. For making the mat, thin glass filaments are cut and blended with water to form a pulp, after which it is made in to a sheet. Any remaining water will be cleaned out from the pulp and a binder is added in.
The process of producing the asphalt shingle is identical for natural or fiberglass shingles. To make the roofing shingles, a roll of either the organic felt or the fiberglass mat is fed right into a dry looper. Asphalt is used in the manufacturing, but not necessarily in the same state as the asphalt used in asphalt pavement. Prior to using asphalt for producing roofing shingles, it must be oxidized. To get this done, air needs to be bubbled through hot asphalt (using the appropriate added catalysts) to spark a chemical reaction. This product is an asphalt that softens at the proper temperatures to make an excellent shingle. After the oxidation method, mineral stabilizers such as finely ground limestone or ash are added to produce the asphalt more durable. Fascinating fact, Gloeocaspa Magma which is a type of cyanobacteria feeds off of the limestone filler and will form the black mold commonly seen on shingle roofs. While roof cleaning can be difficult with moss, black mold isn't as much of a problem yet. Moss removal is best acheived with non aggressive roof cleaning strategies.
The slury then passes through a saturation chamber, where hot asphalt is then sprayed to remove any bits of moisture. Then the material is set inside a hot tank of asphalt to cover the shingle fibers and fillin any holes. As the boiling asphalt cools down it soaks into the felt fibers even more which encourages even more saturation to protect against UV rays and moisture. Then a hot coating of stabilized asphalt with minerals is then applied to the surfaces of the mat. Finally, a thin layer of minerals is applied to the backside surface of the pad and it's also exposed to rollers to ensure the minerals are pushed in to the asphalt. By now, the asphalt has cooled and the felt can go into the cutting piece of equipment. The roofing shingles are cutin the back area right into a specified configuration. The cut asphalt shingles are then stacked into bundles, wrapped, and labeled for sale. Although additives can be added to the shingle manufacturing process to assist against moss growth, roof moss treatment is still an annual event.
Some remnants remain when tabs are cut on the asphalt roofing shingles. In recent times, these remains have been recycled for use in making asphalt for roads.
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