What are shingles made of • The Creation Process of Asphalt Roof Tiles

Asphalt roof tiles, renowned for their variety in hues, textures, and designs, are among the most cost-effective roofing options available. Not only are they budget-friendly, but they also boast remarkable durability, with some even offering lifetime guarantees.

However, they're only suitable for roofs with a sufficiently steep gradient.

Building the Core of the Asphalt Roof Tile

The core of every asphalt roof tile, known as a membrane, can be manufactured from fiberglass or, like in our case, from organic fibers such as woodchips, recycled cardboard, and paper. These huge membrane rolls are fed into a device termed the 'felt looper', which accumulates a significant reserve. This system allows the production process to continue seamlessly, even when the rolls need to be replaced.

Application of Liquid Asphalt

The membrane then advances into a machine called the saturator, where it is thoroughly soaked in hot liquid asphalt, a derivative of petroleum. Upon drying, this saturation renders the membrane impermeable. Following this, a thicker asphalt coating intermixed with powdered limestone is applied to both sides of the membrane, thereby enhancing its flexibility and creating a protective barrier against harsh weather.

Adding Colour and UV Protection

While the coating remains wet, colored ceramic granules are spread across the top surface. This process is twofold: it imbues the tiles with their characteristic color and provides resistance against the sun's ultraviolet rays. Any granules that fail to adhere to the wet asphalt are recycled back into the production line.

Preventing Sticking and the Cooling Process

Subsequently, a cellophane strip is attached to the back surface to prevent the tiles from sticking together during packaging. Additionally, the back surface is showered with powdered stone as an extra anti-sticking measure. The asphalt coating, at this stage, is still exceedingly hot, rendering it unfit for cutting into appropriate tile sizes. Consequently, the material is moved to the cooling section, where cold rollers and water jets effectively reduce its temperature.

Adhesive Application and Cutting

The subsequent machine applies strips of adhesive asphalt, which are activated by the sun's heat to keep the tiles adhered to each other. The same process is employed for all tile colors, but the variations begin with the manner in which the tile's bottom edge is cut, determining its profile.

Final Production Steps

On route to the cutting station, the tile material is passed through the 'finish looper', similar to the earlier felt looper, ensuring production continuity. The tiles are cut to the standard size and profile, measuring 100 by 33.7 centimeters.

Some styles feature a curved bottom, while others have a straight edge. An automated counter monitors production, automatically stacking the tiles for packaging, typically 21 sheets per bundle, covering approximately three square meters of roof.

Variety and Packaging

Asphalt tiles are available in around 50 distinct colors and a dozen shapes and profiles. Each bundle of tiles is wrapped in polyethylene-treated paper to prevent water seepage. These bundles are then placed onto pallets, which are wrapped in a plastic bag that is both water and UV resistant.

Warranty and Durability

Warranties for asphalt tiles vary, ranging from 20 years to a lifetime. Typically, the thickness of the asphalt and granule protective barrier determines the tiles' durability and warranty duration.