Understanding the Manufacturing Process of Shingles and the Importance of Underlayment and Ventilation - West Bend, WI

Did you know that more than 80% of Americans rely on asphalt shingles to shield their homes from the weather? This isn't a coincidence; shingles provide a practical and effective way for your roof to repel water. In this blog post, I aim to explore how shingles are made, examine underlayment and ventilation, and discuss their advantages and disadvantages.

The Making of Shingles

A good place to start would be to talk about how an asphalt shingle is made. The foundation of most modern shingles is fiberglass. During the manufacturing process of shingles, a large roll of fiberglass is run through a machine that applies hot asphalt to both sides of the fiberglass sheet.

Vintage Asphalt Shingle Manufacturing

Older shingles used to have a paper foundation, which was less flexible and had a poor fire rating. While the asphalt is still hot, the sheet of fiberglass is run through a blender, which applies the granules to the shingle. These granules are applied in multiple layers to create a rugged and aesthetically pleasing outer surface. (At this point, the process changes depending on which type of shingle you are making, but for this blog, we will talk about architectural shingles, which are the most common shingle type). Once the granules are added to the shingle, the large rolls are cut to create the iconic tabs. From here, a solid layer of shingle is applied to the back of the tabs using laminating asphalt to create a solid backing (unlike 3-tab shingles). All that is left to do is cut the shingles to the proper length and package them up.

Underlayment's and Ventilation

Shingles are not the only component of a new roof though, underlayment's and venting are essential for proper water resistance and temperature control in the attic.

Lets introduce your Wisconsin underlayment essentials:

Owens Corning (Pro Armor) - Synthetic Underlayment

Synthetic Underlayment: Made of woven polypropylene fibers, synthetic underlayment is a water-repellent layer that goes between the roof deck and the shingles. Unlike older felt underlayment's, synthetic underlayment will not degrade, wrinkle, or crack during Wisconsin's fluctuating seasons.

Grace - Ice & Water Shield

Ice & Water Shield: Made from rubberized asphalt material that is peeled and stuck to the roof decking. Wisconsin winters cause ice damming and ice & water shield is designed to self seal when applied and acts as a thick secondary layer of protection. Ice and water should be used in valleys, eaves, and around all roof penetrations. If you want to prevent ice damming during these brutal Wisconsin winters, ice & water will be your best friend.

Now lets talk about attic ventilation in Wisconsin:

Owens Corning (Venture) - Ridge Vent

Attic ventilation requires the strategic placement of intake and exhaust vents to ensure proper air circulation. Intake vents are typically located in the eaves or soffits, while exhaust vents are positioned near the roof's ridge line. In Wisconsin, the warm, moist summer air is expelled through the ridge vent as fresh air enters through the soffits. In winter, a continuous airflow is drawn into the attic, maintaining a consistent attic temperature. This stable temperature is crucial for preventing ice damming, as it prevents the snow on the roof from repeatedly freezing and thawing.

Shingles vs Other Methods

Having learned how shingles are manufactured and the significance of underlayment and ventilation, we can now evaluate the advantages and disadvantages of asphalt shingles:

Advantages:

• Cost Effective: Thanks to modern advancements in shingle production, consumers can enjoy the cost benefits of mass production.

• Weather Durability: In our local Wisconsin climate, the combination of asphalt shingles, ice & water, and synthetic underlayment is the trifecta for combating the hottest of hots and the coldest of colds... oh and the snow too.

• Aesthetics: Asphalt shingles come in a wide range of colors, enhanced by the granule blender. For architectural and luxury shingles, the manufacturing layering adds depth, making your roof stand out.

Disadvantages:

• Wind & Hail: While asphalt shingles are durable, they are not immune to damage from Wisconsin’s frequent severe weather. High winds can lift or tear shingles, breaking their seal and exposing the underlayment to moisture. Similarly, hail can crack shingles, dislodge granules, and even puncture older or lower-quality shingles. These vulnerabilities can lead to leaks, reduced insulation, and long-term structural damage if left unchecked.

• Lifespan Compared to Alternatives: You can plan on your asphalt shingle roof lasting from 20-30 years. Metal roofing on the contrary can last upwards of 50 years but has an increased cost.

• Issue at Low-Slope: For homes with low-slope roofs, shingles may not provide adequate water runoff, increasing the risk of leaks. This is a critical consideration for some Wisconsin homes.

As we conclude this blog post, I hope you found valuable insights that enhanced your understanding. Knowledge is vast, and even small discoveries can lead to greater awareness. Explore our other posts for a variety of topics, practical tips, and engaging narratives. Whether you're looking for analyses, personal stories, or expert advice, there's something for everyone. Browse through our articles—your next great discovery may be just a click away!