The asphalt shingle recycling industry has experienced a remarkable transformation in Illinois, led by companies like Southwind Recycled Asphalt Shingles (RAS). As the construction industry continues to seek sustainable alternatives for road building materials, the processing and reuse of tear-off asphalt shingles has emerged as a practical solution. This shift mirrors other advances in roofing technology, such as the New Racking Criteria for Asphalt Shingle Roof Systems that address solar integration standards. Southwind RAS, which began operations in 2010, diverted over 70,000 tons of asphalt roofing shingles from landfills in its first year and plans to recycle 100,000 tons annually.
The Rise of Shingle Recycling in Illinois
The story of Southwind RAS begins with founder Mike Vondra, who had operated a sand and gravel mine and a concrete and asphalt pavement recycling facility in Bartlett, Illinois since 1988. Recognizing the potential for shingle recycling as a natural extension of his existing operations, Vondra invested substantial time researching market conditions and product potential before launching the venture.
Company Growth and Expansion
Southwind RAS started with a seminal location in Bartlett and expanded rapidly across Illinois. The company now operates facilities in multiple strategic locations:
- Lyons – Western suburban Chicago location handling significant throughput
- Peoria – Central Illinois facility serving downstate asphalt producers
- South Beloit – Northern Illinois location near the Wisconsin border
- Thornton – Facility under construction in the southern suburbs of Chicago
- Romeoville – New facility in the southwestern corridor of the metro area
- Lake in the Hills and Lake County – Facilities in the zoning and permitting phase
The company employs 25 people and continues to add personnel as additional facilities become operational. Its primary customer base consists of hot mix asphalt (HMA) producers throughout Illinois who incorporate recycled shingle material into their pavement mixes.
The Three Major Benefits of Shingle Recycling
According to M. Slade O’Keefe of Southwind RAS, recycling asphalt shingles delivers three significant advantages that make it an attractive option for state agencies, contractors, and environmental regulators alike.
- Landfill conservation: Shingles consume substantial space in landfills. Recycling diverts this material from disposal sites, preserving precious landfill capacity for materials that cannot be recycled.
- Superior pavement performance: Recycled shingle material creates a better, more durable pavement mix. The asphalt content in shingles enhances binder properties and improves the overall performance characteristics of the finished road surface.
- Cost savings: Using recycled shingles provides measurable cost savings to both contractors and public works agencies. These savings allow transportation departments to complete more projects within their budgetary constraints.
To understand how shingles perform over time in building applications, professionals can review research on Understanding Asphalt Shingle Failure Over Structural Insulated Panels, which provides insight into material behavior under different conditions.
The Shingle Recycling Process Step by Step
The recycling process at Southwind RAS involves a carefully controlled sequence of inspection, cleaning, grinding, and screening steps. Each stage is designed to ensure the final product meets Illinois Department of Transportation (IDOT) specifications while maintaining worker safety.
Receiving and Asbestos Testing
The process begins before material enters the facility. Every truckload of tear-off shingles undergoes a rigorous screening protocol:
- Shingles enter the site and receive an initial visual screening by a Certified Asbestos Inspector.
- The truck is directed to a tipping area where the load is inspected a second time.
- Loads are impounded for formal asbestos testing. IDOT requires two samples per every 250 tons of inbound material.
- Shingles remain impounded until test results are returned and the pile is cleared for processing.
This stringent testing protocol reflects the regulatory environment in Illinois. Asbestos has been a stated concern for state agencies, and compliance is mandatory for all recycling operations. Each facility maintains a Certified Asbestos Inspector on staff, and samples are sent to independent third-party laboratories for analysis.
Sorting and Cleaning
Once cleared, shingles proceed through a multi-stage cleaning process using custom-built conveyor equipment:
- Shingles are loaded into a feeder and pass over a belt magnet to remove steel debris such as nails and flashing.
- Material runs up a conveyor to the sorting station, where workers manually remove paper, plastic, felt, and non-ferrous metals.
- Shingles proceed to a second sort line for final cleaning and quality verification.
- Material passes under a second magnet to ensure no large metal pieces reach the grinder.
After cleaning, the shingles are stockpiled in preparation for grinding. The clean material is processed using a Rotochopper RG1 Shingle Recycler, a machine specifically designed for this application.
Grinding, Screening, and Final Testing
The ground shingle material must meet strict gradation specifications before it can be sold to HMA producers:
| Parameter | Requirement | Testing Frequency |
|---|---|---|
| Passing 3/8 inch Sieve | 100 percent | Per production batch |
| Passing No. 4 Sieve | 93 percent minimum | Per production batch |
| Asbestos content | Non-detectable | 1 test per 500 tons |
| Steel content | Removed to specification | Continuous magnetic separation |
Final gradation is achieved using one of two trommel screens: a Vermeer-Wildcat 621 or a Powerscreen 830. These screens ensure precise particle size distribution. After screening, the material is impounded for a second round of asbestos testing at a rate of one test per 500 tons. Only material that passes all tests is loaded and delivered to HMA producers.
Challenges in the Recycled Shingle Industry
Introducing recycled asphalt shingles as a new product category in Illinois has required substantial effort in education, regulation, and quality control. The challenges faced by Southwind RAS illustrate the work involved in establishing a new recycling industry.
Agency Education and Specification Development
O’Keefe identifies the greatest single challenge as education. Because recycled shingles were a new product in Illinois, significant outreach was necessary for both state agencies and HMA producers. Southwind RAS worked closely with multiple agencies to develop appropriate specifications:
- Illinois DOT (IDOT) – Collaborated on specifications, quality control protocols, and final product acceptance criteria
- Illinois Tollway – Coordinated on gradation requirements and testing procedures for toll highway projects
- Illinois EPA – Worked on permitting and environmental compliance standards
The company invested countless hours supplying technical information, conducting tests, and sharing results with regulatory bodies. Detailed cost analysis summaries were prepared to illustrate the savings achievable through recycled shingle use. Southwind also shared case studies from contractors in other states who had already used RAS material successfully.
Asbestos Management and Worker Safety
Asbestos remains the most sensitive regulatory issue for shingle recycling in Illinois. Southwind RAS has implemented a comprehensive safety program to address this concern:
- Certified Asbestos Inspectors are stationed at every location for visual inspections and sample collection
- All samples are tested offsite by independent third-party laboratories
- Every worker receives site-specific training on asbestos awareness and handling procedures
- Supplier training sessions are conducted with every provider of tear-off shingles
- Semi-annual air sampling is conducted at each facility to ensure worker safety, as required by permits
The principles of material reuse extend beyond shingles. The construction industry has made significant progress in Wastewater Recycling and other material recovery applications that follow similar principles of contamination control and quality assurance.
Supply Chain and Material Sourcing
Currently, Southwind RAS processes primarily tear-off shingles from residential and commercial roof replacement projects. The majority of these shingles are supplied by waste transfer stations. However, the company has begun developing a program to source directly from roofing contractors, which offers several advantages:
- Reduced contamination from mixed waste streams
- Better traceability of material origin
- More consistent material quality for processing
- Lower handling and transportation costs
As the business develops, Southwind plans to begin accepting manufacturer waste shingles in addition to tear-offs, further diversifying its supply base and increasing total throughput capacity.
The Future of Recycled Asphalt Shingles
The outlook for recycled asphalt shingles in Illinois and beyond is positive. As operational experience grows and specifications mature, the industry is positioned for significant expansion.
Operational Refinement and Growth
O’Keefe expects operations to become increasingly streamlined as the company works through the difficulties inherent in starting a new industry. Current focus areas include:
- Improving processing efficiency through equipment optimization and workflow refinement
- Expanding the direct supply program to capture more material from roofing contractors
- Developing new facility locations to reduce transportation distances for HMA producers
- Exploring expansion into surrounding states as the market matures
The company envisions the use of RAS material becoming more widespread as more contractors and agencies gain experience with its performance benefits. For additional context on roofing material selection and installation practices, the Asphalt Shingle Roofing Guide provides comprehensive technical information for building professionals.
Industry Events and Knowledge Sharing
The growth of the shingle recycling industry has been supported by conferences and forums that facilitate knowledge sharing among industry participants. The Asphalt Shingle Recycling Forum, titled A New Era in Asphalt Shingle Recycling: Tear Off Recycling Comes of Age, has become the premier conference in this field. The event brings together:
- Companies entering the shingle recycling market
- Technical experts presenting the latest research on recycled shingle properties
- Regulatory officials discussing specification updates and compliance requirements
- HMA producers sharing field performance data and cost analysis results
Environmental and Economic Impact
The trajectory of shingle recycling in Illinois demonstrates how a well-executed recycling program can deliver simultaneous environmental and economic benefits. With Southwind RAS processing 100,000 tons of material annually, the cumulative impact on landfill conservation, pavement quality, and project cost reduction is substantial. As more states follow Illinois lead in developing RAS specifications, the construction industry moves closer to a truly circular material economy for asphalt products.