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Tar paper
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Tar paper
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Tar paper on a wall exposed by tornado damage in Oklahoma, used as a moisture-resistant backing for a masonry veneer exterior wall

Tar paper, roofing paper, felt paper, underlayment, or roofing tar paper is a heavy-duty paper used in construction. Tar paper is made by impregnating paper with tar, producing a waterproof material useful for roof construction. Tar paper is similar to roofing felt,[1] historically a felt-like fabric made from recycled rags impregnated with melted asphalt, and today evolving into a more complex underlayment of synthetic mesh or fiberglass strands waterproofed by synthetically enhanced asphalt.

Description

[edit]
Workers using roofing shovels to remove asphalt shingles from a roof. They are standing atop a layer of what appears to be tar paper, a bitumen or asphalt impregnated waterproofing layer between the shingles and the wood roof sheathing.

Tar paper has been in use for centuries. It is defined as a Grade D building paper—a designation derived from a federal specification in the United States.[citation needed] Sometimes anachronistically referred to as "building paper", tar paper is manufactured from virgin kraft paper (as opposed to the fabric-based or synthetic mesh substrates of roofing felt) impregnated with asphalt. The result is a lighter-weight but less durable product with similar properties to felt.

Grade papers are rated in minutes: the amount of time it takes for a moisture-sensitive chemical indicator to change color when a small boat-like sample is floated on water. Common grades include 10-, 20-, 30-, and 60-minute. The higher the rating, the heavier and more moisture-resistant the paper. A typical 20-minute paper will weigh about 3.3 pounds (1.5 kg) per square, a 30-minute paper 3.75 pounds (1.70 kg) per square, and a 60-minute paper about 6 pounds (2.7 kg) per square. The smaller volume of material, however, does tend to make these papers less resistant to moisture than heavier felts.

Uses

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Tar paper is used as a roofing underlayment with asphalt, wood, shake, and other roof shingles as a form of intermediate bituminous waterproofing. It is sold in rolls of various widths, lengths, and thicknesses – 3-foot-wide (0.91 m) rolls, 50 or 100 feet (15 or 30 m) long and "15 lb" (7 kg) and "30 lb" (14 kg) weights are common in the U.S. – often marked with chalk lines at certain intervals to aid in laying it out straight on roofs with the proper overlap (more overlap for flatter roofs).

It is typically stapled in place, or held with roofing nails, and is sometimes applied in several layers with hot asphalt, cold asphalt (adhesive), or non-asphaltic adhesives.[2]

Older construction typically used a lighter-weight tar paper, stapled up with some overlap, as a water- and wind-proofing material on walls, largely displaced in recent decades by breathable plastic housewrap, commonly in 8-or-10-foot (2.4 or 3.0 m) widths.

Tar paper shack in Minnesota in 1939

In the 19th and early 20th centuries, shacks of wooden frames covered with tar paper were a common form of temporary structure or very low-cost permanent housing in the rural United States and Canada,[3][4] particularly in the temperate American South.

References

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Tar paper

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Tar paper, also known as roofing felt or asphalt felt, is a heavy-duty, waterproof consisting of a base sheet of paper, mat, or fibers saturated with asphalt, , or to create a durable barrier. It is primarily used in as an underlayment beneath roofing or other exterior coverings, providing secondary protection against water infiltration, wind-driven rain, ice dams, and minor leaks while allowing some vapor transmission to prevent trapped . This material is essential for safeguarding the deck and underlying structure from rot, mold, and deterioration, and it contributes to achieving ratings when combined with compatible roofing systems. The development of tar paper began in the mid-19th century during the , when it was employed to quickly waterproof makeshift buildings and mining camps using simple impregnation techniques with tar on rag or early paper bases. By the early , production advanced to incorporate wood pulp fibers mixed with asphalt for broader commercial use, and some formulations included for enhanced tensile strength until its health risks prompted discontinuation in the . Standardized under ASTM D226 for asphalt-saturated organic felt and ASTM D227 for coal-tar variants, tar paper has evolved into a reliable, breathable option that meets modern building codes for steep-slope roofing and applications. Beyond roofing, tar paper serves as a weather-resistive barrier in exterior walls, siding installations, and temporary enclosures, helping to block liquid water while permitting drying in humid conditions. Common types include #15 and #30 felts, named for their approximate weight in pounds per 100 square feet, with the heavier #30 variant offering greater tear resistance and suitability for low-slope or high-exposure roofs. Although synthetic underlayments have gained popularity for superior tear strength, UV resistance, and ease of installation, tar paper continues to be valued for its affordability, proven longevity of up to 25 years under normal conditions, and compliance with industry standards from organizations like the National Roofing Contractors Association (NRCA).

Overview

Definition and Purpose

Tar paper is a type of saturated roofing felt consisting of heavy or impregnated with asphalt or tar-derived , serving as a foundational in . This material creates a durable, flexible sheet that enhances the overall integrity of roofing systems by acting as an intermediary layer. Its primary purpose is to function as a weather-resistant underlayment, providing secondary to protect the roof deck from infiltration and acting as a semi-permeable layer that retards vapor while allowing limited transmission to help regulate within the . By repelling water while allowing limited breathability, tar paper helps prevent leaks, ice damage, and premature deterioration of primary roofing materials like . This role is essential in ensuring long-term structural protection without compromising the roof's ventilation. The term "tar paper" derives from its historical saturation with coal tar, a byproduct of coal distillation, though contemporary formulations primarily utilize petroleum-based asphalt for improved performance and availability. Standard weights for tar paper, such as 15-pound or 30-pound per 100 square feet, indicate the level of saturation and thus the material's thickness and durability, with the 15-pound variant suited for lighter applications and the 30-pound offering greater robustness for demanding conditions.

Physical Characteristics

Tar paper, also known as asphalt-saturated roofing felt, appears as dark black, flexible sheets due to the asphalt impregnation of the organic felt base material. These sheets typically exhibit a slightly rough or gritty texture from the saturated felt fibers. The material is supplied in rolls, with common dimensions including 36 inches wide by 144 feet long for lighter-weight versions, covering approximately 432 square feet per roll, while heavier variants are often 36 inches by 72 feet, covering 216 square feet. Thickness generally ranges from 0.03 to 0.05 inches for standard #15 felt, increasing to about 0.06 inches for #30 felt, influencing overall weight and handling characteristics. Key performance properties are defined by standards such as ASTM D226 for traditional asphalt-saturated organic felt. Water impermeability is achieved through the asphalt saturation, enabling the material to pass a 4-hour shower resistance test on a 14-degree inclined surface without leakage under ASTM D4869, making it suitable as a secondary barrier. For vapor transmission, it offers semi-permeable characteristics with a rating of approximately 5 to 6 perms when dry, allowing controlled moisture escape while resisting liquid penetration. Mechanical strength includes tensile strength of 40 lbf/in in the machine direction and 20 lbf/in cross-machine for Type II, with Type I having lower values as per standard, ensuring durability during installation and wind uplift. Tear resistance is provided at a minimum of 0.9 lbf in both directions for equivalent heavier-weight specifications under ASTM D4869 Type IV, which aligns with upgraded Type II felt performance. Pliability is tested to pass a 90-degree bend over a 0.50-inch for Type I at 77°F (25°C) and 0.75-inch for Type II, indicating flexibility without cracking under moderate conditions. Durability metrics highlight short-term resistance to environmental exposure, with UV tolerance limited to 30 days maximum before covering to prevent degradation from solar radiation. The material withstands temperatures from approximately 0°F to 140°F (-18°C to 60°C) without significant or softening, though it may become less pliable below freezing and soften in prolonged high heat. Saturation levels meet a minimum of saturant mass at least 1.5 times the dry felt mass for both Type I and Type II, contributing to overall stability and mass per 100 square feet ranging from 11.5 to 26 pounds.

History

Origins and Early Adoption

Tar paper, a waterproof consisting of impregnated with , originated in the United States during the 1840s as an innovative solution for roofing and needs. In , brothers Samuel M. and Cyrus M. Warren established a roofing business based on a technique learned from a Newark roofer, involving the saturation of heavy with and sprinkling it with to create a durable, protective layer. By 1847, the Warrens improved the process by substituting —a of —for , enhancing the material's properties and making it more suitable for widespread construction applications. Early adoption of tar paper accelerated in the 1870s and 1880s, coinciding with America's post-Civil War reconstruction and westward expansion. During this period, the material gained popularity for underlayment beneath shingle roofs and as covering for temporary shelters in camps and settlements. The of 1849 marked one of the earliest documented uses, where miners employed tar paper for quick, inexpensive roofing on makeshift buildings amid rapid population growth in the West. By the 1880s, the expansion of railroads facilitated the distribution of tar paper, enabling its use in urban development and rural homesteads as building demands surged following the Civil War. An explosion of patents for composition roofing materials, including tar-saturated felt, in the 1860s and 1870s further supported its integration into standard construction practices. Despite its utility, tar paper faced initial limitations related to flammability, which prompted scrutiny and regulatory responses in the early . The material's tar saturation, while effective for , raised concerns about spread in wooden structures, leading to debates over its safety in densely built areas. In , Underwriters Laboratories testing rated certain composition roofs poorly for fire retardance, contributing to the development of fire-retardant standards by 1916 that emphasized additional protective measures for roofing underlayments to mitigate risks in growing urban environments.

Evolution in the 20th Century

In the early , particularly during the and , tar paper production shifted from saturation to petroleum-based asphalt impregnation, driven by the explosive growth of the U.S. oil industry following the discovery of major fields like in 1901, which provided a more abundant, consistent, and cost-effective alternative to derived from coke production. This transition improved the material's durability, uniformity, and resistance to weathering, making it suitable for widespread use in roofing underlayment as asphalt shingles gained popularity. By , efforts to standardize tar paper led to the establishment of key specifications by , including ASTM D226, which outlined requirements for asphalt-saturated organic felts used in roofing and , distinguishing Type I (nominal 15 lb per 100 sq ft) and Type II (nominal 30 lb per 100 sq ft) based on weight, saturation, and tensile strength to ensure reliable performance and interoperability. These standards addressed variability in earlier products and supported the material's integration into building codes during the Great Depression-era construction recovery. The post-World War II suburban housing boom from the 1940s to the 1960s dramatically expanded tar paper's application, as federal programs like the and FHA financing fueled mass production of single-family homes with roofs, where tar paper served as essential underlayment to protect sheathing from moisture; approximately 13 million single-family homes were built between 1946 and 1960. In the 1970s, innovations such as self-adhering tar paper emerged, exemplified by the introduction of rubberized asphalt membranes like Grace Ice & Water Shield in 1978, which used a self-sealing layer to better prevent leaks from ice dams and wind-driven rain without requiring separate fasteners. Regulatory advancements in the focused on , with updates to model building codes and NFPA standards incorporating flame-retardant additives like fibers into asphalt felt to achieve Class A ratings under ASTM E108 testing, mitigating flammability risks in residential roofing assemblies amid rising suburban development. These changes, prompted by post-war incidents and insurance requirements, enhanced tar paper's compliance with evolving safety norms while maintaining its core waterproofing function.

Composition and Manufacturing

Key Materials

Tar paper, also known as roofing felt, primarily consists of a base material derived from fibers that provide the structural backbone. The base is typically organic felt made from recycled , such as post-consumer corrugated cardboard or a blend of virgin and recycled wood pulp fibers, which are processed into a thin, uniform sheet. In some variants, inorganic bases like mats are used, particularly in heavier or more durable grades, to enhance tensile strength and resistance to tearing. The key impregnating agent is asphalt, a derived from refining through the of crude oil, which saturates the base material to impart properties. Traditionally, residual —produced as a of —was used for impregnation, though modern formulations predominantly employ petroleum-based asphalt due to its availability and performance characteristics. The saturation level typically ranges from 50% to 60% by weight of the total product, ensuring deep penetration without excessive brittleness; for instance, in standard #15 felt, the asphalt content is at least 6.2 pounds per 100 square feet, comprising about 54% of the saturated mass. Asphalt used in saturation is selected for its viscosity to achieve optimal penetration into the fiber matrix, with common grades such as AC-20 (asphalt cement with a penetration of 60-80 at 25°C) providing the necessary fluidity during manufacturing. Additives may include mineral stabilizers, such as limestone fillers (up to 10% ash content), to improve UV resistance and dimensional stability in exposed applications. In reinforced grades, fiberglass strands are incorporated during felting to bolster overall durability.

Production Process

The production process of tar paper, or asphalt-saturated felt, starts with the formation of the base paper web on a Fourdrinier machine, where a of organic fibers—typically including waste paper, , and wood pulp—is deposited onto a continuously moving wire mesh screen to form a thin sheet, which is then dewatered, pressed, and dried to produce the unsaturated felt base. This dry felt, weighing 20 to 55 pounds per 480 square feet, is unrolled from a feed roll and passed through a dry looper to maintain proper tension before entering the saturation line, where it is optionally sprayed with hot asphalt on one side, though this step is rarely used in modern processes. The core saturation occurs as the felt is drawn over submerged rollers into a dip tank filled with molten asphalt heated to 400–480°F (205–250°C), allowing the viscous material to impregnate the felt's porous structure through immersion and for thorough . Following saturation, the felt travels through steam-heated drying drums and a wet looper, where additional asphalt may be applied to achieve uniform penetration, before passing over water-cooled rolls to solidify the coating and prevent adhesion issues during handling. The cooled material is then fed into a finish looper for final tension adjustment, wound onto large rolls by a winder, and slit to standard widths such as 36 inches for packaging and distribution. Throughout the process, quality controls include automated monitoring of line tension via , asphalt temperature regulation to ensure consistent , and testing for saturation uniformity—often measured by to verify the final product meets standards like 15 or 30 pounds per 100 square feet—along with edge inspections to avoid risks. Modern manufacturing employs continuous high-speed lines, enabling efficient production across multiple parallel operations in dedicated facilities.

Types and Variants

Traditional Asphalt-Impregnated

Traditional asphalt-impregnated , commonly known as tar paper or roofing felt, consists of 100% organic felt fully saturated with asphalt to provide a water-resistant barrier. This classic material is distinguished by its reliance solely on natural fibers derived from wood pulp or recycled , without any synthetic additives or reinforcements. It is available in two primary grades: #15, which is lighter and typically weighs about 15 pounds per 100 square feet, and #30, which is heavier at approximately 30 pounds per 100 square feet, offering greater durability for demanding applications. These grades conform to the ASTM D226 standard, which specifies requirements for asphalt-saturated organic felt used in roofing and , including minimum saturation levels, tensile strength, and pliability to ensure performance. Rolls are standardized for ease of handling, with #15 felt commonly measuring 36 inches wide by 144 feet long, covering 432 square feet, while #30 felt measures 36 inches wide by 72 feet long, covering 216 square feet. Under typical branding, this material is marketed generically as "tar paper" or "," emphasizing its traditional composition and absence of modern polymers. The production process involves impregnating a dry organic base sheet with hot asphalt to achieve full saturation, binding the fibers and imparting properties. When stored properly in a cool, dry environment away from direct , it maintains integrity for about 1 year, after which degradation occurs primarily through oxidation of the asphalt, leading to and reduced flexibility.

Coal-Tar Saturated Felt

A traditional variant is coal-tar saturated felt, standardized under ASTM D227, which uses coal-tar pitch instead of asphalt for saturation. This type provides similar but is more commonly used in built-up roofing systems and historical applications due to its distinct properties and resistance to certain chemicals. It shares the organic fiber base but differs in impregnant, offering comparable durability for low-slope roofs and membranes.

Modern Synthetic Alternatives

Modern synthetic alternatives to traditional tar paper have emerged since the late , incorporating advanced materials to enhance durability and performance in roofing underlayment applications. These innovations, developed post-1980s, focus on polymer-modified compositions that integrate synthetic reinforcements such as or weaves, providing superior tear resistance compared to asphalt-saturated felts. For instance, many synthetic underlayments achieve tensile strengths exceeding 100 pounds in the machine direction (e.g., Owens Corning's UDL50 tests at 178 pounds MD per ASTM D751). A prominent example is self-adhering membranes like GCP Applied Technologies' Grace Ice & Water Shield, introduced in 1978 and widely adopted in the , featuring —a styrene-butadiene-styrene (SBS) polymer-modified —for seamless and adhesion to roof decks. These membranes differ from traditional variants by eliminating the need for separate fasteners in key areas, reducing installation vulnerabilities. modifications in these products enhance flexibility and elasticity, allowing them to conform to irregular surfaces while maintaining integrity under . Performance specifications of synthetic alternatives include higher slip resistance, with non-woven facers providing coefficients of superior to felt in wet or dry conditions to improve installer safety on steep slopes. Additionally, they offer extended UV resistance, typically up to six months of exposure before significant degradation, far surpassing the 30-90 days for traditional felt, which enables longer construction timelines without premature replacement. By the 2020s, synthetic underlayments have captured approximately 40-50% of the global roofing underlayment market, driven by demand for lightweight, high-performance options, according to industry analyses from Global Market Insights and Future Market Insights. This shift reflects a broader transition from organic felts to polymer-based systems, prioritizing longevity and ease of handling in residential and commercial construction.

Applications

Roofing Underlayment

Tar paper functions as a critical secondary barrier in sloped roofing systems, installed directly over the deck and beneath primary coverings such as asphalt shingles to shield the underlying structure from water intrusion. This underlayment material, also known as asphalt-saturated felt, is typically applied in horizontal courses starting at the and extending up the , ensuring a shingle-like layering that directs water downward and away from the building. Its installation requires careful alignment to maintain continuity, with each course overlapping the one below by 2 to 4 inches on slopes of 4:12 or greater, increasing to 19 inches on lower slopes (2:12 to 4:12) to create a double-layer effect for enhanced protection. The material is secured using corrosion-resistant staples or nails, placed in a grid pattern with 6-inch spacing at overlaps and 12-inch spacing in the field, as specified in building standards to withstand uplift forces. Building codes mandate tar paper underlayment in specific scenarios to ensure roof durability and safety. Per the International Residential Code (IRC) Section R905.1.1, underlayment is required for roofs, with enhanced installation and attachment requirements in high-wind design areas to resist component and cladding loads, using approved materials complying with standards like ASTM D226 Type II (No. 30 felt). For roof slopes less than 4:12 but at least 2:12, a double layer of #30 felt is prescribed, applied by doubling the first course at the and lapping subsequent courses to form complete coverage without gaps. These requirements apply universally to new construction and re-roofing, emphasizing full deck coverage to prevent leaks in vulnerable zones. In performance terms, tar paper's asphalt impregnation provides a water-resistant layer that effectively blocks wind-driven rain and mitigates damage from ice dams by sealing around fasteners and overlaps, thereby protecting the roof deck from rot and mold. This barrier role contributes to extending the overall roof lifespan by protecting the deck from moisture exposure, particularly in climates prone to severe weather, allowing the primary roofing material to perform optimally without premature degradation. Its physical impermeability to liquid water, while permitting some vapor transmission, further supports long-term deck integrity without trapping condensation. Historically, tar paper underlayment was routinely applied as full coverage across entire decks in the mid-20th century to provide comprehensive . However, since the , updates to model codes like the IRC have permitted more targeted applications in some jurisdictions, such as limiting traditional felt to valleys, , and penetrations while allowing synthetic alternatives for broader areas, reflecting advancements in material performance and cost efficiency. These evolutions balance needs with practical installation, particularly in low-risk zones, without compromising code-compliant safety.

Siding and Waterproofing

Tar paper, also known as asphalt-saturated felt, serves as a water-resistive barrier (WRB) installed behind or to protect sheathing from moisture infiltration in exterior assemblies. This application complies with International Building Code (IBC) Section 1403.2, which requires a continuous WRB such as No. 15 asphalt felt meeting ASTM D226 Type I standards behind exterior veneers like siding. The material's asphalt impregnation provides resistance to liquid while allowing some vapor transmission, helping to prevent rot in underlying components during normal exposure. In temporary waterproofing scenarios, tar paper is applied as a protective layer in enclosures or for repairs, offering short-term shielding against and wind-driven . It is commonly used during building phases when walls are exposed before permanent cladding installation, such as in phased renovations or after to siding. Asphalt felt can withstand exposure for 2 to 3 months depending on conditions, though UV degradation and mechanical accelerate breakdown in harsh environments. Tar paper finds specialized application in the restoration of 19th-century buildings, where it replicates original layers behind historic siding or sheathing to maintain authenticity. In agricultural structures like barns, it has been employed for moisture protection on walls, often in layered systems to enclose wood framing against rural exposure. These uses leverage its historical prevalence in early American construction for durable, low-cost barriers in non-residential settings. Proper installation for siding applications involves horizontal placement starting from the bottom, with vertical laps of 6 to 12 inches to direct downward and prevent tracking behind the barrier. Seams are sealed with compatible tape or mastic, and the material is fastened with staples or nails spaced 6 to 12 inches apart, ensuring continuity around openings and at corners. This shingle-like overlapping technique enhances performance in vertical orientations, distinguishing it from horizontal roofing methods.

Advantages and Limitations

Benefits in Construction

Tar paper, also known as asphalt-saturated felt, offers significant cost-effectiveness in construction projects, typically priced between $0.15 and $0.30 per , making it one of the more affordable underlayment options compared to synthetic alternatives. This low material cost contributes to overall roofing budget reductions, often lowering total project expenses through simpler labor requirements and compatibility with standard installation practices. Its ease of use further enhances its appeal in building applications, with standard rolls weighing 15 to 30 pounds, allowing for straightforward handling by workers without heavy machinery. The material can be easily cut using common utility knives and integrates seamlessly with most roofing systems, such as asphalt shingles, metal panels, and , reducing preparation time on site. In terms of performance, tar paper provides key gains by blocking liquid water penetration while maintaining breathability, with perm ratings of 5 to 6 that allow vapor to escape and prevent rot in underlying structures. This dual functionality improves roof longevity and helps protect underlying structures and insulation from moisture damage, thereby supporting consistent energy efficiency in building envelopes. Additionally, its physical tensile strength ensures durability during handling and exposure, supporting reliable performance under typical construction conditions. The versatility of tar paper extends its utility across diverse projects, including residential homes, commercial buildings, and DIY endeavors, where no specialized tools are required for basic application under various roofing types like , shakes, or metal.

Drawbacks and Health Concerns

Tar paper, also known as asphalt-saturated felt, exhibits several durability limitations that can affect its performance in applications. It is particularly prone to tearing during installation, especially in windy conditions, which can compromise its ability to serve as an effective barrier. Prolonged exposure to (UV) light further degrades the material, causing it to become brittle typically after 30 to 90 days, reducing its flexibility and increasing the risk of cracks or failure if not covered promptly. Health concerns associated with tar paper primarily stem from its asphalt content. Contact with the material during handling may cause mild , and dust or asphalt odor could lead to respiratory discomfort. Additionally, (VOC) emissions occur during the production process, contributing to potential respiratory and issues with prolonged occupational exposure. Tar paper's asphalt content contributes to the overall flammability of the assembly, and in some cases, additional fire-resistant materials may be required to achieve desired ratings per building codes. Maintenance challenges arise when the material is damaged, as its sticky asphalt composition makes removal difficult and labor-intensive, often requiring specialized solvents or tools to avoid residue that could interfere with repairs. If breached, tar paper can trap moisture, fostering conditions conducive to mold growth and subsequent structural issues if not addressed promptly.

Environmental and Regulatory Aspects

Production Impacts

The production of tar paper, also known as asphalt-saturated roofing felt, is resource-intensive due to the need to heat petroleum-derived asphalt to high temperatures for saturation of the paper base. The process requires significant energy, estimated at 2-5 MJ per square meter primarily for asphalt heating to 205–250°C during the saturation stage, alongside additional energy for paper pulping and drying. Petroleum dependency is high, with asphalt comprising 25–41% of the final product weight, equivalent to approximately 1–2 barrels of oil per ton of tar paper produced, as asphalt is a byproduct of crude oil refining. Emissions from tar paper manufacturing arise mainly from the asphalt blowing and saturation tanks, where volatile organic compounds (VOCs) and particulate matter (PM) are released. VOC emissions are 9.5–13.4 lb per ton of product, while PM emissions are 0.35–0.48 lb per ton. Carbon dioxide () output is approximately 0.6 tons per ton of product, stemming from combustion in heating processes. Water usage in tar paper production is substantial during the paper pulping phase, averaging 17,000 gallons per ton of base paper, or roughly 10,000–20,000 gallons per day per mill, with challenges in treating wastewater contaminated by bitumen residues that can include oils and suspended solids. In the United States, tar paper production contributes modestly to the broader construction sector's environmental footprint, with annual output estimated at around 500 million square feet in the 2020s based on roofing underlayment market data, accounting for about 0.1% of total construction waste generation when considering upstream impacts.

Disposal and Sustainability

Tar paper, primarily composed of asphalt-impregnated felt, poses significant disposal challenges due to its non-biodegradable nature, as the petroleum-derived asphalt content resists and persists in the environment for extended periods. This material commonly ends up in landfills as part of construction and demolition (C&D) , where roofing , including underlayment like tar paper, contributes substantially to the overall volume; for instance, roofing materials can account for up to 20% of C&D in landfills, exacerbating space limitations and potential issues from asphalt components. Recycling options for tar paper remain limited but are advancing through specialized processes focused on asphalt recovery. One notable approach involves grinding and processing used roofing felt to extract , which can then be reused in asphalt production; for example, the Danish firm Tarpaper has implemented a system since the that converts end-of-life roofing felt into a high-quality mix suitable for road paving, preventing disposal and reducing CO2 emissions by approximately 1.7 tonnes per tonne of roofing felt recycled. Pilot programs in , such as those by , have similarly explored asphalt reclamation from roofing waste, though scalability for felt specifically is still emerging. Sustainable shifts in the industry are promoting recyclable synthetic underlayments as direct replacements for traditional tar paper, offering easier end-of-life management without asphalt's persistence. Additionally, efforts as of 2025 are exploring bio-based impregnants derived from plant oils, such as soy or formulations, to create more waterproofing papers that biodegrade more readily or support circular economies. These innovations aim to reduce reliance on non-renewable products while maintaining performance in roofing applications. Regulatory frameworks are driving better disposal practices and adoption of greener options. In the , the Waste Framework Directive designates construction and demolition waste, including roofing materials, as a priority stream, mandating a 70% recovery target by 2030 to minimize landfilling and promote reuse or recycling. In the United States, the rating system awards credits under the Low-Emitting Materials category for low-VOC synthetic or alternative underlayments, incentivizing projects to select sustainable roofing products that lower environmental impact.

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