In roofing, a tear-off removes all layers of shingles and underlayment from a roofing system. A layover typically refers to adding a new layer of shingles over the existing shingles.
In our Chicago area, we almost always do a tear-off. While some municipalities allow by code a second layer, we do not recommend it. Here’s why: covering a roof that is presumably in bad shape (which is the single most common reason for a new roof), with new shingles hides potentially hidden defects in the roof deck such as rotted wood, or delaminated plywood. In fact, we had a roof project this week in Rolling Meadows IL that, when looking at the old roof, looked fine. But there were 19 sheets of plywood that needed to be replaced. The plies were separating, and was not safe.
Another reason to do a tear-off is to add an ice and water shield. Over the past couple of decades the roofing industry has changed, and the International Residential Code now requires an ice and water shield along the drip edge and other parts of the roof. Without stripping the old roof off, it is difficult to determine whether or not this was ever installed, or installed correctly according to current code.
We have had scenarios where someone fell through a rotted garage roof (yes he escaped with only minor injuries), because the “big box” retailer who installed the roof skimped out and didn’t even install felt paper. The roof appeared somewhat normal, and a little weathered, but when walked on, the plywood split, and gave way. I remember that day - what a way to enter a garage. The person’s feet were dangling over the hood of the Buick inside with a 2’ diameter hole above.
Further, adding a layer of shingles adds stress to the roof structure. It is not uncommon for the shingles to weigh 240 pounds for a 10’ x 10’ area, potentially adding tons of additional weight to a typical home. The roof rafters may or may not be designed to handle the load, and may bend/break with the extra weight.
Almost always, it’s not worth saving a few dollars on this one.
Your governing jurisdiction may also have rules about the permissibility of layover vs tear-off.