New discoveries and rapid technological development have not bypassed the construction industry either. The usual materials and technologies are being replaced by new, improved developments. In recent years, composite materials are gaining relevance. For example, basalt and fiberglass structures are replacing iron reinforcement.
Composite reinforcement has several advantages:
- durability due to resistance to corrosion, in contrast to iron counterparts;
- long service life (warranty is 80-100 years);
- strength;
- low specific gravity: 4 times lighter than steel reinforcement;
- dielectricity;
- radio transparency;
- ease of transportation;
- relatively low cost.
According to experts, in 10-15 years, composite reinforcement will replace iron.
Characteristics and scope
Composite materials production technologies are more accessible and simple. The most common types of composite reinforcement:
- Fiberglass - a bundle of continuous glass fibers with a helical transverse corrugation, connected with synthetic resin.
- Basalt is a bearing rod with a continuous spiral ribbing produced by wrapping it with a basalt rope.
- Basalt plastic is a material based on basalt fibers and an organic binder.
- Carbon fiber - reinforcement made of carbon fibers.
Let's consider the principles of production of the first two types. The scope of such fittings is wide:
- construction of concrete structures for civil or industrial facilities;
- road construction;
- all types of foundations, floors;
- installation of reclamation systems, drainage systems, sewerage.
- for fastening thermal insulation;
- structures of brick surfaces by the method of layered masonry.
Production technology
Despite its many advantages, the production of composite rebar is a material-intensive process. It consists of a number of stages. First, the fibers are dipped into the resin, which hardens the material. This is how roving is made. It is guided into a speciation high-strength mold, through which a rod of the required size is formed. The starting material passes through the polymerization stage, heated to predetermined temperatures. To give ribbing, the profile is attached. The base with the wound profile is sent to the drying room, in which the resin is partially polymerized. In another section of the drying room, the unwinding device removes the relief-forming wire from the base. The resulting rod is pulled to the specified parameters and cut into equal parts using a saw, folding in place for finished products.
Selection of premises
Production fiberglass reinforcement, like basalt, requires a specially equipped room. Its length should be 25-30 meters. It will be convenient to work with high ceilings - from 3 meters. Please note that the fluctuation in heights in the production department should not exceed 5 centimeters.
You also need to take care of a stable temperature regime - 16-20 ° C. The room must be well ventilated, the level of air outflow must be at least 0.25 m³ / min.
When looking for the required space, do not forget about a separate warehouse, the dimensions of which will depend on the terms of delivery, having ordered and the overall scale of the project.
Preparation of raw materials
For the production of basalt rebar or fiberglass base, the following raw materials are used:
- roving (glass roving or basalt);
- binding thread (roving for wrapping);
- synthetic resin;
- dicyandiamide;
- ethyl;
- acetone.
Some businesses use a different composition. Sometimes a combined method is used for production - a fiberglass base and basalt ribs.
To bond all elements, it is customary to use special resins with the addition of polymer. To impart toughness properties, it is recommended to use an epoxy phenol binder, which also increases dielectricity.
Equipment purchase
There are many options for equipment for the production of composite reinforcement. But due to their large size and high cost, not all of them will suit the requirements of small businesses. Therefore, before buying, take a look, familiarize yourself with all manufacturers in the construction equipment market. On average, the cost of a line for the production of composite rebar starts from 1.3 million rubles.
Financial business plan
The given data and calculations are approximate, depending on the choice of the supplier and the characteristics of the organization. Initial investment:
- purchase of a line for the production of fittings - 1.3 million rubles;
- purchase of working tools - 250 thousand rubles;
- raw material base - 500 thousand rubles;
- installation of machine tools and other equipment, assembly work - 200 thousand rubles;
- staff salary, delivery, advertising - 250 thousand rubles.
As can be seen from the calculations, 2.5 million rubles are needed to equip the production line and start work.
Calculating the level of profitability
How many fittings do you need to produce to reach the break-even point? Let's consider on approximate calculations:
- manufacture of ASP fittings - 2160 m3 / hour;
- the number of working hours per day - 8;
- line load - 50%;
- number of working days per month - 22;
- production per month - 190,080 meters;
- price for 1 meter (wholesale) - 9 rubles;
- approximate income (excluding expenses) - 1,710,720 rubles;
- the level of operating costs per month - 1,500,000 rubles;
- net profit - 210,720 rubles.
As you can see from the calculations, the payback period is 12 months.
Sales of products
The profitability of the project largely depends on the promotion policy. Since storage of fittings requires large areas, which entails impressive costs, it is recommended to find stable sales markets already at the first stage.
Who can be your client:
- Individuals developers. This direction is typical for the regional market.
- Small construction companies, construction stores. The advantage is the ability to find a network buyer and expand sales markets throughout the country.
- Large construction firms. Advantages - stable sales markets, long-term contracts for the supply of valves.
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Armplast plant production is divided into 4 sections:
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The production of composite reinforcement includes 7 lines AKP-2, which allow the production of fiberglass reinforcement in 2 strands. Manufacturing begins with the preparation of the compound, which includes epoxy resin, hardener, accelerator, defoamer, as well as winding the roving onto spools using a roving twist. At the next stage, the bobbins with roving are placed on the creel and the threads are pulled to the pulling device, the compound is poured into the impregnation bath, and the spools prepared in advance are placed on the forks of the winding unit of the periodic profile, after which the production process itself can begin. The roving threads, being heated in the drying and heating unit, enter the impregnation bath with the compound, which has also reached the required temperature. The compound squeezing unit allows you to remove excess compound from the threads to obtain the highest quality product at the maximum cost. Further, the roving threads are formed into a bundle, and a periodic profile is wound, which allows you to remove possible air residues between the fibers and give additional rigidity and adhesion to the surface of the final product. After the unit for winding the periodic profile, the already formed fiberglass reinforcement rod enters the polymerization tunnel oven, where the reinforcement sintering process actually takes place. From the furnace, the reinforcement goes into a cooling bath, water or air - it depends on the diameter of the reinforcement being produced. The pulling device of the Armplast lines allows pulling reinforcement up to 32 mm in diameter, while not spending a large number of electricity and preventing the engine from overheating and failing. The finished reinforcement is automatically formed into coils on a double-sided coiler, which allows the reinforcement to be coiled on one side in a calm, even rhythm, without stopping the line from winding new coils on the other side.
A similar production process takes place when making a composite mesh, only for its production transverse reinforcement rods are needed, which form a composite fiberglass mesh together.
All products undergo quality control for compliance with all regulatory characteristics that are regulated in GOST.
There is always a sufficient amount of ready-made fittings in the warehouses of Armplast to cover the needs of any construction company.
Armplast managers know the products perfectly, are ready to advise and individually approach each application, each client and are absolutely always polite and courteous, whether it is a large developer or a private buyer. Flexible pricing policy, which we can carry out our own production, allows us to reach a consensus with our buyer.
Armplast is one of the leading suppliers of flexible ties of its own production. The geography of supplies is not limited either by city or region - we have our own transport, an extensive dealer network and contracts with major transport companies. Due to their compactness and relatively low weight, the delivery of composite flexible connections can be carried out by transport companies to absolutely any corner of our country and the world.
The mesh production is quite innovative and the Armplast composite mesh production lines allow you to create a product of excellent quality in accordance with all world quality standards, while they are economical and do not cause any harm to the environment, since the production is environmentally friendly and fiberglass is equated to natural materials, whether that wood or stone.
The ATK-02.1 catalyst production site is equipped with its own laboratory, which makes it possible to produce a proprietary accelerator with consistently reference quality.
The line production area and mechanical assembly workshop of Armplast is a large production facility with a mass of modern metal-working machines and a team of skilled professionals. All Armplast equipment is assembled by our specialists and tested for compliance with international quality standards. For all the time, more than 345 lines have been produced, which were delivered to all corners of Russia, as well as to the CIS countries, near and far abroad.
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Traditionally, construction fittings are made of steel, therefore finished goods with the use of this reinforcement, this is what they call reinforced concrete.
However, alternative materials are becoming more and more popular, for example, instead of steel reinforcement, composite ones are used in construction.
Common name " composite rebar»Combines a class of non-metallic fittings made from various polymeric materials. In particular, composite products are made from glass, basalt, carbon fibers. Therefore, the products are traditionally called according to the main production material - fiberglass reinforcement (FRP) made of fiberglass, basalt plastic reinforcement (ABP) made of basalt fibers, carbon reinforcement (AUP) made of carbon fiber.
The main advantages of composite reinforcement:
- High strength comparable to metal
- Low production cost and inexpensive equipment,
- Available production components,
- Does not conduct electricity
- Convenience and speed of installation, does not require welding,
- Higher corrosion resistance compared to steel reinforcement,
- The final cost for the consumer is 24.9% cheaper than the iron product,
- Savings on unloading, transportation and storage, composite rebar can be stored twisted in coils of 100 running meters. The weight of such a coil does not exceed 10 kg, unloading and loading can be carried out without the use of special equipment and takes little time.
In the manufacturing business, two types of fittings have become widespread - fiberglass and basalt rebar.
Fiberglass reinforcement - made of glass fiber (glass roving) impregnated with thermosetting resins. The basis of the reinforcement is a glass high-strength thread. Differs in extremely low manufacturing cost.
Basalt rebar - made from basalt fibers and resins that bind them. The basis of the reinforcement is basalt, a polymer obtained from minerals. A distinctive feature of glass reinforcement - it has a higher resistance to aggressive media and a higher melting point. The production cost is more expensive than that of ASP, due to the use of a more expensive raw material.
General circuit diagram the production of composite reinforcement consists in the fact that synthetic fibers are twisted together and impregnated with polymer binders, after which the twisted threads undergo polymerization and hardening. In the production process, in order to increase the surface friction force, special ribs are applied to the surface of the product or coated with a quartz sand coating.
Workshop equipment for the production of composite reinforcement
The production of plastic fittings requires a small staff of trained personnel, a specialized workshop or industrial premises with an area of \u200b\u200bat least 200 square meters. The main equipment differs in the volume of production.
Entry-level equipment is capable of producing up to 10 meters of rebar per minute. The basic elements of a production line are the same for any equipment manufacturer and include:
- Unwinding machines for pulling fibers and finished reinforcement,
- Fiber twisting machine,
- Fiber impregnation chamber with polymer resins,
- High temperature polymerization chamber,
- Cooling chamber,
- Auxiliary elements (cutter, creel, etc.)
Modern lines are fully automated and can be operated by one operator. The market abounds with various manufacturers, both domestic and imported (mainly China).
Video of mini-production of composite rebar
Depending on the country of manufacture, capacity and configuration - the cost of equipment varies. Such equipment can be leased under state or non-state programs. We do not recommend that you take supported equipment, since the quality of the manufactured products can vary greatly, which will affect the demand for your product.
Composite rebar application and sales market
For 2015, the use of composite reinforcement in Russia is severely limited in industrial and large construction. This is due to the fact that this type of building material does not yet have the necessary documentation (SNiP, GOST). Therefore, polymer reinforcement is mainly produced by private and small enterprises. However, due to the advantages of the product, composites have found wide application in private and low-rise construction, which provides a stable and rapidly growing demand for products. Therefore, there will be no particular difficulties with sales - your own retail outlet, organizations for the sale of building materials, construction markets, sales via the Internet.
ETIZ Kompozit was established on the basis of the Moscow Composite Materials Plant (MZKM). Specialization - development and production of composite reinforcement made of fiberglass.
But production of fiberglass reinforcement Is not the only direction in the company's work. The catalog also contains flexible ties, fasteners and clamps.
All products are different:
- strength, reliability and durability;
- relatively light weight (saving time and money in logistics);
- low thermal conductivity and dielectricity (do not conduct current);
- immunity to ultraviolet radiation, moisture, low temperatures;
- aesthetics and ease of installation.
The plant's products are 100% compliant with GOST and ISO international standards, which is confirmed by special quality certificates and laboratory test reports. A high result is achieved through quality control of raw materials and the use of automated production lines. It:
1. Eliminates the impact of the human factor.
2. Ensures the quality of products at every stage of production.
3. Reduces the cost of production and the price for the consumer.
In the production process, a patented technology of applying an armored belt is used (patent number - 132106). Adhesion to concrete is ensured by the special structure of the armored belt - 4 threads.
Composite rebar and concrete are compatible materials, since the coefficient of thermal expansion is identical. It is based on the best material for the manufacture of fiberglass reinforcement - alkali-resistant glass roving.
The ETIZ-Composite production technology provides for the production of composite reinforcement with a diameter of 6 to 18 mm and is equipped with a software package that provides automatic equipment settings for the diameter being produced.
Changes to the diameter of the manufactured products are performed by automatically changing the configuration of the equipment and changing the number of roving threads fed into the system.
Physical and mechanical characteristics of fittings ETIZ® Composite
| Indicator name | GOST standards 31938-2012 | ETIZ Composite |
| not less than 800 MPa | more than 1 350 | |
| Tensile modulus, MPa | not less than 50,000 MPa | more than 55,000 |
| Not less than 300 MPa | 340 | |
| Not less than 150 MPa | 190 | |
| Not less than 12 MPa | over 18 | |
| No more than 25% | 15 | |
| Tensile strength of adhesion to concrete, after exposure in an alkaline environment, MPa | Not less than 10 MPa | 12,5 |
| Available diameters, mm | 5-32 |
Test results on the example of ETIZ Composite Rebar, diameter 10 mm
| Specifications | GOST requirements | Armature ASK-10 ETIZ Strong |
| Tensile strength, MPa | Not less than 800 | 1350 |
| Tensile modulus, GPa | Not less than 50 | not less than 55 |
| Compressive strength, MPa | 300 | 347 |
| Diameter measured | by hydrostatic weighing | |
| Tensile strength at cross section, MPa | Not less than 150 | 187 |
| Bond strength to concrete, MPa | 12 | not less than 15 |
| Reduction in tensile strength after exposure to alkaline medium,% | 25 | no more than 15 |
| Tensile strength of adhesion to concrete after exposure in an alkaline environment, MPa | Not less than 10 | not less than 13 |