Material for the production of fiberglass reinforcement. Production of composite reinforcement as a business. Technology for the production of fiberglass reinforcement
Composite rebar is reinforcement made from composite materials rather than steel. Their components are glass roving and/or basalt fibers, which are held together by polymer binders. It, unlike metal, is not welded, but is held together with special clamps. Composite reinforcement is also known as “non-metallic”.
Here we will talk about the production of composite (fiberglass and basalt-plastic) reinforcement, its manufacturing technology, raw materials and equipment for this business.
Composite reinforcement is used primarily, of course, in construction, but it can also be used in everyday life, for example, for assembling greenhouses.
Video review of the material and its advantages
A short visual video about what it is:
Main advantages composite reinforcement:
- When compared with metal, composite has a significantly higher strength index - 1100 MPa, and standard steel - only 390 MPa. Tensile strength compared to steel reinforcement class A III is three times greater;
- Composite reinforcement is a corrosion-resistant material;
- Ideal for use in seawater as it is not subject to acid corrosion;
- More resilient than steel;
- Does not conduct electric current;
- Does not conduct heat energy;
- Composite reinforcement is radio-transparent;
- Does not change its strength characteristics under the influence of electromagnetic fields;
- Does not change its strength characteristics under the influence of low temperatures (down to -70 °C);
- Significantly lighter (more than nine times) compared to metal fittings.
Regardless of the required and desired volume, for production glass plastic fittings investments in the amount of 4-16 million rubles are required.
Technology and equipment for production
Raw materials for the production of composite reinforcement:
- Roving (basalt and/or glass roving);
- Resins;
- Braiding thread (roving that will be used for winding);
- Acetone;
- Ethanol;
- Dicyandiamide.
The raw materials may have a different composition.
Fiberglass (FRP) and basalt-plastic (BPA) reinforcement are the most popular today in Russia, but there is also a combined type - a rod made of fiberglass, and the relief (ribs) from “basalt”.
Thermosetting synthetic resins, including organosilicon and phenol-aldehyde resins (harden during the polycondensation reaction), most often act as binding elements; epoxy and unsaturated (do not emit by-products during the curing process).
Other polymers that have occupied a strong niche include polyimide, polybenzimidazole and polybenzothiosol. These resins are often used with the addition of other polymers.
In order to obtain fiberglass reinforcement at the output with high level resistance to various types of corrosion, an epoxyphenol binder should be used. The polyester binder will give the reinforcement increased electrical properties.
For one kilogram of fiberglass reinforcement, you should use 0.862 glass roving brands such as RBN-10-2520 or RBN-10-2520-4E; epoxy resin requires 0.134 of the following grades: ED-20 or ZIS-1; phenol-formaldehyde resin will require 0.116 grade LBS-1; dicyandiamide – 0.03; ethyl alcohol – 0.015; weave thread – 0.01 kg; acetone – 0.021.
The basis for the production of non-metallic fittings has already become traditional way production of fiberglass - drying and unwinding of the fiber, impregnation with a binder, polymerization.
Video of the manufacturing process:
Equipment for the production of composite reinforcement (fiberglass or basalt plastic):
Line device (it may be different). Prices for such lines start from RUB 3,000,000.
The principle of continuous broaching makes it possible to produce non-metallic reinforcement from any type of fiber, while its manufacturability and temperature conditions for hardening of the binders should be taken into account.
What is fiberglass composite reinforcement actually made of?
Answers CEO LLC "Obninsk Composite Materials Plant" Klimenko Maxim Vladimirovich:
"Good afternoon. Firstly, I would like to immediately note that the products of Obninsk Composite Materials Plant LLC have been produced for 3 years only from the best binding materials and foreign-made fiberglass.
We put "at the forefront" product quality, therefore, agreements have been concluded with world leaders for the production of raw materials for the production of composite materials. What is fiberglass composite reinforcement actually made of?
This is the main material in the production of composite fiberglass reinforcement. The Jushi company (Yushi or Jushi) produces glass rovings based on modified silane lubricants No. 386 and No. 312, which are specially developed and successfully used together in the production of composite fiberglass products using the pultrusion method.
Glass roving manufactured by Jushi is currently the highest quality product on the fiberglass market. It can withstand enormous breaking loads, surpassing competitors several times. Obninsk Composite Materials Plant is the main consumer of Jushi fiberglass in Russia and we have an agreement for the supply of glass roving.
Epoxy resin is the main polymer used in the production of fiberglass reinforcement. For the production of fiberglass by pultrusion, including in the production of composite fiberglass reinforcement, supports - pegs for plants and other products, we use high-quality epoxy resins CYD 128, produced by Sinopec (China) and epoxy resins KER 828, produced by the South Korean brand Kumho. The Obninsk Composite Materials Plant also has long-term contracts with these companies for the supply of epoxy resins.
IMHPA (Isomethyltetrahydrophthalic anhydride) is the main hardener in the production of fiberglass reinforcement. IMTHF is ideal for high temperature curing of epoxy resins. The production of fiberglass reinforcement occurs at high temperatures in special furnaces, the temperature reaches 340C. Therefore, when using IMTHF, composite products acquire excellent physical and mechanical properties and high strength characteristics.
Catalyst is a special compound that combines the properties of Diethylene Glycol Diglycidyl Ether (DEG-1) and Alcofen (DMP). When using these components, the final product acquires high chemical resistance properties."
Armastek company offers new generation equipment for the production of glass and basalt composite reinforcement.
Equipment is produced using our own patented technology, using advanced domestic and foreign developments. Our company's production experience is more than 8 years. Our engineering staff is constantly improving and developing production technologies. The equipment offered for delivery is manufactured under trademark ARMASTEC.
When ordering equipment from us, you also receive comprehensive services for organizing production:
Production technology (recipe, quality manual, technological regulations, etc.)
- list of recommended suppliers of raw materials
- recommendations for the selection of premises, ventilation
- installation and commissioning works
- training
- assistance in obtaining certificates and conducting tests
- consultation with technical specialists of our company
- warranty and post-warranty service
When assembling lines, we use high-quality components from leading manufacturers. Many years of production experience confirms the 100% performance of our equipment. If you wish, you can see this for yourself by visiting our production.
Our production line is designed for the production of composite reinforcement (both glass and basalt fiber) with a diameter of 3 to 30 mm.
Main characteristics of the line:
Operating voltage: 380V/50Hz;
Electricity consumption: 11.5 kW;
Overall dimensions of the line (l/w/h): 17 / 0.8 / 2 m
Available diameters: 3-30 mm
Productivity: 2-10 p.m./min
The proposed Armastek line allows you to simultaneously produce up to 2 bars of reinforcement. The manufactured reinforcement has a constant cross-section, with a frequent winding angle, which ensures the bond strength of the reinforcement with concrete is 15-20% greater than in composite reinforcement produced using traditional technology.
Requirements to production premises
Recommended room length: from 40 m;
- Recommended ceiling height in the room: from 3 m;
- Air temperature in the room is not lower than 15°C
- Since during the operation of the line there is a release of gaseous by-products from polymer curing and cutting of reinforcement (profiles), to organize safe work personnel, the installation of ventilation in the production area is required to ensure normal air exchange and dust and smoke removal.
Line diagram
The installation consists of the following components and assemblies:
1. Rack for roving
2. Drying chamber
3. Impregnation bath, tension mechanism
4. Forming unit - winder
5. Stream separator
6. Control panel
7. Polymerization chambers
8. Staged cooling modules
9. Pulling mechanism
10. Meter counter
11. Auto-cutting unit
12. Receiver of finished products (Winder and/or table for bars)
13. Thread twister
The following materials are used in the manufacture of fittings:
Roving (glass, basalt)
- Components of binders based on epoxy-diane resins
In composite reinforcement, the roving takes on mechanical loads, and the binder is a matrix that protects the reinforcement from the effects of the external environment.
Our company:
* Provides consulting assistance:
- on the optimal choice of premises,
- placement of communications in production
* Provides assistance in passing product testing, obtaining a GOST certificate for products with passing a production audit.
* Provides a package of documents necessary to comply with production standards and pass all state regulations. supervisory authorities.
The price of the equipment already includes:
- supervision of installation of equipment
- commissioning work (with testing of the technological process)
- production recipe
- training
Line cost: price negotiable
Find out more detailed information You can get it by contacting us by phone + 7 964 190 25 98 or by mail pav@site
Could the production of fiberglass reinforcement become an idea? profitable business in the field of building materials? This modern analogue of steel reinforcement is distinguished by a number of positive characteristics that make it extremely popular on the market. We tell you how much money you need to invest in such an enterprise, what equipment you need to purchase, and when you can expect to see a net profit.
Fiberglass or composite reinforcement is a modern analogue of metal reinforcement, surpassing it in quality characteristics. Plastic reinforcement consists of ribbed artificial fiber rods with a diameter of 4 to 18 mm. Often, individual rods are connected to each other with synthetic resins for strength.
This is a popular building material, gradually displacing traditional metal analogues from the market. It is distinguished by an impressive list of useful characteristics:
- High strength. This material is 3 times stronger than steel.
- Wherein plastic material significantly lighter than steel - no less than 6-9 times.
- It does not rust and withstands sea or fresh water, acidic or any other aggressive environment without damage.
- Dielectric - does not conduct electricity, can be used in insulation work.
- Frost-resistant - does not collapse even at very low temperatures.
- Not exposed to electromagnetic fields.
- Long service life - at least 50 years.
- Possibility of seamless styling.
As for the disadvantages, we can note insufficient elasticity and poor resistance to high temperatures. Fiberglass reinforcement is not welded, but tied together - otherwise it will collapse under the influence large quantity heat. Fiberglass rods are so inflexible that you cannot bend them on your own: the rods are bent at the desired angle during production. Also, over time, the strength characteristics of the material decrease.
The material is well known among professionals, but ordinary consumers (they are also potential clients enterprises) do not distinguish this material from steel reinforcement and often give preference to it. Composite rods do not have pronounced marketing advantages, obvious benefits for buyers, which can also be called one of its disadvantages.
Fiberglass or composite reinforcement is a modern analogue of metal reinforcement, surpassing it in quality characteristics
Where is it used?
The main scope of application of plastic fittings is road, industrial and civil construction. This material is used to reinforce concrete structures, including foundations. Fiberglass reinforcement is well suited for fastening thermal insulation and concrete floors: it improves the adhesion of concrete elements. The use of such reinforcements facilitates construction and reduces the cost of work.
Resistance to aggressive environments has made this material in demand in the construction of concrete structures for chemical plants. High strength ensures the popularity of artificial fibers in bank protection, drainage and sewerage construction. When constructing roads, it helps to increase the strength and durability of the road surface.
Is this business relevant?
Any production of building materials is actual business, and the production of modern and innovative ones is even more in demand. There are many areas of application for fiberglass reinforcement, so a manufacturer of a quality product will always find sales channels.
Competition in the field is quite high, but the market cannot be called overcrowded. As a rule, in each region there are from 3 to 10 medium-sized enterprises producing such fittings.
Wherein construction companies and institutions responsible for road construction and bank protection are much larger. It follows from this that there will always be demand for the material, so beginning manufacturers must initially identify competitive advantages and actively promote products.
Composite reinforcement is 6-9 times stronger than steel
Business organization
The production of composite reinforcement requires significant organizational costs. Practice shows that few people manage to create a full-fledged enterprise for less than 3 million rubles. Equipment and raw materials are expensive. In addition, the entrepreneur will have to provide working capital for the period until the company sells the first batches of goods.
A business plan will help you approach your work thoughtfully. It should include not only opening costs, but also a calculation of profitability, a goal for 6 and 12 months, an approximate staffing level, as well as a list of potential partners. How faster businessman finds stable sales channels, the faster the company will reach the level of net profit.
Production technology
The production of composite reinforcement takes place on a conveyor line. Human intervention in the operation of the equipment is minimal. Production begins with the processing of glass roving - the material is drawn into threads with a cross-section of up to 20 microns and impregnated with a special resinizer. The soaked threads are woven into bundles and dried with hot air. After drying, the glass roving is impregnated with epoxy resin.
At the next stage, the threads fall into a special mold for plastic substances (dies), where the diameter of the future reinforcement is determined. Then the workpieces are wrapped with a rope: it provides the necessary thickness and improves the adhesion characteristics to concrete.
The formed and wrapped reinforcement is fired in a magnesite tunnel kiln. There the resins polymerize. At the final stage, the composite fibers are cooled to room temperature in running water. After this, the material is virtually ready for use. It is cut into the right sizes diamond-coated saw. The cut is precise and even.
Equipment
A conveyor of equipment for the production of composite reinforcement will cost 1-1.7 million rubles. This is the main part of the expenses for opening a business. The list of machines and equipment includes:
- Bath for impregnation of glass roving with spin function.
- Dies (forms for plastic substances).
- Machine for drawing reinforcement.
- Apparatus for twisting threads.
- Polymerization oven with temperature control function.
- Cooling apparatus.
- Diamond-coated saw/machine for cutting finished reinforcement.
- Apparatus for twisting finished reinforcement.
All machines are lined up in a conveyor 15-20 meters long. In addition to this equipment, you will need to purchase loaders, scales, racks for raw materials and finished products. This kit will be sufficient for production within a small enterprise.
Production begins with the processing of glass roving - the material is pulled into threads with a cross-section of up to 20 microns and impregnated with a special resinizer
Premises requirements
Since the conveyor of machines for the production of fiberglass reinforcement is at least 15 meters long and about half a meter wide, the room must have a suitable length. The placement of equipment should be comfortable for workers. Therefore, the area of the premises cannot be less than 200 square meters. The workshop is divided into 3 zones: workspace, warehouse, staff room.
The floor of the room must be flat, without differences in height (at most, no more than 5 centimeters). Ceiling height from 2.5 meters. The production of composite reinforcement requires maintaining a stable temperature regime at 16-18 degrees, so it is desirable to have a special heat regulation system. Good lighting guarantees high-quality work; you should not ignore this characteristic. It will not be possible to do without powerful ventilation (with an air outflow of at least 250 liters of air per minute). The location of the workshop does not matter much; you can place it on the outskirts or outside the city.
Raw materials
What materials are needed for the production of composite reinforcement? The basis is glass roving - threads of molten aluminoborosilicate glass with a diameter of 10 microns. When making reinforcement, fibers are supplied in large, hermetically sealed spools. They are transported at temperatures exceeding 35 degrees and at a humidity level of no more than 70%.
The second key component is epoxy resin. This is a colorless or light yellow viscous liquid, with a consistency reminiscent of honey, used in the primary processing of roving. They give future fittings resistance to aggressive environments.
In addition to these two components, the production of composite reinforcement requires:
- weaving thread;
- alcohol;
- acetone;
- Dicyandiamide.
Business costs
Setting up a business for the production of fiberglass reinforcement will require at least 3 million rubles. About half of this amount will be spent on purchasing equipment and equipping the workshop. Approximately 1 million - for the purchase of raw materials and working capital for the first months of work. This also includes the cost of renting a workshop, transportation and other expenses.
The amount of 3 million rubles cannot be called small. Compared to some other building materials industries, the production of composite reinforcement is indeed expensive. High price is associated with the manufacturability and “artificiality” of the material - in fact, it is entirely prepared from chemical components.
Composite reinforcement is widely used in construction and road work.
Profit calculation
Depending on the diameter, the price of composite reinforcement starts from 10 rubles per meter. But the average cost is higher - 50-70 rubles. Moreover, the material is always sold in large quantities, usually from 1000 meters, that is, the minimum purchase price is 50 thousand rubles. A low-power enterprise produces about 2,000 meters of material per hour, that is, 16,000 meters per shift. Revenue per shift is about 800,000 rubles. It seems that this is a lot, but part of the funds (about 40%) will be the cost. The same funds will be used to pay utility costs, employee salaries and other mandatory expenses.
Having stable sales channels will help you recoup your investment in an average of one and a half years. Some manufacturers manage to reach the net profit level faster, but this is rather an exception to the rule. 16-18 months is a more realistic period, given the significant amount of initial investment.
Conclusion
The production of composite reinforcement is undoubtedly a promising area in the building materials market. To organize an enterprise, you will need at least 3 million rubles, while payback is possible within 16-18 months. Fiberglass reinforcement has proven itself due to its strength characteristics, but this product is not yet very widely known on the market.
Composite, or fiberglass, reinforcement is a high-tech material that is suitable for conditions modern market building materials technical characteristics, which requires relatively small capital investments. Fiberglass can easily replace metal in any size concrete structure without requiring as frequent replacement as steel products.
Anyone who is familiar with the technology, room requirements and necessary equipment can start the production of fiberglass reinforcement.
Main advantages of glass fittings
Fiberglass reinforcement is becoming increasingly popular among buyers and, due to its advantages, is ousting its steel counterparts that occupied a dominant position. Its main advantages include:
- lightness in comparison with steel reinforcement: 160 kg of fiberglass by volume is equivalent to two tons of metal material;
- production costs are 30% lower than standard investments for the production of competing analogues;
- high and fast payback;
- tensile strength is 3 times higher than other materials;
- no need for large premises, heavy vehicles and numerous service personnel;
- fiberglass reinforcement is not subject to corrosion.
Raw materials for the production of fiberglass reinforcement
Composite reinforcement is rods with a diameter of 4 to 18 mm with a spiral profile. The structure of the material is represented by a main trunk of parallel fibers and an outer layer, which can vary (single winding, bidirectional winding, sand spraying).
Reinforcement is often found in coils with a diameter of 10 mm, that is, in a twisted form. The two main components of the material are roving and epoxy resin. The former acts as a reinforcing material, and the latter plays the role of a binding component. In addition to the base, you also need:
- acetone;
- weaving thread;
- ethanol;
- Dicyandiamide.
On average, the cost of manufacturing 1 kg of fiberglass reinforcement is 127 rubles.
Necessary equipment for the production of fittings
The central element of the fiberglass reinforcement manufacturing system is a line, or conveyor, specially designed for this purpose. Its components include:
- racks for roving;
- unit for impregnating glass fiber with resin;
- bake;
- wrapper;
- finishing hopper;
- magnesite furnace;
- air cooling unit;
- pulling mechanism;
- cutting machine;
- tray for exiting finished products;
- Control block.
Despite the rapid pace of industry development, not every supplier can offer equipment suitable for the needs of small businesses. Typically, the number of available options is greatly limited by the initial financial capabilities of the entrepreneur.
Some manufacturers offer equipment costing from 1 to 1.7 million rubles - this price range is most optimal for beginners individual entrepreneurs, since the volumes of such production will correspond to the indicators of a small enterprise. In this case, the manufacturing speed of fiberglass reinforcement will be approximately 2–4 m/min. Equipment whose productivity is 6–12 m/min will cost two to three times more.
If you don’t have the funds to buy new equipment, you should think about renting or purchasing a used device. Good value for money is offered both abroad, for example, in China, and on the Russian domestic market.
Requirements for production premises
Even so, you need to remember the safety rules. For this reason, any room chosen for the production of fiberglass reinforcement must comply with generally accepted standards in order to avoid accidents and operational problems production line. The main requirements include:
The premises for the production of fiberglass reinforcement must meet all requirements for normal operation
- remoteness from residential buildings; position;
- the height and length of the room are at least 2.5 and 22 m, respectively;
- good ventilation;
- technical equipment: water supply, electricity and sewerage;
- height difference – no more than 5 cm;
- heating up to 16–18 °C.
In addition, on initial stage production will require an energy source with a capacity of 12 kW. Then after debugging production process, this figure can be reduced to 4 kW. As for ventilation, forced ventilation of the room would be the most acceptable. The tunnel oven requires a separate hood, which can be connected to the general system.
There are no separate requirements for the width of the room, since the conveyor is much longer in length than in width. To reduce rental costs, you can opt for real estate outside the city - even with a simultaneous increase in transport costs, this will significantly reduce the monthly costs of maintaining the business.
Technology for the production of fiberglass reinforcement
The key to producing quality products is strict adherence to the developed technology. Fiberglass reinforcement is produced in several stages.
Roving processing
Glass roving is the basis of composite reinforcement, which is obtained by melting aluminoborosilicate glass. The material is drawn into a thread with a cross-section of 10–20 microns, then the threads are impregnated with lubricant and woven into bundles. Initially, the main material is located on special racks, which evenly feed it further along the line.
The threads collected in a dense bundle are dried and heated with hot air, and then the heated roving passes through an impregnation bath, completely immersed in epoxy resin. The impregnation unit is a mechanism with four grooves through which threads of various diameters (from 12 to 18 mm) are pulled.
Shaping and wrapping
After processing, the roving enters a forming die, which determines the diameter of the future building material, and then onto a rope winding, which adjusts the thickness of the rods to a certain parameter and ensures strength in contact with the concrete base.
Those products that are of the required thickness remain as finished products, and those that are thinner are additionally sprinkled with sand. The wrapper, like the impregnation unit, consists of four streams and is powered by two belt electric motors. Thanks to the circular rotation path, the winding device allows you to obtain products of the correct cylindrical shape.
Winding roving
Furnace for fittings
The formed products enter an 8 m long magnesite tunnel kiln for residual chemical reactions (resin polymerization) to occur.
Final stage
Finished, but still hot, products are sent to a bath filled with running water to cool to room temperature. The last step is a cutting machine that divides the material into rods according to specified parameters. Since even the simplest machines use a diamond-coated circular saw, the cut is precise and even.
The conveyor line for the production of composite reinforcement is fully automated and controlled by a software unit. Before the production of fittings begins, all the necessary parameters of future products are set by the operating engineer.
Composite reinforcement has received many positive reviews from specialists in the construction industry. According to the most conservative estimates, its production on a small scale can pay for itself within a year and a half, provided that the product is fully sold. Fiberglass material is reliable, resistant to external destructive factors, easy to transport and far superior to metal in all technical and economic aspects.
