How fiberglass reinforcement is made. Production of composite reinforcement. Step-by-step plan for opening the production of fiberglass reinforcement - requirements for the premises, guests

05.05.2020

fiberglass reinforcement

Modern technologies made it possible to create non-metallic composite reinforcement, which compares favorably with the traditional one by a combination of increased strength, chemical and corrosion resistance, and low cost.
Technological line, "TLKA-2" designed for the manufacture of composite reinforcement from glass roving and basalt roving, used as a reinforcing element for construction works. Differs in simplicity of installation, speed of production of fittings. maintenance staff 3 people. The lines are available, the chief installation and training is included in the price.
The equipment of our production is characterized by simplicity, ease of maintenance and productivity, while the price of the equipment is lower than that of other manufacturers.
For example: equipment in China costs 3,000,000 rubles, while the speed of manufactured products is two times lower than ours. The cost of English equipment is 8,000,000 rubles. IN Russian Federation prices for technological lines for the production of fittings start from 2,000,000 rubles, or even higher.
The specialists of our company are constantly working to improve the equipment, while practically not increasing its cost. Deliveries of our equipment have a wide geography, this includes cities such as Nizhny Novgorod, Kazan, Orenburg, St. Petersburg, Magnitogorsk, Krasnodar, Yakutsk, Yekaterinburg, Tolyatti, Cheboksary, Krasnodar, Stavropol, Kaliningrad, Orenburg, Tyumen, Chelyabinsk, Irkutsk, Ufa, Samara, Ulyanovsk, Moscow, Lipetsk, Belgorod, Rostov-on-Don, Simferopol, Neftekamsk.

The main properties of the line "TLKA-2":

productivity 5-10 km per shift 8-10 hours
diameter from 4 to 20 mm, the larger the diameter of the reinforcement, the lower the production speed, but the greater the profitability of production
line length 18 m + fiberglass rod length up to 6-12 m, the workshop is needed about 25 m long, the line width is 2 meters.
Profitability 100%.-120%
quantity service personnel at least 3 people
The total power of the engine and heating elements is 15 kW.
Operating power per hour - approximately 10 kWh

Specification of supplied equipment:

Name of equipment	Quantity, PC.	price, rub.	Amount, rub. in view of VAT	Delivery time, working days
Remote Control	1	100000	100000	30
Bobbin creel	1	20000	20000	30
Impregnation bath with tensioning device, spiral winder, leveling device	1	120000	120000	30
Annealing chamber	1	60000	60000	30
Water cooling unit	1	15000	15000	30
Hauling device / cutting unit	1	160000	160000	30
rebar rewinder	1	120000	120000	30
Roving winder	1	80000	80000	30
Technical passport for the line	1	-	-	30

Possible discounts:

When buying with cash.
When buying two or more lines.
When buying a line without installation and training.
Other options are also possible, discussed individually.

It is also possible to purchase the line in parts, but without commissioning. We can manufacture any unit according to your drawings.

Production technology

fiberglass reinforcement, otherwise - "composite", is a hardened rods made of fiberglass and impregnated with a special polymer binder. In construction, such rods replace previously used metal structures, are used in the installation of concrete structures and building foundations. Their main differences are:

lightness (weight is 5 times less than that of metal bars of the corresponding size and quantity);
installation features - fastening with ties instead of standard welding;
dielectric properties and lack of shielding specifics;
high level of extensibility and increased strength of the material;
100-year guaranteed service life of the structure;
resistance to corrosion, impact external environment and atmospheric phenomena;
cheapness of production.

Ease of use causes demand for fiberglass reinforcement not only for industrial construction, but also for a wide range of domestic applications, for the installation of domestic greenhouses or small buildings.

Benefits of a fiberglass rebar business

For entrepreneurs who want to carve their niche in construction business, production fiberglass reinforcement is a good option for rapid development and income generation. Composite reinforcement, which is more profitable in operation, is replacing obsolete metal structures, and the increasing needs of the repair and construction industry guarantee a high purchasing power of this product. The production of fiberglass reinforcement does not require the involvement of a large number employees to carry out the work. The approximate period of production self-sufficiency and reaching profitable indicators is about six months, which allows us to speak about the profitability of production and the prospects for investing in business. positive side there is also the benefit of the production of fiberglass rods, due to the low cost of the initial raw materials and the relative cheapness of the necessary equipment. The units that make up the production line are relatively compact and are serviced by only 2-3 workers involved in the production of composite rods. The price of fiberglass rods is one third lower than that of metal counterparts, therefore, the consumer demand for products with high quality indicators, which at the same time saves estimated costs, is steadily increasing. Given the rapid creation and development of various firms and companies seeking to enter commerce in time and have time to conclude long-term contracts for the supply of materials to developers and contractors, the competitiveness of the enterprise and, accordingly, the successful implementation of composite reinforcement will be higher for manufacturing organizations that have managed to earn the trust of consumers.

Step-by-step plan for opening the production of fiberglass reinforcement - Requirements for the premises, GOSTs

The first step in preparing for the start of production is the selection of premises that meet the requirements for workshops that house complex equipment. For the accuracy and success of high-tech manufacturing of fiberglass rods, the following conditions must be met:

the minimum length of the workshop - from 25 meters;
a flat floor in the room, the maximum level difference is up to 4-5 cm;
constantly maintained optimal air temperature (about 16 degrees);
the presence of high-quality, uninterrupted ventilation with established outflow parameters from 0.25 cubic meters. m per minute;
ceiling height - from 3 meters (permissible limit - from 2.5 meters);
the possibility of a passage width of 1.5 meters between production lines.

It is obligatory to have convenient access roads and the presence of a warehouse for storing products in order to avoid cluttering up the production premises with finished products. It is worthwhile to carry out logistics calculations in advance, allowing you to develop a clear schedule for the supply of raw materials and form a scheme for sending products for sale. This will avoid delays in the production of fiberglass rebar and prevent the formation of surpluses of goods.

Technology for the production of fiberglass reinforcement

The technology for the production of composite rods is inherently quite simple, but it implies a clear implementation and observance of the procedure for manufacturing products. The process consists in the initial impregnation of glass fibers with a special resin and the subsequent formation of rods of the required diameter in the aggregates intended for this, polymerization and the application of a fixing layer. The quality of the produced fiberglass reinforcement depends on the selection of the constituent raw materials and the production process. The raw materials are the following ingredients:

fiberglass;
synthetic resins (phenol-aldehyde - hardening in the process of polymerization and polycondensation, epoxy - not polluting the environment with side emissions during manufacturing process);
polymers - a variety of resins, polybenzothiazole, polybenzimidazole and polyamide (during production they require the addition of other resins);
ethanol (ethyl alcohol), dimethyl ketone (acetone), hardener - dicyandiamide.

Mandatory components for fiberglass rods are rovings (wire threads) used for winding rods and reinforcing the product. The production stages are automated, the business requires minimal human effort in the process of manufacturing composite reinforcement, however, constant monitoring and maintenance of the production line by professionals is required. Production stages:

Immersion of the starting material (continuous strands of fiberglass) in a resin impregnation vessel with hardening components in the composition.
Removal from the details of the wire that served to give relief.
Pulling the resulting rods through a high-temperature polymerization chamber.
Reinforcement surface relief creation by means of winding and profile fastening.
Cooling and drying of blanks.
Feeding the roving to the spinneret, forming a rod of the required diameter and configuration.
Stretching of finished rods, final dewatering and, if necessary, coiling or stacking parts cut to the required length.

Until 2014, clear standards for the standardization of fiberglass rods in the post-Soviet space were not defined. Manufacturers either used the parameters adopted in the countries of America and Europe, or did not certify their products. GOST 31938-2012, which entered into force in January 2014 and was adopted by 8 countries (Russia, Belarus, Moldova, Armenia, Kyrgyzstan, Azerbaijan, Tajikistan and Uzbekistan), regulates the indicators and requirements for the production of fiberglass reinforcement. The rules describe the methods and methods of product quality control and define the exact limits of the content of substances to minimize harm to environment. The text of the document contains normative references, classification and technical requirements required for production.

How to choose equipment for the production of fiberglass reinforcement

When opening an enterprise for the production of reinforcement from fiberglass fibers, it is necessary to equip the workshop with specialized equipment. It is possible to either purchase and install a fiberglass processing line in parts, selecting individual units, or purchase a ready-made set of special devices that provide the entire workflow. For the most part, the machines are universal and suitable for the production of composite rods of various diameters (from 4 to 24 mm), which allows expanding the range of products depending on the level of demand for a particular type of rods. For the smooth operation of production lines, it is necessary to provide a sufficient level of voltage electric current in the network (equipment operation requires 380 V, 50 Hz), take fire safety measures and thoroughly instruct persons who have access to the machines. The complete line consists of the following parts:

bath for impregnating threads, equipped with spin functions and a set of spinnerets;
guillotine-type mechanism for cutting rods;
polymerization oven with temperature control;
cooling unit;
device for pulling reinforcement;
apparatus for twisting threads and winding ribs of rods;
apparatus that twists finished products into coils.

In total, the length of the entire structure reaches from 15 to 20 meters, in width it takes from 0.5 to 1 meter. The arrangement of the workshop should be designed in such a way as to leave the space required by technological standards around the machines and ensure the unhindered movement of maintenance personnel. The list of equipment of the company also includes loaders, with the help of which finished products will be transported to warehouses, equipment for weighing and measuring products, devices responsible for the ventilation system of the workshop, supporting the required temperature regime indoors and built-in fire protection building.

What documents are needed to open

Registration of a business for the production of fiberglass equipment is carried out according to the standard scheme adopted in the Russian Federation for opening small and medium-sized enterprises. The procedure established by law governs the formal registration of a private company. The first step for a novice entrepreneur is usually to contact the state registrar, who clarifies the composition of the initial package of documents being prepared for submission to the state registration authorities. In accordance with the law of the Russian Federation "On state registration legal entities and individual entrepreneurs”, issuing a business registration certificate takes about a week. The documentation package submitted to the registration authority includes:

application of the appropriate form;
copies of identity documents (for individuals) and a selection of documentation on the creation legal entity, including authorized papers;
receipts confirming the payment of state duty.

Appeal to the registration authorities takes place at the place of residence individual entrepreneur or in accordance with the location of the legal entity. Submission of documentation is carried out directly by the owner or head of the business or representatives acting on the basis of a notarized power of attorney. All documentation must be drawn up in accordance with the forms established by law and filled out properly, otherwise, the package of papers is returned to the submitter for revision.

Which OKVED to indicate for the business of manufacturing fiberglass reinforcement

The application for opening a business indicates the direction of activity that meets OKVED ( All-Russian classifier species economic activity). The production of fiberglass reinforcement as a separate field of activity is not included in the classifier, therefore it is supposed to select the most appropriate direction from the list available in the list. The following codes may be suitable:

23.19 - Manufacture and processing of other glass products, including technical glass products;
23.91 - Manufacture of abrasive products;
23.99 - Manufacture of other non-metallic mineral products not included in other groups;
23.14 - Production of fiberglass;
25.24.9 - Provision of services in the field of production of plastic parts;
36.63.7 - Manufacture of other products not included in other groups.

What taxation system to choose for the production of fiberglass reinforcement

An important issue for those wishing to open and develop an enterprise for the production of fiberglass rods is the planning of tax expenses. It is possible to clarify the taxation scheme and determine the approximate amount of deductions when submitting documents and registering a company with tax authorities at the place of registration entrepreneurial activity. Based on the standard calculations carried out when drawing up a business plan for opening manufacturing company, then the approximate list of tax items will look like this:

VAT;
income tax;
taxes from wages;
land tax, transport deductions, etc.

Depending on the form of ownership, types said activity and even the geographic location of the workshop in Russia, the list of mandatory taxes may change, or there will be a urgency to reduce the amount of government fees by taking measures to minimize costs.

Do I need permission to open?

To release products, you must have test reports according to the method of GOST 31938-2012. Where the geometric formats, the results of tensile and compression tests, strength and resilience in cross-section and determination of the limiting service temperature will be determined. Based on this, a conclusion is made on the compliance of the reinforcement with the parameters of GOST, a report on the stability and quality of production. And also a certificate of conformity of products to the requirements of regulatory documentation is issued.

Production technology

For the production of fiberglass reinforcement, the following materials will be needed:

glass roving - a bundle of glass threads;
resins, acetone, dicyandiamide and ethyl alcohol,
braided thread - roving for rebar winding.

The process looks like this. Roving from a special mechanism enters the tensioning device, where it is assembled into right order. Then this completed beam is dried and heated, then it is impregnated and pulled through the spinnerets, which set the desired geometric parameters. After that, the threads go to the winder, where the reinforcement rod is formed and a winding of a given thickness is wound on it. The rebar then passes into a tunnel oven to polymerize the resin in the impregnation. If sprinkling of products is needed, a device for this is provided at the entrance to the oven. After the furnace, the hot bundle is sent to a special bath for cooling. At the end of the process, the cooled reinforcement is cut in accordance with the specified dimensions.

How much money do you need to start this business

When planning the opening of a workshop or mini-factory for the production of fiberglass reinforcing bars, it should be borne in mind that this business requires initial material costs, and entrepreneurs who do not have sufficient sums of money to invest them in a timely manner to start production should better find a more budget option production activities. It is possible to calculate preliminary investments, starting from the specific conditions and the available property and equipment of an individually taken business entity. Estimated costs will consist of the following expenditure items:

Buy or rent land plot where production is supposed to be located (the cost depends on the location and size of the territory).
The cost of procurement of raw materials (from 300 thousand rubles per minimum output).
The cost of registering a business and organizational activity- 20-50 thousand rubles.
Transport and utility costs (from 100 thousand rubles).
Purchase and installation of an integrated line for the production of fiberglass equipment (the price fluctuates depending on exchange rate changes, the brand of aggregate and machine tool manufacturers and the condition of the apparatus. According to a rough estimate, the cost of one line is from 800 thousand to 1.5 million rubles).
The cost of building or renting a production facility (from 50 thousand rubles).
Repair or re-equipment of the workshop in accordance with the requirements and safety standards (depending on the condition of the existing premises, on average it costs 200-300 thousand rubles).
The payroll fund for employees (the mandatory amount of wages is calculated, regardless of the start of making a profit at the first stage of activity - 200-300 thousand rubles).
Reserve stock of material resources for unforeseen expenses - from 50 thousand rubles.

The list of estimated costs can be quite long. And the task of any businessman is the need to independently or with the involvement of third-party specialists to calculate all possible cost flows - both before making a profit from the manufacture of products, and in the process of increasing the turnover of their own business. It is advisable to start production, having an initial capital of 1.5-2 million rubles, this amount is the minimum for investing in a business.

How much can you earn in the production of fiberglass reinforcement

With proper management of the business, investments will begin to pay off in a period of 6 months, but a full return of funds and reaching a positive financial balance in such areas of production is predicted in a 2-year period.

High-tech materials, due to their excellent specifications are in high consumer demand. And it is they who should pay attention to those entrepreneurs who decide to launch a profitable business in a new niche for themselves. And here we include fiberglass reinforcement. If you prepare everything you need - buy equipment for the production of fiberglass reinforcement, order raw materials and rent a room - you can set up a highly profitable enterprise. And huge capital investments, contrary to the opinion of skeptics, are not expected here. Fiberglass reinforcement is a material consisting of a bundle of continuous extremely strong glass fibers, which are combined into a single element. And as a connecting composition that holds the fibers together, synthetic resins act.

Our business valuation:

Starting investments - from 2,000,000 rubles.

Market saturation is low.

The complexity of starting a business is 6/10.

The production of fiberglass reinforcement will be profitable, first of all, due to the demand for products on the market, which is provided by its excellent technical characteristics:

strength,
corrosion resistance,
low thermal conductivity
lightness in weight
resistance to adverse external factors,
non-conductivity of electricity.

Fiberglass reinforcement is not only superior in quality to many other analogues of the material, it is also characterized by a lower cost on the market, which cannot but attract interested customers.
There should not be any problems with the sales market, since fiberglass reinforcement is used today in many areas, and for sure in each region there is far from one who wants to purchase high-quality products for their needs. Where is the material used?

road and civil construction,
arrangement of foundations of various types,
construction of brick structures
strengthening of port facilities,
sewer device.

Fiberglass production will not require huge financial investments to launch a small workshop. Necessary equipment is relatively inexpensive on the market and does not require large production areas. And the simple manufacturing technology of the material makes it possible even to organize home business– without renting premises and hiring additional staff.

After analyzing all the benefits this direction, we can conclude that everyone can open their own business for the production of fiberglass reinforcement, which brings high profits. What will be required for this?

Manufacturing process of fiberglass reinforcement

The material is quite "young" in the construction market, and therefore, before purchasing equipment, it is necessary to properly study the technology for the production of products.

If possible, an experienced technologist can be involved in the work. The specialist will select high-quality raw materials and carry out a trial run of the purchased equipment.

Raw materials for fiberglass reinforcement can be varied. Typically, the following components are used in the process:

roving,
resin,
braided thread,
ethanol,
acetone,
dicyandiamide.

Particular attention when considering proposals from suppliers should be given to the applied roving and resins. The most popular today is fiberglass and basalt-plastic roving. However, on the market you can also find a combined composition, when the rod itself is made of fiberglass, and the ribs are made of basalt. The composition of the binder resins also affects the final properties of the products. Organosilicon, phenolaldehyde, epoxy and unsaturated resin substances are actively used by manufacturers.

To avoid spending on the purchase of all the necessary raw materials, it is better to make bulk purchases from those suppliers that are geographically located closer to the workshop.

The technology for the production of fiberglass reinforcement, despite the many physical and chemical reactions that occur in the process of obtaining products, is relatively simple:

Impregnation of roving with resin substances.
Feeding fiberglass filaments to a shaping die in order to obtain a rod of a certain diameter.
Treatment of the rods in the polymerization chamber in order to strengthen the threads.
Creating a ribbed surface on a rod.

The sale of fiberglass reinforcement will only bring high profits when the technology is thoroughly worked out with the highest quality products at the output.

Technical equipment of the workshop

The manufacture of the material will require special equipment. And the next thing the entrepreneur has to do is to buy a line for the production of fiberglass reinforcement. There are a lot of offers on the market, despite the relative novelty of the business - everyone will choose the appropriate option, focusing on the planned sales volumes and the available finances.

It does not make sense to equip shops just starting their work with high-performance equipment - it is expensive in price. Here it is worth picking up a line with a capacity of 2-4 m / min.

Scheme of the line for the production of fiberglass reinforcement

The plant for the production of fiberglass reinforcement is equipped with the following list of machines and devices:

pulling device
cutting device,
creel,
rib twister,
polymerization chamber,
bosh.

The price of equipment for fiberglass reinforcement varies in a wide range, depending on the power, functionality and degree of automation. To equip the "young" workshop, 1,200,000 rubles will be enough. - this is how much the lines of average productivity cost. And this figure will double, if we talk about a high-performance two-line line.

Not enough money to buy even the cheapest line? It makes sense to think about purchasing used units or renting them.

You can choose a machine for the production of fiberglass reinforcement as a domestic brand (for example, TLKA-2 and PLPSA-20), and foreign. Also, entrepreneurs should pay attention to lines from China - at a low cost, they are characterized by high quality and reliability.

Requirements for a production facility

Even making fiberglass reinforcement with your own hands will require a separate room - even if an empty garage acts as it.

The main requirements put forward to the production premises can be presented in the form of the following list:

Distance from residential areas.
Ceiling height - at least 2 m.
The length of the room is at least 15 m.
Having good ventilation
Supply of electricity, water and sewerage.

To reduce the monthly cost of renting a workshop, you should think about a location outside the city. Here, renting commercial real estate is much cheaper. However, it is important to keep in mind that there will be additional shipping costs.

Sales of finished products

A business plan for the production of fiberglass reinforcement must necessarily contain a clause dedicated to sales finished products. Here it is necessary to think over in what way and to whom exactly the released goods will be sold.

Finding clients should be done as early as possible. Then it turns out that the equipment will start working under the order of a specific client.

If fiberglass reinforcement is sold in bulk, it will bring much higher income. In addition, equipment downtime can be avoided. So, the main bet should be made on the following customers:

large construction companies
wholesale depots and warehouses of building materials.

If at first it is not possible to establish contacts with large wholesalers, you can start cooperation with several small hardware stores or sell products to private individuals.

If finances allow, you can hire a sales representative who would promote the products on the market. Also, it does not hurt to think about creating your own Internet portal - selling or informational.

Economic justification of the project

As practice shows, the price of a line for the production of fiberglass reinforcement of small capacity pays off after 1.5-2 years. But this is an ideal case when channels for wholesale sales of products are established. The payback period also depends on the capital invested in the business.

Purchase of equipment and its commissioning.
Providing a raw material base.
Official registration of the enterprise.
Preparation for work premises.

Starting investments will increase significantly if the entrepreneur plans to organize his own fleet of vehicles to deliver products to customers. But to save money, buying a truck can be postponed until later.

The profit generated by the enterprise will depend on the volume of sales and pricing policy businessman. The average wholesale cost of fiberglass reinforcement is 8-10 rubles per linear meter. m. Its cost at the same time is 3-6 rubles / running. m. If you produce in the shop ≈150000 running meters. m. of finished products (and this is quite realistic), and all this volume is shipped to customers, you can have revenue in the amount of 1,500,000 rubles. Net profit, remaining after subtracting all variable costs, is 80,000-200,000 rubles / month.

As in any other production, its quality plays a key role and is the most
directly affects the final quality of the reinforcement.

TPK "NANO-SK" produces composite reinforcement from three main types of raw materials.

glass fiber

The most popular is glass fiber.

This raw material is a complex thread, which is formed from glass having a special chemical composition. Fiberglass bends, and at the same time does not break, does not tear.

It is the raw material for composite reinforcement guarantees high qualities of strength, not inferior to metal, but with a high modulus of elasticity.

Basalt fiber

Such raw material forfittings, like basalt fiber, is made from natural material melting method
without the addition of chemicals.

Basalt fiber can be staple and continuous.

Basalt-plastic reinforcement has high technical and operational parameters.

TPK "NANO-SK" offers for reinforcement.

Carbon fiber

Another one used by TPK "NANO-SK" in the production process is carbon fiber, which is the result of high-tech chemical production.

Carbon fiber has a high tensile strength, low specific gravity, chemical inertness and low coefficient of thermal expansion.
Carbon is the most expensive.

On modern construction sites a wide variety of objects, structures and structures can be seen more and more often instead of metal reinforcement. An alternative reinforcing material made of composite raises many questions: consumers are interested in the composition of the bars, application features, characteristics and, of course, the technology for the production of fiberglass reinforcement.

The main component of the production of composite rods is roving - a special glass fiber with a thickness of 10-20 microns. Special resins are used to join together a large number of glass fibers into a strong rod. In addition, in technological process acetone, dicyandiamide and ethyl alcohol are also involved in the manufacture of fiberglass reinforcement. If spiral-wound rods are made, then a winding fiber is also required.

Composite rod production line

It should be noted that the process of manufacturing fiberglass reinforcement today is high-tech, carried out on a fully automated production line with minimal human participation. The line with a continuous drawing is served by an operator who controls the process, and at the same time, the production of fittings can be carried out around the clock.

In the technology of production of composite reinforcement, everything starts with a mechanism - a creel, which simultaneously feeds about 60 glass threads to the tension mechanism.
After equalizing the voltage of all fibers, the threads are arranged in the required order and connected into one thread.
Next, the threads go through a heat treatment stage, where excess moisture, oil, dust and other contaminants are removed from the fibers.
The next step in the core manufacturing technology is the immersion of the fibers in a bath with heated binders.
The fibers impregnated with resins are pulled through a mechanism that forms the diameter of the future rod. If a wound rod is produced, then the helical winding of the fiber follows.
In the next oven, the resins, the binder fibers, are subjected to a polymerization process.
At the next stage, the bar is cooled and, finally, it is either fed for winding into coils on a special device or cut into pieces of standard length.