Factory for the production of fiberglass reinforcement. Overview of equipment for the industrial production of fiberglass reinforcement. Historical development and experience of using composite reinforcement in the USSR, Russia and abroad

Reinforcement made of fiberglass or other composites successfully replaces steel counterparts.

The demand for the material in the market is due to the cheapness of raw materials and ease of installation.

Products have a low cost due to the production on automated lines from inexpensive raw materials, in particular recycled glass. This reduces the cost of the final product and saves natural resources.

The demand for non-metallic fiberglass reinforcement for reinforced concrete structures and foundations is constantly growing. It is used in construction and for household needs. Read on to find out how it's made.

Non-metallic fittings have been produced since the middle of the 20th century.

It attracts builders by the fact that during installation the operation of welding is excluded - reinforcing elements connected with clamps.

Often, the material goes into production after processing, which reduces the cost of production.

The basis for the manufacture of the product is glass roving. It is obtained from aluminoborosilicate glass by melting and drawing into filaments.

Roving- this is a bundle of threads impregnated with a lubricant.

As additional Supplies are used:

• epoxy resin;
• special braided thread for winding reinforcement;
• ethyl alcohol, acetone;
• dicyandiamide.

In Russia there is normative base for the production of such fittings.

The document sets out the requirements for the material, in additions - test rules; all standards for the manufacture of composite polymer reinforcement are regulated by GOST 31938-2012.

Regulatory acts contain test methods for determining performance properties:

• 32486-2013 - durability;
• 32487-2013 - resistance to aggressive environments;
• 32492-2013 - mechanical characteristics (ultimate compressive-tensile loads, bending), adhesion strength with concrete.

Comparison of metal and composite

The table shows Comparative characteristics fiberglass and steel reinforcement:

Polymer products cheaper steel. Unlike the latter, she:

• does not corrode in sea water;
• not afraid of exposure to acids;
• does not conduct electricity and warm.

Equipment

Many reinforcing plants have mastered the production of products from composite materials.

They produce rods according to GOST and according to their own specifications.

Products differ in the thickness of the trunks.

Serious enterprises warn buyers about this and provide reliable information about the product.

Factories in the territory of the Russian Federation

1. NZKT, Nizhny Novgorod. It produces fiberglass (and basalt) reinforcement with a diameter of 3-36 mm. Production is carried out on our own equipment. Sells production lines for the manufacture of reinforcement and mesh. Monthly performance the enterprise is 1 million m. The products were used in the construction of metro lines in Moscow. Estimated price of 1 m: 6.3 rubles. (4-22 mm); 158 rub. (24-40 mm).
2. VZKM, Voronezh. Products comply with GOST R 31938-2012. The raw material is Advantex fiberglass. Size range: 4-10 mm in 1 mm increments; 10, 12, 14 mm. Goods are released in bays 50 and 100 m. Productivity - 800,000 m per month. Approximate prices for 1 meter: 0.9 rubles. (4-8 mm); 26-46 rub. (10-14 mm).
3. AlYur Plant, Kaluga. The cost of 1 linear meter: 7-10 rubles. (4-6 mm); 14-30 rub. (8-12 mm).

At the request of the customer, the company produces bar of non-standard diameter.

Fiberglass production lines

The technological cycle of production is carried out on specialized lines.

Standard set of equipment for release composite reinforcement:

• a creel on which bobbins with glass roving are installed;
• the tension device includes a raw material heating unit and an impregnation bath;
• the wrapper is intended for the formation and winding (coiling) of the rod;
• sand spreading machine;
• a tunnel oven is used to heat the bundle of threads after impregnation with epoxy resin;
• bath for water cooling of the bundle after the furnace;
• driven clamping device, automatic cutter.

The length of the room for the installation of the line must be at least 22 meters. Each of the machines is about a meter wide. Average starting power - 12 kW, working - 4 kW.

Technology makes two demands for workshop equipment:

1. A forced draft is supplied to the furnace.
2. Supply (forced or natural) ventilation must be installed in the workshop.

Equipment on the market different companies, designed for different performance and volumes of fiberglass products, therefore, different in price.

Some examples of inexpensive low-power lines for small workshops

Estimated price

A set of units will cost a small enterprise 1.5-1.8 million rubles, a line of average productivity - more than 3 million.

Thus, Mashspetsstroy sells lines and machines for the production of composite fiberglass reinforcement, designed to produce 8 m / min of a rod with a diameter of 12 mm, at a price of $43,000.

Ivanovo Mechanical Plant offers two modifications of lines:

• single-strand for 10 m/min at a price of $29,000;
• two-strand 20 m / min at a price of $ 35 thousand.

Two types of reinforcement can be produced on the units: ribless and coiled. The dimensions, cost and energy consumption of the line for the manufacture of the first type are less.

Unit characteristics

Here are two samples of inexpensive lines.

1. "TLKA-2" Armatura-Sila company. The length of the technological chain is up to 18 m, the length of the rod is up to 12 m, the width is 2 m. The line with a capacity of 5-10 km/shift is served by 2-3 people. The cost is 1.2 million rubles. (with an automatic twister in two threads - 1.75 million). Produces rebar with a diameter of 4-20 mm. The total power of the machines is 12-14 kW.
2. PLPSA-20 PlastOsnova LLC. The two-strand line with a length of 16 m is designed for the manufacture of rebar with a diameter of 4-16 mm. The manufacturer recommends installation in a room with a length of 22, a height of 2.5 m and an air temperature of at least 16⁰С. The cost is 1 million rubles.

Manufacturing technology

A brief technical process for the preparation of glass roving:

• preparation of feedstock - to give the material ductility, it is melted;
• drawing threads up to 20 microns thick;
• applying an oiling agent to the threads;
• the formation of bundles from a plurality of threads, i.e. in fact, glass roving.

Roving is the basis of future fittings.

Its strength and other technical characteristics depend on it.

Therefore, for the manufacture of composite reinforcement, it is very important to use high-quality raw materials.

To reduce the cost of products, it is permissible to add glass, recycled.

The process of heating and separating the threads is carried out on the line units.

The equipment is configured for products of a certain length and diameter.

1. The threads tucked into the creel go to the tension device, which performs several functions. The machine evenly distributes the internal stresses that have arisen in the threads and arranges them in the form of a bundle.
2. Ligaments with applied oil composition are dried and heated with heated air.
3. Prepared bundles of threads are lowered into baths filled with a heated binder.
4. The calibration mechanism forms a rod of a given diameter. In the case of manufacturing reinforcing bars with ribs, braided threads are wound onto the base.
5. The billets enter the tunnel kiln. Preliminarily, fine sand is distributed over the surface of products without winding.

To exit the finished product, it remains only to cool the rods with running water, cut or wind them into coils.

Useful video

This video clearly shows the production technology of fiberglass composite reinforcement from fiberglass on the TLKA-2 line:

Conclusion

Making a technological product with high demand is an attractive idea for organizing an enterprise.

For and fittings from it there are all the prerequisites:

1. Available raw materials and equipment.
2. 2-3 people are enough to service the line.
3. With the same characteristics, the cost of fiberglass reinforcement is lower than steel reinforcement by about 30%.
4. The material is much lighter than the metal counterpart, which reduces transportation costs. So, 2 tons of rolled steel cost the same as 160 kg of composite.

The company has good development prospects, as fiberglass reinforcement is increasingly used in small construction companies.

In contact with

The article reveals the key aspects of the production of fiberglass reinforcement, the choice of equipment and components for its manufacture. As well as ways to implement finished products, including calculations for capital investments and net profit.

fiberglass reinforcement- this is a bundle of continuous, high-strength glass fibers combined into one element (reinforcing rod). The binding link for the fibers are synthetic resins, which provide joint work fibers and protect them both from mechanical influences during the manufacture of the product, and during operation from exposure external environments.

The main characteristics of fiberglass reinforcement

• Tear resistant. 3 times stronger than steel counterparts.
• Not subject to corrosion.
• Resistant to fresh and sea water.
• High elastic properties.
• It is a dielectric (not electrically conductive).
• Has low thermal conductivity.
• It is radio transparent and not affected by electromagnetic fields.
• Does not collapse under the influence of low temperatures.
• With uniform replacement in concrete structures, it is 6-9 times lighter than steel reinforcement.
• Possibility to obtain any design length.

Application area

• Fiberglass reinforcement is used in road and industrial civil construction.
• In buildings for various purposes, including concrete structures.
• When using light and heavy concrete mixtures: all types of foundations, concrete floors, foam concrete.
• For layered masonry brick buildings.
• As fasteners (dowels) for fixing thermal insulation.
• As reinforced rods and meshes.
• In the form of a bearing, facing and rigid layer for bonding multilayer stone and brick walls.
• Used to strengthen the coast, as well as in marine and port facilities.
• All types of water disposal, melioration and sewerage.
• In concrete structures for chemical productions.

Photo options for the use of fiberglass reinforcement

Relevance of the business idea

The construction market, as well as the building materials market, can be confidently attributed to the most developing and promising sector of the economy. In this regard, the production and sale of building materials is always in demand. Including a new product for this market - composite fiberglass reinforcement.

What is the advantage of this business idea?

Who is the potential buyer of the product?

The market for the implementation of fiberglass reinforcement is quite wide: from individual developers to large companies. Consider all distribution channels in more detail.

• The implementation of physical persons (developers). Prospects - the ability to create a strong regional sales market, subject to low productivity of the enterprise.
• Realization to construction shops and small firms. Perspectives - the ability to create a branched trading network both at the regional and national levels.
• Sales to large construction companies. Prospects - the ability to significantly increase the production of s / p fittings through the conclusion of long-term contracts.

How is fiberglass reinforcement made?

The production of fiberglass reinforcement is a high-tech process that consists of the following steps:

• Resin impregnation of fiberglass in the form of continuous threads (roving).
• Feeding the roving into the shaping die to obtain a rod of a certain diameter.
• Pulling the starting material through a polymerization chamber heated to a certain temperature.
• Winding and fastening the profile to create a ribbed surface.

What equipment is required for the organization of production?

Now there is plenty, however, not all of it meets the needs of small businesses. Mainly because of the high cost. Therefore, consider more best option: presented by PLAST OSNOVA.

Line performance meters per minute.

Rebar diameter	one stream	two streams

The cost of a set of equipment is 1,000,350 rubles.

Manufacturing plant requirements

To place the line, the room must meet the following criteria:

• The length of the room is at least 22 m;
• The height of the ceilings in the room is at least 2.5 m;
• Height difference at the equipment placement site - no more than 5 cm;
• The presence of ventilation with an air outflow of at least 250 liters per minute.
• The room must be heated so. air not lower than 16-18°C.

How much money will be required to organize production?

Capital investment

• Acquisition of basic equipment - 1,350,000 rubles.
• Purchase of a working tool, equipment - 250,000 rubles.
• Purchase of raw materials - 500,000 rubles.
• The cost of delivery, installation of the line and equipment of the premises - 200,000 rubles.
• Other expenses associated with organizing a business - 250,000 rubles.
• Total - 2 300 000 rub.

How much can you earn in the production of fiberglass reinforcement?

The calculation of the profitability of activities is presented in the table:

* It takes 3 - 6 months on average to reach forecast revenue.

How many products do you need to produce per month in order for the activity to pay off?

To achieve self-sufficiency, it is necessary to sell products worth 750 thousand rubles per month. (125 thousand linear meters of products). Thus, before starting this type of activity, it is necessary to assess the possibility of selling products (market capacity) in the region where it is planned to open such an enterprise. If the calculations made show that the market capacity is much smaller, then it is not recommended to start this type of activity.

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.

The 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.

Vyacheslav Vyacheslavovich, Irkutsk, Self employed

I have been working with Armplast since 2014. We ordered 2 lines of reinforcing equipment and 1 line for the production of ASP fiberglass mesh, they delivered it just in time, installed and configured the equipment, trained the staff to work on the lines and shared the technology. They told all the subtleties and secrets of the production of fiberglass composites, thanks to which the products are obtained at a higher quality level than those of competitors. We entered the market with ease and paid off very quickly. We also buy raw materials from Armplast, so we do not experience problems with raw materials and we always have something to make fiberglass reinforcement or mesh from. The market in Russia for composite materials is practically unlimited and builders are so conservative that they don’t even know about such a magnificent invention as fiberglass reinforcement and mesh, but everyone is satisfied and as a result low-rise construction almost completely abandon the metal. There have never been any complaints about the work of the lines. Thanks to the specialists of Armplast for the quality work done.

Nikolay, Moscow, construction company

We purchased the line from Armplast equipment manufacturers in 2015. We chose a supplier for a long time, compared various companies, visited their own production workshops, compared the products, namely the quality of the composite materials produced, and as a result, the choice fell on the Armplast company. We quickly completed the installation of reinforcing equipment, within 2 weeks, which is 2 times faster than the specified delivery time. All prices were called “honestly”, which I can’t say about other manufacturers, where various additional markups popped up in order for the line to finally work. We launched and produced a trial batch of products, the quality turned out to be on top. Ensure timely delivery of raw materials. I am satisfied with everything, I hope we will continue to work in the same rhythm.

Mikhail Alexandrovich, Moscow, construction company director

I would like to express my gratitude to the Armplast team for the high-quality equipment that they supplied to us. We bought 3 lines at once and did not even hope for such a short payback period, but it is really real. I can add that the lines are indeed very economical in terms of consumption of both electricity and raw materials and labor. The line can serve only 1 person. A very profitable business indeed and a very good supplier of equipment. The valves produced are very good quality, which allowed us to quickly "move" competitors in our region. We are now planning to develop production in neighboring regions and again we plan to turn to the Armplast plant, because there are no complaints about the work of this team, the guys are really professionals in their field and have trained our employees, who are now also top-class professionals. Thank you for a job well done.

Fiberglass reinforcement (FRP) is gradually replacing the usual metal reinforcement. This building material is actively used in the developed countries of the world. In Russia, it is still not widespread ( market share about 5%), although construction companies are increasingly switching to fiberglass (a trend typical for million-plus cities).

The production of composite reinforcement is a promising line of business. In this regard, we will tell you how to organize manufacturing process and touch on all the points important for the success of the case.

Main characteristics and advantages of ASP

Fiberglass reinforcement is a composite material with a complex composition. It is a glass fiber hardened in a reinforcing bar, “bonded” with synthetic resins. These resins combine heavy-duty glass fibers into one whole, which protect against mechanical damage and aggressive environmental influences.

ASP has high tensile strength - 2-3 times stronger than steel counterparts. Differs in low weight - 6-9 times lighter than steel fittings. Not subject to corrosion, resistant to water (sea or fresh), has a high elasticity. The composite is a dielectric, is not affected by electromagnetic fields, and is characterized by complete chemical inertness. The guaranteed service life of ASP is 100 years.

It is important for business that the cost of such fittings is lower than the cost of metal.

Scope of fiberglass reinforcement

Building materials are used in various areas of construction:

• in road and industrial-civil construction (creation of bridges and airfields);
• when reinforcing all types of foundation (as rods and meshes);
• when reinforcing concrete structures - including in environments that are aggressive for metals;
• to strengthen various kinds concrete using chloride and mineral additives;
• during the construction of agribusiness facilities (due to the absence of fumes harmful to animals);
• to strengthen brick buildings, walls;
• when creating all types of water disposal, sewerage;
• to strengthen the coast in ports.

ASP belongs to the 4th hazard class (low hazard), non-toxic. It can be used in residential construction.

Market situation

The leaders in the use of non-metallic reinforcement are the USA, Japan and China with shares of 40%, 35% and 30% respectively. Entrepreneurs in Russia are showing great interest in this building material. According to the forecast, by 2021 the ASP market is expected to spread by 11.4% annually, and the Russian Federation has good prospects in this regard.

Construction volumes in our country have returned to stable growth after a noticeable drop in last years. According to the Ministry of Construction, as of the beginning of May 2018, 16.7% more housing (20.2 million square meters) was put into operation compared to the same period in 2017.

Construction companies and private developers seek to minimize the cost of housing without compromising quality, and this opens a window of opportunity for the production of composite reinforcement.

Production technology

Building materials are made on special equipment. The process is automated, the staff only controls and maintains the equipment.

1. Fiberglass strands are heated, soaked in resin.
2. The threads are collected in a bundle, tied together, pulled through a spinneret (holes of a certain diameter).
3. The resulting rods pass through a polymerization chamber (tunnel oven) and are processed at high temperature.
4. Composite reinforcement is cooled and dried.
5. ASP is wound into coils or cut into pieces of the desired size, followed by stacking in diameters.

You can make reinforcement of any design length.

Starting investment

You don't need a lot of money to start this business.

Table 1. The amount of initial costs by items for the production of fiberglass reinforcement.

The main expense item - production equipment. The additional costs include the cost of preparing the premises, fuel, electricity.

The calculations are relevant for a city with a population of up to 1 million people.

Raw materials

As the main raw material, the production of fiberglass reinforcement uses glass roving - molten glass fiber in the form of threads with a thickness of 10-20 microns. These threads are collected in bundles impregnated with a special lubricant. Instead of glass, basalt and carbon fiber can be used.

Synthetic resins and polymers are needed. Phenolic and epoxy resins solidify at the final stage of production, "binding" the threads into a heavy-duty rod. Epoxy resins during production do not emit harmful substances. Various polymers (polybenzothiazole, polybenzimidazole, polyamide) are also added, which improve the characteristics of ASP.

Still need ethyl alcohol, acetone and hardener (dicyandiamide).

There are many manufacturers of raw materials for polymer reinforcement on the market. It is important to buy only high-quality materials made according to all technical standards.

The documents

The entrepreneur will sell products construction organizations, work with wholesale and retail companies, supply large quantities of goods. It is recommended to open a business in the form legal entity(OOO). This is more expensive and will take more time, but will allow you to work with major players in the market.

There is no special OKVED code "Production of fiberglass reinforcement". You can choose one of the following:

• 23.19 Manufacture and processing of other glass products, including technical glass products.
• 23.14 "Glass fiber production".
• 36.63.7 "Production of other products not included in other groups."

All norms and requirements for building materials are given in GOST 31938-2012, adopted in 2012. In addition to Russia, 7 other CIS countries adhere to it.

To work, you need a certificate of compliance with the requirements of GOST.

room

• the length of the room where the equipment is located and production is carried out - from 25 m;
• ceiling height - 2.5-3 m;
• the presence of a flat floor with differences of not more than 5 cm;
• the presence of a stable air temperature - 16-18 ° C. This means the presence of heating and air conditioning systems;
• a good ventilation system.

Rent a 150 sq. m. In addition to the workshop, place warehouses for raw materials and finished products, administrative premises, a staff room, and a bathroom here. Choose a location with convenient access roads and space for loading and unloading.

Equipment

Consider the production line PLPSA-20 for the manufacture of reinforcement with a diameter of 4-24 mm. Differs in high productivity: does on 2 bars at the same time.

This is a set of devices for automated work. Comprises:

• devices for feeding glass roving threads;
• tensioning device with the option of heating and impregnation with resin;
• winding mechanism;
• tunnel oven;
• long water cooling unit;
• pulling device;
• rebar cutter;
• bar twisting mechanism, coil winder.

The line is controlled by a remote control. You can turn on the option of cutting bars of a given length or twisting bars into coils. The resulting reinforcement has a constant cross section, 1-2 stiffeners.

Staff

Recruit qualified workers.

Table 2. Number and official duties production personnel.

Job title	Main responsibilities
Senior operator (technical specialist), 1 person	Senior in production (control over the work of the operator, worker, maintenance of equipment)
Operator, 1 person	Work on equipment
Ancillary worker, 1 person	Loading and unloading, supply of raw materials, storage of finished products
Sales manager, 1 person	Development of a policy for the promotion of building materials, establishing the first contact with corporate buyers
Sales representative, 2 people	Conclusion of contracts, work with clients
Driver (with car), 1 person	Logistics, delivery of goods

It is better to “create” a senior operator yourself by sending an employee to a manufacturer / seller of equipment for training. An accountant can be hired by outsourcing.

Sales of finished products

There are several channels for the implementation of composite reinforcement:

• sale directly to private developers;
• sales through construction stores, large networks, wholesale depots, small retail stores;
• work with large construction companies.

For direct selling, you need to send information about the offer through various advertising channels (media, Internet, BTL promotions, posting ads). The implementation of ASP through wholesale and retail networks will allow concluding contracts for the supply of large volumes of goods, gaining a foothold and increasing market share.

It is most advantageous to enter into long-term contracts with construction companies. This will allow you to load production to the maximum, sell more goods.

Financial plan: profitability and payback

1. The amount of initial costs is 2.635 million rubles. (2.7 million rubles).
2. The cost of 1 linear meter of reinforcement with a diameter of 8 mm (the most common type) is 7.6 rubles.
3. Line productivity - 7 m per minute. Accordingly, 7 m × 60 min × 8 h × 22 d = 73,920 linear meters can be produced per month. m.
4. The average price of 1 rm. m of material on the market - 13 rubles. At this price net profit will be 5.4 rubles. (13 - 7.6). When selling all the products produced in a month, you can earn almost 400 thousand rubles.
5. To recoup the costs, to reach zero, in theory, it will take 7 months. But keep in mind that at first you won’t be able to sell everything. The real payback period for a business is 2 times longer - it is approximately 1.5 years.

For clarity, we will draw up the calculations in a table:

Fiberglass reinforcement is a "fresh" product for the Russian construction market. Business in this direction has excellent prospects. It will take less than 3 million rubles to organize a business - given that you are going to open a mini-factory, such costs seem trifling.