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 of selling finished products, including calculations for capital investments and making a net profit.

Fiberglass reinforcement is a bundle of continuous, high-strength glass fibers combined into one element (reinforcing bar). The connecting link for the fibers are synthetic resins, which ensure the joint work of the fibers and protect them both from mechanical influences during the manufacture of the product and during operation from the effects of external environments.

The main characteristics of fiberglass reinforcement

• Tear resistant. 3 times stronger than steel counterparts.
• Does not corrode.
• Resistant to fresh and sea water.
• High elastic properties.
• It is dielectric (not electrically conductive).
• Has a 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 receive any design length.

Application area

• Fiberglass reinforcement is used in road and industrial and 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 brickwork.
• As fasteners (dowels) for fastening thermal insulation.
• As reinforced bars and meshes.
• In the form of a load-bearing, facing and rigid layer for connecting multi-layer stone and brick walls.
• They are used to strengthen the coast, as well as in sea and port facilities.
• All types of drainage, reclamation and sewerage.
• In concrete structures for chem. productions.

Photo of options for the use of fiberglass reinforcement

Relevance of business ideas

The construction market, like 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 - fiberglass composite rebar.

- What is the advantage of this business idea?

Who is the potential buyer of the product?

The market for the sale of fiberglass reinforcement is quite wide: from individual developers to large companies. Let's consider all distribution channels in more detail.

• Implementation of physical persons (developers). Prospects - an opportunity to create a solid regional sales market, provided that the productivity of the enterprise is low.
• Sales to hardware stores and small firms. Prospects - an opportunity to create an extensive distribution network both at the regional and national levels.
• Sales to large construction companies. Prospects - an opportunity to significantly increase the production of sanitary fittings by concluding long-term contracts.

How is fiberglass reinforcement made?

The production of fiberglass reinforcement is a high-tech process, which consists of the following stages:

• Resin impregnation of glass fibers in the form of continuous filaments (roving).
• Roving feeding into a forming die to obtain a rod of a certain diameter.
• Pulling the starting material through the polymerization chamber heated to a certain temperature.
• Winding and fastening the profile to create a ribbed surface.

What equipment is required to organize production?

Now there is enough, however, not all of it meets the needs of small businesses. Mostly due to the high cost. Therefore, we will consider a more optimal option: presented by PLAST OSNOVA.

Line productivity in meters per minute.

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

Requirements for the production workshop

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

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

How much money will be required to organize production?

Capital investment

• Purchase of main equipment - 1,350,000 rubles.
• Purchase of working tools, equipment - 250,000 rubles.
• Purchase of raw materials - 500,000 rubles.
• Costs for delivery, installation of the line and equipment of the premises - 200,000 rubles.
• Other expenses related to business organization - 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 the activity is presented in the table:

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

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

For the activity to reach self-sufficiency, it is necessary to sell products in the amount of 750 thousand rubles per month. (125 thousand running 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 indicate that the market capacity is much less, then it is not recommended to start this type of activity.

• Production technology

Fiberglass reinforcement, otherwise - "composite", represents hardened rods created from fiberglass and impregnated with a polymer binder special composition. In construction, such rods replace the previously used metal structures and 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 rods of the corresponding size and quantity);
• installation features - fastening with ties instead of standard welding;
• dielectric properties and lack of shielding specificity;
• high level of elongation and increased strength of the material;
• 100-year guaranteed service life of the structure;
• resistance to corrosion, environmental influences and atmospheric phenomena;
• low cost of production.

Ease of use creates a demand for fiberglass fittings not only for construction on an industrial scale, but also for widespread use in domestic conditions, for the installation of home greenhouses or small buildings.

Benefits of a fiberglass rebar business

For entrepreneurs who want to find their niche in the construction business, the production of fiberglass rebar is a good option for rapid development and income. Outdated metal structures are being replaced by more profitable composite reinforcement, 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 of employees to perform 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. The positive side is the benefit of the production of fiberglass rods, due to the low cost of 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, consumer demand for products with high quality indicators, while allowing to save estimated costs, is steadily increasing. Taking into account the rapid creation and development of various firms and companies striving to join commerce in time and manage to conclude long-term contracts for the supply of materials to developers and contractors, the competitiveness of the enterprise and, accordingly, the successful sale of composite reinforcement will be higher among manufacturing organizations that have managed to earn the trust of consumers.

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

The first stage in preparation for the start of production is the selection of premises that meet the requirements for the shops in which the complex equipment is located. For the accuracy and success of high-tech production of fiberglass rods, the following conditions must be met:

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

It is imperative to have convenient access roads and a warehouse for storing products in order to avoid cluttering the production area with finished products. It is also worthwhile to carry out logistic 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 reinforcement and prevent the formation of surplus goods.

Manufacturing technology of fiberglass reinforcement

The technology for the production of composite rods is inherently quite simple, but it implies a clear implementation and adherence to 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 units intended for this, polymerization and application of a fixing layer. The quality of produced fiberglass reinforcement depends on the selection of raw material components and the production process. The raw materials are the following ingredients:

• fiberglass;
• synthetic resins (phenolic-aldehyde - solidifying in the process of polymerization and polycondensation, epoxy - not polluting the environment by side emissions during the production process);
• polymers - a type of resin, polybenzothiozole, polybenzimidazole and polyamide (they require the addition of other resins during production);
• ethanol (ethyl alcohol), dimethyl ketone (acetone), hardener - dicyandiamide.

The mandatory components for fiberglass rods are rovings (wire threads) used for winding the rods and reinforcing the product. The production stages are automated, the business requires minimal human effort in the process of manufacturing composite reinforcement, but 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 container for impregnation with resin with hardening components in the composition.
• Removing from parts of the wire, which served to give the relief.
• Pulling the resulting rods through a high-temperature polymerization chamber.
• Reinforcement surface relief by wrapping and securing the profile.
• Cooling and drying of workpieces.
• Roving feeding to the die, forming a rod of the required diameter and configuration.
• Pulling of finished rods, final dewatering and, if necessary, winding into coils or stacking parts cut to the required length.

Until 2014, there were no clear standards for the standardization of fiberglass rods in the territory of the post-Soviet space. 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, 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 for controlling the quality of products and determine the exact limits of the content of substances, which allow minimizing harm to the environment. The text of the document contains normative references, classification and technical requirements that are mandatory for the production of products.

How to choose equipment for the production of fiberglass reinforcement

When opening an enterprise for the production of fiberglass reinforcement, it is necessary to equip the workshop with specialized equipment. You can either purchase and install a line for processing fiberglass in parts, selecting individual units, or purchase a ready-made complex of special devices that ensure the entire workflow. Most of 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 uninterrupted operation of production lines, it is required to ensure a sufficient level of electric current in the network (for the operation of the equipment, 380 V, 50 Hz is required), take fire safety measures and conduct a thorough briefing of persons with access to the machines. The complex line consists of the following parts:

• bath for impregnating threads, equipped with spinning functions and a set of dies;
• guillotine-type mechanism for cutting rods;
• polymerization oven with temperature control;
• cooling unit;
• a device for pulling reinforcement;
• apparatus for twisting threads and winding the ribs of the rods;
• apparatus for twisting 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 the technological standards around the machines and to ensure the unhindered movement of the service personnel. The list of the company's equipment also includes loaders, with the help of which the finished products will be transported to warehouses, equipment for weighing and measuring products, devices responsible for the workshop ventilation system, maintaining the desired temperature regime in the room and built-in fire protection of the building.

What documents are needed to open

The 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 regulates the actions for the official registration of a private company. The first step for a novice entrepreneur is, as a standard, contacting the state registrar, which specifies the composition of the initial package of documents prepared for filing with the state registration authorities. In accordance with the law of the Russian Federation "On State Registration of Legal Entities and Individual Entrepreneurs", the issuance of a business registration certificate takes about a week in duration. The package of documentation submitted to the registering authority includes:

• a statement of the appropriate form;
• copies of identity documents (for individuals) and a selection of documents on the creation of a legal entity, including charter papers;
• receipts confirming the payment of the state fee.

The application to the registration authorities takes place at the place of residence of an individual entrepreneur or in accordance with the location of the legal entity. The filing 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.

What OKVED to indicate for a business for the production of fiberglass reinforcement

In the application for starting a business, the direction of activity is indicated that corresponds to the OKVED (All-Russian Classifier of Economic Activities). The production of fiberglass reinforcement as a separate area of ​​activity is not included in the classifier, therefore it is supposed to select the most appropriate direction from the list on 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 - Fiberglass production;
• 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 categories.

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 of entrepreneurial activity. Based on the standard calculations carried out when drawing up a business plan for opening a manufacturing company, then an approximate list of tax items will look like this:

• VAT;
• income tax;
• payroll taxes;
• land tax, transport deductions, etc.

Depending on the form of ownership, the types of specified activities and even the geographic location of the workshop in Russia, the list of mandatory taxes may change, or the possibility of reducing the amount of government fees by taking measures to minimize costs will become relevant.

Do I need permission to open?

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

Production technology

For the production of fiberglass reinforcement, you will need the following materials:

• glass roving - a bundle of glass threads;
• resins, acetone, dicyandiamide and ethyl alcohol,
• braiding thread - roving for reinforcement winding.

The process looks like this. Roving from a special mechanism goes to the tensioning device, where it is assembled in the desired order. Then this bundled bundle is dried and heated, then impregnated and pulled through the dies that set the required geometric parameters. After that, the threads go to the wrapper, where a reinforcement bar is formed and a winding of a given thickness is wound around it. The reinforcement then passes into a tunnel oven for resin curing in an impregnation. If you need to sprinkle products, a device is provided at the entrance to the oven for this. After the furnace, the hot rope is sent for cooling to a special bath. At the end of the process, the cooled reinforcement is cut in accordance with the specified dimensions.

How much money is needed to start this business

When planning to open a workshop or a mini-plant for the production of fiberglass reinforcing rods, it should be borne in mind that this business requires initial material costs, and entrepreneurs who do not have sufficient funds to invest them in a timely manner in the beginning of production, it is better to find a more budgetary option for production activities. It is possible to calculate the preliminary investment, starting from the specific conditions and the available property and equipment from an individually taken business entity. Estimated costs will consist of the following expense items:

1. Purchase or lease of a land plot where production is supposed to be located (the cost depends on the location and size of the territory).
2. Expenses for the procurement of raw materials (from 300 thousand rubles based on the minimum production output).
3. The cost of registering an enterprise and organizational activities - 20-50 thousand rubles.
4. Transport and utilities costs (from 100 thousand rubles).
5. Purchase and installation of a complex line for the production of fiberglass equipment (the price fluctuates depending on changes in the exchange rate, brands of manufacturers of aggregates and machine tools and the condition of the devices. According to a rough estimate, the cost of one line ranges from 800 thousand to 1.5 million rubles).
6. The cost of building or renting a production facility (from 50 thousand rubles).
7. 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).
8. The wage fund for employees (the required amount of remuneration is calculated, regardless of the start of making a profit at the first stage of activity - 200-300 thousand rubles).
9. 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 calculate all possible expenditure flows independently or with the involvement of third-party specialists - both before the start of 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 competent business management, investments will begin to pay off in a period of 6 months, while a full refund and a positive financial balance in such areas of production are predicted in a 2-year period.

Composite, or fiberglass, reinforcement is a high-tech material with technical characteristics suitable for the conditions of the modern building materials market, which requires relatively small investment. Fiberglass can easily replace metal in concrete structures of any size without requiring as frequent replacement as steel products.

Anyone who is familiar with the technology, the requirements for the premises and the necessary equipment can start the production of fiberglass fittings.

The main advantages of glass fittings

Fiberglass reinforcement is becoming more and more popular with customers and, due to its advantages, is crowding out the dominant steel counterparts. Its main advantages include:

• Lightness in comparison with steel reinforcement: 160 kg of fiberglass in volume is equivalent to two tons of metal material;
• production costs are 30% lower than standard investments for the manufacture of competing analogues;
• high and fast payback;
• tensile strength 3 times higher than other materials;
• no need for a large room, heavy transport and numerous service personnel;
• fiberglass reinforcement is not subject to corrosion.

Raw materials for the manufacture of fiberglass reinforcement

Composite reinforcement consists of rods with a diameter of 4 to 18 mm with a spiral profile. The structure of the material is represented by a main shaft of parallel fibers and an outer layer that can be varied (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 constituents of the material are roving and epoxy. The former acts as a reinforcing material, and the latter plays the role of a binder. In addition to the base, you also need:

• acetone;
• braided 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 impregnation of glass fiber with resin;
• bake;
• wrapper;
• bunker for finishing coat;
• magnesite furnace;
• air cooling unit;
• pulling mechanism;
• cutting machine;
• tray for the exit of finished products;
• Control block.

Despite the rapid pace of development of the industry, not every supplier can offer equipment suitable for the needs of small businesses. Typically, the number of options available is severely limited by the entrepreneur's initial financial capabilities.

Some manufacturers offer equipment worth from 1 to 1.7 million rubles - this price range is the most optimal for beginner individual entrepreneurs, since the volume of such production will correspond to the performance of a small enterprise. In this case, the production speed of fiberglass reinforcement will be approximately 2–4 m / min. Equipment with a capacity of 6–12 m / min will cost two to three times more.

In the absence of funds for the purchase of new equipment, it is worth considering 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 the production area

Even when you need to remember about the safety rules. For this reason, any room chosen for the production of fiberglass fittings must comply with generally accepted standards in order to avoid accidents and problems with the functioning of the production line. The main requirements are:

The room for the production of fiberglass reinforcement must meet all the requirements for normal operation

• remoteness from residential buildings position;
• the height and length of the room - at least 2.5 and 22 m, respectively;
• good ventilation;
• technical equipment: supply of water, electricity and sewerage;
• height difference - no more than 5 cm;
• heating up to 16-18 ° C.

In addition, at the initial stage of production, an energy source with a capacity of 12 kW will be required. Then, after debugging the production process, this indicator can be reduced to 4 kW. As for ventilation, forced ventilation of the room will be the most acceptable. The tunnel oven requires a separate hood that can be connected to the overall 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 costs in the case of renting, you can opt for real estate outside the city - even with a simultaneous increase in transport costs, this will significantly reduce the monthly expenses for maintaining a business.

Manufacturing technology of fiberglass reinforcement

The key to manufacturing 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 pulled into a thread with a cross section of 10–20 microns, then the threads are impregnated with a sizing agent and woven into bundles. Initially, the main material is located on special racks, which evenly feed it further along the line.

The filaments collected in a dense bundle are dried and heated with hot air, and then the heated roving passes through an impregnating bath, completely immersed in the epoxy resin. The impregnation unit is a mechanism with four grooves, along which threads of various diameters (from 12 to 18 mm) are pulled.

Shaping and winding

After processing, the roving goes into the forming die, which determines the diameter of the future building material, and then to the bundle winding, which adjusts the thickness of the rods to a certain parameter and provides strength in contact with the concrete base.

Those products that turned out to be of the required thickness remain in the form of finished products, and those that are thinner are additionally sprinkled with sand. The wrapper, like the impregnation unit, consists of four strands and is powered by two belt motors. Due to the circular trajectory of rotation, the winding device allows you to obtain products of the correct cylindrical shape.

Winding roving

Furnace for fittings

The formed products are fed into an 8 m long magnesite tunnel kiln for residual chemical reactions (resin polymerization) to occur.

The final stage

Ready-made, but still hot products are sent to a bath filled with running water to cool down to room temperature. The last step is a cutting machine that divides the material into rods according to the 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 starting the production of fittings, all the necessary parameters of future products are set by the operator engineer.

Composite reinforcement has managed to get a lot of positive feedback from specialists in the construction industry. According to the most conservative estimates, its production on a small scale can pay off in a year and a half, provided that the goods are fully sold. Fiberglass material is reliable, resistant to external destructive factors, easily transported and is far superior to metal in all technical and economic aspects.

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

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

The 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 conserves natural resources.

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

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

It attracts builders by the fact that the welding operation is excluded during installation - reinforcing elements connected by 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 stretching into threads.

Roving Is a bundle of threads impregnated with a sizing agent.

As additional consumables are used:

• epoxy resin;
• special braiding thread for rebar winding;
• ethyl alcohol, acetone;
• dicyandiamide.

In Russia, there is a regulatory framework for the production of such valves.

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

Normative acts contain test methods for determining performance properties:

• 32486-2013 - durability;
• 32487-2013 - resistance to aggressive environments;
• 32492-2013 - mechanical characteristics (ultimate loads in compression-tension, bending), strength of adhesion to concrete.

Comparison of metal and composite

The table shows the comparative characteristics of fiberglass and steel reinforcement:

Polymer products cheaper steel. Unlike the latter, it:

• does not corrode in seawater;
• not afraid of the effects of acids;
• does not conduct electricity and heat.

Equipment

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

They produce rods according to GOST and their own specifications.

Products differ in the thickness of the trunks.

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

Plants on the territory of the Russian Federation

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

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

Fiberglass production lines

The technological production cycle is carried out on specialized lines.

Standard set of equipment for the production of composite reinforcement:

• creel on which bobbins with glass roving are installed;
• the tensioning device includes a raw material heating unit and a bath for impregnation;
• the wrapper is designed for forming and winding (winding) the rod;
• sand spreading machine;
• a tunnel oven is used to warm up a bundle of filaments after impregnation with epoxy resin;
• bath for water cooling of the harness after the furnace;
• pressure device with drive, automatic cutter.

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

Technology makes two demands to equipping the workshop:

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

Equipment from different companies is presented on the market, designed for different productivity and volumes of fiberglass products, therefore, different in price.

Some examples of inexpensive low power lines for small shops

Estimated price

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

So, "Mashspetsstroy" sells lines and machines for the production of composite reinforcement made of fiberglass, designed for the production of 8 m / min of a rod with a diameter of 12 mm, at a price of $ 43 thousand.

Ivanovskiy Mechanical Plant offers two modifications of the lines:

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

The units can be used to produce fittings of two types: ribless and wound. The dimensions, cost and energy consumption of the line for the production of the first type are less.

Unit characteristics

Here are two examples of inexpensive lines.

1. "TLCA-2" company "Armatura-Force". 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 serviced by 2-3 people. The cost is 1.2 million rubles. (with automatic double strand twist - 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, 16 m long, is intended 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

Brief technical process for preparing glass roving:

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

Roving is the basis for future fittings.

Its strength and other technical characteristics depend on it.

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

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 adjusted for products of a certain length and diameter.

1. The threads threaded into the creel are fed to a tensioning device that 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. The bundles with the applied oil composition are dried and heated with heated air.
3. Prepared bundles of threads are dipped into baths filled with heated binder.
4. The calibration mechanism forms a rod of a given diameter. In the case of the manufacture of reinforcing bars with ribs, braiding threads are wound onto the base.
5. The workpieces enter the tunnel oven. Preliminarily, fine sand is distributed over the surface of the 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 technology for the production of fiberglass composite reinforcement from fiberglass on the TLCA-2 line:

Conclusion

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

There are all the prerequisites for and fittings from it:

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 by about 30%.
4. The material is significantly lighter than its metal counterpart, which reduces transportation costs. So, 2 tons of rolled steel cost the same as 160 kg of composite.

The enterprise has good development prospects as fiberglass reinforcement is increasingly used by small construction companies.

In contact with

Vyacheslav Vyacheslavovich, Irkutsk, Self employed

I have been working with Armplast since 2014. We ordered 2 lines of reinforcement equipment and 1 line for the production of fiberglass mesh ASP, delivered right on time, installed and configured the equipment, trained personnel 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 Russian market for composite materials is practically unlimited and builders are so conservative that they don't even know about such a great invention as fiberglass reinforcement and mesh, but everyone is happy and as a result, low-rise construction almost completely abandons metal. There were never any complaints about the work of the lines. Thanks to Armplast specialists 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 produced composite materials, and as a result, the choice fell on the company “Armplast”. We completed the installation of reinforcement equipment fairly quickly, within 2 weeks, which is 2 times faster than the indicated delivery time. All prices were called "honestly", which I cannot say about other manufacturers, where various additional markups emerged so that the line would eventually work. We launched and produced a trial batch of products, the quality turned out to be at its best. Provide timely supplies of raw materials. I am satisfied with everything, I hope we will continue to work in the same rhythm.

Mikhail Alexandrovich, Moscow, director of a construction company

I would like to express my gratitude to the Armplast team for the high-quality equipment they supplied to us. We bought 3 lines at once and did not even hope for such a short payback period, but this is really real. I can add that the lines are really very economical in terms of consumption and electricity and raw materials and labor. The line can be served by only 1 person. A very profitable business indeed and a very good equipment supplier. The manufactured fittings are of very good quality, which made it possible to quickly "move" competitors in our region. We now plan to develop production in neighboring regions and again 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 trained our employees, who are now also top-class professionals. Thanks for a job well done.