Sandwich panels- multilayer structures used in construction. Consist of 1 or 2 outer layers and insulation. Their production is carried out using cold-rolled galvanized steel - - with a polymer coating. The popularity of their use in construction is due to the following qualities: high thermal insulation qualities, simplicity and speed of construction, ease of transportation, and compactness.

Below is information about the production of sandwich panels, equipment for it, manufacturing technology with a video of how they are made, types of insulation and outer layers. Briefly and in detail about the business.

These wall panels have a special roofing rigidity of the ribs. Zinc increases corrosion resistance. If you install them on the roof, you can save on heat loss and thereby reduce your space heating costs. This has an unlimited service life and retains its properties throughout the entire operational time.

Equipment and manufacturing technology

Insulation

The following insulation materials are used as filler:

• mineral wool (basalt fiber);
• polyurethane foam PUR (polyisocyanurate PIR);
• expanded polystyrene;
• fiberglass;
• polypropylene.

There are also sandwich panels based on polyisocyanurate foam insulation, but at the moment the product is little known.

Outer layers

As a rule, the outer layers are made of galvanized steel, but can also be made of other materials, in particular composites based on wood chips. For steel coatings, the composition of the additional coating is important, the quality of which largely determines the characteristics of the panels (service life, fading of outer layers, etc.).

Main materials used as coating:

• Cink Steel. The durability of the structure is directly proportional to the thickness of the zinc layer. The coating is easy to handle.
• Aluzinc- an alloy of aluminum and zinc, patented by the American company Bethlehem Steel (now Mittal Steel). The exact composition of the substance: 55% aluminum, 43.4% zinc, 1.6% silicon. The coating reflects ultraviolet radiation. Sandwich panels with this top layer can be operated at temperatures up to + 315 °C.
• is a material made from two sheets of construction cardboard with a gypsum core. It is a lightweight and absolutely safe coating for panels; relevant for use in finishing residential premises.
• Plastisol- modified polyvinyl chloride using plasticizers. Due to the increased density, the coating retains its performance properties even in unfavorable environmental conditions. Plastisol tolerates mechanical stress well. Suitable for both interior and exterior decoration.
• Plastic sheets made from rigid PVC, polystyrene or polypropylene. Plastic sheets are used for the production of sandwich slopes when finishing window openings.
• Polydifluorionad(PVF2) - a composition formed from 80% plastisol and 20% acrylic. The polydifluorionad layer reliably protects the panel from the harmful effects of temperature changes, ultraviolet radiation, and corrosion.
• Polyester. It is made from polyesters and has a fibrous structure. It tolerates even constant high temperatures well. The polyester-based coating does not fade and is resistant to mechanical stress.
• Pural- a substance obtained from polyamide-modified polyurethane. Pural protects the surface of the sandwich panel from corrosion, burnout, and destruction under the influence of temperature changes. Can be used both inside and outside the building.
• OSB(English) OSB) - oriented strand board, made by gluing wood shavings under high pressure.
• Moisture-resistant hardboard- a composite material made from wood fibers and shavings based on glue. The degree of moisture resistance of the material depends on the glue used.

Color spectrum

The range of shades for metal panels is determined according to the international color catalogs RR (RaColor - 22 primary colors) and RAL (841 GL - 202 colors, 840 HR - 17 colors). When choosing a color, its ability to absorb/reflect light is taken into account, because, together with the characteristics of the environment, this condition will largely determine the overall service life of the building.

Thermal properties

The most important parameter for the energy efficiency of sandwich panels is thermal resistance (R0), which takes into account heat losses in the locking part of the structure. The minimum heat transfer resistance (at 25 °C) for quality products is given in the table below:

The construction of a building made of sandwich panels can be considered energy efficient if its air permeability is less than 1.5 m 3 / m 2 hour. At the same time, the best samples of panels can achieve air permeability in the range of 0.6-0.9 m 3 / m 2 hour.

Technological process

Production can be carried out on semi-automatic and automatic equipment. The manufacturing process of this material is as follows and consists of several stages:

1. Polishing steel sheets.
2. Glue is applied to the bottom sheet of metal and foam or mineral wool insulation is laid.
3. The top sheet is also greased with glue and covered with it on the future sandwich.
4. The resulting structure is placed under a hot press and excess material is trimmed from the end part.

This production method is quite low-productivity and labor-intensive, since specialists carry out many actions manually.

The excess is cut on a special cutting machine. After this, the finished products are wrapped in a special film and sent to the warehouse in workshop transport. The sandwich panels are supplied with sealants and various additional elements.

In addition to metal sheets, you can use wood or fiber board. This panel is called a 3-layer combined panel, and is used during the construction of buildings made of light metal structures.

Video of how sandwich panels are made:

There are also polyurethane foam panels, which are produced on semi-automatic lines using the foaming method. The essence of the method is that polyurethane foam is sprayed through a syringe onto metal sheets located in special forms. When using this method, there is a risk of formation of dips or voids in the insulating layer.

Sandwich panels is a modern building material consisting of three layers glued together: two sheets of metal, chipboard, and a layer of insulating material between them. Sandwich panels can be roofing or wall.

Sandwich panels are widely used in modern construction due to their advantages over other building and finishing materials - excellent sound and heat insulation, ease of installation, strength and lightness, resistance to fire and ultraviolet radiation, a wide range of colors, etc.

Sandwich panel production business can be quite profitable. Despite the relatively high cost of production, the final cost of a structure made from sandwich panels is significantly lower than the cost of structures made from traditional building materials.

Let's draw up a rough business plan for a sandwich panel production plant.

Before you start a business producing sandwich panels, you should decide on the assortment. It is recommended to start with one or two types of products. Of all the variety of sandwich panels on the market, the most popular are galvanized steel panels with mineral wool insulation.

Equipment for the production of sandwich panels are automated lines, the cost of which ranges from 2.8 million rubles (productivity - 120 m2 of 9-meter panels per shift) to 6.5 million rubles (500 m2 of 12-meter panels). At the same time, the choice of a sandwich panel production line depends not only on the amount of available funds. It is necessary to study the trends in the construction market in the region, forecast sales for the next year and a half, and the level of competition. If there are already enough companies producing sandwich panels on the market, and you cannot offer better prices to customers, opt for cheaper equipment.

If there is a real prospect of rapid sales growth, it is better to immediately purchase a more powerful sandwich panel production line.

In addition, you will need the following equipment for the production of sandwich panels:

Forklift for loading and unloading, transportation - 100 thousand rubles;
beam crane for 5 tons - 160 thousand rubles.

As for the premises for the production of sandwich panels, its area must be at least 1500 m2, and it must be well heated and ventilated.

Raw materials for the production of sandwich panels:

Galvanized steel (0.5-0.7 mm) in rolls 1250 mm wide;
insulation (mineral wool) - packages 1200x600x100 mm;
polyurethane based adhesive.
About 1 million rubles will be required monthly to purchase raw materials.

The technology for producing sandwich panels is simple; the whole process consists of several stages:

Cutting insulation to specified sizes (carried out on a machine);
forming the lock of the insulation lamella (slot for fastening) on ​​a milling machine
unwinding a steel sheet on a drum, applying a pattern (previously, if necessary, applying a protective layer), forming a lamella lock;
applying a layer of glue to the steel sheet and insulation;
connection of layers (profiled sheet - insulation - profiled sheet);
pressing of products;
packaging of finished panels (manually or using automated equipment).

Staff.

If a sandwich panel production enterprise produces about 120 tons of products per shift, 3-4 workers will be required. With round-the-clock production, the number of workers increases to 10 people. In addition, the company will need a sales manager, accountant, and financial director.
The cost of staff salaries will be about 250 thousand rubles. per month.

So, in order to open a sandwich panel production plant, you will need about 6 million rubles of initial investment.

At the start of the business, most likely, the production lines will not be fully loaded, and the plant’s productivity will be about 1350 m2. The cost of 1 m2 is 500-800 rubles, and the market price is 1000-1250 rubles. (the cost of sandwich panels in finished products is about 2000 rubles per 1 m2).

Thus, revenue per month of operation may be more than 1.5 million rubles, while the net profit is 250 thousand rubles.

Payback of a sandwich panel production plant is about two years.

Recently, sandwich panels have found wide application in construction work. And this is completely justified, since this particular material is indispensable for prefabricated objects. Sandwich panels are used both in the construction of new buildings and in the reconstruction of old ones, and are also used in the construction of enclosing structures and in roofing work.

Paneling is carried out both at industrial, commercial and commercial facilities, as well as domestic ones.

Such popularity of this building material can ensure running a profitable and efficient business, so creating and organizing the production of sandwich panels is an excellent business idea for entrepreneurs.

By design, sandwich panels consist of three layers. Two metal layers are made of sheet steel - galvanized or coated with a polymer coating, from domestic or Finnish manufacturers. Between them there is mineral wool or polystyrene foam insulation with a fire retardant additive. All layers are bonded together with one or two-component polyurethane adhesive. In addition, sandwich panels must be covered with a special protective self-adhesive film.

To organize a sandwich panel production business, you first need to select a suitable premises and purchase equipment.

The premises can be either purchased or rented. It should be heated and have good ventilation. The ceiling height is not lower than 4 m. The required area of ​​the room can be approximately 600 sq.m., the height of the ceilings in it must be at least 4 m. It should be noted that the production of sandwich panels does not require any special safety measures; it is non-toxic, and not even dust is generated during the work.

Equipment for production can be purchased both domestic and imported. In addition, it is worth considering that different production lines have different productivity, which ultimately determines its cost.

A set of equipment may consist of an unwinding drum, a receiving table, a rolling mill, a mechanical press, a set of tools for profiles and locks, a device for cutting and selecting slots in lamellas and an automatic control system.

To organize a business for the production of sandwich panels, you will need funds in the amount of approximately 17,000 to 19,000 thousand rubles. Monthly costs for renting premises, wages, raw materials and electricity for production of 450 sq.m. products per shift, subject to full load, will amount to about 10,000 thousand rubles. The monthly income will be 13,000-14,000 thousand rubles.

It is worth noting that at the initial stage of business development in the production of sandwich panels it will not be possible to fully use all production capacities. This is due to the fact that at first it will be necessary to carry out a number of works to set up the production process and organize a sales system. As a rule, it becomes possible to use production capacity at 100% by 5-6 months of operation.

Sandwich panels are a universal product with low weight, good strength and ease of installation. These products have become an indispensable element in the construction of prefabricated buildings. Equipment for the production of sandwich panels is quite expensive, but the existing demand for these products is so high that it pays for itself in just two years.

Types of sandwich panels

The building material is a multilayer structure consisting of a rigid cladding shell and insulation. The following materials are used as facing materials:

• steel (galvanized or aluminum-zinc plated). The thickness of the metal ranges from 0.5 to 0.7 mm. The coating (galvanization) can have a thickness of 7-20 microns (second class galvanization) or more than 20 microns (first class galvanization). The anti-corrosion resistance of the material is directly dependent on the thickness of the coating. The thickness of aluminum zinc usually varies in the range of 13 - 23 microns. Some manufacturers apply a polymer layer (plastisol, pural, etc.) to the surface of the steel sheet over the zinc coating. Thus, they increase the resistance of galvanizing to atmospheric conditions;
• plastisol, polyester. Plastic shells are made from sheets with a thickness of 0.8 to 2 mm.
• drywall;
• OSB panels. Plates with a thickness of 7 - 12 mm are used as a frame. SIP panels and plasterboard products are used mainly for constructing internal partitions.

The thickness of the insulation varies between 50 - 300mm. Panels with a thermal insulation thickness of more than 150 mm are used for the construction of refrigeration chambers. In addition to polystyrene and mineral wool, polyurethane foam and sometimes glass wool are often used.

According to the manufacturing method, sandwiches are divided into three groups:

• adhesive;
• PPU panels;
• cassette (sandwich panels of element-by-element assembly).

Production technology

Several manufacturing technologies are known:

• foaming;
• assembly from individual components;
• automated factory production

Their characteristic features are related to the area of ​​application of the products (walling, roofing). Accordingly, the materials for their production differ.

Assembly from individual elements

Using this method, the material is produced in close proximity to the construction site.

The technological route consists of several operations:

• profiling of steel sheets;
• laying insulation on the bottom sheet;
• applying glue to the surface of the insulation;
• installation of the top steel sheet;
• placing the resulting cake under a hot press;
• trimming the ends to a standard size.

Foam plastic, mineral wool and other heat-insulating materials are used as insulation.

The technology described above is the most labor-intensive because many operations have to be performed manually.

Video: "Technology for manufacturing sandwich panels"

Automated production of adhesive panels

The most highly productive technology is the production of sandwich panels on continuous automatic lines:

• two rolls of galvanized steel with a protective polymer layer pre-applied to its surface are installed on the line;
• using special pushers, a layer of thermal insulation is laid out across the entire width of the sheet;
• Polyurethane glue is applied and at the same time the steel components are profiled. As a result, the insulation and steel become one;
• the semi-finished product enters the press. High temperature and pressure complete the process of obtaining the finished product;
• after pressing, the resulting material is cut according to the specified dimensions (width and length);
• finished panels are packaged.

Foaming

The foaming method does not require complex equipment or instruments, but, nevertheless, the following materials are produced in workshop conditions:

• pre-prepared shell sheets are placed under the press;
• the space between the sheathing sheets is filled with polyurethane foam (its foaming occurs under the influence of a constant pressure force). Polyurethane foam firmly adheres to the shell inside the “pie”.

This method has some disadvantages: in case of uneven supply of insulation, voids are formed inside the skin, which lead to a deterioration in the heat and sound insulation properties of the product.

Sandwich panels of element-by-element assembly

Compared to adhesive and polyurethane foam (PPU) panels, cassette panels are the most economical. They are made by crimping a cassette profile around a layer of mineral wool. The cassette consists of the following elements:

• cassette profile;
• insulation;
• wind barrier (protective membrane);
• decorative panel.

For the production of cassette profiles, galvanized steel strip coated with a protective film is used. It is made by bending or cold stamping. Available in several standard sizes in the range of 100 - 200mm.

To prevent ruptures, the insulation is placed in a cassette in a horizontal position.

The facing panel performs two functions: protective and decorative. For its production use:

• metal sheet (metal siding, corrugated sheet);
• facade slabs made of steel, aluminum;
• fiber cement sheets;
• porcelain stoneware slabs;
• panels made of impact-resistant glass.

Assembly of cassette panels is carried out directly on the construction site. They are used on objects of secondary importance: warehouses, hangars, etc.

Automatic lines

The automatic line, which allows organizing production as a conveyor, consists of the following units:

• drum (used for unwinding rolled galvanized steel);
• sheet profiling line;
• guillotine (designed for cutting material);
• machine that forms the skin of the product;
• hydraulic press.

Video: "Complete automatic line for the production of sandwich panels with mineral wool and polyurethane"

Manufacturers of automatic lines

The leading companies in the Russian market of lines for the production of laminated laminated panels are:

• "Industrial Technologies";
• "TechKom".

The Industrial Technologies company produces products of three classes:

• Economy: line capacity with a product length of 6 meters is 120 sq. m/shift (maximum length - 9 meters). The cost of the line is 3 million rubles;
• Standard: productivity - 300 sq. m/shift of six-meter panels. The maximum panel length also does not exceed 9 meters. The price of the sandwich panel production line is 4 million rubles;
• Business: unlike the first two classes, the line of this category is capable of producing 500 sq. m. per shift. m of six-meter sandwich panels. This equipment can produce a product 12 meters long. Such a line costs 6.2 million rubles.

The TechKom company offers two modifications of the automatic line:

• LP-7M with a capacity of 500 sq. m/shift. The longest length of the product is 7.5 meters. The LP-7M costs 7.25 million rubles;
• LPM-1200: per shift, this equipment can produce 1.2 thousand square meters. m of six-meter panels. The maximum length of the product is not limited. This is the most expensive model: its cost is 14 million rubles.

Equipment for the production of PPU sandwich panels

The list of main equipment includes:

• pumping station (designed to take raw materials from supply tanks, dispense components and supply them to the mixer under pressure);
• mechanical mixer;
• two consumable containers (for raw materials):
• compressor;
• Remote Control.

Equipment Manufacturers

• Zhilpromproekt: produces lines for the production of polyurethane foam sandwich panels of the following standard sizes:

2500x1250 - the cost is 100 thousand rubles;

2800x1250 - at a price of 110 thousand rubles;

3000x1250 - costs 120 thousand rubles.

• FOB (Shanghai): line YMPU-PRL-1 - cost is 1.4 million rubles.

In Russia, many companies are engaged in the production of sandwich panels, so there are no difficulties with their supply. But the buyer should know that the best products are those that are produced using the continuous production method (conveyor method).

Sandwich panel (from the English sandwich - multilayer sandwich) is a building material that has a three-layer structure, consisting of two sheets of rigid material (fibreboard, metal, PVC, magnesite plate) and a layer of insulation between them. All these parts of sandwich panels are glued together using hot or cold pressing.

Let's consider information about the production of sandwich panels made of steel, PVC, PPU, etc., equipment for its production, technology, video of processes.

Types of sandwich panels

There are wall and roof sandwich panels. Accordingly, their sheets are different. Roofing sheets have profiled sheets on both sides or one side, and wall sheets are smooth on both sides. In addition, sheets of wall sandwich panels can be decorative on one (outer) side.

Advantages of this material

Sandwich panels have the following advantages over other materials:

• Fast construction or renovation of buildings;
• Construction can be carried out at any time of the year, almost regardless of temperature;
• High thermal insulation performance;
• Sandwich panels are environmentally friendly, hygienic, safe for humans;
• No unnecessary load on the foundation of the building;
• Ease of transportation;
• No additional finishing required;
• High sound insulation;
• Possibility of using sandwich panels in the food and medical industries. institutions;
• Lack of response to exposure to chemically aggressive substances or biological factors (mold, fungus);
• Low price compared to analogues (brick, concrete, wood).

Raw materials for production

Insulation

It can be used:

• Mineral wool (basalt fiber);
• Polyurethane foam (PPU);
• Expanded polystyrene;
• Fiberglass;
• Polyisocyanurate foam.

Sheet covering

The main materials used as a coating for sandwich panels:

• Cink Steel. Reliably protects the surface from corrosion. The durability of the structure is directly proportional to the thickness of the zinc layer. The coating is easy to handle.
• Aluzinc is an alloy of aluminum and zinc, patented by the American company Bethlehem Steel. Exact composition of the substance: 55% aluminum, 43.4% zinc, 1.6% silicon. Aluzinc reflects ultraviolet radiation. Sandwich panels with such a top layer can be used at temperatures up to + 315 °C.
• Drywall. It is a material made from two sheets of construction cardboard and an inner layer of gypsum. This is a lightweight and absolutely safe material for sandwich panels; Its use is relevant for use in finishing residential premises.
• Plastisol is polyvinyl chloride modified with plasticizers. Due to its increased density, this coating retains its performance properties even in the most unfavorable environmental conditions. Plastisol tolerates mechanical stress well and is also suitable for both interior and exterior decoration.
• Plastic sheets made of rigid PVC, polystyrene or polypropylene.
• Polydifluorionad (PVF2)- a composition formed from 80% plastisol and 20% acrylic. The polydifluorionad layer reliably protects the material from the harmful effects of temperature changes, ultraviolet radiation, and corrosion.
• Polyester It is produced from polyesters and has a fibrous structure. It tolerates even constant exposure to high temperatures well. The polyester-based coating does not fade and adequately withstands mechanical stress.
• Pural- a substance obtained from polyamide-modified polyurethane. Protects the surface of the sandwich panel from corrosion, burnout, and destruction under the influence of temperature changes. Can be used both inside and outside the building.
• OSB (OSB; oriented strand board). It is created by gluing wood shavings together under high pressure.

Glue

Based on the material combinations of the sheets and insulation used, different adhesives are used. We will not write about this here, because... Its manufacturers have different names and consistencies.

Equipment and manufacturing technology

Standard technology

The usual technology for manufacturing sandwich panels looks like this:

1. Glue is applied to the first sheet;
2. Insulation is placed on the surface with glue;
3. Glue is applied to the top of the insulation and a second sheet is placed on it;
4. The workpiece is placed under the press. After drying, the slab is ready.

This technology is applicable to conventional sandwich panels, for example, made of steel or PVC, but they will require different equipment.

To produce steel sandwich panels, an unwinding drum, an insertion follower and a forming machine are required.

For the production of sandwich panels from PVC sheets, the main equipment is a press (see video).

But if you are going to open a “full” cycle enterprise, then you will also need:

• Extrusion line for the production of PVC sheets;
• Installation for cutting foam;
• A machine for milling foam plastic (for making exits for excess glue).

Equipment for the production of PVC sheets / Photo www.azkom.ru / Line composition: 80/156 conical twin-screw extruder – 1 pc.; die 1 piece; system for applying protective film 1 pc.; three-shaft press 1 pc.; shaft temperature sensor 1 pc.; cooling frame 1 piece; broaching mechanism 1 pc.; guillotine 1 pc.; set of electrical equipment; mixer; automatic feeder; crusher; stacker

Manufacturing of panels with polyurethane foam

The equipment for the production of sandwich panels, where the insulation is polyurethane foam (PPU), is significantly different. For their production you need:

• Spray installation(price 120-130 thousand rubles) or installation for pouring polyurethane foam(price 350-750 thousand rubles). The choice of one or another installation depends on the productivity of your enterprise. The pouring installation is, of course, more powerful.
• Mold for filling. Its cost is about 50,000 rubles.

The process itself looks like this (see video):

Please note that polyurethane foam is applied to the sandwich panel form in a small layer, because... in the future it will expand significantly.