The roof is one of the most bulky building elements. When visually inspecting the house, the first thing to look at is the roof. Therefore, the material of the roof is not only the protection of the structure, but also the decoration of the entire structure. And an aesthetic roof is also an indicator of the status of a homeowner. A pleasant appearance affects the cost of the coating, as a rule, the more interesting the material, the higher its cost. For those who are looking for an inexpensive and beautiful coating, polymer shingles (PCH) are suitable.
Material characteristic
Polymer coatings have become widespread relatively recently: the first tiles based on polymers appeared in Europe three decades ago. The material appeared during the search for an alternative to traditional expensive and bulky tiles. The desired coating should have been more durable with the same external parameters. It is these indicators that PPP began to possess. The material weighs much less than a traditional coating, but at the same time it has greater strength. And thanks to the production of polymer tiles in our country, it has become available to a larger number of consumers.
Advantages of polymer-sand tiles
Roofing material must have a long service life, increased strength and affordable cost. All of these indicators have a polymer tile, but in addition, it has a number of other positive qualities:
An important advantage of PFC is a long service life. On average, the coating lasts from 15 to 35 years (depending on the base composition).
Production technology
The production of polymer tiles includes a lot of stages and features. The simplified technology can be described as follows:
- mixing of the polymer composition;
- heat treatment of blanks in industrial furnaces.
A prerequisite for the premises for the creation of PFC is high-quality ventilation, since the production of material using polymers is harmful to humans.
Coating composition
The basis of polymer-sand tiles is quartz sand and recycled plastic. To give the material a particular shade, various pigments are used. The dye does not just color the composition, it binds sand particles and polymer inclusions together. The secondary composition consists of the following plastics:
- Agglomerate. The material is a product of heat treatment of polyethylene. During the preparation of the material, polyethylene is sprayed with water to form balls. These granules are used in the production of PFC.
- hard polymer. This component is individual in different technologies. Some companies use polystyrene, others polypropylene - the recipe can be almost anything.
The production technology of tiles requires strict adherence to proportions. The first stage of creating the material includes grinding the agglomerate and mixing it with sand and a coloring composition in a ratio of 24:75:1. The correct resin tile formula is 75 percent sand, 24 percent resin, and 1 percent dye.
Important! If the production does not observe strict proportionality of the components, the PFC may not meet high quality indicators. In this case, its strength and durability are reduced.
Equipment and production process
The technology for creating polymer tiles begins with crushing plastic into powder. At this stage crushing installations work. Sand, which is part of the coating, undergoes mandatory drying in special equipment.
After grinding the plastic and drying the sand, they begin to knead the composition. At this stage, extrusion plants are used. In them, under the influence of high temperatures, all the components of the tiles are mixed and turned into an elastic mass, similar to yeast dough.
A ball is made from the resulting composition, which is left in cold water to cool. After that, the ball is pulled out and left at room temperature. This process allows the constituent parts to react. When the mass has completely cooled down, it is once again placed in the crushing chamber. After these manipulations, the composition is ready for pouring into the mold.
The crushed particles of the composition are amenable to heat treatment. In this installation, the components of the mass are melted and mixed. High temperatures contribute to the fact that the sand is evenly impregnated with polymers, which forms a homogeneous composition. After mixing the polymer-sand tiles, a mixture with a temperature of more than 175 degrees comes out of the equipment. Each piece of mass must have a weight of no more than 2000 g, the process is monitored automatically and by the machine operator.
The crushed and mixed pieces of the composition go into a mold in which they form coating blocks. In addition to molds, PFC is processed at low temperatures. The range of indicators ranges from minus 45 to plus 80 degrees.
Cons of polymer tiles
Like any other material, polymer tiles have their drawbacks, which you need to familiarize yourself with before purchasing:
Note! Polymer tiles create a comfortable microclimate in the room in any weather: in hot weather it will be cool in the building, and very warm in winter. Because of this feature, the coating is often used for finishing attic spaces.
Features of installing polymer tiles
Even a novice master can handle the installation of polymer tiles. The first step in installing the material is to assemble the crate. For this, both an untreated board and an ordinary timber are suitable. The design will serve as the basis for the tile flooring.
Each block of polymer tiles is equipped with protrusions on the wrong side, with the help of which the coating is mounted on the crate. The blocks are connected to each other on the side fasteners. With this assembly, a durable roofing carpet is formed.
The assembly of the coating begins from the bottom of the roof. Blocks are mounted loosely, but so that they can move in the process of thermal expansion. Thanks to this technology, the material will remain intact during roof movements and precipitation.
Frequent occurrences on the tiles are rusty smudges. To prevent such shortcomings from spoiling the appearance of the roof, galvanized or anodized fasteners are used during installation.
Shingles quality
If you decide to purchase a polymer tile - do not save on the purchase. In recent years, counterfeits of material have increasingly appeared on the market. Such a product absolutely does not correspond to the qualities of polymer-sand tiles.
With a decrease in the cost of goods, an unscrupulous manufacturer receives poor-quality flimsy material with heterogeneous polymers in the composition. The roof of such a coating will quickly burn out and will not last long. Therefore, to decorate your home, use the product of trusted companies.
Remember that any manufacturer wants to sell their product. Therefore, no matter what the seller tells you, be sure to check the documents for the product, which can confirm its quality and origin.
Approaching any village or suburb, against your will, your gaze lingers on the roofs of houses. Therefore, we can say with confidence that the first opinion about a residential building is formed by the roof, because the roof is also part of the image of the homeowner. But in pursuit of the beauty of the roofing, you can also face the high cost. And in order to find the optimal ratio, in many construction supermarkets, experts recommend polymer-sand tiles.
Material Features
For the first time such tiles appeared on the European market in the early 90s. Then the developers were looking for a replacement for the ceramic roof, such that it did not differ much in appearance from traditional material, but would have higher performance characteristics. In connection with the rapid development of the polymer industry, they began to study this material more carefully. As a result polymer-sand tiles appeared on the market. Its main difference from the usual one is its higher strength combined with a lower volumetric weight. And not so long ago, the production of polymer-sand tiles became available in our country.
Advantages of polymer-sand tiles
When choosing a roof covering, attention is paid to such points as long service life, durability and affordable price. All these qualities are combined in a polymer-sand tile, but it also has many other important advantages:
- shingles resistant to sudden climate change, perfectly tolerates large frosts;
- due to the low cost of raw materials used for its production, the cost of polymer sand tiles is low;
- provides the best level of heat and noise insulation;
- complete absence of corrosion;
- due to the fact that tiles are painted on equipment using a UV stabilizer in bulk, and not just on the surface, they have high resistance to fading;
- is a good dielectric, you do not have to additionally install lightning protection;
- does not require special skills when laying;
- polymer sand tiles have high impact resistance, thereby reducing the likelihood of a fight and marriage during the transportation of the material and its installation;
- differs in high chemical resistance to acids and alkalis;
- polymer sand tiles has self-extinguishing properties, no fire is terrible with her;
- environmentally friendly, does not emit harmful substances.
The service life of polymer-sand tiles is on average 15-30 years, depending on how high-quality material was used in production.
Production features
The production of polymer sand tiles includes a whole scheme of technological processes. But by and large it consists of two stages:
- preparation of the polymer mass;
- baking polymer-sand tiles on special equipment.
Production equipment is better to install in well ventilated areas because working with polymers is harmful to human health.
Components of a tile
The raw materials for polymer sand tiles are quartz sand and recycled plastics, as well as dyes. Thanks to a wide range of modern dyes, you can get roofing material of any shade. It is also worth noting that the dye acts in this technological process production also as a "binder" component for sand and polymers.
Recycled plastics include:
Agglomerate, which is obtained by melting polyethylene. The process of obtaining the agglomerate is also interesting. During melting, water is sprayed onto the polyethylene, and balls are formed. It is these balls that are used in the manufacture of polymer-sand tiles;
hard polymer. It can be either polystyrene, polypropylene or ABS plastics and many others.
During the production process, it is very important to observe the correct mixing proportions of the components. At the initial stage of production, the agglomerate is crushed and mixed in special equipment with sand and dye in a ratio of 24:75:1. That is, the correct composition of this roofing should consist of 75% sand, 24% polymers and 1% colorant. If the correct proportions are not observed, the polymer-sand tile at the output can be of much worse quality, and not so durable in operation.
Production technology and equipment used
The technological process of manufacturing polymer-sand tiles begins with the grinding of plastics into smaller particles, for this use crushing equipment. The sand used in the manufacturing process must be dry. Specialized equipment is used to dry quartz sand.
Now that the polymers are crushed to the required size, and the sand is well dried, you need to mix all these components. An extrusion machine is suitable for this. Inside this equipment under the influence of temperature all components are mixed and melted, turning into a viscous mixture, which is somewhat reminiscent of yeast dough.
This mixture forms a ball. Next, the ball is immersed in water for cooling, then, having already taken it out of the water, it is allowed to cool at room temperature. This procedure is carried out specifically so that all components react with each other and seize well. After the balls have cooled, they are again returned to the crushing machine for grinding, and only now the resulting mass is ready to become polymer sand tiles.
Crushed balls send in a thermomixer. In this equipment, all components are again heated and mixed. Sand under the influence of temperature is enveloped in polymers, as a result there should not be a single lump. The mixture comes out of this unit with a temperature of about 180 degrees. Each lump that comes out of this equipment should not exceed 2 kg in weight, this should be monitored by the operator.
The finished cakes of the mixture are sent under the press, where already and polymer sand tiles are formed. Molds help to form tiles to the marketable appearance that we are used to. And the gloss on the outer surface is obtained due to uneven cooling in the molds. In the upper part, the heating temperature reaches 80 degrees, and in the lower part - about 45 degrees. Polymers are squeezed into these molds, which fill the pores between the sand particles.
Disadvantages of polymer sand tiles
Despite all these advantages, polymer sand tiles have a number of disadvantages that must be taken into account before buying:
- surface can erode. Over time, the thickness of the tiles can become thinner under the influence of ultraviolet rays. But given that the thickness of the product is not so small and the erosion process is not fast, this can hardly be considered a serious drawback;
- each tile of polymer sand tiles weighs up to 2 kg, which can cause a lot of trouble during installation and transportation;
- although the tile tolerates climate change well, with temperature changes it occurs linear deformation. As a result, depressurization of the lock joints may occur, which will cause the roof to leak. This, perhaps, is its main drawback.
Under such a roof it will be good to be in any weather, it will be cool in the heat, and warm in winter. Therefore, it is often used for floors of attic rooms and attics.
Rules for the installation of polymer tiles
Installation of polymer tiles is also quite simple. Before starting the installation, it is necessary to build a crate from an unedged board or timber, it is the direct basis for laying tiles.
Each polymer-pasted tile has special protrusions on the top from the back side, with the help of which it is attached to the crate. Between themselves, the tiles are fixed with side locks. As a result, we get a continuous roofing.
It is best to start laying the material from the bottom row. It is not necessary to fasten the elements to each other very tightly, while leaving room for free movement. This will help to avoid deformation of the material from different weather changes.
Rust streaks are noticeable on some roofs, to avoid this, it is advised to use galvanized nails or anodized self-tapping screws when laying.
Material quality
If you decide to replace your roofing, don't chase the low price. Unfortunately, many unscrupulous manufacturers only wait for such buyers and sell them low-quality goods.
In an attempt to reduce the cost of the output product, they use low-quality and short-lived dyes or heterogeneous polymers in the production. During the operation of such a tile, then you can encounter early paint burnout, and a short service life. Therefore, when deciding to refresh the facade of your home, pay special attention to finding a reliable manufacturer.
And keep in mind that no matter what the sellers tell you, no matter how you are assured that the best raw materials and only modern equipment were used in production, it is advisable to check the available documents confirming the quality of the material several times.
LINE FOR THE PRODUCTION OF POLYMER SAND PRODUCTS
The line for the production of polymer sand products (hereinafter referred to as LPPI) is intended for the manufacture of polymer sand products (sewer hatches, GTS hatches, tiles, roofing elements of varying complexity, paving slabs, road curbs, posts, road and sidewalk gratings, MAF, etc.)
Thus, LPPI is equipment for the production of polymer sand tiles, equipment for the production of polymer sand tiles, equipment for the production of polymer sand hatches, equipment for the production of various other polymer sand products.
Compared to traditionally used cement paving slabs and ceramic tiles, polymer sand products have a number of unique properties. They are twice as light, have almost zero water absorption, are more than twice as strong in bending, have excellent frost resistance (more than 150 frost cycles), and have low abrasion, which is especially important for paving slabs.
Purpose
PURPOSE OF THE LINE FOR THE PRODUCTION OF POLYMER SAND PRODUCTS LPPI:
The line for the production of polymer-sand products (hereinafter referred to as the line) is intended for the manufacture of polymer-sand products (tiles, roofing elements of varying complexity, paving slabs, road curbs, road posts, sewer manholes, HTS hatches, small architectural forms, road construction elements, TOTAL MORE THAN 20 TYPES OF PRODUCTS AT THE DESIRE OF THE CUSTOMER, etc.).
The raw materials for the production of polymer sand products are primary polymers, secondary polymer raw materials and polymer waste: polyethylene waste, used polyethylene film, polymer waste, secondary polymers, various polymers (PET, PVD, PVC, HDPE, PP, PS) and plastics obtained from the sorting and selection of municipal waste, as well as screened sand and dye pigments.
Advantages of equipment for the production of polymer sand products and the selected technology:
- Availability of cheap secondary polymer raw materials (bags, greenhouse film (used), industrial waste from polymer production).
- Ability to work in a long production cycle (2-3 shifts).
- Manufactured products in the production process can be painted in any color at the request of the Customer.
- High level of profitability, not less than 100%.
- Small staff of workers.
- Small footprint, compact placement possible.
Part of the equipment
THE STANDARD PACKAGE INCLUDES:
Sand heating plant with overpass(designed to heat sand):
- Overall dimensions: 3000x3400x3100 mm
- Heating power: 19.2 kW
- Sand volume: 0.13 m3
- Hopper weight (without sand): 400 kg
- Productivity: 150-250 kg/h
Polymer concrete mixer(designed for a mixture of sand and polymers and extrusion of the finished mass):
- Overall dimensions: 3500x900x1400 mm
- Engine power: 15 kW
- Heating power: 12.5 kW
- Weight: 907 kg
- Productivity: 150-500 kg/h
Press 100 t/s(one for all product molds, designed for pressing the polymer-sand mass into finished products):
- Overall dimensions: 2200x1450x960 mm
- Weight: 2.5
- Drive: 4 kW
- Pressing force: 60-100 t/s
Switchboard(designed to control technological equipment lines):
- Overall dimensions: 660x510x1900 mm
Agglomerator of polymeric materials:
- Overall dimensions: 1200x620x1600 mm
- Engine power: 18.5 kW
- Weight: 450 kg
- Productivity: 150-200 kg/h
Designed for grinding polymer film waste and obtaining an agglomerate suitable for further processing in extruders and injection molding machines into finished products.
Shredder of polymers and films(designed for grinding polymers for further production of a polymer sand mixture):
- Overall dimensions: 1325x1156x1843 mm
- Engine power: 15 kW
- Weight: 1 t
- Productivity: 180-200 kg/h
Press forms- according to the catalog of molds.
Received products: tiles, roofing elements of varying complexity, paving slabs, road curbs, road posts, sewer manholes, small architectural forms, elements of road construction.
Photo
Sand heating plant:
Polymer concrete mixer:
Switchboard:
Shredder of polymers and films:
Products
Below are some samples of products obtained on the production line of polymer sand products: polymer sand tiles, tiles, hatches.
Video
Line for the production of polymer sand products in operation.
Frequently asked questions about polymer sand products
How long has polymer-sand tiles been present on the Russian market?
For the first time this finishing material emerged in the early 2000s when Russian production imported technologies for the manufacture of composite products from a half-sized sand mixture (sand, polymer, pigment) began to be introduced. Since then, the products of this product group have been confidently leading in the implementation of various projects, seriously competing with analogues made of concrete and metal. Our company has been working in this direction since 2007, which allows us to talk about serious experience in the production of polymer sand products. According to our data, finishing materials in this category are trusted by an increasing number of users who have been able to appreciate the numerous advantages of polymer pavement in practice.
What is the scope of polymer sand paving slabs?
Polymer sand tiles can be laid on almost any area - sidewalks, garden paths, industrial premises, service stations, livestock complexes, including private garages. At the same time, the scope of use is not limited to climatic conditions. Necessary condition installation of polymer functional decor in areas with increased weight impact - this is the presence of a concrete base on which a sand cushion is installed.
How to pave a porch with polymer tiles?
When installing tiles on the porch, it is recommended to use a metal corner as a fixing limiter. Otherwise, the process is similar to the usual installation on a cement-sand base, followed by filling the joints with a dry cement-sand mixture. The allowable seam size is 6-8 mm.
How to lay tiles on a plinth and an exploited flat roof?
At installation work of this type, special supports are used to support piece elements. In order to lighten the weight of the structure, the tiles are laid on a layer of fine gravel, which is installed directly on the roof waterproofing.
Is it advisable to install a polymer paving slabs at car washes?
In this case, there are risks of washing out the fillings of tile joints, which sooner or later will lead to surface deformation, so it is better to use tile adhesive. At the same time, the tile can be successfully used for paving car services and parking lots as a chemically passive material with high climatic resistance.
How to cut polymer tiles?
With the help of the usual "Bulgarian". Moreover, in this case, there will be much less dust and waste than when sawing a concrete analogue.
How do polymer tiles react to the main climatic factors?
Due to the extremely minimal porosity and low water absorption coefficient, the use of this road decor, unlike ordinary paving stones, does not deform under the influence of rain and cold weather.
Equipment for the production of polymer sand products
At the same time, polymer tiles perfectly withstand critical heat, practically without fading under the influence of active ultraviolet radiation.
What weight loads are polymer tiles designed for?
It all depends on the thickness of the piece decor. Terrace tiles 22 mm thick are designed for paving pedestrian pavement and landscape areas for a wide range of purposes. Paving slabs with a thickness of 35 mm can easily support the weight of a truck.
What are the environmental characteristics of polymer sand tiles?
This finishing material is made from three main components - natural sand, polymer (stretch and PVD) and coloring pigment. The last two components have the highest environmental safety, which is reflected in the relevant certificates. And the ecological cleanliness of the prepared sand does not raise questions.
Is it possible to reuse polymer paving slabs in other areas?
This high-end travel décor is not deformed even after prolonged use. Therefore, dismantling allows the tiles to be reused for finishing pavements of the appropriate specification. The created surfaces are highly maintainable, allowing you to quickly replace damaged piece elements without much labor.
What are the features of the operation of polymer sand paving slabs in the winter season?
Polymer tiles compare favorably with an anti-slip coating that provides good adhesion of the soles or wheels of vehicles to the working surface. Snow and ice are easily removed from the respective areas. At the same time, even accidental strong blows of a crowbar are not capable of fatally damaging piece elements that have an enviable impact strength. With any slightest thaw, the tile, like a small heat accumulator, immediately absorbs the necessary portion of heat, which contributes to the rapid thawing of the ice crust without outside interference.
How long does the color of the tile last with active solar exposure?
If the manufacturer conscientiously observes the technology for the production of polymer sand products, namely, the percentage ratio of the components of their quality. For example, if the production process does not save on pigmenting dye, the tile will look attractive throughout its entire service life (up to 25 years). Such priority is provided by the principle of production technology, which forms a combination of pigment with other components at the molecular level. That is, the color of the finished tile is its natural physical and chemical state.
As for pricing, in this case you can directly buy polymer sand paving slabs from the manufacturer without unnecessary trade margins.
How strong heating affects the strength of the tile coating?
With active prolonged exposure to sunlight, the tile can expand within the tile joints, that is, in a linear manner. Such changes are laid down in the technical operating conditions. Thus, there can be no talk of any serious deformation, and even more so of subsidence or “swelling” of the surface.
Can polymer tiles "swell" after installation during use?
Only in case of non-compliance with the laying technology - as a result of the wrong selection of components for the "cushion", the creation of too large or small seams, as a result of poor-quality tamping, etc. Subject to all technical recommendations (TR - 158-04) for the installation of sidewalks, there should be no problems with the operation of polymer tiles!
Production of polymer-sand tiles, paving slabs, hatches
Photo galleryDelivery Production Certificates
The raw materials used in the production of polymer sand tiles are polymer materials in various types: packaging, plastic containers, household items. More and more more items packaged in polymers, a growing range of building materials made from plastics. Raw material preparation
The proposed technology for the production of polymer sand tiles from polymer waste involves cleaning and deep sorting of raw materials. It is proposed to adhere to the ratio of 40-50 / 60-50 of the so-called soft (polyethylene) and hard (polypropylene, polystyrene, ABS plastics, PET, etc.) polymers. In addition to polymers, sand is required in the production of tiles. It is used as a filler and must be dry, sifted without clay and dust inclusions. It doesn't matter what color the sand is and where it came from. Permissible sand fraction up to 3 mm. Other fillers, more readily available in the locality, may also be used, but before commercial use, it is necessary to investigate its effect on product quality.
Pre-processing of raw materials
At the first stage, the selected and sorted plastics are crushed in a crushing machine. It is desirable to have a 50/50 ratio of hard and soft polymers. For example: polyethylenes behave better at negative temperatures and it is easier to get a gloss on a product, but “hard” polymers will add rigidity and strength when heated in the sun. It is better and more convenient to work with granulate or polymer of the same brand. It turns out geometrically even and regular tiles. Polymer-sand tiles are obtained the better, the more evenly mixed polymers and sand.
Preparation of polymer sand mass
After the first grinding, the plastic enters the extrusion machine, where it is mixed under heat. Any chemist will say that it is impossible and unscientific to mix dissimilar polymers; It's like mixing kerosene with water. But such a task is not set - to mix the polymers at the molecular level, it is enough to mix them using the properties of the viscosity of the melted polymers. Polyethylene and polypropylene films occupy a large place in the structure of polymeric materials. They are added to the extrusion machine without grinding. The resulting polymer-sandy mass with the consistency of yeast dough is removed by the operator with a mitten at the outlet of the extrusion unit of the line, and, having rolled a ball (agglomerate up to 100 mm.) With his hands, throws it into the water for cooling. Taken out of the water, not completely cooled, but already hardened, the agglomerate dries quickly, cooling down. The entire cooled agglomerate is subjected to repeated grinding into chips with a fraction size of up to 1-10 mm. Thus, a ready-made raw material for the polymer-sand mixture is obtained.
Obtaining polymer sand mass and molding tiles
This stage of the production of polymer sand tiles is the final one. Some separate it from the harvesting area, located in a separate room. In addition to aesthetic considerations (the preparation of an average polymer mixture is accompanied by the release of gases, and requires the provision of an exhaust), there are also practical benefits: it is easier to control and account. The mixing of sand, polymers and dyes takes place in a thermal mixing unit (Melting and Heating Unit). It is important to keep the mass of the mixture in the APN constant, adding new portions as the finished mass is consumed. The crushed polymer-sand mass is mixed with sand and dyes in different proportions, depending on the products being manufactured. For, for example, tiles, this ratio is: 29/70/1, and for paving slabs it can be 24/75/1.
The ratio of sand and polymers also affects performance - the mass that has more sand in its composition will take longer to heat up. This property should be taken into account when calculating the cost and accounting for products.
It is important to obtain a high-quality mixture - sand particles must be completely enveloped in polymers, without gaps. This is achieved by a unique shaft design, calculated by the "Polymer Technology" Orsk. More precisely, not calculated, but tortured by experimental designs and scientific research. As a result, the blades on the shaft are located in such a way that when the shaft rotates, the mass advance rate is different in 3 heating zones, which ensures complete polymer melt and high-quality mixing with the filler.
By the way, in this node we see some design flaws, the change of which leads to an increase in the productivity of the entire line.
Thus, the resulting polymer-sand mass with an outlet temperature of about 170-190 degrees and the consistency of a tight dumpling dough is squeezed out of the machine after the damper is opened. The operator cuts off the required amount with a knife, weighs it on the scales, and having received the right amount (about 2 kg.), Puts it into the mold with an ordinary scoop.
Price for polymer sand equipment
The form, mounted on a press with a movable bottom plate, is cooled in different ways.
The upper part has a temperature of about 80 degrees, and the lower 45, or cooled as much as possible, for the fastest formation of tiles (30-50 seconds).
This is done to create a gloss on the outside of the polymer sand tiles, as if the polymer is squeezed up, filling the pores between the filler. This is another secret of technology. Although such uneven cooling can lead to the bending of the tiles, for which it is placed on the cooling table and pressed with a load until the final molding.
To obtain a matte surface of polymer-sand tiles, it is enough to cool the upper mold as much as the lower one. This is used for the production of polymer-sand paving stones. The dye may not be added, and the product turns out to be gray in color, like concrete.
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NOT BUY FROM US IF YOU DON'T BELIEVE US!
Most manufacturers motivate the overpricing of their polymer-sand products by the high cost of high-quality raw materials. But this is correct only when the manufacturer does not have the equipment and production facilities for the preparation of polymer raw materials on their own.
Learn more about the production of polymer-sand products at Polisand.
NOT BUY FROM US IF YOU BELIEVE NOT US!
Time is running fast and everything around is changing. Now we all communicate through cell phones, although some 15 years ago it was an unaffordable luxury. You look out into the yard: on playgrounds, instead of wooden swings, in almost all yards there are brand new, "anti-vandal" children's attractions. Break them - don't break them ... They won't break anyway. New technologies make it possible to increase the consumer qualities of goods several times over.
Who would have thought that there would be paving slabs that do not crack from impacts, do not absorb moisture and are not destroyed by time? Over the past decade, we have become accustomed to the fact that new technologies bring relief to our daily work, speed up work processes and decisions, and improve the quality of life in general. And we are ready to take a chance and try to lay out the grounds and paths of our beloved dacha with new tiles, but ... only if it lasts long enough to justify the investment made. The only thing that holds back is the questions that arise before applying the novelty that has not been tested by time: what if it darkens or burns out in the summer? How will she survive the winter? Will it not split? And in general - the manufacturer writes only about positive qualities, what if it will be worse than classic cement? Suddenly it will be harmful, will it emit any odors or gases when heated?
We will try to answer the questions that inevitably arise from the buyer.
It is safe to say that any product in this category, manufactured conscientious manufacturer, is of high quality and will last a long time. And one more thing: equipment for the production of polymer sand tiles is expensive.
Overview of machines for the manufacture of polymer sand tiles
And there are no cheap analogues. In a garage, you can’t make such a tile, unlike cement, using a artisanal method. And it will not be possible to greatly reduce the cost of technology through the use of low-quality cheap materials. By the way, high-quality concrete tiles are made only large companies, and it is expensive, and everything else that is sold in the markets and is cheaper, and will last less. That is, in most cases, the quality of polymer sand tiles should obviously be higher.
As for odors, it is necessary to refer to the composition of the polymer sand composite. Composition: quarry sand (75%), a mixture of plastics (25%): high and low pressure polyethylene (allowed for storage food products and absolutely safe plastics with marking and in international system), and a heat-resistant dye. These components are heated at a temperature of 250 °C. These plastics are absolutely harmless and do not emit carcinogens into the atmosphere when heated. In addition, you need to understand that 75% of the product still consists of sand, and plastic is a binder.
In general, the presence of plastic as a binder (compared to cement - the binder of concrete tiles) gives advantages to polymer sand tiles.
Let's analyze all the properties in order:
+ Water repellency plastics give polymer sand tiles almost zero water absorption, and this extends the service life of polymer sand tiles up to 20 years without destruction. Polymer-sand tiles do not collapse in the thaw with sudden temperature changes. Recall physics: during the phase transition from liquid to solid state (ice), water increases in volume, which leads to the fact that water, having absorbed into the pores of the product, and then freezing, increases in volume and literally breaks the tile with high water absorption from the inside. That's why it happens that in the spring on a freshly laid last fall concrete paving stones and paving slabs are already showing signs of destruction. A polymer-sand tile is whole and dry.
+ The water resistance of polymer-sand products makes them attractive also because on the surface of products ice does not form in winter- the tile is absolutely non-slip, and the snow is easily removed with a shovel.
+ The low water absorption explains and increased frost resistance of the material(i.e. full freeze-thaw cycles in a state of full moisture saturation) - more than 500 cycles.
+ Plastic is lighter than concrete, so polymer sand products 3-4 times lighter than concrete(This allows for easy loading/unloading, hand-carrying along the track or track). This property enables our customers to independently organize the delivery and laying of garden paths, blind areas, porches and burial sites. This property of the polymer-sand material was quickly appreciated by electrical installation companies - a plate for closing a cable made of a polymer-sand composite completely replaced a brick for protecting 0.4-35 kV cable lines in two or three years from the moment of its invention.
Anyone who has ever tried "in work" products made of polymer sand composite no longer refuses them - their use is very convenient and affordable.
+ The presence of polyethylene in the composition gives products unique impact resistance– plastic is a more elastic and astringent material, which gives advantages in load tests. 20 mm thick polymer sand tiles withstand the load of pedestrian areas comparable to the load on concrete tiles or paving stones 40 mm thick! In addition, it refers to "anti-vandal" materials - such material can only be split with considerable effort. Polymer-sand tiles do not break during cargo transportation and when falling.
+ The plastic envelops every grain of sand and paint in the mixture and, when melted, provides uniform coloring throughout the entire product. In addition, the ability to stain plastic is higher than that of cement - such products are brighter, their color is more resistant, paint does not fade. If pigments with high hiding power are used, polymer-sand materials do not lose color for a long time, continuing to delight with the brightness of color even after several years.
+ Plastic, as you know, durable material not destroyed by time. It also transfers these properties to polymer sand products. The declared service life of the coating without destruction is 20 years.
+ The properties of the plastic also give the material: acid resistance, alkali resistance, low abrasion, non-sparking. This is important for coatings with high traffic (entrance groups), as well as coatings: garages, industrial premises, livestock farms etc.
± Plastic, as a binder, transfers paving slabs from the non-combustible (NG) section to the low combustible (G1) and flame retardant(IN 1). The material in the fire does not burn and does not melt (because it contains ¾ of sand), but is charred. This means that when exposed to an open flame for a long time, the polymer sand material may begin to smolder, however, as soon as the source of fire dries up, smoldering will immediately stop.
+ Environmental friendliness of the polymer sand composite undeniable - "food" plastic, building sand and dye - are absolutely inactive at elevated temperatures and in aggressive environments and are harmless to humans. These are not harmful plastics polyvinyl chloride (PVC) and polystyrene (PS), which emit toxic compounds when exposed to them. It is simply impossible to work with such plastics in polymer sand production - after all, the production is carried out by high-temperature processing, which is possible only for harmless plastics.
± Plastic gives polymer sand products longitudinal thermal expansion. At an unstable temperature (sharp warming) in the bright sun, a slight increase in geometric shapes in horizontal surface- up to 1-2 mm. The solution is to leave gaps between the plates - 3-5 mm. If this fact is not taken into account, individual slabs may be pushed out of the coating - perhaps the tile will rise like a “house” and the coating will have to be shifted. This feature must be taken into account when laying, especially since not only polymer-sand tiles have such features - even concrete slabs on the highway rise from the heat.
The expansion of polymer-sand tiles should not worry gardeners - after all, they do not have a question about strict fixation of their coating - for the arrangement of paths, the tiles are laid on the ground with a sand cushion (prepared site) and rammed with a mallet. From the sides of the track must be securely fixed with curbs. Subject to thermal seams, this coating will serve for many years without requiring re-laying. If, when laying tiles, geotextiles are used as a substrate, then there will be issue resolved aggressive growth of weeds - after a while, only small weeds with a superficial root system, easily removed from time to time, may appear on such paths.
By the way, in winter the reverse process does not occur - the tile does not shrink during cooling, but remains within its linear dimensions.
± The presence of plastic reduces the adhesion (adhesion of surfaces) of polymer sand tiles and cement mortar- on the cement mortar, the tile will be held due to the presence of internal grooves into which the mortar will fall. It is allowed to lay on a mortar bed layer (the most dense sand-cement mortar). However, tile adhesive, such as EK-3000, with filling the joints with grout or sealant in the color of the coating, fixes the polymer-sand tiles to the concrete coating much better.
+ And finally, plastic in the composition of products gives ease of processing(using an angle grinder, the so-called "Bulgarian", a cutting wheel for stone), it is sawn evenly, easily, without "battle" and cement dust like cutting concrete tiles.
In the early 90s of the last century, an innovative material appeared on the European construction market - polymer sand tiles. Composite roofing, compared to conventional ceramics, is characterized by increased strength and impact resistance, low specific gravity, and a wide range of colors. An additional plus is the democratic price, explained by the availability of raw materials. It is necessary to organize the flow of secondary waste, find a room, purchase machines and arrange them in accordance with the technological scheme.
Production technology and necessary equipment
The raw materials for molding are quartz sand, pre-recycled plastic waste and dyes, which also play the role of a binder in the mixture.
1. Polymer component. It is a combination of an agglomerate obtained during the melting of conventional polyethylene and a solid part (polystyrene, polypropylene, ABS plastic). Thanks to soft polyethylene, the future roof will not be afraid of frost and will acquire gloss, and the “hard” product will provide heat resistance under the influence of sunlight.
No need to carefully sort, wash and dry waste. It is enough just to launch 40-50% soft and 60-50% hard plastics - approximately in this ratio they go to landfills. It is advisable to immediately separate refractory polycarbonates, fluoroplastics, rubber, small scrap metal, foil. Paper and fusible inclusions burn out during the remelting of raw materials.
2. Sand (filler) must be coarse (3 mm), dry, without clay and dust particles. To the origin and color of the bulk material special requirements are not presented.
3. A variety of pigments make it possible to obtain polymer tiles of any desired shade at the output. To prevent the roof from fading ahead of time, you should look for a reliable brand of paint.
It is important that the production is carried out in compliance with the correct proportions of all components: polymer material - 24%, sand - 75%, dye - 1%.
The production of tiles occurs in stages:
- Drying sand. It is poured into the loading hopper, then it enters the feeder, which delivers it in doses to the conveyor, and then into the chamber, where gases or air heated by the burner are supplied. Ready sand enters the unloading chamber.
- Shredding of plastic waste. In order for the polymer component of various sizes to become homogeneous, it is passed through a crushing machine.
- Mixing. For this operation, extrusion equipment is used, into which crushed solid polymer product is loaded, as well as polyethylene and polypropylene films. A high temperature is created inside the extruder machine, at which the components are mixed and fused to form a viscous pasty mass. Balls up to 10 cm in diameter are formed from it and immersed in water to cool. Then they are removed from the liquid and kept in air for complete cooling and setting.
- Re-grinding. The cooled balls are again passed through the crusher.
- Preparation of polymer-sand mixture. This production is harmful, it should be isolated from the harvesting area. In the room where the machine will work, powerful ventilation is installed to remove harmful gaseous waste.
Crushed polymer semi-finished product, dry sand and pigments are loaded into a thermal mixer. The finished mass, heated to 180 ° C, is squeezed out of the chamber when the damper is opened. The operator cuts off with a knife a portion weighing approximately 2 kg - this is how much is spent on the manufacture of one polymer tile.
After weighing, the cake is placed into the mold with the help of a scoop and sent under the press. The last stage has its own nuances.
- In order to obtain glossy products, the press equipment is set up for uneven cooling of the mold. Its upper half has a temperature of 80 o, and the lower half - only 45 o. The bottom must be cooled as quickly as possible so that the shingles are formed in 30-50 seconds. Under such conditions, the polymer composition rises and fills the pores between the grains of sand on the surface.
- To prevent unevenly cooled products from “driving”, they are placed on the table and pressed down with a load. If this condition is not met, the roof will be uneven.
- The production of the matt variety requires uniform rapid cooling of the upper and lower molds.
Overview of popular machine models
The manufacture of polymer-sand tiles is within the power of small entrepreneurs. In this case, it makes sense to buy affordable compact units (you can use them) and place them in a suitable room. Equipment is selected according to the following criteria:
- Dryer. For this purpose, drum sets of various capacities are mainly used. When the chamber rotates, the sand is poured and dries faster (the process is accelerated if there are blades on the inside of the drum for mixing the bulk product).
- Shredder of polymeric waste. It is advisable to buy a crusher that can grind any plastic raw materials: cans, canisters, film, basins.
- extruder. It is chosen depending on the projected output. The maximum productivity reaches 1000 kg/h.
- Press for molding. The machine should have a force of approximately 100 tons. If it is planned to manufacture not only polymer-sand tiles, but also paving slabs, curbs, it is advisable to choose a table with adjustable dimensions.
Sometimes, in order to reduce costs, used equipment is purchased, but it is better not to save on it. Only high-quality molds made of alloyed steels with subsequent heat treatment are able to work out 5 million molding cycles and ensure the production of conditioned products.
As an example, we give several models of machines for operations included in the technological cycle.
1. Drum type dryer SBP.
It is used for any bulk materials, it works on natural gas or diesel fuel. An electric drive is rigidly fixed on the frame, which transmits rotation to the drum tires. At the time of unloading, the sand is heated to +80 o, so you can additionally purchase a cooler.
The equipment of the SBP series is characterized by a wide range of performance characteristics:
- dimensions - from 3000x950 to 13500x2200 mm;
- drum capacity - from 2.12 to 51.3 m3;
- burner power - from 100 to 16000 kW;
- productivity - from 1.25 to 50 t / h;
- electric drive power - 5-15 kW.
2. Impact crusher IPR (polymer grinder).
The machine is assembled from such units: bed, rotor, body, hopper, electric drive. The housing and the electric motor with a belt drive are fixed on the frame. In the body part, a cutting device (rotor) with knives attached to the side disks rotates on bearings. Waste is placed in the loading neck manually or automatically. The dimensions of the finished fraction depend on the dimensions of the grid cells fixed at the bottom of the grinder.
The crusher features a rigid structure, no dust, minimal noise and high efficiency. The machine has the following technical data:
- rotor diameter - 250-500 mm;
- rotor speed - 450-1100 rpm;
- engine power - 7.5-45 kW;
- weight - 500-2700 kg.
3. Extruder EG-300.
Serves for melting of different-fraction soft and hard plastic. The machine consists of a metal case with a loading hopper, an electric drive (motor and gearbox), electric tape heaters, a temperature controller, an unloading window.
Specifications:
- productivity - not less than 300 kg / h;
- power source - 3-phase AC network with a voltage of 380 V;
- electric motor power - 2.2 kW;
- total power consumption - 11.2 kW;
- dimensions - 3600x1200x400 mm.
4. Thermo screw machine APN.
The melting and heating unit operates on the principle of continuous operation. Serves for mixing crushed polymers with sand filler and dye, as well as preparing hot mass for feeding into the press. The amount of the working mixture in it is maintained at the same level, adding the following portions as it is unloaded. In order for the polymer-sand tile to turn out to be of high quality, the grains of sand must be completely covered with a polymer shell.
The APN consists of a frame, a body-pipe, a bunker, a damper, an auger, a drive (motor, a chain coupling and a reducer), heaters, a damper, a fence, and two temperature control sensors. The body is insulated with heat-insulating material, dimensions - 520x3200x1230 mm.
5. Hydraulic molding press PASH-1.
The machine for pressing polymer sand tiles generates a force of up to 100 tons. The equipment is equipped with a gear hydraulic pump NSh-10, a three-phase electric motor with a power of 5.5 kW, dimensions - 1000x500x2000 mm.
Full cycle lines
If you plan to produce large volumes of products, it is better to purchase a set of installations that fully support the entire process. It is produced in Russia, and the cost is very acceptable.
1. Polimerstroy 18 (Izhevsk).
The company supplies high-quality machines from China, and also practices the manufacture of its own developments. The latter include extruders, melting and heating equipment (up to 600 kg / h), presses with a force of 100-400 tons. Grinding polymer scrap (hard, soft, film) is offered on crushers of domestic and Chinese production. Their power is not more than 300 W, the resulting fraction is 5-8 mm.
2. Monolith (Chrysostom).
The complex includes:
- radial crusher of used polymers (plastic thickness up to 8 mm) - 100 kg / hour;
- extruder of own design "Mastek" - 500-600 kg/hour;
- semi-automatic press - force 100 tons.
Additionally, you can purchase a dryer-sifter for sand, an agglomerator for producing polyethylene granules, a forced mixer.
Rates
The cost of equipment for the manufacture of tiles from polymer waste.
For the device of the roof today, a wide variety of materials are used that meet any consumer needs in terms of quality and reliability, appearance and price. One of the most common types of roofing materials, combining such qualities as durability, environmental friendliness, frost resistance, aesthetics, is tile. The Russian tile roofing market is in the growth stage. The production of tiles as a business has great potential for development.
Types of tiles and their properties
A tile is a piece material that forms an integral covering of a building during installation. It is produced from clay, cement and lime-sand mixtures, thermoplastic polymers, bitumen and even from metal. The properties of a tile depend on the material from which it is made.
So, the most durable are ceramic and cement-sand products. Their service life is more than a hundred years. They have high rates of heat and frost resistance, provide good sound insulation. However, along with this, they are also the heaviest, their weight ranges from 36 to 60 kg / sq.m. Therefore, the use of these roofing materials dictates the need for a powerful and frequent lathing.
Lightweight roofs include soft bituminous and metal tiles. With a weight of 5 to 10 kg / sq. m these materials have good flexibility, so they can be used for roofs of any geometry. Their service life is about 30 years. Color solutions can be very diverse. In many ways, their properties are similar, but the essential difference is that bituminous tiles are not subject to corrosion and decay, unlike metal tiles.
One of budget options tiled roofing is the use of polymer sand materials. Externally, polymer-sand tiles are practically no different from expensive ceramic tiles, but the price is several times lower. In addition, it is lighter (about 20 kg / sq. M) and practical.
If we segment the tile roofing market by product material and analyze the attractiveness of each segment for organizing a business, then the production of bituminous, polymer sand and ceramic tiles will receive high marks.
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How bituminous tiles are made
In the production of flexible shingles, fiberglass, polyester, compressed wood chips and even recycled cardboard are taken as the basis.
Raw materials come to factories in the form of sheets wound into wide rolls. During the production process, the material is unwound on a looper and processed in two stages with hot liquid bitumen - a product of oil refining. Saturation with bitumen occurs under pressure in a special device - a saturator.
At the first stage, the effect of hydrophobicity of porous canvases is achieved (they become waterproof when the applied layer dries). Secondary processing is necessary to improve the viscosity, flexibility and mechanical strength of the material, it takes place using ground limestone.
Before the bituminous-limestone layer is completely dry, it is covered with ceramic chips, basalt or slate granules, which gives future products the necessary shade (there are about 50 possible shades in total) and brightness, and also provides protection from solar ultraviolet radiation.
An adhesive layer is applied to the lower surface of the canvas, then it is pasted over with a siliconized film and sprinkled with ground limestone so that the products do not stick to each other during storage and transportation.
The next step is cooling the material. At this stage, a drum is used, which supplies jets of cold water to the base of the future tile.
Strips of sticky bitumen are applied to the cooled material, which later (during installation) will serve to ensure a strong connection between the products. Then the coating is sent to the cutting zone, where products of the desired size and shape are formed from the strips of material. The standard size of one tile is 100 cm × 30 cm. The shape of the shingle can be different: rectangular, round, etc.
The final stage of production - packaging and warehousing finished products.
The production of soft tiles is carried out on large-scale automated lines operating on the principle of continuous in-line action. The minimum cost of a complex with a capacity of up to 45 meters per minute is approximately 6 million rubles.
Production of ceramic tiles
The raw material for the manufacture of ceramic tile roofing is plastic low-melting clay, so its production is tied to the deposits of this natural raw material.
A significant part of the funds start-up capital when organizing a business, it will go to developing a quarry (conducting research, drawing up a plan, obtaining approvals from Gosgortekhnadzor, land work, forming access roads, etc.).
An enterprise engaged in the production of clay tiles, as it should be located in close proximity to the quarry. Delivery of raw materials to the enterprise can be carried out by transport or conveyor way.
The production technology includes the following steps:
- preparation of clay - the raw material received at the plant is crushed, foreign inclusions are removed from it, after which the material is aged for several days;
- obtaining a clay mass - clay is mixed with water, various plasticizers (thinners) are added to it;
- molding tiles - carried out by extrusion (pushing the mixture through special holes) followed by cutting and stamping;
- drying - molded semi-finished products are dried in chambers for two days;
- glazing or engobing - applying a special coating to eliminate surface defects of products, giving them the desired shade and shine;
- firing - products are sent to tunnel kilns and subjected to heat treatment at temperatures up to 1000 ° C.
The production of high-quality roofing material is impossible without modern equipment, which should include: clay looseners and stone-releasing rollers - for the primary processing of raw materials, fine grinding rollers, mixers and clay grinders - for grinding and obtaining clay mass, extruders and plastic molding presses or turret presses - for molding products, kilns for firing, etc. d.
Important! From April 1, 2016, the production of ceramic tiles must be carried out in accordance with the standards of GOST R 56688-2015 “Ceramic tiles. Specifications".
The construction and technical equipment of even a small plant for the production of ceramic tiles will cost, according to the most conservative estimates, about 50 million rubles. And the production itself is associated with high energy costs, which cannot but affect the cost and the final price of the product.
Production of polymer sand tiles
This type of roofing material is obtained from a mixture of sand and thermoplastic composite (a material that includes thermoplastic polymers and fillers with the addition of paint). Raw materials can be, for example, plastic bottles, packaging materials, household appliances, etc.
The technology for the production of polymer sand tiles (PPS) is simple, and the equipment used for these purposes is relatively inexpensive - a fully equipped line can be purchased for about 2 million rubles (used for 1.5 million rubles). If necessary, you can issue.
How PPP is made:
- first, plastic waste is crushed using a crusher (it is also possible to use ready-made plastic granules as raw materials);
- then all raw materials, including polymers and sand, are dried;
- at the next stage, the starting materials are mixed, various additives are introduced (for dyeing in the desired color, increasing plasticity, etc.) and heated to the melting point of polymers (160-180°C);
- the resulting mixture is poured into molds and stamped;
- the containers are cooled, and the finished material is removed from them.
The finished product has the form of a one- or two-wave rectangular sheet with protruding sides for connection, its typical size is 40 × 31 × 0.7 cm and weighs 2-2.5 kg.
List necessary equipment and indicative prices are presented in the table:
On such equipment for one work shift can be made up to 120 sq. m tiles. In addition, if you purchase additional molds, you can expand the product range to include manhole covers, manhole covers, paving slabs (see), paving stones, curbs and other products that are also made from a polymer sand mixture.
To install the line, you will need a room with an area of at least 150 square meters. m height from 4 m, equipped with a supply and exhaust ventilation system and connected to communication systems.
Income and expenses of the PPP business
The cost of the finished PFC ranges from 300 to 600 rubles. for 1 sq. m. The price depends on the color, the presence of additional elements, the number of units in the package.
The productivity of the workshop per month with one-shift work can reach 3600 square meters. m per month (30 days × 120 sq. m). Thus, if the equipment will work without downtime, the monthly income of the enterprise will be from 1,080,000 rubles.
The cost of production consists of the cost of materials (polymers, sand, coloring pigment and additives), electricity, labor employees. Also, overhead costs include administrative and marketing expenses (costs for the purchase of containers and packaging, payment for the lease of premises, transport services, advertising, etc.). It is useful to know
