Sip panels production technology. Making SIP panels with your own hands: materials and tools for production

In Western countries, SIP technologies are very common. With us, they are just starting to take root. In the material manufacturing industry, SIP technology has been advancing rapidly in the past few years. The construction industry does not stand still, it is developing, and every year it needs new materials, technical innovations, new raw materials. Therefore, the production of sandwich panels has become a promising type of business. It does not require initial costs, quickly pays off, and there is always a sale of products sold.

Sip panels are used in low-rise construction. They are relatively inexpensive compared to other similar materials. Sip panels have proven themselves in operation. Due to the fact that sip panels are not expensive, they are always in high demand, even during crises.

Organization of a mini business for the production of SIP puff panels.
The business for the production of sip panels in Russia is developing rapidly. To buy good new equipment, you will need an amount equal to $100,000 USD. If you purchase Chinese equipment, then you can meet 700,000 rubles. Chinese equipment for the production of sip panels works in manual mode, and not in automatic mode like European ones. Therefore, for a cheaper mini-production, a larger number of workers will be required.

Equipment for the production of sip panels:
Two transfer trolleys are used to organize the supply, which are located in front of the glue sprayers; 16 pound unloading trolley; pneumatic press, for laminates, rear loading; scissor lift 4x16 pounds, for layering panels; and two glue applying machines (upper and lower).

For the production of sip panels, it is necessary to have permits for production, and certificates of product conformity. If you do not have certificates of conformity for your products, you will not be able to sell them in full.

Technology for mini production of sip panels.
Manufacture of sandwich panels. An OSB sheet is taken, a layer of glue is applied to it, a sheet of polystyrene foam is placed on top, of the required thickness. It is also smeared with glue, and a second OSB sheet is laid on it. First, this panel is dried, and only then, it is sent for construction work, to the construction site. As we can see, the technological process for the production of sip panels is not very complicated, but it requires the implementation of certain rules.

Firstly, special equipment is required, without it, manually, you will not be able to produce good quality sip panels.

Secondly, during the mini-production of sip panels, the adhesive foams strongly during polymerization, and accordingly increases several times. Therefore, the sip panel must be strongly compressed so that all layers adhere well to each other. To do this, you need a force of 18 tons. And this means that for the production of sip panels, a powerful press is needed.

Thirdly, the manufacturing process of sip panels must be very fast. Since the glue, in a non-hermetic state, can be applied only for 3-5 minutes. After all, after 10 minutes, the glue begins the polymerization process. The adhesive that flows out cannot be removed with any solvent. It is removed mechanically, or when heated to 300-500 degrees.

Fourth, very stringent requirements are put forward for glue. It must comply with environmental requirements. It should also be of a special purpose, namely, for the manufacture of sandwich panels. The adhesive must not contain toxic, harmful substances that could pollute the environment. Also, throughout the entire service life, the adhesive should not lose its properties. It must be durable, moisture resistant, and withstand temperature extremes, from -40 degrees to +50 degrees.

Differences in world production.
For the manufacture of sip panels, in Russia and in the West, various technologies are used. In Russia, in the manufacture of vulture panels, dry planed timber is used. Products from this timber are stronger, more durable, with increased thermal conductivity. The dimensions of the manufactured panels are: width-1250 mm, length-2800mm and 2500mm. If, the panels are cut, at the factory, then they are obtained in a width of approximately 625mm.

Marking of sip panels in Russia -PSB-259 expanded polystyrene, suspension, pressless, self-extinguishing. In the West, completely different sip panels are produced from a different material and have a completely different marking. The dimensions of American sip panels do not correspond to our Russian panels.

Video mini production of SIP panels:

The Russian construction industry has recently changed markedly due to the influence of the global market. This also applies to the technology of building private houses. Canadian construction ideas have gained popularity, according to which reliable and durable objects are being built. With this area, the production of SIP panels is being improved. The method of building houses becomes cost-effective, which results in an excellent result. Business will be profitable in this area.

Definition

SIP panels - wood chip building material. It should be borne in mind that it is in great demand at the present time, as it helps to build houses at low cost. Consumers are interested in products because of the high technical and operational performance of the material, which makes the business profitable.

The production of SIP panels is in demand because the products are used in panel-frame construction. These sheets allow you to perform high-quality insulation. Classic frame houses were popular due to the speed of construction and affordable cost, but in terms of performance they are inferior to traditional log cabins. The production of SIP panels solves this problem. A business from scratch in this area provides a stable income. Such materials are resistant to various loads.

Manufacturing technique

Naturally, excellent characteristics appear after a complex raw material processing procedure. The whole process involves the implementation of 3 main stages:

• assembly;
• cutting;
• gluing.

The first 2 stages of creation are carried out on the central line, and the 3rd - on special equipment. The assembly procedure involves the combination of polystyrene foam sheets, OSB and PSB boards. At the same time, workpieces are trimmed based on predetermined dimensions.

At the end, polyurethane or another type of glue is used, which is provided by Canadian technologies for creating SIP panels. You can glue several products, but everything is determined by the capacity of the workshop. This work is performed by pressing machines with a load of about 5 tons. This is the production of SIP panels.

Raw material

According to the requirements for the manufacture of materials, oriented strand boards and non-shrinking suspension polystyrene foam sheets are required. The binder is a polyurethane composition. The adhesive base is considered one of the important components in the kit. Such production of SIP panels allows you to create a durable material, but hardly anyone will believe that it is environmentally friendly. Now new adhesives are being produced, thanks to which a high binding function is provided, but no less harmful. Most likely, with the development of a new adhesive, new directions in panel manufacturing technology will appear.

Equipment

There are 2 options for organizing the production of materials. The first method involves the installation of a complex, where there is the necessary equipment for the production of SIP panels. Such a mini-workshop consists of:

• communication nodes;
• pressing machine;
• cutting point.

The price of the finished line is in the range of 2-3 million rubles. This option is ideal for businesses that may be installing a new container. The plant for the production of SIP panels will work smoothly and therefore will bring a stable income. From there, materials will be supplied to shops and construction markets. To open a small private line, you need a separate production of SIP panels. Business in this case is more promising. In the future, you can think about expanding. To create such a workshop, you need a small room to accommodate a cutting machine, a press and a thermal knife.

room

There are no strict requirements for the workshop where the panels will be manufactured. It includes several sections:

• area for storage of raw materials;
• the main area for production;
• place for drying the material;
• warehouse for storing panels;
• additional premises.

Each room must be equipped on the basis of sanitary and hygienic standards. Ventilation is required as the adhesive releases volatile components. Communication should be standard.

Material investments

Most of the expenses will go to the purchase of equipment. If a ready-made workshop is bought, then about 2.5 million rubles will be required. Self-assembly costs between 200-300 thousand rubles. You also need to spend money on accessories, rent, purchase of raw materials and maintenance. All this takes about 50-70 thousand per month.

The production of materials quickly pays off, since the production of houses from SIP panels is considered a sought-after industry. The cost of 1 unit of the product is 1,000 rubles. How payback will occur depends on performance. Sometimes it takes a couple of months, and in some cases a year.

Additional expenses

If production is organized from scratch, then costs are required for:

• registration of the company;
• hiring workers;
• passing inspections;
• purchase of fire and burglar alarms.

The final payback rates depend on various factors. This is affected by the cost of raw materials. The press may have different speeds. Production also depends on the glue used, manual labor.

Profitability of the mini-workshop

If you properly organize production, you will get a very profitable enterprise. It will take at least 1 million rubles to open a workshop. The costs include registration of an individual entrepreneur, since everything must be legally executed.

You can save money if you buy cheaper equipment. In practice, the creation of panels brings a stable income if sales are established. For a mini-workshop, it will be enough to produce up to 5 square meters. m of production per hour. If every day it takes 12 hours to work, then you can get up to 800 thousand rubles from the sold products, and the net profit will be at least 100,000.

Sales of materials

The main clients will be construction companies that carry out the construction of wooden houses. This area is still in demand on the Russian market. And the prevalence of Canadian technologies only increased the list of services provided by such enterprises. The buyers of SIP panels will be individual developers who plan to independently implement projects. As can be seen from practice, direct interaction with the manufacturer of building materials provides many advantages for consumers.

Conclusion

Although objects made of stone and brick still symbolize quality, durability and reliability, many other technologies remain competing for them. If panel-frame technologies can be inferior in strength, then their cost and energy efficiency are considered an advantage.

The manufacture of this building material takes place according to Canadian standards, but Russian versions of the technology still appear. The change in the classic idea is related to the characteristics of wood materials. In Russian forestry, high-quality raw materials are used, which are better than foreign ones in some properties.

Construction is developing more and more every day, and new technologies and materials are emerging. Each of them has its own characteristics and positive aspects. They directly depend on the type and size of buildings. The most common material for high-quality construction are sip panels.

Currently, buildings for permanent residence and life of people, which are built according to Canadian technology using SIP, are very popular. This also includes low-rise buildings (warehouses, townhouses, and others).

Usually, any manufacturing plant that creates such panels independently manufactures all the necessary elements in the construction of buildings. This is very important as it cuts down on customer costs. They no longer need to look for architects separately - many of them immediately acquire a turnkey finish. Construction is carried out quickly, mainly due to an individual approach to each customer.

In the manufacturing process, as a rule, each manufacturing plant actively uses high technology and its professional experience, which combine excellent quality, minimum time and reasonable price.

What are SIP panels?

Sip panels are an absolutely pure material that is popular in the construction of suburban premises. Houses built from them are endowed with a high degree of reliability, durability and have a low price.

Each manufacturer of sip materials, as a rule, provides a wide range of price and architectural options, which allows you to choose their sizes with each customer individually.

Any factory specializing in such panels uses the method of building panel houses, which appeared more than forty years ago. And since then it has been widely distributed in America and Europe. This technology is considered the best of its kind and has been successfully operating in a wide variety of conditions in many countries.

Benefits of SIP Technology

1. The SIP production technology is the most up-to-date and advanced of the whole range of house building technologies. It meets all the necessary requirements that are provided when creating residential premises around the world. Such buildings are no worse than stone and wooden houses. And according to several characteristics, they even have superiority over them. For example, in terms of the quality of energy insulation, thermal insulation, and so on.
2. It involves reducing the cost by reducing the construction cycle, reducing the number of costs for finishing the premises, functioning with inexpensive types of foundation. All this does not affect the reliability and quality of the building.
3. SIP houses, which are being built by a reliable manufacturing plant, combine low cost, efficiency in operation, the highest architectural quality and durability. Such a suitable combination of aesthetics, quality and price increases the demand for houses and buildings built using this technology.
4. The calibrated beam, pre-treated, is a supporting frame - an important element when joining panels. The rigidity of the building structure is created using the bearing capacity of sip panels.

Material

The panels are based on special oriented strand boards. Between them, under high pressure, a thick layer of polystyrene foam is glued, which has a solid base.

This design of the plates guarantees high strength of the walls in compression and rupture. And the layer between the plates creates maximum sound and heat insulation throughout the house.

The largest completed SIP panel has the following dimensions: 2.8 by 1.25 meters, and the thickness varies in the range of 174-224 mm. Despite the rather large dimensions, it has a slight weight. This is another advantage in the functional construction of houses. With such a weight of panels, a minimum of professionals is required when performing installation work.

Production

Based on the experience of Western specialists, Russian manufacturing plants create their own new production lines every day, which, in turn, make it possible to produce sip panels quickly and efficiently.

Production features

For SIP panels, the basis is:

• OSB-2 - used in a dry environment inside the walls;
• OSB-3 - used in a humid environment inside and outside the walls;
• OSB-4 - are used for load-bearing structures of buildings with high mechanical loads and high humidity for internal and external walls.

All boards consist of special pressed wood shavings. It fully complies with the European standard EN-300-OSB, which means that the material is completely environmentally friendly and created for construction work.

The special composition of the plate, ideal for the construction of houses and their proper functioning. Inside the plates is expanded polystyrene, consisting of styrene - an absolutely safe substance for the life and health of any person.

Due to low heat treatment and correct structure, SIP material can be used at different temperatures (from -180 to 80 degrees Celsius).

The plates are pressed under high pressure.

At the very end of production, almost the whole house is brought to the construction site. After that, it is assembled from pre-prepared materials by professional workers without the use of lifting equipment. Then the complete order of all panels is completed. Each client can choose doors and windows for a complete set.

Now SIP-technologies have become widely used in the Russian market of construction services. There is a significant increase in the appearance of structures and structures from panels of this type in many places in Russia. Since the climate in the country is quite diverse (from subarctic to temperate), therefore, their use is especially necessary. Each customer must choose a manufacturing plant and start creating the perfect home.

• What is SIP (SIP) panel
• Staff
• Raw materials for production
• What equipment to choose
• Production technology

A full-fledged business in the production of SIP panels can be opened with an amount of less than 500,000 rubles. The main costs are associated with the purchase of equipment and raw materials for the production of products. A heated hangar of 200 sq. m. The production technology is quite simple and does not require the employment of highly qualified specialists. The cost of purchasing the line, subject to 100% implementation, pays off already in the first month of the enterprise.

What is SIP (SIP) panel

SIP is an insulating panel consisting of a layer of insulation, fastened with OSB sheets (OSB) on both sides. Most often, foam is used as an interlayer, as it is cheaper and easier to cut. The very idea of ​​using SIP panels came from Canadian house building technology. Houses using Canadian technology are being built very quickly, and in many respects they are superior to houses made of stone materials, including brick, foam concrete or aerated concrete. Useful properties of SIP panels in our country are still underestimated. So, only 17 cm of SIP panel thickness in terms of thermal insulation replaces 2.5 meters of brickwork.

The difference in the cost of building a wall from SIP panels and bricks is very large (not in favor of the latter). It is also worth noting the light weight of the product. 1 m2 of panel weighs no more than 20 kg, while a brick in this size will weigh more than 500 kg. That is, the delivery of products will be much cheaper. Savings on loaders on the face. Complete house of 50 sq. m. to be erected from SIP panels in just three weeks. That is, in terms of short construction times, houses made of panels have no equal.

In terms of sound insulation and resistance to aggressive environments, this material is also in the lead. The popularity of SIP panels as a building material in our country is increasing. Brick and other stone materials will gradually be replaced as they are more expensive and time consuming to lay. If the demand for SIP panels grows, then the production of this material will turn out to be more profitable and cost-effective for small businesses.

Room for the production of SIP panels

To organize a mini production of SIP (SIP) panels, at least 200 sq. m. area of ​​the premises. From engineering networks, three-phase electricity is required without fail, while water supply and sewerage may be absent. Requirements for such production are described in SanPiN 2.2.4.548-96. The temperature in the room should not be lower than +15 gr. (so that the glue does not lose its properties). Therefore, for year-round production, you will need to find a heated room. For 200 - 300 sq. m. will have to pay at least 80,000 rubles. rent per month. The warehouse of finished products can be located on the street, the main thing is to protect the plates from direct sunlight. This can be done by constructing a canopy over a street warehouse. In general, with the proper work of the sales department, finished products will not be delayed in the warehouse, but immediately shipped for sale.

Staff

The staff of a mini-production may include from 5 to 8 people. No more than 3 people are required directly to service the line. Special education of line operators is not required, since the technology is quite simple. The only thing that is important is the availability of a technologist, whose training can be carried out by the equipment supplier. In addition to operators and a technologist, it will be necessary to employ a warehouse worker, an accountant, a sales manager and a supply manager.

Raw materials for production

To organize production, you will need to find suppliers of three main components: OSB board, foam and glue. If you organize independent production of polystyrene, then saving on raw materials will be about 15%. However, the initial investment for the purchase of equipment will increase. Among domestic suppliers of ready-made foam plastic blocks, Alfapor and Angarsk Polymer Plant can be distinguished. Abroad, foam plastic is usually purchased from Xingda, Perla, BASF, etc. OSB boards can be purchased from Russian companies Novovyatsky Ski Plant and DOK Kalevala. Glue for SIP panels can be purchased from TOP-UR LLC, KLEIBERIT LLC or Avenir LLC.

What equipment to choose

The cost of the line for the production of SIP panels depends on the productivity and automation of the production process. So, for the production of 50 panels per shift, it is enough to purchase a small line, including:

• Styrofoam cutting machine - 110,000 rubles.
• Manual glue application device - 4,500 rubles.
• Compressor for glue application device - 32,000 rubles.
• Mechanical press - 80,000 rubles.
• Milling machine - 90 000 rubles.
• Machine for cutting SIP (SIP) panels - 190,000 rubles.
• The total cost of the kit, including delivery and installation, will be approximately 550,000 rubles.

This equipment is easily placed on an area of ​​​​100 square meters. m.

Only 3 people are needed to operate this line When entering a new level of production, it will be possible to purchase several automatic machines to speed up the production process and reduce the need for personnel. Automatic gluing and pressing machines can help with this. The price of one machine is more than 1,000,000 rubles.

At the same time, the productivity of the line is increased by 2.5 times, and the need for personnel is reduced to 2 people. On the Internet, you can find videos that show how you can make SIP panels with your own hands without spending money on buying expensive lines. This, of course, is one of the options for starting a “business from scratch”, however, in terms of quality and quantity, such manual production will be inefficient and most likely unprofitable.

Step-by-step plan for the production of SIP panels

Let's carry out a small calculation of the production efficiency of SIP panels with a size of 2500x1250x174. The area of ​​the SIP panel is 3.125 m2, and the thickness of the foam layer is 15 cm. The cost per unit of production will consist of:

• OSB-3 (12 mm) - 1300 rubles. for 2 sheets
• Styrofoam - 860 rubles. (consumption 0.432 m3)
• Glue - 270 r. (consumption 1.25 kg)
• Wages and other expenses - 310 rubles.

Total - 2740 rubles. That is, the cost of production of one SIP panel with an area of ​​3.125 m2 is 2740 rubles.

How much can you earn on SIP panels

Such a panel is sold at a price of at least 3600 rubles. That is, the profit per unit of production is 860 rubles. (minus taxes, USN). To pay back the minimum set of equipment, it is required to produce and sell a little more than 267 SIP panels. For understanding, for the construction of a small house of 50 square meters. m. about 100 panels are required. That is, for the payback of the equipment, it is required to sell products for three small country houses. The task, even in times of crisis, is more than real.

How much money do you need to start a business

To open a production facility for the manufacture of SIP panels, an initial capital will be required, which will be about 3 million rubles. This includes:

• 500 thousand rubles - inventory for the purchase of equipment and materials;
• 30 thousand rubles required for the registration of the future enterprise;
• 1 million 800 thousand rubles necessary for the delivery, purchase, adjustment and installation of the production line;
• 400 thousand rubles - for renovation work in the premises.

Which OKVED to indicate when registering a business

Production of plywood, veneer, panels and wooden boards - OKVED code 16.21. When registering a business for the manufacture of SIP panels, you can use the OKVED code 16.21.1 - the manufacture of wood layered materials and plywood panels, wood-based panels and plywood from other lignified materials. You can also specify the OKVED code 16.21.2 - production of plywood veneer, facing sheets and pressed wood.

What documents are needed to open

When organizing an enterprise engaged in the production of SIP panels, you must have the following documents:

• a document confirming the registration of an LLC or individual entrepreneur;
• quality certificates for products to be produced;
• passport details and identification code of the owner;
• receipt of timely payment of state duty.

Do I need permission to open

When opening a business for the manufacture of SIP panels, each entrepreneur must have the following list of permits:

• the conclusion of the sanitary and epidemiological service that meets all the hygienic indicators of manufactured products;
• quality certificates of the material used;
• conclusion on the fire safety of the room in which the production of panels will take place;
• expert opinion on the scope of use of SIP panels.

Production technology

Technologically, the manufacture of SIP panels is possible using the following materials:

• OSB sheets (oriented strand boards);
• expanded polystyrene;
• thermal insulation;
• the table on which the material will be cut;
• transfer and unloading carts;
• glue sprayers;
• scissor lift;
• pneumatic press;
• machines for applying glue.

Which taxation system to choose for business registration

When registering a business for the creation of SIP panels, there is no consensus on choosing a successful taxation system. You can choose a simplified or general taxation system. Which option to choose - the entrepreneur decides.

The domestic construction sector has undergone significant changes in recent years under the influence of the global market. In particular, this applies to technologies for the construction of private houses. Canadian building ideas have become especially in demand, involving the rapid construction of strong, environmentally friendly and energy-efficient homes. Along with this, the production of SIP panels is also developing, which act as the main material for such buildings. The manufacturing technology is not only highly profitable, but also, in general, allows you to get a decent result in the form of a modern residential facility.

What is a SIP panel?

In essence, this is a kind of wood-shaving building material. I must say that the segment of multilayer panels, even apart from Canadian technologies, is quite popular these days, as it allows you to quickly implement a project at minimal cost. Also, consumer interest is stimulated by relatively high technical and operational indicators of the material, which, in turn, motivates business. The production of SIP panels is distinguished precisely by its focus on popular technology. These are three-layer structural sheets, which also have high-quality external insulation.

Traditionally, frame houses benefited due to the high speed of construction and affordable price, however, in terms of quality performance parameters, they were noticeably inferior to classic log cabins. SIP panels made it possible to solve this problem by improving the physical parameters of the material. In practice, this improvement is expressed in strength, resistance to weathering and mechanical stress.

Manufacturing technology

It is clear that high technical and physical characteristics are achieved in the process of a complex process of processing raw materials. The full technological cycle provides for the implementation of three main stages - assembly, cutting and gluing. The first two stages of production are carried out on the central line, and the third - on separate equipment. Assembly activities, in turn, involve the combination of polystyrene foam sheets, OSB and PSB boards. In parallel with this, the workpieces are also trimmed in accordance with the initially conceived dimensions. After that, the final stage begins, in which polyurethane or other glue is used, which provides for the Canadian production of SIP panels in its regulations. The technology also allows the possibility of simultaneous gluing of several panels, but this already depends on the capacity of a particular workshop. Physically, this process is carried out by pressing machines that provide a load of about 5 tons.

Raw materials for panels

In accordance with the requirements of the technology, the basic set of raw materials should include oriented strand boards and non-shrinking suspension polystyrene foam sheets. A polyurethane composition is used as a binder. However, it is the adhesive base that is the most controversial ingredient in this set. The fact is that the production of SIP panels gives the final product the necessary margin of safety, but environmental friendliness is still being questioned. Today, new adhesives are being developed that can provide a high binding function, but at the same time will have less harmful effects. Perhaps the emergence of a new and cleaner glue will give a new impetus to the development of technology.

Equipment for the production of SIP panels

There are two approaches to organizing a production line for SIP panels. In the first case, it is planned to install a fully equipped complex with all the necessary units for the manufacture of building materials. Such a mini-workshop includes supply communication units, a pressing machine, a cutting point, etc. The cost of finished lines varies from 2 to 3 million rubles. Of course, this option is more suitable for enterprises that already have the ability to build a new conveyor. If it is planned to organize a small private line, then it makes sense to arrange a separate production of SIP panels. in this case, it is more promising and retains all the possibilities for further expansion. Those who wish to organize such a workshop will need a small room in which it will be possible to install a cutting machine, a press and a thermal knife.

Financial investments

The main item of expenditure can be equipment. In the case of the purchase of a finished workshop, the costs will average 2.5 million, and if we are talking about self-assembly, then we can talk about 200-300 thousand. Of course, in addition to this, we should add the costs of accessories, rent, regular purchase of raw materials and maintenance. About 50-70 thousand per month will also go to these points. However, the production of SIP panels quickly pays off these investments, since one unit of material on average brings a profit of 1 thousand. Depending on productivity, investments can be recouped either in a few months or in a year.

Material distribution channels

The basis of the client base can be private construction companies that are engaged in the construction of wooden houses. This segment is still in demand on the Russian market, and the fashion for Canadian technologies has only expanded the range of services of such enterprises. Also, the production of SIP panels can be focused on the supply of individual developers who plan to independently implement projects. As practice shows, the possibility of direct interaction with the manufacturer of building materials gives a great advantage to consumers of different levels.

Conclusion

Although stone and brick houses are still associated with quality, durability and reliability, alternative building technologies are serious competition for them. If comparisons in terms of strength do not always take into account panel-frame technologies, then affordability and energy efficiency are the undeniable advantages that houses made of SIP panels have. The production of this building material is largely focused on Canadian standards, but Russian modifications of the technological process are increasingly appearing. The departure from the classical idea is associated with differences in the characteristics of wood materials. Russian forestry makes it possible to use a high-quality raw material base, which, in some respects, outperforms North American products.