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SIP panels are actively used around the world for the construction of durable and inexpensive residential buildings. The popularity of such building products is due to their special properties.
SIP panels are an excellent material for building a private house
Structural Insulated Panel (SIP) are building products made of two OSB (oriented strand) boards, between which a layer of expanded polystyrene is placed. To connect these elements to each other, a polyurethane one-component adhesive is used. The finished panel is attached to a timber beam. Oriented strand boards are made from sawdust about 13–14 cm long and about 0.6 mm thick. An important point. The sawdust is oriented in different directions (this is how the well-known plywood is produced). A resinous special composition is added to them. It glues wood components into one structure.
Expanded polystyrene acts as a heater. This material has high strength and low weight. It does not get wet, it is completely hygroscopic. Rodents do not start in polystyrene foam. In addition, it practically does not deform during long-term operation. The connection of SIP products to each other is carried out according to the standard "thorn-groove" scheme. Such panels for building a house are characterized by a whole range of positive properties:
- Insignificant load on the ground due to the low specific gravity. Due to this, the requirements for the foundation for structures made of SIP panels are minimal.
- High reliability and durability of the houses under construction. The panels we are interested in can easily withstand loads of up to 2 tons in the transverse direction and up to 10 in the vertical direction.
- Increased heat and sound protection performance.
- Fire and environmental safety.
It is easy to build a house from SIP panels with your own hands in a really short time (3–3.5 months). A finished residential building built according to the recommended technology is guaranteed to serve at least 75–80 years. Later we will talk in more detail about the rules for the construction of such houses.
What do you need to purchase for independent production of SIP boards?
Do-it-yourself SIP panels are relatively easy to make. True, you will have to correctly select materials for such an operation and stock up on special equipment. The outer layers of the panels are made from OSB-3 boards. It is desirable that they be produced by a well-known company. Then you can be sure that they use environmentally friendly resins. Expanded polystyrene should be taken grades C-25-35. Adhesive requires special attention to connect all layers into one. For self-made SIP panels, it is necessary to use compositions that have a long service life, a wide range of application temperatures (from +50 to -40 ° C) and a high moisture resistance. Recommended adhesive for SIP products:
- Macroplast UR 7229 or 7228;
- Clayberite;
- Avenir;
- TOP-UR (15–40).
These adhesives do not contain volatile compounds, solvents harmful to health, plasticizers, expensive fillers. They are designed specifically for SIP panels, characterized by increased adhesive strength and the required process viscosity.
Any polyurethane adhesive from the list above provides moisture and heat-resistant, as well as elastic connection of the components of SIP products.
You will also need a press used in the manufacture of sandwich panels. If there is none, you can replace it with a vacuum pump. Another must-have tool is a thermal cutter (or thermal knife). It is a kind of tubular electric heater mounted on a heat-insulated handle. A thermal knife is necessary for cutting products into pieces of the desired size and melting the insulation. Making SIP panels with your own hands should be carried out on a flat surface (on a table) of a certain length. Its dimensions are always taken large in relation to the geometric parameters of the manufactured products. We will apply glue to the layers of SIP panels either with a notched rubber trowel or with a special sprayer.
We make SIP products with our own hands - a simple technology
Lay the OSB sheet on the desktop, apply glue to the surface of the plate. You should get not a continuous layer of composition, but with grooves. Depending on the tool used (trowel, spray gun), the adhesive consumption per square meter of the sheet is 150–200 g. straighten it out. It is impossible to delay the process, since the glue polymerizes quickly enough. If this happens, the finished product will be unreliable and low-strength. Building a house from SIP products of this type will be problematic.
Now make glue grooves on the polystyrene foam, put a second oriented strand board on it, press it. Next, the product is sent under the press. In the absence of such, it should be done differently. You need to make 5-7 panels at once according to the described method (each subsequent product is assembled directly on the previous one), and then cover the resulting stack with an awning fabric. From the latter it is necessary to make an airtight cover. Just glue the fabric along the edges with Kosmofen or any other fast setting adhesive.
Take a vacuum pump, use it to pump out air from under the cover. This action leads to the fact that each square of homemade panels is under pressure of about one ton. The technique is called vacuum pressing. The panels are kept in a vacuum for approximately 60 minutes. After that, remove the tent fabric and leave a stack of SIP products (in a horizontal position) for 24 hours. A day later, attach with the help of a side wooden beam to the panel (to one of the sides). It provides rigid fastening of SIP plates between themselves during the construction of frame houses. The beam can not be glued, but screwed with fasteners that are suitable in size. The panel is ready for use!
Perform all work in goggles, gloves, and a long-sleeved robe. The production of panels must be carried out in a well-ventilated and lit room. At home, you can produce SIP products of any size. It is desirable that they correspond to the dimensions of the house indicated in the project. The standard dimensions of the panels we are considering are 250 by 125 and 1280 by 125 cm. It is easiest to work with such structures. They are suitable for any typical construction project for the construction of a private dwelling. When using products with similar dimensions, a minimum of connecting seams is obtained, which means that the built house will be truly warm.
We build a house using frame technology - the first stages of the operation
Residential buildings made of SIP panels are allowed to be installed on pile-screw, strip, slab foundations. The type of base is selected on the spot. Here it is important to take into account the condition of the soil. If there is no groundwater on the site, and the ground is flat, make a simple strip foundation. For heaving, swampy soils, pile foundations are more suitable. Next, we give a diagram of how to build a house on a strip foundation:
- 1. You clear the land allocated for the construction of a house from tree roots and debris. Dig a small recess for the foundation (manually or with the help of heavy construction equipment).
- 2. Make a wooden formwork using standard technology, pour concrete mixture into it.
- 3. Install cinder blocks on the fabricated tape base. Reinforce them and then fill them with concrete. Cinder blocks are not required. They are recommended for cases when a house is being built in swampy areas, in regions with frequent rains and heavy snowfalls. Instead of blocks, you can simply fill the basement of the future structure with concrete mix.
- 4. Lay a waterproofing layer on the foundation (usually roofing material).
- 5. Mount the first SIP panel directly onto the waterproofing. The very first product should be clearly aligned with the corner of the equipped foundation. Next, lay the next panels, filling the areas of their joining with mounting foam.
After completing all these steps, you will receive a full-fledged floor in your home. It will be highly durable. Here it is only important to constantly check the level of installation of SIP panels in order to eliminate the risk of deviations of the floor base from the horizontal. One more moment. The ends of the mounted products must be closed with strapping boards. The latter are attached to the panels with mounting foam. Do not forget also about the need to drill technological holes in the floor. They are needed for the organization of the sewer and plumbing system. Holes in SIP boards should be prepared in advance - before the installation of the finished floor.
We assemble a residential building - we act carefully, but confidently!
The assembly of a house from SIP panels begins with the construction of load-bearing walls and. This must be done clearly according to the drawings and diagrams of the construction project. And then proceed to install the SIP products directly into the finished frame. Panels are fastened without voids and gaps. The tightness of the connection guarantees comfort and warmth in the house. All joints must be filled with foam. Use polyurethane compounds for these purposes.
The panels are connected to each other by gluing a beam (mounting foam is used), which should evenly fit into their grooves. Fixing SIP products to ceilings and a floor platform is done according to a similar (thorn-groove) scheme. In this case, the function of the spike is performed by the strapping boards (upper and lower, respectively) of the required dimensions. Note. The thickness of the bottom board (it is often called the installation board) is taken at least 2.5 cm (optimally - 4 cm).
Corner connections are made in the same way. But the installation board in such a situation is fixed to the panels mounted vertically. The fastening of panels at the joints is usually performed with wood screws. They provide the necessary strength. Some craftsmen prefer to use not self-tapping screws, but nails (you will need a special one). After assembling the frame, floors and a wooden beam are laid. It remains to make the roof. It is also equipped with SIP panels. Experts advise building a special structure to hold the truss system. On the latter, after its erection, SIP products are mounted.
At this assembly work can be considered completed. Start laying electrical wiring and other utilities, installing door and window structures. Panels inside the house are usually finished with natural wood products. A more budget option is facing with plasterboard sheets. Outside, finishing is best done with siding. The roof can be covered with ondulin or metal tiles that are popular these days. Other roofing materials may also be used.
The construction of a small residential building using SIP slabs will take 2-3 people no more than 90-100 days. If a building is being built on two floors, the time for completing the work does not increase. But in this case, you will have to attract a few more assistants to work at heights or use special lifting and transport devices. Good luck with your construction!
The practice of using SIP (Structural Insulated Panel) panels as the main building material is not only widespread in Western and foreign countries, but at the same time is rapidly developing and is widely used in our country.
Why choose SIP panels?
The composition of the sip panel
The panels are special structures made of a wooden bar and two oriented strand boards (OSB) attached to it, the internal space between which is filled with expanded polystyrene. The resulting layers are glued together with a one-component adhesive based on polyurethane.
The plates are assembled in such a way that it is easy to use the tongue-and-groove system.
, erected using this kind of panels, are primarily distinguished by their low specific gravity, thereby significantly reducing the load on ground soils and the requirements for the foundation, respectively. In addition, significant, erected using this technology, is the highest level of strength and reliability. Thus, the panels are able to withstand a load in the vertical direction of up to 10 tons, and in the transverse direction - up to 2 tons throughout the entire operational period, which exceeds 80 years. In addition, in the shortest possible time, in general, not exceeding a 3-month period.
Excellent sound and heat insulation characteristics, complete fire safety and an absolute level of environmental friendliness - all these qualities determine the success of SIP panels.
In addition, SIP panels, with proper observance of technology and the use of proven materials, can be produced by hand at home, further reducing their cost.
Tools and materials used in the production process of SIP panels
Sip panel insulation The following materials and equipment are used in the process of manufacturing sandwich panels:
- Oriented strand board OSB-3;
- Expanded polystyrene or other insulation;
- Wooden beam;
- Single component polyurethane based adhesive. Oriented strand boards (OSB) are panels with a thickness of 10-12 mm and are the result of pressing wood chips with a length of no more than 1.5 cm and a diameter of at least 0.6 mm under high temperature using specialized resins. Chips are usually laid in 3 layers perpendicular to each other. Such material is easily sawn, drilled and holds any fastening material.
- universal insulating raw material, consisting of foamed polystyrene. In the process of manufacturing sandwich panels, expanded polystyrene grades C-25-35 are usually used. This material is 95% carbon dioxide and is distinguished not only by its low weight, but also by its low cost compared to other heaters.
As an adhesive, such compositions are used as, for example, Kleiberit 502.8, top-ur 15, Macroplast UR 7228 and Macroplast UR 7229. Special requirements are imposed on such compositions: an increased level of moisture resistance, a wide temperature range (from -40 to +50 degrees Celsius). Celsius), possessing absolute environmental friendliness and correspond to the long service life of the panel.
The working surface should be a table larger than the OSB-3 sheet in size, and both a special sprayer and a device made of a canister and a rubber spatula with teeth can be used as a means of applying the adhesive.
In addition, you will need a machine for pressing sandwich panels. The press will cope with this task or, if there is none, a powerful vacuum pump is used, with the help of which the desired result is achieved.
For the manufacture of panels, you also need a thermal knife or a thermal cutter. This device is a heating element heated from the network on the handle, it is necessary for melting the insulation. Using a knife, SIP panels are cut into pieces.
Production of SIP panels
Vacuum press for SIP panels How to make a sip panel? The OSB-3 sheet is laid on a flat work surface (special table), and glue is applied to it using a sprayer, glue, brush, roller, spatula with teeth or any other device. As a rule, the consumption of adhesive composition is 150-200 gr. for each sq.m, but, in turn, it strongly depends on the method of application. The composition is aged for 8-10 minutes, after which expanded polystyrene grades C-25-35 are placed.
In the process of making sandwich panels with your own hands, the speed of the actions performed plays a special role. Do not allow the adhesive to cure between layers. Otherwise, the resulting structure will be characterized by a low level of strength and reliability; such a panel cannot be used in further construction.
The laid sheet of expanded polystyrene is carefully leveled, a uniform layer of adhesive is applied to it. On top of the insulation, the next layer is laid, consisting of an OSB panel. Next, the second plate is formed according to the above algorithm.
It is necessary to assemble the panels at least 5, and you should also take care of the need to put pressure on them. For this purpose, a vacuum pressing technique is used. A pre-aligned stack of panels is covered with an awning fabric cover glued together with a special adhesive, for example, Cosmofen SA-12. Having previously clamped the edges or provided the proper level of tightness using any other method, air is pumped out from under the cover. Look at the photo above, in it the panels are under a vacuum press.
Thus, a significant pressure of the order of 1 ton per square meter is exerted on the panel. The holding time under vacuum is 40-60 minutes, after which you can start producing the next “stack” of panels.
For 8 hours of continuous work, about 25-35 sandwich panels can be glued together. It is worth noting that already finished plates must remain in a horizontal position for at least a day in order to finally acquire the expected performance.
Compliance with safety regulations in production
Applying glue to the base for gluing insulation As in any production process, safety in the production of sandwich panels plays an important and far from the last role. So, all work should be carried out in a spacious, well-lit and ventilated room. All work with sandwich panels is carried out in special clothes with long sleeves, hands are protected with gloves, eyes, if necessary, goggles.
How profitable is manual production of panels?
Manual production implies the following items of expenditure:
- Glue;
- OSB-3 sheets;
- Styrofoam;
- Vacuum pump for pumping air;
So, using the example of 100 panels, we need:
200 sheets of OSB-3 for 500 rubles. each - 100 thousand rubles;
from the consumption of 2 kg. glue (average price per kg. 150 rubles) per sheet - about 40 thousand rubles;
vacuum pump - 15 thousand rubles;
expanded polystyrene from the consumption of 0.5 cubic meters. m. per panel - 90 thousand rubles. Compared to industrial panels, manual production saves at least 100 thousand rubles, which is important in the current conditions. The cost of the plate is 1300 rubles per square meter. In general, the price depends on the thickness of the plate.
Finished panels are cured after production Video
Watch a video on how to make a sandwich panel with your own hands:
Many Russians would change their city apartment for a country house if it were possible to build it quickly and inexpensively. This allows you to make a relatively new material - SIP panels (sandwich panels). In the construction of private houses, they are used to build walls and partitions. SIP technology expands the possibilities of frame construction, making the walls warmer. In Russia, this material has been used recently, demand is increasing, so the production of SIP panels in some regions can be quite profitable.
By design, the SIP panel is a layered material consisting of two moisture-resistant boards connected by a heater.
Various plates are used in production:
- oriented strand (OSB-1, OSP-2, OSP-3)
- drywall
- cement-bonded
- fiberboard
According to traditional technology, solid polystyrene foam is used as a heater, but some manufacturers replace it with extruded polystyrene foam, polyurethane foam, and mineral wool. The choice of raw materials depends on the scope of application (for walls or partitions). In Russia, OSB is sometimes replaced with dry planed timber, which increases strength. If it is made to order, when choosing raw materials, they are guided by the wishes of the customer.
Manufacturing technology
The technology does not depend on the type of raw material and consists of several stages.
The first is assembly:
- laying on the table (machine platform) of the OSB sheet
- application of the normative volume of glue and water
- laying insulation
- applying glue and water
- laying the second sheet
If the company uses a production line, up to 3 panels are folded at the same time.
In order for the elements to be firmly connected, a press (hydraulic, pneumatic, membrane-vacuum) is required, capable of squeezing the panels with a force of 25-20 tons for 10-15 minutes. If panels of non-standard sizes are required (to order), the next step is cutting using a special machine. After cutting with a thermal knife, docking grooves are created.
Purchase of equipment
You need to decide on an assortment. Although experts believe that with a small amount of initial investment, it is better to start with a traditional material consisting of OSB-3 and solid polystyrene foam. In the future, the range can be expanded, to start manufacturing plates to order.
There are enough automatic lines and separately sold devices on the market. The choice depends on the planned production volumes and financial capabilities.
Required:
- compressor (without it it is impossible to evenly apply glue)
- press
- cutting machine
The price of equipment depends on the capacity and level of automation. Automatic lines are expensive (from 1.5 million rubles), but they allow you to save on salaries in the future. The purchase of individual elements is cheaper (from 600 thousand rubles), but 2-3 employees will be required.
It is possible for 60 thousand, but large quantities for wholesale with the help of a table, a spray gun and a saw cannot be made.
Cash investment and profitability
In addition to the cost of equipment, it is necessary to pay the costs of:
- repair of production and storage facilities
- (LLC), certification, advertising
- supply, installation, launch of the line
- purchase of additional equipment (beam crane, loader, trolleys) and tools
- purchase of raw materials
- activities to payback (salaries, rent, utility bills, electricity)
For the organization of production and a warehouse with an area of at least 200 m2. Water supply and sewerage are optional, the main thing is a three-phase electrical network (SanPiN 2.2.4.548-96). It is impossible to do without heating, since the glue loses its properties at temperatures below + 15C.
The rent will be from 80 thousand rubles. monthly. It is possible to store finished products even on the street, if the site is equipped in such a way as to protect it from moisture.
The legal status of the enterprise will depend on the volume of production. The 200 m2 production line is a small enterprise that is registered as an individual entrepreneur. Before visiting the Tax Inspectorate (multifunctional center), you must select. For SIP panel manufacturers not using mineral wool, this is 25.23 (manufacturing of prefabricated buildings from plastics).
Taxation system OSNO or. The first option should be chosen if wholesale deliveries are planned, VAT deducted. The second option is preferable for a small enterprise, as it allows you to adjust the rate by taking into account production costs.
The following is submitted to the tax office (MFC):
- the passport
- receipt certifying the payment of the state duty (800 rubles)
- TIN (if assigned)
- application (form Р21001)
- statement on the application of the chosen taxation system
After 3 days, the tax authorities will issue:
- IP state registration certificate
- registration certificate
SIP panels do not require mandatory certification, but you need to issue a GOST certificate. Its presence will increase the confidence of customers in the products offered.
The equipment is usually supplied, installed and launched by the seller for a fee. Raw materials are best ordered in bulk from reliable suppliers. Boards, insulation and glue must be supplied with a certificate of conformity. It is not worth saving at this point, since the sales volume will depend on the quality of the raw materials.
The minimum must be within a million rubles. Half will be spent on the purchase of individual elements of the production line, the rest - on registration, the purchase of raw materials and additional tools, and the provision of expenses for 2 months. If you buy an automatic line, you will have to spend 1.8-6 million rubles on it. The cost can be reduced if you buy equipment made in China or used.
A small enterprise can produce 5-10 m2 of panels per hour, 40-80 m2 per shift, 880-1760 m2 per month. The wholesale cost depends on the length, width, thickness of SIP panels, lot size and varies within 1,500-4,000 rubles per piece. This means that revenue can reach 7 million rubles, income - 880,000 rubles.
But it must be taken into account that such indicators are achieved only if the products are produced without interruptions and are immediately sold to construction and repair organizations, shops or distributors. When selling material to private individuals in small batches, SIP panels will accumulate in the warehouse.
Experts believe that approximately 20% of the initial costs pay off in 9-16 months. The term depends on the cost, which consists of current costs for raw materials and wages. Monthly income is higher if an automatic line is used, which does not require a large number of workers to service. Simple equipment is more convenient at the initial stage, but limits the opportunities for growth and increases the cost price at the expense of the wages of workers.
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It becomes more and more popular every day. The only factor that stops many developers is the price.
However, you can save a lot if you make such panels with your own hands. So building a house will cost the least losses for the family budget. Using sandwich panels, you can build a house in the shortest possible time.
The composition of SIP panels
Let's talk in more detail about how to make SIP panels at home. First you need to figure out what the building structure consists of. Sandwich panels include three layers: 1 internal (heat insulator), 2 external (fencing).
The inner layer
As a heat insulator, you can use:
- mineral wool (non-combustible, does not cake);
- expanded polystyrene (low fire resistance, lightness, strength, low cost, resistance to deformation);
- polyurethane foam (high moisture resistance, rigidity).
To determine the brand and thickness of the insulation, consider the purpose of the building and make a thermal calculation.
outer layer
For the outer layer of sandwich panels, use OSB boards. They include sawdust, which are connected using a resinous composition.
Some believe that this is huge, since it is not known what the resin consists of. To avoid low-quality materials, choose a trusted manufacturer.
For the shell of SIP panels, materials such as:
- aluminum
- galvanized steel sheet
- plastic
- wood
What is needed for assembly
To assemble this building structure, you will need a table, a press, OSB boards, a heat insulator (polystyrene foam) and glue. The latter can be one- or two-component.
One-component adhesive composition hardens in air. It is mainly used in semi-automatic or manual assembly, since a thin layer of glue may not lose its properties for a long time. You can increase the lifetime of the glue if you cool the room in the working room and lower the humidity in it.
In turn, the two-component polymerizes only after a chemical reaction of its components. It does not lose this property throughout the life of the panels (50 years).
In addition to durability, the adhesive must be safe, heat and moisture resistant. It should not lose its properties both at -40 degrees Celsius and at +50.
Assembling a SIP panel with your own hands requires careful preparation of materials. Check OSB boards, heat insulator. Clean them if necessary.
Manufacturing process
The manufacture of SIP panels implies strict adherence to all of the following steps:
- Lay the OSB board on a hard surface.
- Coat with polyurethane adhesive. As the latter, it is better to choose Kleiberite.
- To properly apply the adhesive, you will need a notched trowel or a special spray gun and a brush. As a result, you should get a furrowed layer. Consumption should be a little more than 150 g /.
- Leave the adhesive on the surface for about ten minutes.
- Put a layer of Styrofoam on top.
- Apply another layer of glue already on the heat insulator.
- Wait ten minutes
- Lay on top of the Second OSB board.
- Hold the resulting sandwich panel under pressure until the adhesive is completely cured.
In more detail, the entire process of assembling sandwich panels can be viewed in this video. Critics did not pass the time, they called the main disadvantage of such a manufacture of sip panels too high labor intensity:
Assembly difficulties
The main difficulty in self-manufacturing panels is working with glue. The glue foams a lot when applied to the surface.
High-quality assembly of sip panels requires the correct choice of pressure force to obtain the correct density and thickness of the adhesive layer. Therefore, only a press will help here, in which the panel should be kept for about 4 hours.
The glue polymerizes very quickly, and this leaves no time to think when assembling. If it hardens, then no solvent will help you, you will have to remove it mechanically. It is better to work with someone in a pair, because it is difficult to cope with such a load alone.
Profiled panels
In addition to the above option for assembling panels, they can be made from corrugated board. The difficulty lies in the fact that the company uses hot pressing to create them. And at home to perform such manipulations is quite difficult.
Honeycomb material is also laid between the lining. For greater strength, several layers of insulation can be added to the panel.
The use of corrugated board gives the panels special rigidity and reliability. In this case, the walls are obtained in three times thinner, and also reduces the load on the building structure. But this in no way affects the quality of construction. Such panels are more resistant to changes in temperature and mechanical stress.
To make panels with your own hands, you will need: and a filler (mineral basalt wool, polyurethane foam or expanded polystyrene).
You can make various types of structures yourself. To do this, a heater is laid between the metal corrugated board.
On the sheets of corrugated board there are lock fasteners. This variety is convenient to use in the construction of wall sandwich panels or roofing.
How to make a castle
As already known, SIP panels are interconnected according to the “lock” principle. In a commercial plant, the joint is formed under pressure. But a manual press will not be able to perform such a function.
How to make a castle with your own hands? Between the outer layers of the panel on one side, lay a wooden beam. It should slightly go beyond the boundaries of the OSB board. From the other end you will have a heater. Feel free to cut off the excess. That, in fact, is all.
How to dry the panel if there is no press
If you do not have the opportunity to use the press, then you can do do-it-yourself press for sip panels. Thus, you should get a vacuum pump. Here the process is very different:
- Collect each new panel on the old one, you should get a stack of five pieces.
- The panels are covered with an awning fabric and tightly clamp the edges. With the help of awning matter, an airtight cover is formed that does not allow air to pass through.
- Using a vacuum pump and hose, air is pumped out. In such a vacuum pressure (1 ton / 1 assembled panels can withstand about an hour.
- The resulting building structures are laid on a flat surface for a day.
With this pressing process, you can make about thirty panels in nine hours. Another important advantage of self-assembly is saving half the budget.
You can also make a press yourself. The machine can be welded from a profile pipe (100 * 100). Thus, you will get a fairly rigid structure.
The pressure can be applied by means of two car jacks (2 tons each), which can be mounted by setting them apart from both sides.
It will be enough to make a machine for loading four panels, you can make it more or less. It all depends on your convenience and desire.
Further, with a conventional drill, it is recommended to bring the machine to the required level and tighten everything with an ordinary adjustable wrench. To adjust the same degree of compression, measure the distance with a tape measure and jack up to the desired point.
The clamping bed can be lifted with a winch. In order for the pressing surface to get free play, hinges can be welded to it. This will also allow you to evenly press down all parts of the panel.
On the sides, weld the thrust beams. This will help not to expose the panels each time by roulette, but simply put them, as in a jig.
You can also try to build a screw press. It will need six M24 studs. Weld the frame using an equal-angle corner, you can also make cross beams from it. After you have laid a few panels, lay some beams along the top. They should be pressed with the help of channels and tighten the press with a pressure of 15 kgf for each nut.
Before you make a press for sip panels with your own hands, complete the drawings of the future design:
Dimensions and thickness
The main dimensions of the manufactured sandwich panels are 2.8 m * 1.25 m and 2.5 m * 1.25 m. With manual assembly, you yourself adjust the size of your panels. But do not forget that it is necessary to strictly follow the construction project.
The thickness of the OSB plates is 1.2 cm. But the dimensions of the heat insulator depend on its purpose. So, for example, for the facade it is better to take a thick insulation (20 cm), and for internal walls, 10-14 cm is enough.
Conclusion
Of course, self-manufacturing of sandwich panels has its drawbacks. At home, it is important to strictly follow the assembly technology, even if it takes a lot of time. Otherwise, your home may lead to high energy costs in the future.
Select only high-quality materials and properly dry the manufactured panels. Only this will help you build a strong and warm home.
SIP, SIP, sandwich panel are the names of one building material that is used in the construction of houses. The SIP panel is a three-layer block, both outer layers are made of OSV or chipboard sheets, between them is a layer of polystyrene. High thermal insulation performance, ease of installation, low cost - make the business of manufacturing these materials attractive. All that is required to start production is an automatic line for the production of sip materials, raw materials, several workers and a room. The presence of a high level of demand for such panels suggests a quick return on investment.
Required raw materials
For the manufacture of sandwich panels, various sheet materials can be used:
For the inner layer can be used:
- polystyrene;
- polyurethane foam;
- mineral wool.
But the classic option is a combination of OSB and polystyrene sheets, the layers are interconnected with glue.
Table of material consumption and its cost for the manufacture of one SIP panel 2500 * 1250 * 174 mm (L * W * H).
Manufacturing plant requirements
The room in which the sip panel production line will be located should be more than 200 m 2. It is also necessary to equip a warehouse for raw materials and finished products. If the area is small, you can save on a warehouse for finished products - you can store it on the street, but only organize a canopy that protects from rain and snow. It would be advisable to place managerial personnel near the production, they will need a non-production area of 30 m 2. The workshop must have three-phase electricity, the presence of water supply and sewerage is optional. It is necessary to control the temperature - to prevent a decrease to -15 ° C. If you rent a room, the monthly costs will be - 40 thousand rubles (rent and utility bills).
Service staff
Four people will be needed to organize the operation of the sip material production line, with an average output of 100 panels per shift. If a larger volume is planned, additional workers will be required accordingly. Management staff - director, purchase and sales manager, accountant. The monthly wage fund will be 120 thousand rubles.
Equipment for the production of
There are different types of lines for the production of sip panels, they differ in technical characteristics, the principle of operation is the same for all. The line for the production of 100 panels per shift has the following components:
Line for the production of SIP panels from mineral wool - mechanism for applying glue and pressing;
- device for cutting foam;
- device for cutting panels;
- milling machine.
The glue applicator can be fully automated or manually operated. Automated saves glue, applies more evenly, speed can be adjusted. Characteristics:
The foam plastic cutting device cuts the feedstock according to the specified parameters. The mechanism consists of a frame and two moving portals on which cutting nichrome threads are fixed. The gear motor drives the portals, and the tension cable drives the threads. Cutting is carried out with hot threads, with a diameter of up to 0.8 mm. Characteristics:
The device for cutting SIP panels is designed for cutting finished products in accordance with the required parameters. Cutting is carried out on the frame with a circular saw running at high speeds with the help of an electric motor. Characteristics:
A milling machine is needed to form the groove of the SIP panel, with which the elements will be attached to each other. The size of the groove can be set by the customer individually for a separate project. Characteristics:
- power - 2.2 kW;
- voltage - 380 V;
- milling depth - up to 60 mm;
- dimensions - 1200 * 3000 * 1200 mm;
- weight - 250 kg;
- cost - 93 thousand rubles.
Thus, the price of the line for the production of sip panels can be 662 thousand rubles.
Technological process
The manufacturing process of SIP panels The manufacturing process of SIP panels is quite simple. The first step is to assemble the panels. The OSB sheet is laid on the pressing machine, a layer of glue is applied on it, a layer of polyurethane foam is laid on top, and again a layer of glue, then water is sprayed so that the glue is better saturated, and the structure of the OSB sheet is fixed. At the next stage, the blanks are glued under pressure.
The pressing unit can be part of the glue application unit. In order to save money, you can complete the sip panel production line with an inexpensive glue application device. A manual spray gun costs 4,500 rubles, while its performance will be at a high level - 20 - 30 seconds applying glue to one side. A screw press will cost 79 thousand rubles. But it should be borne in mind that these two machines will require more manual labor, and will increase the consumption of materials due to losses and marriage. In general, the gluing stage is carried out in 20 minutes, the duration of the process will ensure a tighter fit of the sheets and their bonding to each other.
The final step is cutting the panels. With the help of special cutting and milling equipment, the finished material is given the necessary shape, dimensions, cutouts for fittings, doors, windows. This process is carried out according to the individual plan of the customer.
Profitability of the production of SIP panels
Profitability of production represents the value of the ratio of profit to costs.
2200 panels will be produced per month (100 per shift * 22 working days).
The cost of manufacturing products per month will be:
- raw materials - 2428 * 100 * 22 \u003d 5,341,600 rubles;
- salary - 120,000 rubles;
- rent of premises and utility bills - 40,000 rubles;
- transport and other expenses - 20,000 rubles;
- total cost - 5,521,600 rubles.
The market value of one plate will be 2,900 rubles.
Revenue per month - 2900 * 100 * 22 \u003d 6,380,000 rubles.
Profit - 858,400 rubles.
Unrecorded administrative expenses, taxes, and the advance cost of raw materials for the next production cycle should be deducted from the profit. The remaining amount will partially cover the cost of the equipment. The profitability of production will be 40%, with the full implementation of the produced panels, it is possible to recoup the cost of the sip module production line within six months.
Video: Factory production of SIP panels
