Could the production of fiberglass rebar become an idea for a profitable business in the field of building materials? This modern analogue of steel reinforcement is distinguished by a number of positive characteristics that make it highly demanded in the market. We will tell you how much money you need to invest in such an enterprise, what equipment you need to purchase and when you can expect to reach a net profit.

Fiberglass or composite reinforcement is a modern analogue of metal reinforcement, surpassing it in terms of quality characteristics. The plastic reinforcement is made of artificial fiber ribbed rods with a diameter of 4 to 18 mm. Often, individual rods are interconnected with synthetic resins for strength.

It is a popular building material that is gradually replacing traditional metal counterparts from the market. It is distinguished by an impressive list of useful characteristics:

1. High strength. This material is 3 times stronger than steel.
2. Moreover, plastic material is much lighter than steel - at least 6-9 times.
3. Does not rust and without damage tolerates exposure to sea or fresh water, acidic or any other aggressive environment.
4. Dielectric - does not conduct electricity, can be used in insulation works.
5. Frost-resistant - does not deteriorate even at very low temperatures.
6. Not affected by electromagnetic fields.
7. Long service life - at least 50 years.
8. The ability to make a seamless styling.

As for the disadvantages, we can note the lack of elasticity and poor resistance to high temperatures. Fiberglass reinforcement is not welded, but tied - otherwise it will collapse under the influence of a large amount of heat. Fiberglass rods are so inflexible that they cannot be bent on their own: the rods are bent at the right angle during production. Also, over time, the strength characteristics of the material decrease.

The material is well known among professionals, but ordinary consumers (they are also potential customers of the enterprise) do not distinguish this material from steel reinforcement and often prefer it. Composite rods do not have pronounced marketing advantages, obvious benefits for buyers, which can also be called one of its disadvantages.

Fiberglass or composite reinforcement is a modern analogue of metal reinforcement, surpassing it in terms of quality characteristics

Where is applied

The main field of application of plastic fittings is road, industrial and civil construction. This material is used to reinforce concrete structures, including foundations. Fiberglass reinforcement is well suited for fixing thermal insulation and concrete floors: it improves the adhesion of concrete elements. The use of such reinforcements lightens the structure and reduces the cost of work.

Resistance to aggressive environments made this material in demand in the construction of concrete structures in chemical plants. High strength ensures the popularity of artificial fibers for bank protection, drainage and sewerage construction. When building roads, it helps to increase the strength and durability of the road surface.

Is such a business relevant

Any production of building materials is a relevant business, and the production of modern and innovative ones is even more in demand. There are a lot of areas of application for fiberglass reinforcement, so a manufacturer of a quality product will always find distribution channels.

The competition in the field is quite high, but the market is not overcrowded. As a rule, in each region there are from 3 to 10 medium-sized enterprises producing such valves.

At the same time, there are much more construction companies and institutions responsible for road construction and bank protection. From this it follows that there will always be demand for the material, therefore, novice manufacturers should initially identify their competitive advantages and actively promote their products.

Composite reinforcement is 6-9 times stronger than steel

Business organization

The production of composite rebar requires an impressive organizational cost. Practice shows that very few people manage to create a full-fledged enterprise for less than 3 million rubles. Equipment and raw materials are expensive. In addition, the entrepreneur will have to provide for working capital for the period until the company sells the first consignments of goods.

A business plan will help you think over your work. It needs to include not only the opening costs, but also the calculation of profitability, the goal for 6 and 12 months, the approximate staffing, as well as a list of potential partners. The sooner an entrepreneur finds stable distribution channels, the faster the company will reach the level of net profit.

Production technology

Composite reinforcement is manufactured on a conveyor line. Human intervention in the operation of the equipment is minimal. Production begins with the processing of glass roving - the material is pulled into threads with a cross section of up to 20 microns and impregnated with a special grease agent. The impregnated threads are woven into bundles and dried with hot air. After drying, glass roving is impregnated with epoxy resin.

At the next stage, the threads fall into a special mold for plastic substances (dies), where the diameter of the future reinforcement is determined. Then the workpieces are wrapped with a rope: it provides the required thickness and improves the characteristics of adhesion to concrete.

Formed and wound fittings are fired in a magnesite tunnel kiln. There the resins are polymerized. At the final stage, the composite fibers are cooled to room temperature in running water. After that, the material is actually ready for use. It is cut to size with a diamond saw. The cut is precise and even.

Equipment

A conveyor of equipment for the manufacture of composite reinforcement will cost 1-1.7 million rubles. This is the main part of spending on starting a business. The list of machines and equipment includes:

1. Bath for impregnating glass roving with wringing function.
2. Dies (molds for plastic substances).
3. Rebar pulling machine.
4. The device for twisting threads.
5. Polymerization oven with temperature control function.
6. Cooling apparatus.
7. Diamond saw / rebar cutter.
8. Apparatus for twisting finished reinforcement.

All machines line up in a conveyor with a length of 15-20 meters. In addition to this equipment, you will need to purchase forklifts, scales, racks for raw materials and finished products. Such a kit will be sufficient for production within a small enterprise.

Production begins with the processing of glass roving - the material is pulled into threads with a cross section of up to 20 microns and impregnated with a special grease

Requirements for the premises

Since the conveyor of machines for the production of fiberglass reinforcement takes at least 15 meters in length and about half a meter in width, the room must have a suitable length. Placement of equipment should be comfortable for workers. Therefore, the area of ​​the premises cannot be less than 200 square meters. The workshop is divided into 3 zones: a workspace, a warehouse, a staff room.

The floor of the room should be flat, without height differences (in extreme cases, no more than 5 centimeters). Ceiling height from 2.5 meters. The manufacture of composite reinforcement requires maintaining a stable temperature regime at the level of 16-18 degrees, therefore, it is desirable to have a special heat regulation system. Good lighting guarantees quality work, this characteristic should not be ignored. It will not be possible to do without powerful ventilation (with an air outflow of at least 250 liters of air per minute). The location of the workshop does not really matter; you can place it on the outskirts or outside the city.

Raw materials

What materials are required for the production of composite rebar? The basis is glass roving - threads made of molten aluminoborosilicate glass with a diameter of 10 microns. In the manufacture of reinforcement, the fibers are supplied in large, hermetically sealed bobbins. They are transported at temperatures exceeding 35 degrees and at a humidity level of no more than 70%.

The second key component is epoxy. It is a colorless or light yellow viscous liquid with a honey-like consistency and is used in the primary processing of roving. It makes future fittings resistant to aggressive media.

In addition to these two components, the production of composite reinforcement requires:

• braided thread;
• alcohol;
• acetone;
• dicyandiamide.

Business costs

Setting up a business for the production of fiberglass reinforcement will require at least 3 million rubles. About half of this amount will be spent on purchasing equipment and equipping the workshop. Approximately 1 million - for the purchase of raw materials and working capital for the first months of work. It also includes the cost of renting a workshop, transportation and other expenses.

The sum of 3 million rubles cannot be called small. Compared to some other building materials industries, the manufacture of composite rebar is really expensive. The high price is associated with the manufacturability and "artificiality" of the material - in fact, it is entirely prepared from chemical components.

Composite rebar is widely used in construction and road works

Profit calculation

Depending on the diameter, the price for composite reinforcement starts at 10 rubles per meter. But the average cost is higher - 50-70 rubles. Moreover, the material is always sold in large quantities, usually from 1000 meters, that is, the minimum purchase price is 50 thousand rubles. A low-capacity enterprise produces about 2000 meters of material per hour, that is, 16,000 meters per shift. The revenue per shift is about 800,000 rubles. It seems that this is a lot, but part of the funds (about 40%) will be the cost price. The same funds will be used to pay utility bills, employee salaries and other mandatory expenses.

The presence of stable distribution channels will help to recoup the investment in an average of one and a half years. Some manufacturers manage to reach the level of net profit faster, but this is rather an exception to the rule. 16-18 months is a more realistic period, given the significant amount of initial investment.

Conclusion

The production of composite reinforcement is undoubtedly a promising direction in the building materials market. To organize an enterprise, at least 3 million rubles will be required, while payback is possible within 16-18 months. Fiberglass reinforcement has proven itself well due to its strength characteristics, but this product is not yet widely known on the market.

Fiberglass rebar is a building material made from glass roving, bonded with an epoxy compound based on thermosetting resins. The main feature is lightness, the indicator of mass per unit volume is only 2g / mm³. Working with fiberglass reinforcement is more convenient and cost effective than with metal reinforcement. Significantly less costs are required for logistics and directly for reinforcement.

In addition, due to the fact that fiberglass does not react to an aggressive environment, the reinforcement protects the concrete from premature destruction, thereby increasing the service life of the facility. Fiberglass reinforcement reacts to temperature changes similarly to concrete, which also has a good effect on the strength of the structure.

The strength of fiberglass in comparison with metal is 2.5 times higher. With all this, the thermal conductivity index is 100 times lower than the thermal conductivity index of steel. Therefore, the structure, which is reinforced with fiberglass, does not freeze (does not form "cold bridges") and an object built with the use of fiberglass will be warmer than a building based on metal reinforcement. This allows you to reduce heating costs, and therefore the material is actively used in the construction of modern energy-efficient buildings.

Also, the indisputable advantages that may interest builders are the fact that fiberglass is an amazingly durable material, which for 100 years after installation does without additional repair work. This is what fiberglass reinforcement for the foundation is famous for.

Fiberglass fittings have found their application in many areas of industry, construction, utilities:

• in construction, it is used in the construction of civil and industrial construction projects as a basis for foundations, floors, crossbeams, as well as in the construction of earthquake-resistant belts;
• in the construction and repair of roads, reinforcement is used in the arrangement of embankments, road beds, in the construction of bridges and highway barriers. It is resistant to the effects of reagents that are applied to road surfaces (for example, anti-icing reagents), therefore it can be used both in Moscow and in colder regions.

Fiberglass reinforcement will be the ideal base for concrete and brick structures. It is used in the creation of supports for power lines and lighting, in the construction of road, sidewalk and fence plates, as well as in the construction of sleepers on railway tracks. Reinforcement for ceilings, where a mesh of reinforcement is used, even together with metal, is widely used.

Fiberglass is applicable in building structures such as monolithic foundations and foam concrete. It is also actively used in the creation of structures that must have increased resistance to the effects of chemicals, for example:

• during the construction of storage facilities for chemical waste and components;
• when arranging sewerage, water supply systems, land reclamation systems;
• in the construction of port facilities and in the strengthening of coastlines.

Despite the uniqueness of the product, fiberglass reinforcement, the price in Moscow for which is indicated on our website, is an affordable material for both construction organizations and individuals. Its cost is 40-50% lower than the cost of steel reinforcement, which can significantly reduce costs and at the same time improve the quality of the facilities being built. In general, composite rebar can be called one of the most reliable and efficient building materials of our time.

This reinforcement is made of straight strands of glass or basalt fibers (respectively ASP and ABP), which are collected in a bundle, impregnated with a thermosetting polymer binder, molded, heated (polymerized) and cooled. As a result, a monolithic rod of high strength is obtained, according to the test results it is 3 times higher than the tensile strength of steel, and the weight, in an equal strength ratio, is 9 times less.

As a standard, it is produced in the form of rods of any length, at the request of the customer. With a diameter of up to 8 mm inclusive, it can be made in the form of coils (coils) containing 100 meters of reinforcement. Overall dimensions of the bay: height - up to 8 cm, diameter - up to 1 meter.

form of issue

With a diameter of 10 mm and 12 mm, it can be made in the form of coils (coil fittings) with a length of 50 meters. Overall dimensions of the bay: height - up to 5 cm, diameter - up to 1.5 meters.

By agreement with the customer, it is possible to manufacture rods and coils of any length.
It can be made with a smooth, building, periodic profile:

• ASP-ABP of periodic profile, used instead of steel reinforcement class A-III (A-400);
• ASP-ABP smooth profile, used instead of steel reinforcement class A-I (A-240).

Fiberglass reinforcement is becoming more and more popular and its use is becoming more and more relevant every year, because it is a complete replacement for traditional rods made of steel of different grades. High strength indicators, optimal performance properties, low specific weight and low price are the factors that determine the popularity of the use of non-metallic reinforcing elements in all areas of construction.

Fiberglass reinforcement

Modern technologies have made it possible to create a non-metallic composite reinforcement, which favorably differs from the traditional one by the combination of increased strength, chemical and corrosion resistance and low cost.
Technological line, "TLCA-2" designed for the manufacture of composite reinforcement made of glass roving and basalt roving, used as a reinforcing element for construction work. Differs in ease of installation, speed of production of valves. service staff 3 people. The lines are in stock, installation supervision and training are included in the price.
The equipment of our production is distinguished by simplicity, ease of maintenance and productivity, while the price of the equipment is lower than that of other manufacturers.
For instance: equipment in China costs 3,000,000 rubles, while the production rate is two times lower than ours. The cost of the English equipment is 8,000,000 rubles. In the Russian Federation, prices for technological lines for the production of valves start at 2,000,000 rubles, or even higher.
The specialists of our company are constantly working to improve the equipment, while practically not increasing its cost. The supplies of our equipment have a wide geography, this includes cities such as Nizhny Novgorod, Kazan, Orenburg, St. Petersburg, Magnitogorsk, Krasnodar, Yakutsk, Yekaterinburg, Tolyatti, Cheboksary, Krasnodar, Stavropol, Kaliningrad, Orenburg, Tyumen, Chelyabinsk, Irkutsk, Ufa, Samara, Ulyanovsk, Moscow, Lipetsk, Belgorod, Rostov-on-Don, Simferopol, Neftekamsk.

Basic properties of the TLCA-2 line:

• productivity 5-10 km per shift 8-10 hours
• diameter from 4 to 20 mm, the larger the diameter of the reinforcement, the lower the production speed, but the greater the profitability of the product
• the length of the line is 18 m + the length of the fiberglass rod is up to 6-12 m, the workshop is needed about 25 m long, the width of the line is 2 meters.
• Profitability 100% .- 120%
• the number of service personnel is at least 3 people
• The total power of the engine and heating elements is 15 kW.
• Working power per hour - about 10 kWh

Supplied equipment specification:

Discounts are possible:

• When buying for cash.
• When buying two or more lines.
• When buying a line without installation and training.
• Other options are also possible, it is discussed individually.

It is also possible to purchase the line in parts, but without commissioning. We can make any unit according to your drawings.

As in any other production, its quality plays a key role and the most
directly affects the final quality of the reinforcement.

TPK "NANO-SK" produces composite reinforcement from three main types of raw materials.

Glass fiber

The most demanded is glass fiber.

This raw material is a complex thread, which is formed from glass with a special chemical composition. Fiberglass bends without breaking or tearing.

It is a raw material for composite rebar guarantees high qualities of strength, not inferior to metal, but with a high modulus of elasticity.

Basalt fiber

Such raw material forfittings, like basalt fiber, is produced from natural material by melting
without the addition of chemicals.

Basalt fiber can be staple and continuous.

Basalt-plastic reinforcement has high technical and operational parameters.

TPK "NANO-SK" offers for reinforcement.

Carbon fiber

Another one used by TPK “NANO-SK” in the production process is carbon fiber, which is the result of high-tech chemical production.

Carbon fiber has high tensile strength, low specific gravity, chemical inertness and low coefficient of thermal expansion.
Carbon is the most expensive.

What is fiberglass composite rebar actually made of?

The General Director of Obninsk Plant of Composite Materials LLC Klimenko Maxim Vladimirovich answers:

"Good afternoon. Firstly, I would like to note right away that the products of Obninsk Plant of Composite Materials, LLC, have been manufactured only from the best binding materials and foreign-made fiberglass for the past 3 years.
We put "at the forefront" product quality, therefore, contracts were concluded with world leaders for the production of raw materials for the production of composite materials. What is fiberglass composite rebar actually made of?

It is the main material in the production of composite fiberglass reinforcement. The Jushi company (Yushi or Jushi) produces glass roving based on modified silane lubricants No. 386 and No. 312, which are specially developed and successfully used together in the production of composite fiberglass products by pultrusion.
Jushi glass roving is currently the highest quality fiberglass product on the market. It can withstand enormous breaking loads, surpassing its competitors several times. Obninsk Composite Materials Plant is the main consumer of Jushi fiberglass in Russia and we have a contract for the supply of glass roving.

Epoxy resin is the main polymer used in the production of fiberglass reinforcement. For the production of fiberglass by pultrusion, including the production of composite fiberglass reinforcement, pegs for plants and other products, we use high-quality epoxy resins CYD 128, produced by Sinopec (China) and epoxy resins KER 828, produced by the South Korean brand Kumho. Obninsk Composite Materials Plant also has long-term contracts for the supply of epoxy resins with these companies.

IMTHFA (isomethyltetrahydrophthalic anhydride)- It is the main hardener in the production of fiberglass reinforcement. IMTGFA is ideal for high temperature curing of epoxy resins. The production of fiberglass reinforcement takes place at high temperatures in special furnaces, the temperature reaches 340C. Therefore, when using IMTGFA, composite products acquire excellent physical and mechanical properties and high strength characteristics.

Catalyst is a special compound that combines the properties of Diethylene glycol Diglycidyl Ether (DEG-1) and Alkofena (DMP). By using these components, the final product acquires high chemical resistance properties. "