Business plan for the construction of houses from sip panels. Unsuccessful personal business experience in building houses from sip panels

SIP, SIP, sandwich panel are the names of one building material which 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 management personnel near the production site, 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 communal payments).

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

Exist different kinds lines for the production of sip panels, they differ in technical specifications, the principle of operation is the same for all. The line for the production of 100 panels per shift has the following components:

• mechanism for applying glue and pressing;
• device for cutting foam;
• device for cutting panels;
• milling machine.

The adhesive 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

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, it is possible to 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 keep in mind that these two machines will require more volume 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, and windows are made. This process is carried out according to individual plan 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

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 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 thermal 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

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 the influence of 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 95% consists of carbon dioxide and is distinguished not only by its low weight, but also by its low cost compared to other heaters.
      Compounds such as Kleiberit 502.8, top-ur 15, Macroplast UR 7228 and Macroplast UR 7229 are used as adhesives. Special requirements are imposed on such compounds: elevated level moisture resistance, a wide temperature range (from -40 to +50 degrees Celsius), the possession of absolute environmental friendliness and correspond to the long 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 jerrycan 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, through 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

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 manufacturing sandwich panels with my own hands a special role is played by the speed of the actions performed. 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

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.

Video

Watch a video on how to make a sandwich panel with your own hands:

Many Russians would change city ​​apartment on the Vacation home if it were possible to build it quickly and inexpensively. This allows comparative 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, 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
• insulation laying
• 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. Purchase individual elements 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. warehouse finished products you can even outdoors if the site is equipped 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 go to the purchase of individual elements of the production line, the rest - to registration, purchase of raw materials and additional tool, providing 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 that does not require maintenance a large number workers. Simple equipment is more convenient at the initial stage, but limits growth opportunities and increases the cost price due to wages workers.

Write your question in the form below

Currently, the Canadian SIP technology (structural thermal insulation panel) is considered to be one of the most advanced technologies used in the construction of prefabricated buildings. There are two methods for the production of such "sandwich" panels, differing mainly in the way of pressing: bench and continuous. Bench development implies periodic pressing of products and includes a number of sequential and discrete operations. This method is effective for small orders. For the production of "sandwich" panels of the highest quality, a technology based on the use of continuous method. It provides the production of a wide range of "sandwich" panels.

Production of building structural elements

Our company has the necessary set of equipment for the production of high quality SIP panels.

Assembly of sandwich panels (SIP panels):

• - Place the first sheet of OSB (Oriented Flat Chip Board) on the assembly table and apply adhesive to it.
• - Then lay the styrofoam board and apply the next layer of glue.
• - Place a second sheet of OSB on top of the adhesive layer.

As a result of the manipulations, a three-layer panel is obtained, consisting of two layers of OSB and a glued intermediate layer of expanded polystyrene. It should be noted that when laying the second layer of OSB, it is necessary to ensure that its position relative to the first layer is such that the ribs formed by the corners of the sheets are perpendicular to the common plane of the panel.

At this stage of the production cycle, blanks are cut, which are “sandwich” panels, gluing and installing wooden beams in them, as well as manufacturing other related wooden structural elements (glued beams, brackets, etc.).

On cutting tables along the perimeter of the panels, grooves are selected that are equal in thickness to the expanded polystyrene. At the same time, their depth should correspond to the dimensions of the wooden frame.

The next step is to cut openings in the panels for windows, doors, etc.

At the end of the cutting operation, the panels are glued into the formed grooves. wooden bars that form the framework. After gluing the timber, it is additionally fastened with screw or ring nails 45 or 70 millimeters long, depending on the requirements of the project documentation.

Upon completion of the assembly of the construct, the house kit is prepared for shipment to the construction site.

Adhesive polymerization start speed

The polymerization of the adhesive composition starts at a rate of about 12 minutes, so as many layers of panels can be glued on the table at once as workers can pick them up during this time.

Gluing panels under pressure

Pressurized plates should be kept for approximately 60 minutes. Exact time pressure plates are determined by the characteristics of the adhesive used.

Structural thermal insulation panel

The structural heat-insulating panel consists of two layers of OSB oriented strand board, between which a polystyrene foam board with a thickness of 100 to 200 millimeters, a grade of at least 25 kg / m 2, is pressed with a special binder. A wooden beam is inserted along the ends of the panel.

The thickness of SIP panels varies depending on their purpose and in ready-made ranges from 110 to 250 millimeters.

The scope of "sandwich" panels is quite wide. Almost all major structural elements buildings: exterior wall panels, floor panels and floors, large beams and lintels, window sill panels, load-bearing and non-bearing partitions, panels roof structures etc.

To connect the SIP-panel to the frame structure, special nails and self-tapping screws are used.

These structures do not require additional insulation. The roof covering is laid directly on the roof panel, without additional insulation.

During construction, a separately erected building frame is not used. Its role is played by the upper and lower strapping beams and individual bars glued into the panel at the factory.

Structural rigidity achieved through exceptional properties OSB boards. The SIP panels themselves are the main load-bearing structural element.

In the manufacture of heat-insulating SIP-panels and the installation of houses, no labor is needed highly qualified. It is enough to have one specialist in supervisory supervision for the manufacture and assembly of houses. The process of producing modules and assembling houses is so simple that workers can master it within a few days. Quick installation wall panels achieved with the help of thorn-groove locks.

Wiring is usually outside the panels, heating is in pipes under the floor, and holes for plumbing and plumbing are made in the usual way. When building houses small size truss structures are not needed, one ridge beam is enough.

With the same wall thickness, all buildings made of SIP panels are almost 1.5 times warmer than ordinary wood-frame ones and 8 times warmer brick houses. In addition, they are considered environmentally much cleaner than brick and concrete.

Internal and external finishing at home can be made using absolutely any materials, in accordance with the desire and financial capabilities of the customer.

Houses built from "sandwich" panels can be operated in the temperature range from -50°С to +50°С and provide comfortable living even in the most severe climatic conditions.

Estimated load on the floor panel, kg / sq.m.

Maximum axial load on the outer wall depending on the force of the wind, kg/sq.m.

domestic construction sector last years has undergone significant changes 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 with 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 won due to the high speed of erection 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 blanks are also trimmed in accordance with the originally 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 made up of private construction companies that are engaged in the construction wooden houses. This segment is still in demand Russian market, and the fashion Canadian technology 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 construction 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 SIP-panel houses 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.