Raw materials for the production of plastic fittings. Overview of equipment for the industrial production of fiberglass reinforcement. How much money is needed for the production of composite reinforcement

Composite, or fiberglass, reinforcement is a high-tech material that is suitable for the conditions of the modern building materials market. technical specifications which requires a relatively small capital investment. Fiberglass can easily replace metal in any size concrete structure without requiring replacement as often as steel products.

Anyone who is familiar with the technology, requirements for the premises and the necessary equipment can start the production of fiberglass reinforcement.

The main advantages of glass fittings

Fiberglass reinforcement is becoming increasingly popular with customers and, due to its advantages, is crowding out the steel counterparts that occupied a dominant position. Its main advantages include:

lightness in comparison with steel reinforcement: 160 kg of fiberglass in volume is equivalent to two tons of metal material;
production costs are 30% lower than standard investments for the manufacture of competing analogues;
high and fast payback;
tensile strength is 3 times higher than other materials;
no need for a large-sized room, heavy vehicles and numerous service personnel;
fiberglass reinforcement is not subject to corrosion.

Raw materials for the manufacture of fiberglass reinforcement

Composite reinforcement is rods with a diameter of 4 to 18 mm with a spiral profile. The structure of the material is represented by a main shaft of parallel fibers and an outer layer that can vary (single winding, bidirectional winding, sand spraying).

Often there is reinforcement in coils with a diameter of 10 mm, i.e., in a twisted form. The two main components of the material are roving and epoxy resin. The first acts as a reinforcing material, and the latter plays the role of a binder. In addition to the base, you also need:

acetone;
braided thread;
ethanol;
dicyandiamide.

On average, the cost of manufacturing 1 kg of fiberglass reinforcement is 127 rubles.

Necessary equipment for the production of fittings

The central element of the fiberglass reinforcement manufacturing system is a line or conveyor specially designed for this purpose. Its components include:

racks for roving;
glass fiber impregnation unit with resin;
bake;
wrapper;
bunker for finishing coating;
magnesite furnace;
air cooling unit;
pulling mechanism;
cutting machine;
exit tray finished products;
Control block.

Despite the fast pace of development of the industry, not every supplier can offer equipment suitable for the needs of small businesses. Usually the number of options available is severely limited by the initial financial possibilities entrepreneur.

Some manufacturers offer equipment costing from 1 to 1.7 million rubles - this price range is the most optimal for beginners individual entrepreneurs, since the volume of such production will correspond to the indicators of a small enterprise. In this case, the speed of manufacturing fiberglass reinforcement will be approximately 2–4 m/min. Equipment whose productivity is 6-12 m / min will cost two to three times more.

In the absence of funds for the purchase of new equipment, it is worth considering renting or purchasing a used device. Good value for money is also offered abroad, for example, in China, and in the Russian domestic market.

Requirements for a production facility

Even if you need to remember the safety rules. For this reason, any room chosen for the production of fiberglass rebars must comply with generally accepted standards in order to avoid accidents and problems with the functioning of the production line. The main requirements include:

The room for the production of fiberglass reinforcement must meet all the requirements for normal operation

remoteness from residential buildings position;
height and length of the room - not less than 2.5 and 22 m, respectively;
good ventilation;
technical equipment: water supply, electricity and sewerage;
height difference - no more than 5 cm;
heating up to 16–18 °C.

In addition, on initial stage production will need a power source with a capacity of 12 kW. Then, after debugging the production process, this figure can be reduced to 4 kW. As for ventilation, forced ventilation of the room will be most acceptable. The tunnel oven requires a separate hood that can be connected to a common system.

There are no separate requirements for the width of the room, since the conveyor is much longer in length than in width. To reduce costs in the case of renting, you can opt for real estate outside the city - even with a simultaneous increase in transport costs, this will significantly reduce the monthly cost of maintaining a business.

Technology for the production of fiberglass reinforcement

The key to manufacturing quality products is a strict adherence to the developed technology. Fiberglass reinforcement is produced in several stages.

Roving processing

Glass roving is the basis of composite reinforcement, which is obtained by melting aluminoborosilicate glass. The material is drawn into a thread with a cross section of 10–20 microns, then the threads are impregnated with a lubricant and woven into bundles. Initially, the main material is located on special racks, which evenly feed it further along the line.

The threads collected in a dense bundle are dried and heated with hot air, and then the heated roving passes through the impregnation bath, completely immersed in the epoxy resin. The impregnation unit is a mechanism with four grooves, along which threads of various diameters (from 12 to 18 mm) are pulled.

Shaping and wrapping

After processing, the roving enters the shaping die, which determines the diameter of the future building material, and then - to the winding with a bundle, which adjusts the thickness of the rods to a certain parameter and ensures strength in contact with the concrete base.

Those products that turned out to be of the desired thickness remain in the form of finished products, and those that are thinner are additionally sprinkled with sand. The wrapper, as well as the impregnation unit, consists of four strands and is powered by two belt motors. Due to the circular trajectory of rotation, the winding device allows to obtain products of the correct cylindrical shape.

Winding roving

Armature furnace

The molded products go into an 8 m long magnesite tunnel kiln for the residual chemical reactions (resin polymerization) to take place.

Final stage

Finished, but still red-hot products are sent to a bath filled with running water to cool to room temperature. The last step is a cutting machine that divides the material into rods according to the specified parameters. Since even the simplest machines use a diamond-coated circular saw, the cut is precise and even.

The conveyor line for the production of composite reinforcement is fully automated and controlled by a software unit. Before starting the production of fittings, all the necessary parameters of future products are set by the operating engineer.

Composite reinforcement has managed to get a lot of positive feedback by experts in the construction industry. According to the most conservative estimates, its production on a small scale can pay off in a year and a half, provided that the goods are fully sold. Fiberglass material is reliable, resistant to external destructive factors, easy to transport and far superior to metal in all technical and economic aspects.

Composite rebar is rebar made from composite materials rather than steel. Their components are glass roving and/or basalt fibers, which are held together by polymer binders. It, unlike metal, is not welded, but fastened with special clamps. Also, composite reinforcement is known as "non-metallic".

Here we will talk about the production of composite (fiberglass and basalt-plastic) reinforcement, its manufacturing technology, raw materials and equipment for this business.

Composite reinforcement is used primarily, of course, in construction, but it can also be used in everyday life, for example, for assembling greenhouses.

Video review of the material and its advantages

A short visual video about what it is:

The main advantages of composite reinforcement:

Compared to metal, composite has a much higher strength index - 1100 MPa, and standard steel - only 390 MPa. Tensile strength compared to class A III steel reinforcement - three times more;
Composite reinforcement is a material that is not susceptible to corrosion;
Ideal for use in sea water, as it is not subject to acid corrosion;
More elastic than steel;
Does not conduct electricity;
Does not conduct heat;
Composite reinforcement is radio transparent;
Does not change its strength characteristics under the influence of electromagnetic fields;
Does not change its strength characteristics under the influence of low temperatures (up to -70 ° C);
Significantly lighter (more than nine times) compared to metal reinforcement.

Regardless of the required and desired volume, the production of fiberglass reinforcement requires investments in the amount of 4-16 million rubles.

Technology and equipment for production

Raw materials for the manufacture of composite reinforcement:

Roving (basalt and/or glass roving);
resins;
Braided thread (roving, which will go for winding);
Acetone;
Ethanol;
Dicyandiamide.

Raw materials may be different in composition.

Fiberglass (SPA) and basalt-plastic (BPA) reinforcement are the most popular today in Russia, but there is also a combined type - a fiberglass rod, and a relief (ribs) from "basalt".

Thermosets are most often used as binding elements. synthetic resins, among which are organosilicon and phenolaldehyde (they harden during the polycondensation reaction); epoxy and unsaturated (do not emit by-products during the curing process).

Other polymers that have occupied a solid niche include polyimide, polybenzimidazole, and polybenzothiazole. These resins are often used with the addition of other polymers.

In order to obtain fiberglass reinforcement with a high level of resistance to various kinds of corrosion at the output, an epoxyphenol binder should be used. The polyester binder will give the reinforcement enhanced electrical properties.

For one kilogram of fiberglass reinforcement, 0.862 glass bundle-roving of such brands as RBN-10-2520 or RBN-10-2520-4E should be used; epoxy resin requires 0.134 of the following grades: ED-20 or ZIS-1; phenol-formaldehyde resin will require 0.116 brand LBS-1; dicyandiamide - 0.03; ethyl alcohol - 0.015; braided thread - 0.01 kg; acetone - 0.021.

The basis for the production of non-metallic reinforcement has already become the traditional method for the production of fiberglass - drying and unwinding the fiber, impregnating it with a binder, and polymerization.

Video of the manufacturing process:

Equipment for the production of composite reinforcement (fiberglass or basalt plastic):

Line device (it may be different). Prices for such lines start from 3,000,000 rubles.

The principle of continuous drawing makes it possible to produce non-metallic reinforcement from any type of fiber, while taking into account its manufacturability and temperature regimes of binder curing.

For a novice entrepreneur, the production of fiberglass fittings is one of the promising options for starting a business. Since it does not require huge investments and labor costs.

Of course, today in the construction industry a lot of materials are used, the production of which can make good money.

If you establish a business in the production of composite reinforcement good quality, with an appropriate organization of production and a well-developed clientele, it is possible to short time return primary costs and receive net proceeds in the next 2-3 years after opening.

At its core, fiberglass or composite reinforcement is a bundle of solid glass fibers characterized by high strength. The thinnest threads are interconnected by means of synthetic resin into a strong rod.

Such products, as a rule, are used in the field of construction production and decoration or in everyday life (for example, for the assembly of greenhouses). In addition, unlike metal fittings, fiberglass products are not welded, but fastened with special fasteners (clamps).

Also, fiberglass (composite) reinforcement is known as "non-metallic".

Equipment for the production of composite reinforcement

How much money do you need to start a business for the production of composite reinforcement

Amount for starting investments(opening a business for the production of composite reinforcement) is approximately 1,400,000-1,700,000 rubles.

How to start a fiberglass rebar business

Assessing the fiberglass rebar business, we can say the following:

The saturation of the market is still in the middle stage and still has free niches for it to be filled by new entrepreneurs.
The difficulty of opening on a 10-point scale is 6 points.

Of course, for perspective development business, first of all, it is necessary to purchase high-quality and warranty equipment. By purchasing it, setting up and launching production, it is possible to supply demanded fiberglass (composite) fittings to the market, both for small private builders and large construction companies.

However, even with a slight investment investment, execution of documents and selection of a site for building a workshop, for successful development affairs in this field, it is necessary to carefully work out a business plan for the production of fiberglass reinforcement, in which the following points must be taken into account:

analytical forecast of market development and competitive base in this area;
production technology;
technical equipment of the workshop premises;
financial justification for the production of products from fiberglass reinforcement.

How much can you earn in a fiberglass rebar business

For example, with an average productivity of 150 thousand running meters. of finished monthly products, its cost on the wholesale market will be about 6-10 rubles per linear meter, with a revenue of 1.5 million rubles. At the same time, in order to reach the figure of net profit, it will be necessary to calculate from total revenue variable costs to purchase raw materials, pay taxes and wages employees, as well as expenses for communication, transport and utility deductions.

From practice, it becomes obvious that the monthly net revenue of the enterprise will be about 100,000 rubles, that is, in such a favorable scenario, the payback of the business will be 2-2.5 years.

All these indicators, with full sales of products, must be calculated in the business plan. Since in this case it will be seen whether the production is profitable or not.

What equipment to choose for the production of fiberglass reinforcement

Since special equipment is used in the production of fiberglass reinforcement, which must be maintained and operated under certain conditions, when starting a business, it is necessary to understand and know what it includes and what parameters of the conditions of the premises will need to be taken into account in the production of building fiberglass material.

So, the equipment for the production of composite reinforcement includes the following list of key points:

creel, which is a machine for unwinding roving threads (fiberglass threads or basalt fiber);
an impregnating device for impregnating threads with a binder material;
impregnation bath, which will contain a special mixture based on epoxy resin;
rib wrapper, a device for forming a profile and twisting a thread;
thermal polymerization chamber;
fixtures for cooling fittings;
pulling device;
a device for winding reinforcement on a drum or a cutting device;
computerized line control system.

Similar line technological production can be adjusted in one or two streams. At the same time, upon delivery of the ordered equipment, it is recommended to purchase a set of technological and technical documentation, and installation and commissioning with the launch of a trial batch, a selection of recipes and technological parameters for the production of composite reinforcement, taking into account individual conditions for the production of products, training of service personnel to be included in the cost of the order.

The conditions for the premises in the production of fiberglass reinforcement are as follows:

The air temperature should be from +16 to +20ºС.
The room must have a height of 250cm and above, with a minimum length and width of 25x4m.
The production workshop must be equipped with an exhaust ventilation and fire extinguishing system, with access and water flow of at least 0.5 m 3 / h.

Subject to all indicators, as well as the data specified in the business plan for the implementation of composite reinforcement, designed for high profitability, under the conditions of 100% sales of goods and the maintenance of packages of documents in the proper order, it is quite realistic and profitable to open the production of fittings. Good luck!

How much money is needed for the production of composite reinforcement

The main operating costs are:

Rent of the workshop and its equipment in accordance with the standards - 100 thousand rubles;
Purchase of a special production line - 1 million rubles;
Acquisition additional tool- 200 thousand rubles;
Purchase of raw materials - 400 thousand rubles;
Registration and other expenses economic activity- 100 thousand rubles.

What OKVED must be specified for business

When registering fiberglass reinforcement, the OKVED code 23.14 is indicated.

What documents are needed to start a business project

Best Choice legal form is registration legal entity, namely LLC. For its execution, it is worth providing an appropriate package of documents, which includes the company's charter and the decisions of all founders to organize a production workshop. Business is designed to cooperate with large construction companies who are more willing to cooperate with a legal entity than with an individual entrepreneur.

What taxation system to choose for the production of composite reinforcement

It is rational to use the simplified tax system for both ITP and LLC. The tax rate is chosen individually: 6% or 15%. Record keeping and decision legal issues It is worth entrusting the company providing accounting and legal services.

Do I need a permit to operate

The organization of the production workshop is not subject to licensing. But it is necessary to obtain permission from the fire inspectorate and other regulatory authorities. The document is issued for compliance with the premises standards. You should also issue certificates for products.

Technology for the production of composite reinforcement

Composite reinforcement is a popular building material. But you should not count on super profits in the first months of work. Regular customers appear over time. If we talk about the production process, it is worth noting that it consists of several stages:

To begin

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

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

It's in demand construction material, gradually displacing traditional metal analogues from the market. It has an impressive list of useful features:

High strength. This material is 3 times stronger than steel.
At the same time, plastic material is much lighter than steel - not less than 6-9 times.
Does not rust and without damage tolerates exposure to sea or fresh water, acidic or any other aggressive environment.
Dielectric - does not conduct electricity, can be used in insulation work.
It is frost-resistant - does not collapse even at very low temperatures.
Not exposed to electromagnetic fields.
Long service life - at least 50 years.
Possibility to make a seamless installation.

As for the shortcomings, one can note insufficient 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 it is impossible to bend them on your 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 clients enterprises) do not distinguish this material from steel reinforcement and often give preference to it. Composite rods do not have pronounced marketing advantages, obvious benefits for buyers, which can also be called one of its shortcomings.

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

Where applicable

The main scope of plastic fittings - road, industrial and civil construction. This material reinforces concrete structures, including foundations. Fiberglass reinforcement is well suited for fastening thermal insulation and concrete floors: it improves the adhesion of concrete elements. The use of such fortifications facilitates structures and reduces the cost of work.

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

Is this business relevant?

Any production of building materials is actual business, and the production of modern and innovative is even more in demand. There are a lot of applications 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 cannot be called crowded. As a rule, in each region there are from 3 to 10 medium-sized enterprises producing such fittings.

At the same time, construction companies and institutions responsible for road construction and shore protection, much more. It follows from this that there will always be a demand for material, so novice manufacturers must initially designate competitive advantages and actively promote products.

Composite reinforcement is 6-9 times stronger than steel

Business organization

The production of composite reinforcement requires impressive organization costs. Practice shows that 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 working capital for the period until the company sells the first batches of goods.

A business plan will help you think through your work. It should include not only the opening costs, but also the calculation of profitability, goals for 6 and 12 months, an approximate staff, and also a list of potential partners. The sooner an entrepreneur finds stable distribution channels, the faster enterprise reach the level of net income.

Production technology

The production of composite reinforcement takes place 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 drawn into threads with a cross section of up to 20 microns and impregnated with a special lubricating 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 enter a special mold for plastic substances (dies), where the diameter of the future reinforcement is determined. Then the blanks are wrapped with a bundle: it provides the necessary thickness and improves the adhesion characteristics to concrete.

The formed and wrapped reinforcement is fired in a magnesite tunnel kiln. The resins polymerize there. 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

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

Bath for glass roving impregnation with spin function.
Drawers (forms for plastic substances).
Rebar pulling machine.
Apparatus for twisting threads.
Curing oven with temperature control function.
Apparatus for cooling.
Diamond-coated saw/machine for cutting finished rebar.
Apparatus for twisting finished fittings.

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

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

Requirements for the premises

Since the conveyor of machines for the manufacture of fiberglass rebar is at least 15 meters long and about half a meter wide, 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: workspace, warehouse, 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, so it is desirable to have a special heat control system. Good lighting guarantees quality work, do not ignore this characteristic. 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 matter much; you can place it on the outskirts or outside the city.

Raw material

What materials are needed for the production of composite reinforcement? The basis is glass roving - threads of molten aluminoborosilicate glass with a diameter of 10 microns. In the manufacture of rebar, the fibers are supplied in large hermetically packed reels. They are transported at a temperature exceeding 35 degrees and at a humidity level of not more than 70%.

The second key ingredient is epoxy. It is a colorless or light yellow viscous liquid, similar in consistency to honey, used in the primary processing of roving. It gives future fittings resistance to aggressive environments.

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

braided thread;
alcohol;
acetone;
dicyandiamide.

Business costs

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

The amount of 3 million rubles cannot be called small. Compared to some other building materials industries, the production of composite rebar is indeed expensive. The high price is associated with 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 of composite reinforcement starts from 10 rubles per meter. But the average cost is higher - 50-70 rubles. At the same time, 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 2,000 meters of material per hour, that is, 16,000 meters per shift. 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. The same funds are to be paid Communal expenses, employee salaries and other obligatory 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. The organization of the enterprise will require at least 3 million rubles, while the payback is possible within 16-18 months. Fiberglass rebar has proven itself well due to its strength characteristics, but this product is not yet widely known on the market.

Fiberglass reinforcement (FRP) is gradually replacing the usual metal reinforcement. This building material is actively used in developed countries peace. In Russia, it is still not widely used (the market share is about 5%), although construction companies are increasingly switching to fiberglass (the trend is typical for million-plus cities).

The production of composite reinforcement is a promising line of business. In this regard, we will tell you how to organize manufacturing process and touch on all the points important for the success of the case.

Main characteristics and advantages of ASP

Fiberglass reinforcement is a composite material with a complex composition. It is a glass fiber hardened in a reinforcing bar, “bonded” with synthetic resins. These resins combine heavy-duty glass fibers into one whole, which protect against mechanical damage and aggressive environmental influences.

ASP has high tensile strength - 2-3 times stronger than steel counterparts. Differs in low weight - 6-9 times lighter than steel fittings. Not subject to corrosion, resistant to water (sea or fresh), has a high elasticity. The composite is a dielectric, is not affected by electromagnetic fields, and is characterized by complete chemical inertness. The guaranteed service life of ASP is 100 years.

It is important for business that the cost of such fittings is lower than the cost of metal.

Scope of fiberglass reinforcement

Building materials are used in various areas of construction:

in road and industrial-civil construction (creation of bridges and airfields);
when reinforcing all types of foundation (as rods and meshes);
when reinforcing concrete structures - including in environments that are aggressive for metals;
to strengthen various kinds concrete using chloride and mineral additives;
during the construction of agribusiness facilities (due to the absence of fumes harmful to animals);
to strengthen brick buildings, walls;
when creating all types of water disposal, sewerage;
to strengthen the coast in ports.

ASP belongs to the 4th hazard class (low hazard), non-toxic. It can be used in residential construction.

Market situation

The leaders in the use of non-metallic reinforcement are the USA, Japan and China with shares of 40%, 35% and 30% respectively. Entrepreneurs in Russia are showing great interest in this building material. According to the forecast, by 2021 the ASP market is expected to spread by 11.4% annually, and the Russian Federation has good prospects in this regard.

Construction volumes in our country have returned to stable growth after a noticeable drop in recent years. According to the Ministry of Construction, as of the beginning of May 2018, 16.7% more housing (20.2 million square meters) was put into operation compared to the same period in 2017.

Construction companies and private developers strive to minimize the cost of housing without compromising quality, and this opens a window of opportunity for the production of composite reinforcement.

Production technology

Building materials are made on special equipment. The process is automated, the staff only controls and maintains the equipment.

Fiberglass strands are heated, soaked in resin.
The threads are collected in a bundle, tied together, pulled through a spinneret (holes of a certain diameter).
The resulting rods pass through a polymerization chamber (tunnel oven) and are processed at high temperature.
Composite reinforcement is cooled and dried.
ASP is wound into coils or cut into pieces of the desired size, followed by stacking in diameters.

You can make reinforcement of any design length.

Starting investment

You don't need a lot of money to start this business.

Table 1. The amount of initial costs by items for the production of fiberglass reinforcement.

The main expense item is production equipment. The additional costs include the cost of preparing the premises, fuel, electricity.

The calculations are relevant for a city with a population of up to 1 million people.

Raw materials

As the main raw material, the production of fiberglass reinforcement uses glass roving - molten glass fiber in the form of threads with a thickness of 10-20 microns. These threads are collected in bundles impregnated with a special lubricant. Instead of glass, basalt and carbon fiber can be used.

Synthetic resins and polymers are needed. Phenolic and epoxy resins solidify at the final stage of production, "binding" the threads into a heavy-duty rod. Epoxy resins do not emit harmful substances during production. Various polymers (polybenzothiazole, polybenzimidazole, polyamide) are also added, which improve the characteristics of ASP.

Still need ethyl alcohol, acetone and hardener (dicyandiamide).

There are many manufacturers of raw materials for polymer reinforcement on the market. It is important to buy only high-quality materials made according to all technical standards.

Documentation

The entrepreneur will sell products construction organizations, work with wholesale and retail companies, supply large quantities of goods. It is recommended to open a business in the form of a legal entity (LLC). This is more expensive and will take more time, but will allow you to work with major players in the market.

There is no special OKVED code "Production of fiberglass reinforcement". You can choose one of the following:

23.19 Manufacture and processing of other glass products including technical glass products.
23.14 "Glass fiber production".
36.63.7 "Production of other products not included in other groups."

All norms and requirements for building materials are given in GOST 31938-2012, adopted in 2012. In addition to Russia, 7 other CIS countries adhere to it.

To work, you need a certificate of compliance with the requirements of GOST.

room

the length of the room where the equipment is located and production is carried out - from 25 m;
ceiling height - 2.5-3 m;
the presence of a flat floor with differences of not more than 5 cm;
the presence of a stable air temperature - 16-18 ° C. This means the presence of heating and air conditioning systems;
a good ventilation system.

Rent a 150 sq. m. In addition to the workshop, place warehouses for raw materials and finished products, administrative premises, a staff room, and a bathroom here. Choose a location with convenient access roads and space for loading and unloading.

Equipment

Consider production line PLPSA-20 for the manufacture of fittings with a diameter of 4-24 mm. Differs in high productivity: does on 2 bars at the same time.

This is a set of devices for automated work. Consists of:

devices for feeding glass roving threads;
tensioning device with the option of heating and impregnation with resin;
winding mechanism;
tunnel oven;
long water cooling unit;
pulling device;
rebar cutter;
bar twisting mechanism, coil winder.

The line is controlled by a remote control. You can turn on the option of cutting bars of a given length or twisting bars into coils. The resulting reinforcement has a constant cross section, 1-2 stiffeners.

Staff

Recruit qualified workers.

Table 2. Number and official duties production personnel.

Position	Main responsibilities
Senior operator ( Technical Specialist), 1 person	Senior in production (control over the work of the operator, worker, maintenance of equipment)
Operator, 1 person	Work on equipment
Ancillary worker, 1 person	Loading and unloading, supply of raw materials, storage of finished products
Sales manager, 1 person	Development of a policy for the promotion of building materials, establishing the first contact with corporate buyers
Sales representative, 2 people	Conclusion of contracts, work with clients
Driver (with car), 1 person	Logistics, delivery of goods

It is better to “create” a senior operator yourself by sending an employee to a manufacturer / seller of equipment for training. An accountant can be hired by outsourcing.

Sales of finished products

There are several channels for the implementation of composite reinforcement:

sale directly to private developers;
sales through construction stores, large chains, wholesale bases, small retail stores;
work with large construction companies.

For direct selling, you need to send information about the offer through various advertising channels (media, Internet, BTL promotions, posting ads). The implementation of ASP through wholesale and retail networks will allow concluding contracts for the supply of large volumes of goods, gaining a foothold and increasing market share.

It is most advantageous to enter into long-term contracts with construction companies. This will allow you to load production to the maximum, sell more goods.

Financial plan: profitability and payback

The amount of initial costs is 2.635 million rubles. (2.7 million rubles).
The cost of 1 linear meter of reinforcement with a diameter of 8 mm (the most common type) is 7.6 rubles.
Line productivity - 7 m per minute. Accordingly, 7 m × 60 min × 8 h × 22 d = 73,920 linear meters can be produced per month. m.
The average price of 1 rm. m of material on the market - 13 rubles. At this price, the net profit will be 5.4 rubles. (13 - 7.6). When selling all the products produced in a month, you can earn almost 400 thousand rubles.
To recoup the costs, to reach zero, in theory, it will take 7 months. But keep in mind that at first you won’t be able to sell everything. The real payback period for a business is 2 times longer - it is approximately 1.5 years.

For clarity, we will draw up the calculations in a table:

Fiberglass reinforcement is a "fresh" product for the Russian construction market. Business in this direction has excellent prospects. It will take less than 3 million rubles to organize a business - given that you are going to open a mini-factory, such costs seem trifling.

It might be useful to read: