- 1. SAVINGS:
Our price paving slabs low for the benefits that you will receive if you decide to buy it. Polymer sand tiles the price will be cheaper than good ceramic, which cracks, cheaper than rubber and WPC (wood-polymer composite) tiles, which do not have sufficient hardness, and not much more expensive than concrete (cement-sand) with all its disadvantages;
- 2. INCREASED PRODUCT DURABILITY:
The increased durability of Tetto polymer sand tiles is due to a whole range of special technological measures during its production and the UNIQUE COMPOSITION of the polymer composite. At the production stage of the product, specially selected and prepared modified polymers and components, special additives and minerals are introduced into its composition, which give the tile additional PROTECTION FROM THE ENTIRE SPECTRUM OF SOLAR RADIATION, additional frost resistance, resistance to aggressive environments and temperature changes, which in turn increases the durability of the product by an order of magnitude COMPARED TO COMPETITORS' PRODUCTS.
- 3. INCREASED IMPACT RESISTANCE OF THE PRODUCT:
The material itself has high strength, as a result of which it is characterized by a COMPLETE ABSENCE of breakage during loading and unloading operations, especially those performed manually, transportation, falling from a height, or processing with a cutting tool.
- 4. ADDITIONAL PROTECTION OF TILES FROM UV rays:
Tetto polymer sand tiles DO NOT LOSE COLOR when exposed to sun rays and does not require additional painting, like competitors' products. HIGH UV RESISTANCE is achieved thanks to a large percentage of sand in the composite, a selection of special coloring pigments, additives, minerals and modified polymers, which significantly SLOW DOWN THE AGING PROCESS of the tiles from the sun.
- 5. ADDITIONAL PROTECTION OF TILES FROM INFRARED RADIATION:
Most manufacturers of polymer sand tiles DO NOT APPLY additional protection of the composite from infrared radiation and at best are limited to UV protection. Our company introduces special components into the tiles that PROTECT PRODUCTS from the effects of this negative factor and INCREASES DURABILITY BY AN ORDER.
- 6. IMPROVED TILE FROST RESISTANCE:
The entire structure of the material is MICRO-REINFORCED, which gives the tiles additional frost resistance, and also increases the overall strength and durability of the product. Our tiles are perfectly adapted to DIFFERENT CLIMATIC CONDITIONS. Resistance to frost and temperature changes is provided by polymer sand composite reinforcement. Our company was the FIRST IN RUSSIA TO APPLY and is applying the technology of reinforcing polymer sand products.
- 7. INCREASED RESISTANCE TO AGGRESSIVE ENVIRONMENTS:
The unique composition of Tetto tiles provides excellent RESISTANCE TO ALL KNOWN NATURAL PHENOMENA such as acid rain, the activity of bacteria and lower plants, heat and frost, hail and hurricanes, and radiation from the ultraviolet and infrared parts of the solar spectrum. The low water absorption of the material adds durability and does not allow ice to “grow” to its surface and structure in winter, and ice easily breaks off from the surface when it is removed;
- 8. EASY INSTALLATION:
One of the main advantages of Tetto tiles is the CONVENIENCE of WORKING with them; they are easy to process cutting tools without cracking and DOES NOT break during work. Installation of polymer sand tiles is SO SIMPLE that, if desired, it can be carried out even by a non-specialist. The material of the tile is viscous, which allows you to screw anything to it with a self-tapping screw.
- 9. LOW WEIGHT:
The low weight of the products in comparison with other types of coatings allows you to take away at once MORE tiles and SAVE significantly on freight transportation. And on exploited roofs, the weight of the tiles is of no small importance
- 10. AESTHETICS:
We offer a WIDE color scheme tiles Polymer sand tiles look very AESTHETIC and will give a head start to many floor coverings in beauty, variety of textures, shapes, colors.
- 11. ECO-FRIENDLY:
The water we drink from plastic bottles, and which is supplied to the tap by plastic pipes absolutely normal and harmless. Thus, the harmlessness and environmental friendliness of polymer sand tiles has been confirmed by MANY YEARS OF USE OF PLASTIC PRODUCTS IN HOUSEHOLD. The material is environmentally friendly and does not emit cement dust that is formed during operation. concrete slabs, does not emit carcinogenic substances, unlike asphalt in the heat.
- 12. UNIFORMITY:
All elements of Tetto polymer sand tiles are HOMOGENEOUS IN COMPOSITION and thus such a factor as a different expansion coefficient is excluded, the coating FUNCTIONS AS A SINGLE STRUCTURE.
- 13. LOW THERMAL CONDUCTIVITY AND RISK OF INJURY:
It has LOW THERMAL CONDUCTIVITY and high heat capacity, which gives it THERMAL INSULATING PROPERTIES, which is important, for example, for stables, cowsheds, and enclosures. When used as a covering for children's playgrounds, INJURIES AND ILLNESS ARE REDUCED, since the tiles are warm and have plasticity.
- 14. COLOR SAMPLE:
Sand-polymer tiles Tetto are presented in a WIDE RANGE OF COLORS, which will certainly add sophistication to any architectural solution. The color palette that you prefer to see will not be lost over time, since the material is colored throughout the entire thickness of the product.
On this moment sand-polymer paving slabs are almost the most popular product on the construction market. Produced with high quality and laid evenly, it makes the street very attractive compared to ordinary, even very evenly laid asphalt or previously traditional concrete. Therefore, many businessmen and owners of private houses prefer this material.
The demand for services related to paving slabs is becoming increasingly higher, even despite the considerable cost of this material. If you are interested in production polymer-sand tiles, then you should prepare for a collision with a fairly large number of competitors, but at the same time such a business can still be considered very promising.
Properties of polymer-sand tiles
- Impact resistance external factors. This type of material copes excellently with various atmospheric precipitations. It is not typical for tiles to open up into small abrasive parts; in addition, they have a high degree of resistance to various mechanical damage.
- Durability. The manufacturer's warranty is currently 30 years.
- Decorative. Tiles can have any shape, surface type and color.
- Multiple uses.
- Polymer-sand tiles can be used anywhere, due to which the demand for these products is constantly increasing.
Business registration
To get started polymer production, it will be enough to get registration individual entrepreneur. Paving slabs belong to a category of products that are not subject to special certification, and this greatly simplifies the entire process of registering a business.
However, if you want to have a document indicating the proper quality of your products, you can order a study from a certification service, where polymer sand tiles will be tested for abrasion, strength, frost resistance and other properties. After this, you will be issued a product quality certificate indicating the main characteristics.
Main job
This type of manufacturing of paving slabs involves the use of advanced technologies that involve the processing of secondary raw materials, that is, polymer products should be obtained. This process indicates a change not only in the thinking, but also in the attitude towards making a profit for producers.
Thanks to the ongoing global changes, we can talk about the transformation of the resource-based economy into a modern high-tech form, which allows rational use of available resources and does not lead to pollution environment. Naturally, such production requires considerable financial investments, however, they will quickly return once they start working.
The essence of the process
The production of polymer products requires the presence of ordinary sand, dyes, as well as appropriate used material. The ratio of components for the manufacture of paving slabs should be as follows: 94% sand, 1% dyes and 5% polymer waste. The latter can be purchased quite cheaply at recycling points or at any landfill. This waste does not have to be cleaned of food and paper residues, since in the end it will all burn, which will not affect the quality in any way finished products.
You can use absolutely any polymer materials. Please note that old plastic film and used bags are soft polymers, while polystyrene, polypropylene and plastic bottles These are hard polymers. It is better to take the ratio of these two types in the final mixture in half. In Russia, the cost of a ton of such waste is within 3,000 rubles.
Polymer technology involves the use of sand, the humidity of which should not exceed 10%, and the impurity content should not exceed 20%. The price of sand is approximately 300-350 rubles per ton. The use of dye is not necessary, but without it the products will have an unattractive color. Equipment for polymer-sand tiles consists of an extruder, a molding press and a melting and heating unit. The area of the room required for the installation of all equipment, as well as for ventilation, must be at least 150 square meters.
Processes of processing and manufacturing of products
The extruder heats polymer materials, after which they are mixed and crushed into homogeneous particles small sizes. Next this prepared polymer material mixed with sand and dye, after which the mass enters the melting and heating unit.
There, the polymers can be melted, and the rotating blades mix all the listed components efficiently and evenly. The resulting mass resembles a tight dough and is homogeneous. It is placed in a molding press, in special forms, which are then slowly cooled. To add shine to products top part in the mold they cool much more slowly than in the lower mold.
Equipment
The production of paving slabs can be carried out in one of two ways - vibration casting or vibration pressing. Both options require the use of specialized equipment. For production using the vibration casting method, you will need a vibrating table, the cost of which is approximately $4,000, you also need molds costing $1-18 apiece, as well as a concrete mixer costing about $800. The vibratory compaction method will require you to have other equipment: a vibrating press, which costs about $20,000, a concrete mixer costing $5,000-6,000, and a punch – $3,000.
Manufacturing process
Since polymer production can be carried out in one of two ways, it is necessary to describe the technology for each of them. The vibration pressing method, in addition to being used for making tiles, is often used to create borders, wall and partition stones, and other things. This method includes the following steps.
- Concrete preparation. A concrete mixer is used to prepare it. In the case of the production of a single-layer product, one device is required, for a two-layer product - two. Once the mixture is formed, it must be placed in the matrix of a brick making machine.
- Molding. After loading the molding sand into the matrix, the work of the punch and vibrators begins. The material is compacted due to vibration pulses. This operation takes 305 seconds. Next, the matrix and punch are raised, and the products remain on a special pallet. It is sent for drying, and the production of another batch of tiles is carried out on the next pallet.
- Drying. To obtain the finished tile, it is necessary to dry it using a heat-moisture method. For these purposes, water vapor is used. To reduce production costs, sand-polymer tiles can undergo a drying stage in a production facility without the use of heat and moisture treatment. When the concrete strength is 1.5-2 MPa, you can remove the tiles from the pallets. It usually takes 5-8 hours to achieve this strength.
The second production method is the vibration casting method. It's a little different from the first one. Sand-polymer tiles are made using this method as follows:
- First, the concrete mixture is prepared;
- then the latter is placed in special forms located on the vibrating table;
- then the forms are placed on pallets;
- It is necessary to keep the molds with the mixture in natural conditions for 48 hours;
- products are knocked out of molds on a vibrating table.
For the last stage, the products are heated at temperatures up to 60-70 degrees Celsius for about two minutes, after which they should be knocked out on a vibrating table.
Choosing premises for organizing production
Polymer production can be located in any room, that is, there are no specific requirements for it. The main thing is a sufficient area for arranging equipment, from 70 square meters or more. It is important that an electrical voltage of 360 volts is available in the room. You should look for a place for drying chamber, where the temperature should be approximately 35-45 degrees.
Staff
When organizing a workshop whose productivity does not exceed 50 square meters of tiles per day, three workers will be enough. They control all polymer production. Their responsibilities include preparing concrete, filling molds, controlling pressing, and drying products.
Business profitability
If we talk about the profitability of the production of polymer-sand tiles, then experts call 100-135%. It turns out that this is very profitable business. Of course, the production process cannot do without a certain percentage of defective products, but they can also be used wisely, for example, in the construction process.
Sales
When polymer production is fully established, you can begin selling finished products. To attract maximum number It is necessary to provide customers with a wide choice of types of products, so it is advisable to make tiles of different shapes, sizes and colors. Not worth it initial stage strive to receive large orders. It is better to start the journey by establishing connections with individuals and small business owners who intend to purchase tiles to decorate their territories.
Advantages and disadvantages of such a business
The overall picture seems very profitable. Anyone can start polymer production. A relatively simple process of manufacturing products, quick payback, high profitability - all these can be called the advantages of such a business. However, there are also disadvantages. First of all, we can talk about the seasonality of orders. In addition, it is difficult to call this activity interesting, since the production process is quite monotonous and boring.
The final stage
After you have drawn up a business plan, you can begin to open the production process itself, where polymer sand tiles will be created. First, you will need to register with the administration, where you will write a statement indicating your desire to become an entrepreneur and open own production paving slabs.
After submitting the application and registering it, within two to three days you should be issued an appropriate certificate, which will automatically make you an entrepreneur. Next, you are required to register with the tax service within three days after receiving the certificate. There you will have to choose the form and code of activity, as well as the type of business.
Now you can choose a room or prepare the one you have already chosen. It all depends on the planned production volumes. The premises must have concrete floors, lighting and running water. It is advisable to have a shed near the building, since you will store materials on the premises.
All owners of private houses strive to improve their yard. They choose quality material for laying paths so that it lasts for many years. The most suitable coating for paving personal plot is a polymer sand paving slab. This new building material is of high quality and comes in a variety of colors.
Material composition
The polymer sand composition includes the following components:
- crushed polymers (polystyrene, polypropylene, polyethylene high pressure), which are a binder and make up 25% of the total volume;
- sand;
- dyeable pigments.
Tile production
When making tiles, first of all, the components are prepared, which must be of high quality. The most stringent requirements apply to sand. It must be sifted, washed, calcined and have a medium grain size. Then the components are thoroughly mixed by vibration. Next, the finished solution is loaded into the extruder, heated to a temperature above 250 ° C, and then formed and pressed under pressure in special forms. This technology makes it possible to obtain products of strict geometric shapes with a clearly defined pattern and the absence of voids.
Strength, density, uniformity, aesthetics - these are the qualities that distinguish polymer sand paving slabs. The equipment used to produce this high-tech building material, is a modern automated line that provides it with high performance.
Technical characteristics and physical and chemical properties
Polymer sand production, which is carried out using the vibrocompression method, has excellent physicochemical characteristics. The main ones:
- compressive strength 50.2 MPa;
- density 2.05 g/cm;
- % abrasion - 0.06;
- hardness (HRB) - 68-82;
- frost resistance - 300 cycles;
- % water absorption - 0.52.
Polymer sand is produced in 25, 35 and 40 mm. Its dimensions are 330x330 mm, 1 m2 - 9 pieces.
Advantages
Thanks to its polymer sand, it has much superior characteristics to its cement-sand counterparts.
- Strength. Binders give the material plasticity. Unlike concrete tiles, they do not chip or crack, so their costs during storage, transportation and operation are minimal.
- Durability. This material is impact-resistant, resistant to temperature changes, and has high abrasive resistance. The operational life of the coating is more than 50 years.
- Environmental friendliness. When heated, polymer sand paving slabs do not emit or form concrete dust that is dangerous to others.
- Convenience. Tiles are laid with 3-5 mm gaps, thanks to which water falling on the surface seeps into the ground without any obstacles, without forming puddles. The coating is easy to clean, does not absorb moisture and has anti-slip properties.
- Easy to install. The tiles are easy to process, which allows you to implement a variety of design ideas. You can lay it manually or using specialized machines. Installation of tiles is simple and quick.
- Low cost. Polymer sand paving slabs (their price per 1 m2 is 450 rubles and more) meets all consumer requirements.
How to choose high-quality polymer paving slabs
When purchasing material, you should pay attention to the quality of painting and color uniformity. The coloring pigment determines how long the aesthetic appeal of the coating will last. Extraneous inclusions and stains on the tiles are the result of using low-quality dye or a violation of production technology. This significantly deteriorates the quality of the material, reduces its strength and durability. The highest quality dyes are made in Germany.
Tile laying technology
Polymer sand paving slabs are laid on a sand base, concrete screed using a solution or a cement-sand dry mixture. Most often, the installation of the covering under the paths is carried out on a layer of sand, which requires compliance with the laying technology:
- In the place provided for laying the covering, 15-25 cm of soil is removed.
- The surface is leveled taking into account the slope and compacted.
- To do this, grooves are made, their bottom is compacted, covered with a 5 cm layer of sand. The sand is well watered and compacted.
- A string is pulled over the driven wooden pegs to mark the line of borders.
- The bottom of the grooves is filled with cement and curbs are laid.
- Geotextiles are laid on the surface for laying tiles, sand is poured, each layer is watered, leveled and compacted.
- The tiles are laid with a gap of at least 3 cm and using rubber mallet the horizontal line is aligned.
- To the surface laid tiles sand is poured out to fill the seams.
Using this simple technology, polymer-sand paving slabs can be laid. The price of its masonry is from 420 rubles per 1 m 2 of material.
Polymer sand paving slabs are superior in their characteristics to conventional cement paving slabs. Polymer sand tiles are durable, frost-resistant, have a wide range of colors, can be of any shape and size, with a variety of patterns. The method for producing polymer sand tiles is simple and consists of several stages: preparing the mixture components, mixing the initial components, melting the mixture, molding and pressing the products, the hardening process, storing the finished product.
Polymer sand tile production technology
To produce polymer sand tiles, three components are required: polymers (primary or secondary), sand of a uniform fine fraction without clay inclusions, and heat-resistant pigment. HDPE polymers (polyethylene) are suitable for the production of tiles. low pressure), LDPE (high-density polyethylene), crushed film. The use of recycled polymers will help save on the purchase of raw materials and solve the problem of waste disposal. Secondary polymers are obtained by crushing and granulating industrial waste and products made of polymers (pipes, containers, packaging materials, films, etc.). At the first stage, the polymers are crushed or ready-made polymer crumbs are purchased.
The second stage of production of polymer sand tiles includes mixing the components in the proportion of 69% sand, 30% polymer and 1% pigment in a mixing plant. Pigments can be used both mineral and organic. The color of the future tile will depend on the choice of pigment. At the third stage of production, the thoroughly mixed dry mixture is placed in a melting unit (APN). The resulting homogeneous mass, ready for molding, is loaded into molds. During the solidification process, a homogeneous monolithic, high-strength solid structure is obtained. From the mold, the tiles are laid out on a flat surface, where they should lie until they cool completely and harden. Ready material placed on pallets and sent for storage.
Equipment for the production of polymer sand tiles
We offer a set of equipment for the production of polymer-sand paving slabs:
- Shredder RRM-1 for crushing recycled plastic or its modification
- Agglomerator AGL-01 for plastic processing
- Mixing installation - 2 pieces
- Extruder (APN)
- Press
- Press form
- General purpose scales
Equipment for the production of polymer sand tiles allows you to create a finished product of any shape and color, with or without a pattern. To crush polymers, you can purchase a crusher. To organize a business for the production of polymer-sand paving slabs, a heated room is required.
Advantages of equipment for the production of polymer sand tiles:
- Economical. Possibility of using industrial waste as raw material, low energy consumption.
- Profitability. The products are in demand on the market, production costs are recouped in a short time.
- Reliability, warranty and warranty service of equipment
- Affordable prices.
When ordering equipment for the production of polymer-sand tiles, our company, at the customer’s request, will deliver the equipment, carry out commissioning of equipment, train specialists, carry out further service and equipment repair.
When the need arises to somehow cultivate the area around your home, the natural desire is for the materials purchased for laying paths and platforms to last a long time and be attractive. It is for these purposes that polymer sand paving slabs are produced.
General concepts about polymer sand tiles
Polymer tiles used for arranging paths look like a flat product with different shapes and sizes. Its purpose is to create a flat and durable surface for the movement of people and machines. The product can withstand heavy loads and does not crack. The tile consists of:
How to prepare raw materials?
According to technical standards, the humidity of sand should not exceed 10%, and its structure should be free of foreign inclusions. To do this, it is sifted and dried.
Polymers use primary ones in the form of granules and secondary ones, which are more attractive from an economic point of view. Using polyethylene waste as a raw material, it is crushed literally to dust, which facilitates uniform mixing of the components. Plastic waste is carefully sorted, washed and dried.
Iron oxide pigment added to the tile mass gives it an orange or red-brown color, chromium oxide gives it a green color, and titanium dioxide gives it a white color.
Positive traits
Composite tiles differ from cement-based tiles in their higher elasticity and strength. It is almost impossible to split it, you can lay it on uneven substrate. There are other advantages:
Tile manufacturing technology
Production process polymer tiles simple, consists of:
Mechanisms used and required premises
To organize the production of tiles, you need a certain list of equipment:
- dispensers;
- shredders RRM-1 for grinding secondary waste;
- agglomerators AGL-01 for grinding plastic;
- mixing plants;
- heating and melting unit;
- press and molds.
The use of specialized equipment makes it possible to produce products of any shape and color with or without a pattern. Purchasing a crusher will make it easier to crush plastic.
Usage technical means has a number of advantages:
- saving. Possibility of using inexpensive material in the form of waste;
- due to high profitability, quick payback of products;
- reliable operation of the equipment.
To organize a business producing polymer-sand paving slabs, you need to own or rent heated industrial premises. The workshop where the equipment will be located has a minimum area of 70 m2. Warehouse for storing raw materials and materials 35 m 2, warehouse for finished products 100-200 m2, can be installed in an open area.
Business profitability
Most of the profit will come from wholesale but, despite this, we should not forget about retail trade. For these purposes, a small store is installed near the main production, where summer residents can purchase manufactured products.
As can be seen from practice, the payback of such production is quite fast. To put into operation a small workshop for the production of tiles, you need to invest about 1 ml rubles in it. Investments consist of the following amounts:
- registration of title documents;
- purchasing or renting necessary equipment;
- purchase or lease of production space;
- arrangement of premises with engineering and technical communications;
- procurement of raw materials;
To calculate the profitability of a tile production enterprise, we take as an example a small workshop with a productivity of 60 m2 per 8 hours of work. The workshop will produce about 1200 m2 of tiles per month. The average cost of a product on the market is up to 500 rubles per m 2. If all manufactured products are sold, the revenue will be 600,000 rubles. To calculate net income, total revenue is reduced by current costs:
- wages and taxes;
- rent;
- payments for electricity and water;
- depreciation of equipment.
After deducting current costs, net revenue will be 60,000 rubles per month.