The specialized PKF "Metinvest-Service" sells rolled metal products in an assortment. The company organizes the production of corrugated sheets to order. We organized the production of corrugated sheets in the Moscow region on an automated line (CNC), with control at every stage production process.In particular, rolling speed. This allows you to optimize all parameters technological process.
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Our technical capabilities allow us to organize the production of corrugated sheets with the characteristics required by the customer. The production line includes:
A special device that allows you to secure and unwind rolled products;
. Roll forming mill;
. Guillotine type cutting mechanism;
. Receiving node.
If necessary, it is possible to connect additional equipment(stamp, packaging device finished products, perforation block).
Our customers have the opportunity to buy corrugated sheeting from the manufacturer with the required geometry:
According to the height of the completed profile (corrugations):
Profiled sheet from a manufacturer in the Moscow region At Metinvest-Service you can select according to the type of protective coating:
Using profiled sheet from the manufacturer, the buyer has the opportunity to qualitatively cover the roof of any configuration in a short time.
The ability to quickly re-adjust the production line allows, within the agreed time frame, to fulfill any order for production of profiled sheets. For ease of selection, products are labeled according to standard 27772-88 (as amended on 06/01/89):
If it is needed buy profiled sheet from the manufacturer, the quality of which is guaranteed to comply with the provisions of current standards, contact Metinvest-Service. All products are manufactured in accordance with the provisions of current regulations:
In cases where paintwork materials are not applied to the finished product, no additional markings are affixed. And when they are applied, in accordance with the standard 30246-2016 (GOST), the designation of the paintwork materials used is affixed.
Corrugated sheet production
Profiled sheet refers to a building material that is used for roofing, wall cladding, fence cladding, and also as floors. Galvanized sheet steel is used for production; the cold rolling method through a rolling machine is used to form the corrugation (profile). The shape of the profile depends on the type of production line and the area of application of the corrugated sheet; the catalog presents the following profile types: trapezoidal and wavy.
Production technology
The production technology consists of two procedures: first of all, the workpiece is passed through rollers, after which the resulting sheet is cut according to the required geometric dimensions. The rigidity of the corrugated sheet depends on the thickness of the galvanized sheet and the height of the profile. The main operational parameters include: the thickness of the metal and zinc layer, the type and thickness of the polymer coating layer used. All products comply with GOST 24045-94.
Type of coating used
In the production of profiled sheets, galvanized steel is used with an additional protective coating applied to it. polymer coating(color is selected according to the RAL table). The main objective of this coating is to increase the protection of the sheet from corrosion, giving it aesthetically pleasing due to the wide color palette.
The main types of polymer coatings used:
Marking
Depending on the area of application, all corrugated sheets are marked as follows: the letter designation indicates the type of sheet (H - load-bearing, C - wall, HC - universal, PC - roofing corrugated sheet), the digital index indicates the profile height (varies in the range from 8 to 350 mm).
Advantages and disadvantages
Among the main advantages of corrugated sheets, the following should be highlighted:
Disadvantages include:
In this article:
Corrugated sheeting – universal material, indispensable in many areas of construction. Despite the fact that the production of profiled sheets has long been nothing new to domestic manufacturers, the popularity and demand for this building material increases every year in proportion to the increase in construction volumes.
The production of corrugated sheets is a promising and highly profitable business. But competition in this area is also high, since profiled sheets are produced both by metal rolling plants on an industrial scale and by individual entrepreneurs.
Therefore, before opening the production of corrugated sheets, you should evaluate the prospects of the region according to the following parameters:
An LLC is recommended as an organizational form for a business producing corrugated sheets. common system taxation.
OKVED codes:
Corrugated sheeting is not subject to mandatory certification, but when manufacturing it, it is recommended to adhere to the standards of GOST 24045-94.
Sales of corrugated sheets are planned in the following areas:
Corrugated sheets are made from rolled products of the first and highest categories:
Metal for the production of corrugated sheets in the form of rolled blanks (for automated lines) and finished metal sheets (for manual profiling) are offered domestic producers, China, South Korea, European factories (Slovakia, Germany, England, Ukraine).
To open production, it is planned to rent a workshop with an area of 300 m2, divided into a production area (150 m2), a raw material storage area (50 m2) and a finished product warehouse (100 m2). It is advisable that there be several gates into the room (for receiving raw materials and unloading finished products).
The production workshop must be equipped in accordance with the following requirements:
Capital investments:
Total: 1,700,000 rub.
At the initial stage it is planned to hire 4 people:
8-hour single-shift work is planned (24 shifts per month).
1) The material for the production of corrugated sheets (roll of galvanized steel with or without coating) is installed on the unwinding device. One end of the metal coil is fixed on the filling stand of the rolling mill and is fed at a given speed in the form of a continuous belt.
2) The line is programmed to produce corrugated sheets according to the required parameters (only the width remains unchanged), any length (usually does not exceed 12-13 m, since it is limited by the dimensions of the transporter).
3) In addition to the filling station, the profiling mill has several working pairs of stands (shafts), each of which is equipped with sets of rolling rollers that provide the necessary geometry and height of the corrugation. The rolled metal strip, passing between the upper and lower shafts, takes on a programmed shape.
The advantage of automated manufacturing technology is that all corrugations are rolled simultaneously, which makes it possible to obtain high-quality material without defects.
4) A press with guillotine shears cuts the rolled sheet, which arrives at the receiving table.
5) At the receiving table, finished corrugated sheets are stacked in bundles and sent to the finished product warehouse.
Transportation and storage of profiled sheets, including climatic features of different regions, is standardized by GOST 15150.
Corrugated sheets must be packaged for transportation in bundles with a tie belt (polypropylene, metal), laid on a wooden lining and securely secured against movement. Gaskets are placed at the corners of the bundles at the points of contact between the corrugated sheet and the constriction to prevent damage to the coating.
Loading and unloading is carried out using soft slings to reduce the risk of mechanical damage.
During storage and transportation, packs are placed in one tier. A two-tier layer is permissible only in cases where the total mass of 1 m 2 of the profiles of the upper levels does not exceed 3000 kg/m 2. Storage in open areas is permitted.
Raw materials– galvanized steel, 0.45 mm thick.
Weight of 1 linear meter roll calculated by the formula: Thickness * width * specific gravity metal 0.45 mm * 1250 mm * 7.85 g = 4,415.63 g (4.42 kg)
Roll width standard– 1250 mm, but after profiling the width is reduced. So, for a profiled sheet with a corrugation height of 8 mm, the width of the sheet at the outlet will be 1,195 mm, with a constant weight of 1 linear meter at the inlet and outlet.
Weight of 1 m 2 corrugated sheeting grade S-8 calculated by the formula: 1 linear meter(kg) / width of 1 running meter of finished corrugated sheeting (m) 4.42 kg/1.195 m = 3.70 kg/m 2
In total, from 1 ton of rolled steel you will get 270 m2 of corrugated sheeting grade S-8 (1000 kg/3.7 kg/m2)
Cost of 1 m 2 of galvanized corrugated sheeting grade S-8= cost of 1 ton of raw materials/quantity of finished corrugated sheeting: 50,200 rubles/270 m 2 = 185.93 rubles
It is planned to produce 500 m2 of corrugated sheets in one shift; monthly output – 12,000 m2
With a wholesale selling price of corrugated sheeting of 240 rubles/m2, and 24 workers/shifts per month, the projected revenue will be: 500 m2 * 24 working days * 240 rubles/m2 = 2,880,000 rubles/month.
Profit: 2,880,000 – (185.93 * 12,000 m2) = 648,840 rubles/month.
Total: RUB 338,923
Net profit: 648,840 – 338,923 = 309,917 rubles/month.
With a production of 12,000 m 2 /month, capital investments of 1,700,000 rubles will pay off: 1,700,000 rubles/309,917 rubles/month = 6 months.
Corrugated sheeting has long acquired the status of a universal and reliable coating. The area of its use of this modern roofing material includes production facilities, warehouses, private buildings, various hangars and structures quick assembly. Modern technologies production allows us to obtain high-quality corrugated sheeting used for the manufacture of roofing and as a material for constructing facades.
In this article, we set the task of acquainting the reader with the main features of corrugated sheet production. As for installation techniques for this popular material, this is a topic for a separate review.
Corrugated sheets are made from thin steel sheets that have a special decorative or zinc coating. These sheets undergo a process called profiling. The result is corrugated metal sheets, which we are accustomed to calling corrugated sheets.
Profiled sheets are most often used:
Corrugated sheets can be made with a coating of polymer material, and also with different heights corrugations.
In enlarged form, the production cycle for the manufacture of this material is as follows:
To produce high-quality profiled sheets, it is necessary to have highly specialized technological equipment that is designed for the production of this type of product.
Important Note! High-quality corrugated sheets that match technical parameters requirements regulatory documentation can only be produced on equipment with the appropriate technical characteristics.
The use of handicraft and low-quality equipment entails a lot of various deviations from the established quality requirements, including discrepancies in the size and shape of the sheets.
Corrugated sheeting is a bent profile made from metal sheets, having corrugations in the shape of a trapezoid. To give sheets this shape, it is necessary to use a special technological equipment.
produced by cold profiling. As source material Durable steel is used.
At the request of the consumer, profiled sheets are produced with or without coating.
A profile without a coating is used for formwork equipment in construction. For external use, a coated material is required.
Corrugated sheeting is available in various thicknesses. Sheets made of high-quality steel have a zinc coating with a thickness of 20 - 26 microns.
If the coating thickness is reduced to 10 - 12 microns, then such a profile may be subject to premature wear.
Important information . To organize the production of corrugated sheets on our own it is necessary to have special equipment manufactured industrially. Production must be carried out from high-quality raw materials with a 1st grade coating.
When designing the production of profiles for corrugated sheets and the corrugated sheets themselves, the following requirements must be met:
When organizing the production of profiled sheets on your own, it is necessary to comply with the requirements for the placement of equipment.
Important! If all specified requirements are met and there is professional equipment It is possible to produce corrugated sheets in lengths from 1 to 12 m.
Equipment for the production of corrugated sheets with sheet lengths up to 25 m is also produced.
The production of corrugated sheets begins with the development of a drawing or design sketch and execution necessary calculations, the sheet thickness and the color of the protective coating are selected.
Then you can proceed directly to the production of floor, roofing or wall profiled sheets.
The main stages of the technological process for manufacturing profiled sheets:
The production of corrugated sheets can be carried out using hot or cold methods. More popular are machines for cold rolling without using heating of the original metal.
This process is called profiling because it results in flat sheet takes the form of a certain profile. The production lines carry out rolling and cutting of finished profiles.
To produce corrugated sheeting of various modifications depending on the application, equipment is needed various types. To obtain different corrugation heights, the profiling equipment must develop the appropriate force.
Depending on the level of mechanization, equipment for the production of corrugated sheets is:
Mobile equipment is convenient if it is necessary to organize the production of arched corrugated sheets in the field or directly at the construction site. This type of corrugated sheeting is used in the construction of structures with arches: granaries, hangars, etc.
Manual equipment can produce corrugated profiles in small sizes and in small quantities. All technological operations in this case are performed manually. Manual mechanisms are used by construction companies in small workshops engaged in metalworking in the manufacture of additional elements.
When we're talking about about automated equipment, we mean automatic or semi-automatic lines. They include full set equipment and mechanisms located in the flow, that is, the order in which technological operations are performed. Automated equipment allows you to obtain high-quality profiles when high level productivity.
Production line composition
In general, a corrugated sheet production line consists of the following equipment:
The manufacturing technology is as follows:
Depending on the configuration, the production equipment may include clamping fixtures for forming edges, roller conveyors, electromechanical scissors, touch control panel, special containers for waste collection.
The basis of the entire complex is the rolling mill, since it is it that is responsible for the production of profiles that meet the requirements of consumers.
Taking into account the constantly growing demand for corrugated sheets, we can confidently assume that with economic point from the point of view of investing funds in the production of this building material will have good prospects.
To produce materials High Quality, meeting modern requirements and in sufficient quantities, you will need to set up a production line that includes modern high-tech equipment.
https://www.youtube.com/watch?feature=player_embedded&v=z1rB27HG0sw
A profiled metal sheet is rolled steel, the surface of which, as a result of processing on special equipment, has acquired a wavy or corrugated shape.
The purpose of this operation is to increase the longitudinal stiffness and bearing capacity source material. This allows the use of cold-rolled steel of relatively small thickness for the manufacture of various building structures, including those subject to significant static and dynamic loads.
Machine for making corrugated sheets using simultaneous rolling technology
Modern corrugated sheets are made from steel with a thickness of 0.45 to 1.2 mm. Depending on the purpose, metal profiled sheets are divided into two main groups - load-bearing and wall. They differ in profile shape and metal thickness. The corrugated sheet has high performance characteristics at a relatively low cost, which makes its production quite attractive and profitable investment funds.
The production technology of corrugated sheets is quite simple. It is based on the method of cold rolling of thin sheet metal. Using special equipment, a roll of galvanized steel or polymer-coated steel is produced metallic profile with a given surface geometry.
There are two methods of metal profiling: simultaneous and sequential (or combined).
In the first case, the corrugated sheet manufacturing technology involves rolling all corrugated sheet corrugations simultaneously, starting from the first stand of the rolling mill. At the same time, production space is significantly saved, since the machine for simultaneous rolling is approximately 1.5 times smaller than the equipment for the sequential or combined method of producing profiled sheets. In addition, the first method of metal processing profiles the sheet more evenly, eliminating the possibility of defects at the edges of the original workpiece.
The corrugated sheet production line includes:
The coherence and continuity of operation of the equipment is ensured by an automated control system, which ensures that the technology for producing corrugated sheets is not disrupted. Such lines are designed for the production of corrugated sheets from galvanized steel in accordance with GOST 14918 and from thin sheet steel with a polymer coating in accordance with GOST 30246-94, GOST 9045, GOST 1050.
From a roll installed on the unwinder, thin sheet steel is fed into a forming machine, where the metal surface is profiled. Then the finished sheet of corrugated sheeting falls on hydraulic shears, which cut the product in accordance with the specified dimensions. The profile of the profiled sheet is curled from the shape of the rollers installed on the rolling mill.
Corrugated sheet production technology - standard production line layout
All stages of the production process are controlled by a control system, which allows you to set the rolling speed, as well as the length and number of corrugated sheets. After trimming, the finished sheets of corrugated sheets fall into the receiving device.
Thus, the production of corrugated sheet steel consists of the following steps:
The finished product is taken out of the receiving device, labeled and packaged for shipment to the consumer.
Below I will dwell in detail on the functions of each individual unit of the machine for the production of corrugated sheets.
This device is designed to feed rolled sheet steel into a forming machine. Like all mechanisms of the corrugated sheet production line, the unwinder is controlled by an automated control system. In addition, the unwinder has its own automation system, which, using a braking device, synchronizes the feed speed of the metal strip with the metal rolling speed.
It is installed after the unwinder and is used for cutting metal if it is necessary to replace, for example, a roll of galvanized steel with polymer-coated steel to complete another order.
This is the main element of any production line for the production of profiled sheets. It is this that is the key link in the corrugated sheet manufacturing technology and turns a smooth metal sheet into a corrugated profile. Surface profiling is carried out by rolling the metal through rollers special form, the choice of which depends on the required corrugation shape of the profiled sheet. The formation of corrugated sheet metal begins with the first stand, and the number of stands depends on the complexity of the corrugated shape of the profiled sheet.
By design, molding machines can be pneumatic or hydraulic. In a pneumatic rolling mill, a metal sheet is pressed into a die using a punch under the influence of compressed air. A pneumatic forming machine can produce profiled sheets up to 2.5 m long, with a bend angle of the profile corrugation up to 90° from metal, up to 1.5 mm thick.
Operating principle of hydraulic molding machine rolling mill is the same as that of the pneumatic one. But hydraulically driven rolling mills are more powerful and can produce profiled sheets of any length, which is limited only by the convenience of transporting the finished product to the consumer.
The program assigned to the control system of both pneumatic and hydraulic rolling mills allows you to automatically change punches and dies, selecting their configurations when viewing a graphical model of a profiled sheet, as well as set any operating rolling speed.
They are used for cutting the finished profiled sheet according to the specified dimensions automatic system management. Cutting is carried out with a knife, the shape of the blade exactly repeats the shape of the corrugation of the profiled sheet.
