Polymer-sand paving slabs are superior in their characteristics to ordinary 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 production method of polymer sand tiles is simple and consists of several stages: preparation of the mixture components, mixing of the initial components, mixture melting, product molding and pressing, hardening process, storage finished products.

Technology for the production of polymer sand tiles

For the production of polymer sand tiles, three components are required: polymers (primary or secondary), sand of a homogeneous fine fraction without clay inclusions, heat-resistant pigment. For the production of tiles, polymers HDPE (low pressure polyethylene), PVD (high pressure polyethylene), crushed film are suitable. 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 as a result of crushing and granulating industrial waste and polymer products (pipes, containers, packaging materials, films, etc.). At the first stage, polymers are crushed or ready-made polymer chips are bought.

The second stage of the 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. In the process of solidification, 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 completely cooled and hardened. The finished material is stacked 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:

1. Shredder PPM-1 for shredding recycled plastic or its modification
2. Agglomerator AGL-01 for plastic processing
3. Mixing plant - 2 pieces
4. Extruder (APN)
5. Press
6. Press form
7. General 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. For grinding 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:

• Profitability. The possibility of using industrial waste as a raw material, low energy consumption.
• Profitability. Products are in demand in the market, production costs pay off 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 request of the customer, will deliver the equipment, start up and adjust the equipment, train specialists, carry out further maintenance and repair of the equipment.

Modern materials, characterized by good quality indicators, quickly gain the trust of consumers. This can also be safely attributed to polymer tiles, which are actively used in the construction industry for the construction and repair of structures.
This business is good because the production of products does not require huge costs, and all investments pay off pretty quickly. So why not start your own workshop? Let's talk about how to open your own production of polymer tiles from scratch with minimal investment.

Technical equipment of the workshop

The manufacturing technology of polymer sand products is not particularly complex. As a rule, all operations are carried out on special machines. The main raw materials here are sand, polymer waste and dyes. The cost of all the necessary components, if purchased directly from the manufacturer, is minimal.
The first thing you need to do to organize a workshop is to buy equipment for the production of polymer tiles. Buying a ready-made line will be more profitable than buying each device separately.
The standard line includes the following set of machines:

• Radial crusher. It is used for grinding polymer raw materials to a homogeneous fraction. It is better if the crusher is universal, so that it is possible to process not only solid waste, but also film waste.

• extruder. In this unit, all prepared raw materials are mixed and heated to a certain temperature. The output is a homogeneous mass of thick consistency. Extruders differ in their performance. For a small workshop, a capacity of 100 m 2 of finished products per day will be sufficient.

• Forming press. Further, the production of polymer-sand paving slabs is reduced to laying the molten mass in special forms and processing it under excessive pressure. The finished product is cooled and transported to the warehouse.

• Press forms. It is in them that the mixture is poured. The molds themselves are made of high quality alloy steel. It has a special cooling system. The configuration of these forms will depend on the type of products you plan to produce. If production is limited to tiles, then you won't need a wide variety of molds.

The average price of equipment for the production of polymer tiles varies in a wide range, depending on the capacity of the line. To produce high-quality products, you will have to spend at least 1,200,000 rubles. 3 people per shift will be able to serve the line of low productivity.
To accommodate the machines, you will need a room of 100 m 2. Considering that you will be working with polymers, there must be good ventilation and treatment facilities. Do not forget about compliance with fire safety standards.

The financial side of the issue

The production of polymer-sand tiles will eventually begin to bring a consistently high income. The main thing is to properly establish distribution channels.
Your potential clients:

• industrial enterprises,
• base building stores,
• building stores,
• private buyers.

But when will all the investments pay off?

Assume that the plant will produce 100 m 2 of finished material per day.
Let's present the profitability calculations in the table:

We have proven that the production of polymer paving slabs is profitable business with relatively fast payback. With the establishment of distribution channels, you will be able to ship all products to customers and receive consistently high profits.

A good alternative to traditional concrete pavers is polymer sand tiles. Due to its high performance, the product easily copes with the tasks assigned to it. Finished elements are distinguished by low weight, high strength and wear resistance, a large selection of colors and shapes. In this regard, many entrepreneurs decide to build their business on the manufacture of this paving. The article will describe polymer sand tiles and its production. We will also describe the manufacture of polymer tiles at home.

Characteristics and advantages of polymer tiles

Polymer sand paving products have the following composition:

• the main volume (3/4) is occupied by quartz sand;
• a quarter of the composition is high-pressure plastic;
• pigments.

Thanks to this composition, the polymer raw material is resistant to external influences and at the same time plastic, which facilitates the molding of the future product. The advantages of this material include the following:

1. Such pavement tiles will last up to thirty years.
2. A special production technology makes it possible to produce a product that is resistant to temperature changes and its limits(withstands up to minus 70°С). Plastic in the composition of the tile increases the moisture resistance of the product. Thanks to the sand components, the pavement is resistant to aggressive liquids and oils. The tile can withstand significant loads.
3. In the manufacturing process, the product is given the desired color and shape, which guarantees a wide range of products. There is also a choice of surface options (matte, structured, glossy).
4. PVC waste recycling ( plastic bottles, boxes, packages) solves the problem of their disposal.
5. Light weight, strength and low abrasion.
6. Under sunlight, the product does not emit toxic fumes.
7. Maintainability and easy installation.
8. The coating does not accumulate dirt and is easy to clean.
9. Possibility of making at home.
10. Extensive scope of use (as pavement coatings and areas in private households and in public places).

Material used

The production of polymer tiles requires the following raw materials:

• used as a binder crushed polymers, they occupy a quarter of the volume (usually polystyrene, polypropylene and LDPE are used);
• sand acts as the main filler (it accounts for 75% of the total volume), well-sifted medium-sized sand is chosen (it must be washed and heated to high temperatures;
• inorganic pigments(iron oxide is used to produce red, orange or brown tiles, chromium oxide is used to produce green coatings, titanium dioxide produces white tiles).

In order to reduce the cost of purchasing raw materials, it is practiced to manufacture tiles from plastic bottles and other PVC products, for example, boxes or even films (but in the latter case, no more than half the volume of all polymers). Because the polymer is neutral chemical composition, nitric acid acts as a solvent. To obtain a homogeneous mixture, the plastic is melted at a temperature of 180°C and high pressure. The melting process is called extrusion.

Necessary equipment

The manufacture of paving slabs from plastic bottles is impossible without the use of special equipment:

• plastic crushing machine;
• scales;
• melting apparatus;
• Press forms;
• press;
• extruder;
• listing equipment for the production of polymer sand tiles, it is worth mentioning devices for cooling products;
• forklifts are needed to move finished products.

For the production of plastic tiles at home, a molding press, a melter and an extruder are enough. If production is established on an industrial scale, then a molding unit, a thermal screw-mixing machine and a polymer crusher cannot be dispensed with.

Important! In the manufacture of tiles for their own needs, a drill with a mixing nozzle is used to mix the components.

Also, for the production of tiles from plastic bottles, you will need molds for pouring the mixture. They are bought online. There are molds made of plastic, rubber and fiberglass. Rubber molds are the most durable (withstand up to 500 cycles), but also expensive. Fiberglass products are suitable for large tiles, but require additional lubrication. The most commonly used molds are made of ABS plastic.

Advice! Don't forget to buy curb stone molds.

Technology for making tiles at home

The production of polymer-sand tiles is carried out in several ways:

1. Method of hot pressing of a polymer mixture.
2. Vibrocasting with the use of plasticizers.

Vibrocasting allows to obtain products with low porosity. The hot pressing method produces tiles with excellent technical and operational characteristics. At the factory, for the production of polymer sand coating, the technology of vibrocasting and hot pressing is used simultaneously.

Tiles for own needs are produced directly on the street or in well-ventilated areas.

The manufacturing sequence is as follows:

1. Plastic bottles are placed in an extruder for grinding raw materials. Instead of bottles, old plastic boxes are sometimes used.
2. The heated mixture is then poured into a melter. Moistened sand and dyes are also added there. As a result of mixing and simultaneous heating, a mixture of a viscous consistency is obtained.
3. This composition is poured into molds and pressed on special equipment.
4. Finished products are cooled.

Coating technology

Do-it-yourself polymer sand tiles are quite easy to install. Laying is carried out on one of two types of base:

• rubble;
• sandy.

When laying on a sandy base, work is carried out in the following sequence:

1. In the place where the tiles are supposed to be laid, the soil is removed to a height of 150-200 mm.
2. The soil is leveled and a surface slope is created for the drainage of sedimentary water. The surface is rammed.
3. On the sides of the path or platform, ditches are made for laying curbstones. The bottom of the ditches is compacted.
4. Then, sand is poured into the prepared ditches for the curb to a height of 50 mm. The sand is moistened with water and rammed.
5. Strictly along the line of the curb, pegs are driven into the ground and the cord is pulled.
6. The bottom of the grooves is filled with cement mortar and curbs are installed.
7. Strips of geotextile with an overlap of up to 20 cm are laid on the compacted base of the tracks. The edges of the strips are connected with adhesive tape.
8. Next, sand is poured in several layers, followed by wetting with water. Also, do not forget about tamping each layer.
9. A reinforcing mesh with a mesh size of 5 by 5 cm is laid on the sand. A dry mixture of sand and cement is backfilled over the mesh (observe the proportion of 3 to 1). The backfill is slightly wetted with water.
10. Now start laying the tiles. The elements are laid out on the sand at a distance of 3-5 millimeters from each other. Use a rubber mallet for leveling.
11. Seams between paving elements are filled with sand.

If desired, you can compare with

At the moment, sand-polymer paving slabs are almost the most popular product on the market. construction market. Well-made and evenly laid, 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 associated with paving slabs is becoming higher, even despite the considerable cost of this material. If you are interested in the production of 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

1. impact resistance external factors. This type of material perfectly copes with various atmospheric precipitation. The tile is not characterized by opening into small abrasive parts, in addition, a high degree of resistance to various mechanical damage.
2. Durability. The manufacturer's warranty is currently 30 years.
3. Decorative. Tiles can have any shape, surface type and color.
4. Multiple use.
5. Polymer-sand tiles can be used anywhere, so the demand for these products is constantly increasing.

Business registration

In order to start 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 facilitates the entire process of registering a business.

However, if you have a desire to have a document indicating the proper quality of your products, you can order a study at the certification service, where polymer sand tiles will be tested for abrasion, strength, frost resistance and other properties. After that, you will be issued a product quality certificate indicating the main characteristics.

Main job

This type of production 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 speaks of a change not only in thinking, but also in the attitude towards making a profit of producers.

Thanks to the ongoing global changes, we can talk about the transformation of the resource-based economy into a modern high-tech form that allows the rational use of available resources and does not lead to environmental pollution. Naturally, such production requires considerable financial investments, however, they will quickly return after the start of work.

The essence of the process

The production of products from polymers assumes the presence of ordinary sand, dyes, as well as the corresponding 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 centers or at any landfill. These wastes do not have to be cleaned of food and paper residues, since in the end it will all burn out, which will not affect the quality of the finished product.

You can use absolutely any polymeric materials. Keep in mind that old polyethylene film and used bags are soft polymers, while polystyrene, polypropylene and polyethylene bottles are hard polymers. The ratio of these two species in the final mixture is best taken in half. On the territory of Russia, the cost of a ton of such waste is within 3,000 rubles.

Polymer technology involves the use of sand, the moisture content of which should not exceed 10%, and the content of impurities should not exceed 20%. The price of sand is approximately 300-350 rubles per ton. The use of a dye is not necessary, however, without it, the products will have an unattractive color. The 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 production of products

The extruder heats up polymer materials, after which they are mixed and crushed into homogeneous particles of small sizes. Further, this prepared polymeric material is 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 qualitatively and evenly mix all the listed components. The resulting mass is similar to a tight dough and is homogeneous. It is placed in a molding press, in special molds, which are then slowly cooled. To give products a shine, the top of the mold is cooled much more slowly than the bottom.

Equipment

The production of paving slabs can be carried out in one of two ways - vibrocasting or vibrocompression. Both options involve the use of specialized equipment. Vibratory casting requires a vibrating table, which costs about $4,000, molds for $1-18 each, and a concrete mixer, which costs about $800. The vibrocompression method will require you to have other equipment: a vibropress, which costs about $ 20,000, a concrete mixer that costs $ 5,000-6,000, 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 vibrocompression method, in addition to being used for the manufacture of tiles, is often used to create borders, wall and partition stones, and other things. This method includes the following steps.

• Concrete preparation. For its preparation, a concrete mixer is used. In the case of the production of a single-layer product, one device is required, for a two-layer product, two. After the mixture is formed, it must be placed in the vibropress matrix.

• Molding. After loading the molding sand into the matrix, the work of the punch and vibrators begins. The material is compacted due to the action of vibration impulses. This operation takes 305 seconds. Further, the matrix and punch rise, 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. For getting finished tiles you need to dry it with a warm-moisture method. For these purposes, water vapor is used. To reduce production costs, sand-polymer tiles can be dried in the production room without the use of heat and moisture treatment. When the strength of the concrete is 1.5-2 MPa, you can remove the tiles from the pallets. It usually takes 5-8 hours to achieve such strength.

The second production method is the vibrocasting method. It is slightly different from the first one. Sand-polymer tiles are made according to this method as follows:

• the concrete mixture is prepared first;
• then the latter is placed in special forms located on the vibrating table;
• further forms are placed on pallets;
• 48 hours it is necessary to withstand the forms with the mixture in natural conditions;
• products are knocked out of the molds on a vibrating table.

For the last stage, the products are heated at a temperature of up to 60-70 degrees Celsius for about two minutes, after which they should be knocked out on a vibrating table.

The choice of premises for the organization of production

Polymer production can be placed 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 the voltage of the electrical network 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, the productivity of which does not exceed 50 square meters of tiles per day, three workers will be quite enough. They control all polymer production. Their duties include concrete preparation, mold filling, pressing control, and product drying.

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, manufacturing process cannot do without some 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 start selling finished products. To attract the maximum number of customers, it is necessary to provide them with a wide range of products, so it is advisable to make tiles different forms, sizes and colors. It is not necessary at the initial stage to strive to receive large orders. A better place to start is by networking with individuals and small business owners who are looking to purchase tiles to decorate their spaces.

Advantages and disadvantages of such a business

The picture as a whole seems very profitable. Everyone can start polymer production. A relatively simple manufacturing process, 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 draw up a business plan, you can start opening the production process itself, where polymer sand tiles will be created. To get started, you will need to register with the administration, where you will write an application that will indicate 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 with the appropriate certificate, which will automatically make you an entrepreneur. Next, you are required to register with the tax office within three days after receiving the certificate. There you will also have to select the form and code of activity, as well as the type of business.

Now you can choose a room or engage in the preparation of an already selected one. It all depends on the planned production volumes. The room must have concrete floors, lighting and plumbing. It is desirable to have a canopy near the building, since you will store materials on the territory.

LINE FOR THE PRODUCTION OF POLYMER SAND PRODUCTS

The line for the production of polymer sand products (hereinafter referred to as LPPI) is intended for the manufacture of polymer sand products (sewer hatches, GTS hatches, tiles, roofing elements of varying complexity, paving slabs, road curbs, posts, road and sidewalk gratings, MAF, etc.)

Thus, LPPI is equipment for the production of polymer sand tiles, equipment for the production of polymer sand tiles, equipment for the production of polymer sand hatches, equipment for the production of various other polymer sand products.

Compared to traditionally used cement paving slabs and ceramic tiles, polymer sand products have a number of unique properties. They are twice as light, have almost zero water absorption, are more than twice as strong in bending, have excellent frost resistance (more than 150 frost cycles), and have low abrasion, which is especially important for paving slabs.

Purpose

PURPOSE OF THE LINE FOR THE PRODUCTION OF POLYMER SAND PRODUCTS LPPI:

The line for the production of polymer-sand products (hereinafter referred to as the line) is intended for the manufacture of polymer-sand products (tiles, roofing elements of varying complexity, paving slabs, road curbs, road posts, sewer manholes, HTS hatches, small architectural forms, road construction elements, TOTAL MORE THAN 20 TYPES OF PRODUCTS AT THE DESIRE OF THE CUSTOMER, etc.).

The raw materials for the production of polymer-sand products are primary polymers, secondary polymer raw materials and polymer waste: polyethylene waste, used polyethylene film, polymer waste, secondary polymers, various polymers (PET, PVD, PVC, HDPE, PP, PS) and plastics obtained when sorting and selecting municipal waste, as well as screened sand and dye pigments.

Advantages of equipment for the production of polymer sand products and the selected technology:

• Availability of cheap secondary polymer raw materials (bags, greenhouse film (used), industrial waste from polymer production).
• Ability to work in a long production cycle (2-3 shifts).
• Manufactured products in the production process can be painted in any color at the request of the Customer.
• High level of profitability, not less than 100%.
• Small staff of workers.
• Small footprint, compact placement possible.

Part of the equipment

THE STANDARD PACKAGE INCLUDES:

Sand heating plant with overpass(designed to heat sand):

• Overall dimensions: 3000x3400x3100 mm
• Heating power: 19.2 kW
• Sand volume: 0.13 m3
• Hopper weight (without sand): 400 kg
• Productivity: 150-250 kg/h

Polymer concrete mixer(designed for a mixture of sand and polymers and extrusion of the finished mass):

• Overall dimensions: 3500x900x1400 mm
• Engine power: 15 kW
• Heating power: 12.5 kW
• Weight: 907 kg
• Productivity: 150-500 kg/h

Press 100 t/s(one for all product molds, designed for pressing the polymer-sand mass into finished products):

• Overall dimensions: 2200x1450x960 mm
• Weight: 2.5
• Drive: 4 kW
• Pressing force: 60-100 t/s

Switchboard(designed to control technological equipment lines):

• Overall dimensions: 660x510x1900 mm

Agglomerator of polymeric materials:

• Overall dimensions: 1200x620x1600 mm
• Engine power: 18.5 kW
• Weight: 450 kg
• Productivity: 150-200 kg/h

Designed for grinding polymer film waste and obtaining an agglomerate suitable for further processing in extruders and injection molding machines into finished products.

Shredder of polymers and films(designed for grinding polymers for further production of a polymer sand mixture):

• Overall dimensions: 1325x1156x1843 mm
• Engine power: 15 kW
• Weight: 1 t
• Productivity: 180-200 kg/h

Press forms- according to the catalog of molds.

Received products: tiles, roofing elements of varying complexity, paving slabs, road curbs, road posts, sewer manholes, small architectural forms, elements of road construction.

A photo

Sand heating plant:

Polymer concrete mixer:

Switchboard:

Shredder of polymers and films:

Products

Below are some samples of products obtained on the production line of polymer sand products: polymer sand tiles, tiles, hatches.

Video

Line for the production of polymer sand products in operation.

Frequently asked questions about polymer sand products

How long has polymer-sand tiles been present on the Russian market?

For the first time this finishing material appeared in the early 2000s, when in Russian production imported technologies for the manufacture of composite products from a half-sized sand mixture (sand, polymer, pigment) began to be introduced. From now on, the products of this commodity group confidently lead in the implementation various projects, making a serious competition to analogs from concrete and metal. Our company has been working in this direction since 2007, which allows us to talk about serious experience in the production of polymer sand products. According to our data, finishing materials in this category are trusted by more and more users who have been able to appreciate the many advantages of polymer pavement in practice.

What is the scope of polymer sand paving slabs?

Polymer sand tiles can be laid on almost any area - sidewalks, garden paths, industrial premises, service stations, livestock complexes, including private garages. At the same time, the scope of use is not limited to climatic conditions. Necessary condition installation of polymer functional decor in areas with increased weight impact - this is the presence of a concrete base on which a sand cushion is installed.

How to pave a porch with polymer tiles?

When installing tiles on the porch, it is recommended to use a metal corner as a fixing limiter. Otherwise, the process is similar to the usual installation on a cement-sand base, followed by filling the joints with a dry cement-sand mixture. The allowable seam size is 6-8 mm.

How to lay tiles on a plinth and an exploited flat roof?

At installation work of this type, special supports are used to support piece elements. In order to lighten the weight of the structure, the tiles are laid on a layer of fine gravel, which is installed directly on the roof waterproofing.

Is it advisable to install polymer paving slabs in car washes?

In this case, there are risks of washing out the fillings of tile joints, which sooner or later will lead to surface deformation, so it is better to use tile adhesive. At the same time, the tile can be successfully used for paving car services and parking lots as a chemically passive material with high climatic resistance.

How to cut polymer tiles?

With the help of the usual "Bulgarian". Moreover, in this case, there will be much less dust and waste than when sawing a concrete analogue.

How do polymer tiles react to the main climatic factors?

Due to the extremely minimal porosity and low water absorption coefficient, the use of this road decor, unlike ordinary paving stones, does not deform under the influence of rain and cold weather.

Equipment for the production of polymer sand products

At the same time, polymer tiles perfectly withstand critical heat, practically without fading under the influence of active ultraviolet radiation.

What weight loads are polymer tiles designed for?

It all depends on the thickness of the piece decor. Terrace tiles 22 mm thick are designed for paving pedestrian pavement and landscape areas for a wide range of purposes. Paving slabs with a thickness of 35 mm can easily support the weight of a truck.

What are the environmental characteristics of polymer sand tiles?

This finishing material is made from three main components - natural sand, polymer (stretch and PVD) and coloring pigment. The last two components have the highest environmental safety, which is reflected in the relevant certificates. And the ecological cleanliness of the prepared sand does not raise questions.

Is it possible to reuse polymer paving slabs in other areas?

This high-end travel décor is not deformed even after prolonged use. Therefore, dismantling allows you to reuse tiles for decoration. pavement corresponding specification. The created surfaces are highly maintainable, allowing you to quickly replace damaged piece elements without much labor.

What are the features of the operation of polymer sand paving slabs in the winter season?

Polymer tiles compare favorably with an anti-slip coating that provides good adhesion of the soles or wheels of vehicles with working surface. Snow and ice are easily removed from the respective areas. At the same time, even accidental strong blows of a crowbar are not capable of fatally damaging piece elements that have an enviable impact strength. With any slightest thaw, the tile, like a small heat accumulator, immediately absorbs the necessary portion of heat, which contributes to the rapid thawing of the ice crust without outside interference.

How long does the color of the tile last with active solar exposure?

If the manufacturer conscientiously observes the technology for the production of polymer sand products, namely, the percentage ratio of the components of their quality. For example, if the production process does not save on pigmenting dye, the tile will look attractive throughout its entire service life (up to 25 years). Such priority is provided by the principle of production technology, which forms a combination of pigment with other components at the molecular level. That is, the color of the finished tile is its natural physical and chemical state.

As for pricing, in this case you can directly buy polymer sand paving slabs from the manufacturer without unnecessary trade margins.

How strong heating affects the strength of the tile coating?

With active prolonged exposure to sunlight, the tile can expand within the tile joints, that is, in a linear manner. Similar changes are included in specifications operation. Thus, there can be no talk of any serious deformation, and even more so of subsidence or “swelling” of the surface.

Can polymer tiles "swell" after installation during use?

Only in case of non-compliance with the laying technology - as a result of the wrong selection of components for the "cushion", the creation of too large or small seams, as a result of poor-quality tamping, etc. Subject to all technical recommendations (TR - 158-04) for the installation of sidewalks, there should be no problems with the operation of polymer tiles!

Production of polymer-sand tiles, paving slabs, hatches

Photo galleryDelivery Production Certificates

The raw materials used in the production of polymer sand tiles are polymer materials in various types: packaging, plastic containers, household items. More and more goods are packaged in polymers, and the range of building materials made from plastics is growing. Raw material preparation

The proposed technology for the production of polymer sand tiles from polymer waste involves cleaning and deep sorting of raw materials. It is proposed to adhere to the ratio of 40-50 / 60-50 of the so-called soft (polyethylene) and hard (polypropylene, polystyrene, ABS plastics, PET, etc.) polymers. In addition to polymers, sand is required in the production of tiles. It is used as a filler and must be dry, sifted without clay and dust inclusions. It doesn't matter what color the sand is and where it came from. Permissible sand fraction up to 3 mm. Other fillers, more readily available in the locality, may also be used, but before commercial use, it is necessary to investigate its effect on product quality.

Pre-processing of raw materials

At the first stage, the selected and sorted plastics are crushed in a crushing machine. It is desirable to have a 50/50 ratio of hard and soft polymers. For example: polyethylenes behave better at negative temperatures and it is easier to get a gloss on a product, but “hard” polymers will add rigidity and strength when heated in the sun. It is better and more convenient to work with granulate or polymer of the same brand. It turns out geometrically even and regular tiles. Polymer-sand tiles are obtained the better, the more evenly mixed polymers and sand.

Preparation of polymer sand mass

After the first grinding, the plastic enters the extrusion machine, where it is mixed under heat. Any chemist will say that it is impossible and unscientific to mix dissimilar polymers; It's like mixing kerosene with water. But such a task is not set - to mix the polymers at the molecular level, it is enough to mix them using the properties of the viscosity of the melted polymers. Polyethylene and polypropylene films occupy a large place in the structure of polymeric materials. They are added to the extrusion machine without grinding. The resulting polymer-sandy mass with the consistency of yeast dough is removed by the operator with a mitten at the outlet of the extrusion unit of the line, and, having rolled a ball (agglomerate up to 100 mm.) With his hands, throws it into the water for cooling. Taken out of the water, not completely cooled, but already hardened, the agglomerate dries quickly, cooling down. The entire cooled agglomerate is subjected to repeated grinding into chips with a fraction size of up to 1-10 mm. Thus, a ready-made raw material for the polymer-sand mixture is obtained.

Obtaining polymer sand mass and molding tiles

This stage of the production of polymer sand tiles is the final one. Some separate it from the harvesting area, located in a separate room. In addition to aesthetic considerations (the preparation of an average polymer mixture is accompanied by the release of gases, and requires the provision of an exhaust), there are also practical benefits: it is easier to control and account. The mixing of sand, polymers and dyes takes place in a thermal mixing unit (Melting and Heating Unit). It is important to keep the mass of the mixture in the APN constant, adding new portions as the finished mass is consumed. The crushed polymer-sand mass is mixed with sand and dyes in different proportions, depending on the products being manufactured. For, for example, tiles, this ratio is: 29/70/1, and for paving slabs it can be 24/75/1.
The ratio of sand and polymers also affects performance - the mass that has more sand in its composition will take longer to heat up. This property should be taken into account when calculating the cost and accounting for products.
It is important to obtain a high-quality mixture - sand particles must be completely enveloped in polymers, without gaps. This is achieved by a unique shaft design, calculated by the "Polymer Technology" Orsk. More precisely, not calculated, but tortured by experimental designs and scientific research. As a result, the blades on the shaft are located in such a way that when the shaft rotates, the mass advance rate is different in 3 heating zones, which ensures complete polymer melt and high-quality mixing with the filler.
By the way, in this node we see some design flaws, the change of which leads to an increase in the productivity of the entire line.
Thus, the resulting polymer-sand mass with an outlet temperature of about 170-190 degrees and the consistency of a tight dumpling dough is squeezed out of the machine after the damper is opened. The operator cuts off the required amount with a knife, weighs it on the scales, and having received the right amount (about 2 kg.), Puts it into the mold with an ordinary scoop.

Price for polymer sand equipment

The form, mounted on a press with a movable bottom plate, is cooled in different ways.
The upper part has a temperature of about 80 degrees, and the lower 45, or cooled as much as possible, for the fastest formation of tiles (30-50 seconds).
This is done to create a gloss on the outside of the polymer sand tiles, as if the polymer is squeezed up, filling the pores between the filler. This is another secret of technology. Although such uneven cooling can lead to the bending of the tiles, for which it is placed on the cooling table and pressed with a load until the final molding.
To obtain a matte surface of polymer-sand tiles, it is enough to cool the upper mold as much as the lower one. This is used for the production of polymer-sand paving stones. The dye may not be added, and the product turns out to be gray in color, like concrete.

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NOT BUY FROM US IF YOU DON'T BELIEVE US!

Most manufacturers motivate the overpricing of their polymer-sand products by the high cost of high-quality raw materials. But this is correct only when the manufacturer does not have the equipment and production facilities for the preparation of polymer raw materials on their own.

Learn more about the production of polymer-sand products at Polisand.

NOT BUY FROM US IF YOU BELIEVE NOT US!

Time is running fast and everything around is changing. For now, we all communicate using cell phones, although some 15 years ago this was an unaffordable luxury. You look out into the yard: on playgrounds, instead of wooden swings, in almost all yards there are brand new, "anti-vandal" children's attractions. Break them - don't break them ... They won't break anyway. New technologies make it possible to increase the consumer qualities of goods several times over.

Who would have thought that there would be paving slabs that do not crack from impacts, do not absorb moisture and are not destroyed by time? Over the past decade, we have become accustomed to the fact that new technologies bring relief to our daily work, speed up work processes and decisions, and improve the quality of life in general. And we are ready to take a chance and try to lay out the grounds and paths of our beloved dacha with new tiles, but ... only if it lasts long enough to justify the investment made. The only thing that holds back is the questions that arise before applying the novelty that has not been tested by time: what if it darkens or burns out in the summer? How will she survive the winter? Will it not split? And in general - the manufacturer writes only about positive qualities, what if it will be worse than classic cement? Suddenly it will be harmful, will it emit any odors or gases when heated?

We will try to answer the questions that inevitably arise from the buyer.

It is safe to say that any product in this category, manufactured conscientious manufacturer, different high quality and will last a long time. And one more thing: equipment for the production of polymer sand tiles is expensive.

Overview of machines for the manufacture of polymer sand tiles

And there are no cheap analogues. In a garage, you can’t make such a tile, unlike cement, using a artisanal method. And it will not be possible to greatly reduce the cost of technology through the use of low-quality cheap materials. By the way, high-quality concrete tiles are made only large companies, and it is expensive, and everything else that is sold in the markets and is cheaper, and will last less. That is, in most cases, the quality of polymer sand tiles should obviously be higher.

As for odors, it is necessary to refer to the composition of the polymer sand composite. Composition: quarry sand (75%), a mixture of plastics (25%): high and low pressure polyethylene (allowed for food storage and absolutely safe plastics with marking and in international system), and a heat-resistant dye. These components are heated at a temperature of 250 °C. These plastics are absolutely harmless and do not emit carcinogens into the atmosphere when heated. In addition, you need to understand that 75% of the product still consists of sand, and plastic is a binder.

In general, the presence of plastic as a binder (compared to cement - the binder of concrete tiles) gives advantages to polymer sand tiles.

Let's analyze all the properties in order:

+ Water repellency plastics give polymer sand tiles almost zero water absorption, and this extends the service life of polymer sand tiles up to 20 years without destruction. Polymer-sand tiles do not collapse in the thaw with sudden temperature changes. Recall physics: during the phase transition from liquid to solid state (ice), water increases in volume, which leads to the fact that water, having absorbed into the pores of the product, and then freezing, increases in volume and literally breaks the tile with high water absorption from the inside. That's why it happens that in the spring on a freshly laid last fall concrete paving stones and paving slabs are already showing signs of destruction. A polymer-sand tile is whole and dry.

+ The water resistance of polymer-sand products makes them attractive also because on the surface of products ice does not form in winter- the tile is absolutely non-slip, and the snow is easily removed with a shovel.

+ The low water absorption explains and increased frost resistance of the material(i.e. full freeze-thaw cycles in a state of full moisture saturation) - more than 500 cycles.

+ Plastic is lighter than concrete, so polymer sand products 3-4 times lighter than concrete(this allows for easy loading/unloading, hand-carrying along the track or track). This property enables our customers to independently organize the delivery and laying of garden paths, blind areas, porches and burial sites. This property of the polymer-sand material was quickly appreciated by electrical installation companies - a plate for closing a cable made of a polymer-sand composite completely replaced a brick for protecting 0.4-35 kV cable lines in two or three years from the moment of its invention.

Anyone who has ever tried "in work" products made of polymer-sand composite no longer refuses them - their use is very convenient and affordable.

+ The presence of polyethylene in the composition gives products unique impact resistance– plastic is a more elastic and astringent material, which gives advantages in load tests. Polymer sand tiles 20 mm thick withstand the load of pedestrian areas, comparable to the load on concrete tiles or paving stones 40 mm thick! In addition, it refers to "anti-vandal" materials - such material can only be split with considerable effort. Polymer-sand tiles do not break during cargo transportation and when falling.

+ The plastic envelops every grain of sand and paint in the mixture and, when melted, provides uniform coloring throughout the entire product. In addition, the ability to stain plastic is higher than that of cement - such products are brighter, their color is more resistant, paint does not fade. If pigments with high hiding power are used, polymer-sand materials do not lose color for a long time, continuing to delight with the brightness of color even after several years.

+ Plastic, as you know, durable material not destroyed by time. It also transfers these properties to polymer sand products. The declared service life of the coating without destruction is 20 years.

+ The properties of the plastic also give the material: acid resistance, alkali resistance, low abrasion, non-sparking. This is important for coatings with high traffic (entrance groups), as well as coatings: garages, industrial premises, livestock farms, etc.

± Plastic, as a binder, transfers paving slabs from the non-combustible (NG) section to the low combustible (G1) and flame retardant(IN 1). The material in the fire does not burn and does not melt (because it contains ¾ of sand), but is charred. This means that when exposed to an open flame for a long time, the polymer sand material may begin to smolder, however, as soon as the source of fire dries up, smoldering will immediately stop.

+ Environmental friendliness of the polymer sand composite undeniable - "food" plastic, building sand and dye - are absolutely inactive at elevated temperatures and in aggressive environments and are harmless to humans. These are not harmful plastics polyvinyl chloride (PVC) and polystyrene (PS), which emit toxic compounds when exposed to them. It is simply impossible to work with such plastics in polymer sand production - after all, the production is carried out by high-temperature processing, which is possible only for harmless plastics.

± Plastic gives polymer sand products longitudinal thermal expansion. At an unstable temperature (sharp warming) in the bright sun, a slight increase in geometric shapes in horizontal surface- up to 1-2 mm. The solution is to leave gaps between the plates - 3-5 mm. If this fact is not taken into account, individual slabs may be pushed out of the coating - perhaps the tile will rise like a “house” and the coating will have to be shifted. This feature must be taken into account when laying, especially since not only polymer-sand tiles have such features - even concrete slabs on the highway rise from the heat.

The expansion of polymer sand tiles should not worry gardeners - after all, they do not have a question about the strict fixation of their coating - for the construction of paths, the tiles are laid on the ground with a sand cushion (prepared site) and rammed with a mallet. From the sides of the track must be securely fixed with curbs. Subject to thermal seams, this coating will serve for many years without requiring re-laying. If, when laying tiles, geotextiles are used as a substrate, then the issue of aggressive growth of weeds will be resolved - after a while, only small weeds with a superficial root system, easily removed from time to time, may appear on such paths.

By the way, in winter the reverse process does not occur - the tile does not shrink during cooling, but remains within its linear dimensions.

± The presence of plastic reduces the adhesion (adhesion of surfaces) of polymer sand tiles and cement mortar- on the cement mortar, the tile will be held due to the presence of internal grooves into which the mortar will fall. It is allowed to lay on a mortar bed layer (the most dense sand-cement mortar). However, tile adhesive, such as EK-3000, with filling the joints with grout or sealant in the color of the coating, fixes the polymer-sand tiles to the concrete coating much better.

+ And finally, plastic in the composition of products gives ease of processing(Used by angle grinder, the so-called "Bulgarian", cutting wheel on stone), sawn evenly, easily, without "battle" and cement dust like cutting concrete tiles.