Manufacturing line for the fiber-reinforced polymer rebar grid

Key Achievements

Certification

ISO 9001:2015 TÜV AUSTRIA

Global Partnerships

Joint venture in Brazil
3 agreements on JV creation in China

Production

3 generations of equipment
6 types of machine lines
Delivered to 9 countries

Patent Portfolio

20 PCT patents for inventions
6 patents in India
4 patents in China
National-level registration in progress in 14 countries

Innovation Award

Winner of the Bortnik Fund competition (2022) for innovative developments in composite technologies. Received a grant for R&D of an automated production line with minimal human participation.

Exporter of the Year

6× recipient of the award. In 2022, the CEO received the All-Russian Exporter of the Year Award at the Kremlin from Andrey Belousov, First Deputy Chairman of the Russian Government.

Requirements

Electricity consumption:

30-40 kW/h – average

50-80 kW/h – peak

380 V, 50 ±1 Hz – power supply

Water consumption:

1 m³ per production cycle (closed-loop system recommended)

Minimal staffing:

Only 2 operators per shift required — full cycle automation reduces labor costs

Budget to Start:

Only $240,000 to run the plant

Plant space:

280 m² required for installation and operation

Dimensions:

Length: 35 m
Width: 6-8 m
Height: 4 m

Only
$240,000
and 280 sq.m.  to run the plant

Results

Quantity of streams produced simultaneously:

1–10 mm or 2–12 mm – in 1 stream

Daily Output:

Equivalent to 8 tons of steel rebar – high-volume composite production per 24 hours

Production speed:

4,000 m² of 3 mm rod for 200x200 mm cell per day (at a recommended speed)

Yearly Capacity:

Up to 17,000 tons (steel equivalent) – consistent high-volume performance

Capacity equivalent
17.000
tons of steel p.y.

Key notes

Payback:

Less than 0.83% of the production cost over a 10-year cycle

Warranty:

Standard warranty — 12 months,  optional extension available

Material Cost:

1$/kg

Cost Advantage:

3 times cheaper than steel

Eco-friendly:

Permitted within 500 m of residential buildings – meets local environmental standards

Recycled Glass:

Can be used as raw material – supports sustainable production

Cost 3 times cheaper than steel

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Contact Information

Office Address

36/1, 2nd Paveletskaya Street, Office 303, Chelyabinsk, Chelyabinsk Region, 454047 Russia

Business Hours

Monday–Friday: 09:00—18:00 (GMT+5)

Messanger

Recomended speed

Cell size:

Roving:

is coated with a silane-based sizing compatiblewith unsaturated polyester, vinyl ester, and epoxy resins. It is designed for filament winding, pultrusion, and weaving applications.
should be stored in a cool and dry place. The temperature should not exceed 35 ° C, and the relative humidity should be maintained below 75%.
must remain packed immediately before use. It is necessary to avoid damage to the packaging during storage. If moisture gets into it, it becomes unsuitable for further use.

MSDS for Roving

View Download

Epoxy resin storage:

save in cool, dry and well ventilated place.
save applicable laws and regulations.
avoid direct sunlight.
no open fire.
prevent static electricity and keep away from combustible materials or heat sources.
collected them in sealed containers.
store away from water and sewer.

MSDS for Epoxy Resin

View Download

MTHPA:

significantly improves the technical characteristics of the finished product that is obtained as a result of solidification of the epoxy binder.
characterized by high moisture resistance, chemical resistance, and electrical insulation properties of cured materials
is capable of absorbing waterfrom the air
dissolves perfectly in water and is converted into the appropriate acid. It is soluble in organic solvents (toluene, acetone, benzene), easily mixes with epoxy compounds.

MSDS for Hardener

View Download

Basic delivery set

Manufacturing line for the fiber-reinforced polymer rebar grid

Roving rack

included: 4 units

Holds and feeds fiber rovings into the production line in a stable and controlled manner.

Kneading station

included: 0 unit

Mixes and prepares a polymer from all the components which is used to coat the reinforcement

Impregination and pressing units

included: 3 units

Impregnates fiberglass with a polymer mixture.

Periodic profile forming device

included: 1 unit

Forms a ribbed surface of the reinforcement.

FRP mesh forming and weaving unit

included: 1 unit

Places longitudinal and transverse impregnated bundles into a cell and mechanically interweaves and presses the intersections with rapid fixation with epoxy.

Separator

included: 1 unit

Separates the streams to lay them across the knitting in a mesh

Control panel

included: 1 unit

Allows to customize the reinforcement diameter, and production speed.

Cross bar pulling unit

included: 1 unit

Moves the hardened transverse rebar further along the line

Two-tunnel polymerization chamber

included: 1 unit

Has automatic temperature control and a protective screen.

Water cooling unit

included: 1 unit

Сools the mesh web with a water jet until the polymers harden

Return wheel

included: 1 unit

Returns the hardened reinforcing threads to the separator

Pulling unit

included: 1 unit

Moves the finished canvas further along the line.

Cutting unit

included: 1 unit

Сuts the mesh canvas to the required area.

Manufactoring method

Composite fiber-reinforced rebar is manufactured by the needletrusion method. With this method of production, the rod, consisting of fibrous threads impregnated with a polymer binder, is first separated into separate parts, passed through separate channels, and then reconnected with a simultaneous spiral braid and tension of a weaving harness embedded in a bundle of fibers.

This is the main difference between needletrusion and pulltrusion, in which reinforcing fibers (glass, carbon, basalt) impregnated with a polymer resin (polyester, vinyl, epoxy resins) is stretched through the die heated to the polymerization temperature. Rebar made by needletrusion has high anchoring properties in concrete media, reliable fastening of the spiral rib (a periodic profile) on the main rod, as well as high physical and mechanical properties.

Production speed:

Up to 800–1,200 m²

per 8-hour shift (depending on mesh configuration and bar diameter)
End product diameter range:

Ø2 – 12 mm

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Bottom heater

need: 1 pc

2kW, with thermostat

Dissolver

need: 2 pcs

supplied with 120 mm milling cutter

Drill

need: 1 pc

750W

Nozzle head-mixer for drill

need: 1 pc

Cordless drill screwdriver

need: 1 pc

Bits for cordless drill-screwdriver

need: 2 pcs

Angle grinder

need: 1 pc

125 mm diameter

TURBO diamond cutting disk

need: 20 pcs

Cutting disk for metal

need: 10 pcs

Vernier caliper

need: 1 pc

range 0–150 mm

High-precision scales

need: 1 pc

accuracy of 0.5 g

Coil weighing scales

need: 1 pc

for coils up to 20 kg

Barrel lever pump

need: 6 pcs

for oils, 300 ml/stroke, GROZ GR44100 – LBP/04

Hand cart for barrels

need: 2 pcs

for 200L barrels

Working gloves

need: 30 pcs

reinforced nitrile coating on the cuffs

Power strip on coil

need: 1 pc

IP-44, thermo connecting wire, PVC insulation 3x2.5, 4 sockets, 25 m

Scales with high stand and label printing

need: 1 pc

accuracy of 5 g, weighing limit up to 30 kg

Current pliers

need: 1 pc

with CEM DT-3341 temperature sensor

Vacuum cleaner

need: 1 pc

for collecting chips and dust