Equipment for the production of polymer sand tiles. The process of producing polymer tiles at home Making polymer sand tiles

The Rostpoliplast company is engaged in the production and sale of products such as plastic paving slabs, which will always decorate your yard in any weather, and the price will not disappoint you, since it is available to all customers.

Polymer sand paving slabs are durable and strong. Unlike vibro-pressed concrete, polymer-sand tiles are almost impossible to split. High heat resistance, frost resistance, durability, excellent appearance, various colors!

The characteristics of polymer-sand paving slabs are many times superior to concrete vibro-pressed paving slabs.

Polymer sand paving slabs. Concrete vibropressed tiles.

Comparative characteristics of polymer-sand paving slabs

Comparison of our polymer and concrete tiles

Polymer sand paving slabs

Considering the relatively low weight of polymer-sand paving slabs, the costs of transporting large volumes of products are significantly reduced. The combination of all properties makes it possible to use it in places of mass attendance (both external and internal use). This the best option for covering areas of recreational areas (parks, cafes, etc.).

The tile production technology ensures complete repeatability of sizes, shapes and colors, so with the help of such tiles you can reproduce any geometric and color combinations. The result obtained is an order of magnitude superior to the use of conventional tiles both in appearance and in operational parameters.

Indeed, polymer-sand paving slabs are much more durable, more resistant to external environment than usual. Especially if it is an urban environment, where there must be resistance to abrasion, high mechanical loads, exposure to oils and acid-containing liquids, hardness and strength, resistance to pinpoint splitting and many other reliability indicators.

The theoretical (calculated) durability of the polymer sand material exceeds 150 years, and in terms of color fastness, the tiles do not lose the color of the pattern forever. It is painted with modern dyes that do not fade even in direct sunlight to the full depth of the material.

An important feature is the absence of dust emission from the surface of the coating (which is typical for other materials) and fumes during the hot season. Even under the scorching sun, the coating does not “gas” carcinogens, like asphalt. Polymer sand paving slabs are easy to wash, are designed for repeated use, and make it easy to repair, disassemble and re-lay individual sections of the coating.

Technologies do not stand still, but at the moment among paving coverings, polymer sand tiles are the most effective material in terms of durability and cost, which is universal in use due to its unique properties.

5 reasons to buy our polymer sand tiles:

• Your yard, playground, paths will always look beautiful, well-groomed, and clean!
• The area paved with our polymer sand tiles can withstand significant loads and is excellent for production premises, car washes, parking lots, etc.
• Durable, beautiful, safe coating for many years to come! The service life of polymer sand tiles is more than fifty years.
• You save on transporting tiles, because... It's lightweight and easy to stack!
• Our polymer sand tiles consist exclusively of environmentally friendly materials: river sand, polymers, mineral dyes!

Our company produces paving slabs using modern and professional equipment and is based on customer needs. Products can be ordered in any volume and quantity. The cost of polymer sand tiles can be clarified by contacting our specialists.

Technology for the production of polymer-sand products

Polymer sand tiles and paving slabs - production technology
Preparation of raw materials (waste polymers and sand)
The incredibleness and uniqueness of this technology is that the raw materials used in the production of polymer sand tiles are free, lying under your feet. This is polymer waste various types: packaging, plastic containers, household products that have become unusable. A shortage of raw materials is not expected, but on the contrary, the volume of polymer waste will only grow, and the need for it will only increase.
Of course, there are effective technologies for their processing that allow polymers to be reused. As a rule, careful sorting of plastic waste, washing and drying is required. These are expensive and time-consuming processes. And the quality of processed raw materials is low, and does not allow it to be used 100% instead of the original one.

The proposed technology for the production of polymer sand tiles from polymer waste does not involve cleaning and deep sorting of raw materials. It is only suggested to adhere to the ratio of 40-50/60-50 so-called soft (polyethylenes) and hard (polypropylenes, polystyrenes, ABS plastics, PET, etc.) polymers. This is approximately the ratio of waste that ends up in landfills.
Refractory polymers (polycarbonates, fluoroplastics) and rubber are NOT suitable. Low-fusibility materials, such as PVC, can partially burn out, but this does not affect the quality of polymer sand tiles. Impurities (paper, food waste) also burn out and moisture evaporates.

In addition to polymer waste, sand is required in the production of tiles. It is used as a filler and must be dry, sifted without clay and dusty inclusions. It doesn't matter what color the sand is or what its origin is. The permissible sand fraction is up to 3 mm. Another filler that is more accessible in the selected area may be used. So this incredible new technology obtaining building materials from free raw materials.

Pre-processing of raw materials.
At the first stage, 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 low temperatures and it is easier to obtain 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. The result is a geometrically even and regular tile.
The better the quality of polymer sand tiles, the more evenly the polymers and sand are mixed. There is no need to pre-clean plastic waste. The only pest may be the machine oil that comes with the canisters. But its quantity, as a rule, is insignificant, does not affect the quality of the tile, and even if it appears as a stain on the tile, it disappears during recycling. The remaining impurities burn out. In the future, building materials made from a polymer-sand mixture are resistant to oils and other chemicals. products.

Preparation of polymer sand mass
After the first grinding, the plastic waste goes into an 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 posed - to mix polymers at the molecular level; it is enough to mix plastic waste using the viscosity properties of molten polymers.
In the structure of polymer waste, films of polyethylene and polypropylene occupy a large place. They are added to the extrusion machine without grinding.
The operator removes the resulting polymer-sand mass with the consistency of yeast dough with a mitt at the exit from the extrusion unit of the line, and, having formed a ball with his hands (agglomerate up to 100 mm), throws it into water for cooling. When taken out of the water, not completely cooled, but already hardened, the agglomerate dries quickly as it cools.
It happens that the polymer mass overheats, and it flows out of the extrusion machine onto the floor until the operator turns off the heating. Once this mass has cooled down, it is then suitable for use. The entire cooled agglomerate is re-crushed into chips with a fraction size of up to 1-10 mm. Thus, ready-made raw materials for the polymer-sand mixture are obtained.

Obtaining polymer sand mass and molding tiles
This stage of tile production is the final one. Some separate it from the procurement area and place it in a separate room. In addition to aesthetic considerations (preparing a polymer homogeneous mixture is accompanied by the release of gases and requires the provision of exhaust), there are also practical benefits: it is easier to carry out control and accounting. And in cases of work in correctional institutions, it is simply necessary due to the regime of the enterprise.
Mixing of sand, polymers and dyes occurs in a thermo-mixing unit (Melting-Heating Unit). It is important to maintain 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 product being manufactured. For, for example, tiles this ratio is: 24/75/1, and for paving slabs it can be 5/94/1.
The ratio of sand and polymers also affects performance - the mass that contains more sand will take longer to heat up.
This property should be taken into account when calculating costs and accounting for products.

It is important to obtain a high-quality mixture - the sand particles must be completely enveloped in polymers, without gaps. This is achieved by a unique shaft design, calculated experimentally. More precisely, not calculated, but tortured by experimental designs and scientific research. As a result, the blades on the shaft are located so that when the shaft rotates, the speed at which the mass moves is different in 3 heating zones, which ensures complete melting of the polymer and high-quality mixing with the filler.
By the way, in this unit 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 tight dumpling dough is squeezed out of the machine after opening the damper. The operator cuts off the required amount with a knife, weighs it on scales, and having received the required amount (about 2 kg), puts it into the mold with a regular scoop.
The mold, mounted on a press with a movable bottom plate, is cooled differently.
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 the tiles (30-50 seconds).
This is done to create gloss on the outside of the polymer-sand tiles; the polymer is, as it were, squeezed upward, filling the pores between the filler.
This is another secret of technology. Although such uneven cooling can lead to bending of the tiles, for this purpose they are placed on a cooling table and pressed with a weight until final shaping.
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 gray in color, like concrete.

Range of products
Depends directly on the availability of additional forms. Of course, it makes the business competitive. Market building materials is not saturated, and while some manufacturers schedule sales of only tiles months in advance during the season. Is it possible to release a large assortment products for construction: tiles, trays, bricks, elements of permanent formwork, manhole covers for wells. Chemically resistant polymer sand tiles laid, for example, on a basement floor will also serve as waterproofing.

Problems arising in connection with the production of building materials from polymer sand mixture
By room
Equipment manufacturers recommend using premises of 150-300 m2. The dimensions of the equipment for the production of tiles are small, and will allow it to be placed in smaller areas - about 50 m2, but it is still necessary to have space for storing raw materials and finished polymer tiles. Recommended ceiling height is 4 meters. The press has a height of 1780 mm.

By raw materials
If you use raw sand, then during the heating process gases will be released, leading to pore formation in the product, which is extremely undesirable. Large inclusions can also lead to loss of tile quality and wear of the forming tool. It is necessary to avoid getting machine oil and metal inclusions into the polymer-sand mixture.

Other
In general, manufactured tiles are not subject to mandatory certification, as is the equipment, since they are non-standard. But here are the requirements for premises, labor protection and environment may be presented. It is necessary to establish control over the quality and accounting of products.
There is a risk of equipment failure when starting the engine. The screw cannot rotate in a polymer or polymer-sand mixture that has not been heated to the plasticization temperature.

Equipment for the production of polymer sand tiles
The productivity of the proposed lines allows us to produce about 40 m2 of polymer-sand tiles per shift. All equipment is serviced by 7 people. There are 9 tiles in one square meter, including overlap, weight 1 m2 - 20 kg. Electricity consumption 26-28 kW/hour, installed power 42 kW, three-phase power supply.

Waste crusher
The crusher used in the line can be replaced with any other one used in the production of polymers and products made from them. Crushes waste into fractions up to 30 mm. and agglomerate up to 10 mm. Engine installed: W, 3000 rpm. The productivity is high, sufficient to provide 3 lines with polymer raw materials.
Overall dimensions: 1000x1100x1200 (WxLxH) Weight 420 kg.

Extrusion plant
It differs from traditional ones in that the volume of the heating and plasticizing zone of polymers changes by changing the outer diameter of the working cylinder. Justified by the ease of manufacture, and the task that is set - to mix the plastics by heating.
A disadvantage of the design is frequent jams of the mass at the point where the diameter of the working cylinder changes, which leads to overheating of the mass and a delay in loading polymers. Heating elements are used as heating elements, which can be easily replaced if they fail. The shaft is centered by a polymer mass at the output and has a low rotation speed. A design disadvantage is that the thrust bearing is not installed, because the shaft is also subject to linear load. The productivity is sufficient to ensure the operation of 2 presses and thermal mixing units.
Overall dimensions: 520x3300x1230 (WxLxH) Weight 580 kg.

Thermal mixing plant (APN - melting and heating unit)
A unique node in the entire line. To achieve a high-quality mixture of polymer and sand, the loaded mass passes at different speeds and different modes heating through the pipe. A shaft with blades arranged in a special way was installed, and their arrangement was often changed to achieve high-quality mixing of the polymer-sand mixture. The shaft bears a large load, including linear load, and the thrust bearing is not installed. The auger blades wear out quickly.
Two temperature control devices are installed in two zones to control mass heating. Works continuously, ensures the operation of one press.
Overall dimensions: 520x3200x1230 (WxLxH) Weight 800 kg.

Press
A small hydraulic press with a movable bottom plate. 4 hydraulic cylinders dia. 125 mm, stroke 300 mm. Working pressure 10 MPa. A matrix with cooling and ejectors is installed on the bottom plate. Moreover, the temperatures of the matrix and the punch are different, which is achieved by two different cooling circuits.
The press is equipped with a hydraulic station and tanks for cooling the coolant. The productivity of the line depends, among other things, on the productivity of the press, the cooling rate and the molding of the product. The components used in the manufacture of the press are available if they need to be replaced. Overall dimensions: 2600x1500x1780 (WxLxH) Weight 1300 kg.

Additional molds for making paving slabs, tiles, paving stones and much more
A large selection of forms is offered, allowing the production of an expanded range of products, thereby making the business competitive. At the very least, paving slabs are required in the kit.

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

Workshop technical equipment

The technology for manufacturing 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 costs for all the necessary components, if you buy them directly from the manufacturer, are minimal.
The first thing you need to do to organize a workshop is to buy equipment for the production of polymer tiles. Purchasing a ready-made line will be more profitable than purchasing each device separately.
The standard line includes the following set of machines:

• Radial crusher. Used to grind 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 productivity. For a small workshop, a capacity of 100 m2 will be sufficient. finished products per day.

• Molding press. Further, the production of polymer-sand paving slabs comes down to placing the molten mass in special molds and processing it under excess pressure. The finished product is cooled and transported to the warehouse.

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

The average price of equipment for the production of polymer tiles fluctuates over 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 service the low-capacity line.
To place the machines you will need a room with an area of ​​100 m2. Considering that you will be working with polymers, good ventilation and wastewater treatment plants. Don't forget to comply with fire safety standards.

Financial side of the issue

The production of polymer-sand tiles will begin to bring in stable income over time. high income. The main thing is to properly establish sales channels.
Your potential clients:

• industrial enterprises,
• base of construction stores,
• construction stores,
• private buyers.

But when will all the investments pay off?

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

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

Polymer sand equipment makes it possible to produce new types of materials that have unique properties and consumer qualities, which distinguishes them from classic types of products made from concrete and plastic building materials.

Garden products

• Polymer sand garden tiles
• Polymer sand garden fences
• Polymer sand board

Road surface products

• Polymer sand paving stones
• Polymer sand paving slabs
• Polymer sand borders
• Polymer sand channels for water drainage
• Polymer sand sewer hatches
• Polymer sand country hatches

Roofing materials

• Polymer sand tiles
• additional elements for roofing

Facing materials

• Polymer sand plinth tiles
• Polymer sand board
• Wood-polymer board (WPC)

Polymer sand composite is an artificially created material not found in nature. and combining qualities unusual for other materials: high strength and reliability, durability, light weight, attractive appearance and ease of installation.

Production technology

Composition of the composite mixture for the manufacture of polymer-sand products includes filler (sand), polymer and dye. Instead of sand, waste from mining and processing plants and rock screenings can be used.

At the first stage of production, polymer waste (plastics, plastic) is crushed, or in the case of polyethylene, agglomeration is carried out to obtain polymer from recycled materials.

At the second stage, the main components are uniformly mixed: filler + polymer + dye. The color of the future product will depend on the choice of pigment.

At the third stage, the thoroughly mixed dry mixture is placed in a melting unit (AFN) and subjected to heat treatment, as a result of which each particle of the filler is enveloped in polymer.

During subsequent molding and hardening, the polymer sand mass forms a homogeneous monolithic structure with high strength. The finished material is placed on pallets and sent for storage.

Basic equipment

Melting and heating unit (APN)

APN is intended for mixing and heating the components of a polymer-sand composite (sand, polymer, pigment) and obtaining a homogeneous mass with the consistency of a tight dough.

A pre-prepared, evenly mixed mixture of polymer components is fed into the heated working chamber of the APN through the receiving hopper, and is pushed deep into the chamber by a screw. The rotating screw ensures mixing of the composite mixture and its advancement inside the working chamber, passing through the heating zones.

Molding press

The press is used for molding products. The resulting mass in the extruder is placed into a mold installed on the press work table, the product is molded under pressure while the mold is cooled, which can significantly increase productivity, the finished product is removed from the mold automatically by lower pushers and is ready for storage on pallets without additional aging (unlike cement products).

Press forms

Molds are installed on a molding press and allow the production of a wide range of products.

Crusher

The purpose of the crusher is to prepare polymer from recycled materials (crushing to a homogeneous fraction) for further use, the proposed crushers are universal, since they can process both hard and soft film materials (agglomeration is not required), depending on the intensity of production, the crushers can have different productivity , cans, bottles, canisters and other polymer waste can be recycled.

Polymer-sand equipment can be used in the production of composite materials with various formulations, for the manufacture of a wide range of products based on them (polymer-sand, polymer-glass, polymer-rubber, polymer-faience, etc.). 100% composed of secondary constituents by weight.

A number of unique technical solutions were used in the design of the equipment, which made it possible to achieve high quality and reliability indicators for products manufactured on it.

The advantages of the equipment also include the possibility of using difficult-to-process types of plastics in production: layer plastics, packaging materials made of cross-linked polyethylene, plastic materials with a foil layer, trimmings of polyester needle-punched pile thermally bonded fabric, etc. Such waste is transported for disposal to solid waste landfills or burned.

Using the proposed polymer equipment, you can create a full production cycle - from the preparation of raw materials to finished product By favorable price. This allows us to produce a wide range of products

PRODUCTION LINE FOR POLYMER SAND PRODUCTS

The line for the production of polymer sand products (hereinafter referred to as LPPI) is intended for the production of polymer sand products (sewer manholes, hydraulic structures manholes, tiles, roofing elements of varying complexity, paving slabs, road curbs, bollards, 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 PRODUCTION LINE FOR POLYMER SAND PRODUCTS LPPI:

The line for the production of polymer-sand products (hereinafter referred to as the line) is intended for the production of polymer-sand products (tiles, roofing elements of varying complexity, paving slabs, road curbs, road columns, sewer manholes, hydraulic structures hatches, small architectural forms, road construction elements, TOTAL MORE THAN 20 TYPES OF PRODUCTS AT THE CUSTOMER’S REQUEST, 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, LDPE, PVC, HDPE, PP, PS) and plastics obtained when sorting and selecting municipal waste, as well as sifted 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).
• During the production process, manufactured products can be painted in any color at the request of the Customer.
• High level of profitability, at least 100%.
• Small staff of workers.
• Small footprint, compact placement possible.

Part of the equipment

THE STANDARD PACKAGE INCLUDES:

Sand heating plant with overpass(designed for heating 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
• Motor power: 15 kW
• Heating power: 12.5 kW
• Weight: 907 kg
• Productivity: 150-500 kg/h

Press 100 t/s(one for all molds of products, intended for pressing 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
• Motor power: 18.5 kW
• Weight: 450 kg
• Productivity: 150-200 kg/h

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

Polymer and film shredder(designed for grinding polymers for further production of polymer-sand mixture):

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

Press forms- according to the mold catalogue.

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

Photo

Sand heating installation:

Polymer concrete mixer:

Switchboard:

Shredder of polymers and films:

Products

Below are some samples of products produced on the line for the production 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 have polymer sand tiles been on the Russian market?

This finishing material first appeared in the early 2000s, when Russian production Imported technologies for the manufacture of composite products from a half-sand mixture (sand, polymer, pigment) began to be introduced. From this moment on, products of this product group are confidently leading in the implementation of various projects, providing serious competition to analogues made of 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 evaluate in practice the many advantages of polymer road surfaces.

What is the scope of application of polymer sand paving slabs?

Polymer sand tiles can be laid on almost any area - sidewalks, garden paths, industrial premises, service stations, livestock farms, including private garages. However, the area of ​​use is not limited by climatic conditions. A necessary condition for installing polymer functional decor in areas with increased weight impact 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 a porch, it is recommended to use a metal corner as a fixing stop. Otherwise, the process is similar to conventional installation on a cement-sand base, followed by filling the joints with a dry cement-sand mixture. The permissible size of seams is 6-8 mm.

How to lay tiles on a plinth and a used flat roof?

At installation work This type uses special support stands for piece elements. In order to lighten the weight of the structure, the tiles are laid on a layer of fine crushed stone, which is installed directly on the roof waterproofing.

Is it advisable to install a polymer paving slabs at car washes?

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

How to cut polymer tiles?

Using an ordinary grinder. Moreover, in this case there will be much less dust and waste than when sawing a concrete analogue.

How do polymer tiles react to major 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 of decor. Terrace tiles with a thickness of 22 mm are intended for paving pedestrian road surfaces and landscape areas for general purposes. Paving slabs with a thickness of 35 mm can easily support the weight of a truck.

What are environmental characteristics polymer sand tiles?

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

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

This high-quality road decoration is characterized by the absence of deformation even after prolonged use. Therefore, dismantling allows the tiles to be reused for paving to the appropriate specification. The created surfaces are highly maintainable, allowing you to quickly replace damaged piece elements without much labor.

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

Polymer tiles are distinguished by their anti-slip coating, which ensures good adhesion of the sole or wheel of a vehicle to the working surface. Snow and ice are easily cleared from the relevant areas. Moreover, even occasional strong blows from a crowbar are not capable of fatally damaging piece elements that have enviable impact strength. With any slight 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 intervention.

How long does the color of tiles last when exposed to active sunlight?

If the manufacturer conscientiously follows the technology for producing polymer sand products, namely the percentage of components, their quality. For example, if during the production process you do not skimp on pigmenting dye, the tile will look attractive throughout its entire service life (up to 25 years). This priority is ensured 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 markups.

How does extreme heat affect the strength of tile flooring?

With active, long-term exposure to sunlight, the tiles can expand within the tile joints, that is, in a linear manner. Similar changes are included in technical conditions operation. Thus, there can be no talk of any serious deformation, much less subsidence or “swelling” of the surface.

Can polymer tiles “swell” after installation during use?

Only in case of non-compliance with the installation technology - as a result of incorrect selection of components for the “cushion”, creation of too large or small seams, as a consequence of poor-quality compaction, etc. If all technical recommendations (TR - 158-04) for the installation of sidewalks are followed, 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 forms: packaging, plastic containers, household products. More and more goods are packaged in polymers, and the range of building materials made from plastics is growing. Preparation of raw materials

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 a ratio of 40-50/60-50 of so-called soft (polyethylenes) and hard (polypropylenes, polystyrenes, 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 dusty inclusions. It doesn't matter what color the sand is or what its origin is. The permissible sand fraction is up to 3 mm. Another filler that is more accessible in the selected area can be used, but before its industrial use, it is necessary to study its effect on product quality.

Pre-processing of raw materials

At the first stage, 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 low temperatures and it is easier to obtain 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. The result is a geometrically even and regular tile. The better the quality of polymer sand tiles, the more evenly the polymers and sand are mixed.

Preparation of polymer sand mass

After the first grinding, the plastic enters an 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 posed - to mix polymers at the molecular level; it is enough to mix them using the viscosity properties of molten polymers. In the structure of polymer materials, films of polyethylene and polypropylene occupy a large place. They are added to the extrusion machine without grinding. The operator removes the resulting polymer-sand mass with the consistency of yeast dough with a mitt at the exit from the extrusion unit of the line, and, having formed a ball with his hands (agglomerate up to 100 mm), throws it into water for cooling. When taken out of the water, not completely cooled, but already hardened, the agglomerate dries quickly as it cools. The entire cooled agglomerate is re-crushed into chips with a fraction size of up to 1-10 mm. Thus, ready-made raw materials for the polymer-sand mixture are obtained.

Obtaining polymer sand mass and molding tiles

This stage of production of polymer-sand tiles is final. Some separate it from the procurement area and place it in a separate room. In addition to aesthetic considerations (preparing a polymer homogeneous mixture is accompanied by the release of gases and requires the provision of exhaust), there are also practical benefits: it is easier to carry out control and accounting. Mixing of sand, polymers and dyes occurs in a thermo-mixing unit (Melting-Heating Unit). It is important to maintain 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 product 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 contains more sand will take longer to heat up. This property should be taken into account when calculating costs and accounting for products.
It is important to obtain a high-quality mixture - the sand particles must be completely enveloped in polymers, without gaps. This is achieved by a unique shaft design designed by Polymer Technology in Orsk. More precisely, not calculated, but tortured by experimental designs and scientific research. As a result, the blades on the shaft are located so that when the shaft rotates, the speed at which the mass moves is different in 3 heating zones, which ensures complete melting of the polymer and high-quality mixing with the filler.
By the way, in this unit 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 tight dumpling dough is squeezed out of the machine after opening the damper. The operator cuts off the required amount with a knife, weighs it on scales, and having received the required amount (about 2 kg), puts it into the mold with a regular scoop.

Price list for polymer sand equipment

The mold, mounted on a press with a movable bottom plate, is cooled differently.
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 the tiles (30-50 seconds).
This is done to create gloss on the outside of the polymer-sand tiles; the polymer is, as it were, squeezed upward, filling the pores between the filler. This is another secret of technology. Although such uneven cooling can lead to bending of the tiles, for this purpose they are placed on a cooling table and pressed with a weight until final shaping.
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 gray in color, like concrete.

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

Most manufacturers justify inflating prices for 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 space to prepare polymer raw materials on their own.

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

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

Time flies quickly and everything around changes. Now we all communicate using cell phones, although some 15 years ago this was an unaffordable luxury. You look out into the courtyard: instead of wooden swings on the playgrounds, almost all courtyards have brand new, “vandal-proof” children’s rides. Break them, don’t break them... They won’t break anyway. New technologies make it possible to improve the consumer quality of goods several times.

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 risk and try to lay out the platforms and paths of our beloved dacha with new tiles, but... only if they last long enough to justify the investment made. The only thing that holds us back are the questions that arise before using a time-untested new product: what if it darkens or fades in the summer? How will she survive the winter? Won't it split? And in general, the manufacturer writes only about positive qualities, but what if it is worse than classic cement? What if 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, differs high quality

and will last a long time. And one more thing: equipment for the production of polymer sand tiles is expensive.

Review of machines for making polymer sand tiles And there are no cheap analogues. In a garage, you cannot make such tiles using a makeshift method, unlike cement ones. And it will not be possible to significantly reduce the cost of technology through the use of low-quality cheap materials. By the way, high-quality concrete tiles are made only, and it is expensive, and everything else that is sold in the markets 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%), mixture of plastics (25%): high and low pressure polyethylene (allowed for storage food products and absolutely safe plastics with markings in the international system), and heat-resistant dye. These components are heated at a temperature of 250 °C. These plastics are absolutely harmless and do not release carcinogenic substances into the atmosphere when heated. In addition, you need to understand that 75% of the product still consists of sand, and plastic is the binder.

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

Let's look at all the properties in order:

+ Water repellent properties plastics give polymer sand tiles almost zero water absorption, and this extends the service life of polymer sand tiles to 20 years without destruction. Polymer sand tiles do not collapse during thaws and sudden temperature changes. Let's remember physics: water during a phase transition from liquid to solid state (ice) increases in volume, which leads to the fact that water, absorbed into the pores of the product and then freezing, increases in volume and literally tears apart the tile with high water absorption from the inside. That's why it happens that in the spring on freshly laid last fall concrete The paving stones and paving slabs already show signs of destruction. And the polymer sand tiles are intact and dry.

+ The water resistance of polymer sand products makes them attractive also because on the surface of the products no ice forms in winter– the tiles do not slip at all, and snow can be easily removed with a shovel.

+ Low water absorption explains increased frost resistance of the material(i.e. cycles of complete freezing and defrosting in a state of complete moisture saturation) - more than 500 cycles.

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

Anyone who has tried at least once “in use” products made from polymer-sand composite no longer refuses them - their use is very convenient and accessible.

+ The presence of polyethylene in the composition gives the products unique impact resistance– plastic is a more elastic and astringent material, which gives advantages during load tests. Polymer sand tiles 20 mm thick can withstand the load of pedestrian areas comparable to the load on concrete tiles or paving stones 40 mm thick!

+ In addition, it belongs to “vandal-proof” materials - such material can only be split with considerable effort. Polymer sand tiles do not break during cargo transportation or when dropped. The plastic embraces every grain of sand and paint in the mixture and, when melted, provides uniform coloring throughout the entire mass of the product. In addition, the coloring ability of plastic is higher than that of cement - such products are brighter, their color is more durable, the paint is not subject to fading

+ . Provided that 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 the color even after several years. Plastic, as we know, durable material

+ , not destroyed by time. It transfers these properties to polymer sand products. The declared service life of the coating without destruction is 20 years. The properties of plastic also give the material: acid resistance, alkali resistance, low abrasion, non-sparking

± . This is important for coatings with high traffic (entrance areas), 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-flammability (G1) and low-flammability

+ Environmental friendliness of polymer sand composite undeniable - “food grade” plastic, construction 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 release toxic compounds when exposed to them. It is simply impossible to work with such plastics in polymer-sand production - after all, production is carried out using high-temperature processing, which is only possible for harmless plastics.

± Plastic imparts longitudinal thermal expansion to polymer sand products. At unstable temperatures (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 you do not pay attention to this fact, it is possible that individual slabs will be pushed out of the coating - perhaps the tile will rise like a “house” and you will have to re-lay the coating. 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 “hill” from the heat.

The expansion of polymer sand tiles should not worry gardeners - after all, they do not have a question about strictly fixing their coating - to create paths, the tiles are laid on the ground with a sand cushion (prepared area) and compacted with a mallet. The sides of the path must be securely secured with curbs. If the thermal seams are observed, this coating will serve for many years without requiring refurbishment. 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 that can be easily removed from time to time may appear on such paths.

By the way, in winter the reverse process does not occur - the tiles do not shrink when cooling, but remain within their linear dimensions.

± The presence of plastic reduces the adhesion (adhesion of surfaces) of polymer sand tiles and cement mortar– the tiles will stick to cement mortar due to the presence of internal grooves into which the mortar will fall. Laying on a layer of mortar bed (maximum thick sand-cement mortar) is allowed. However, tile adhesive, type EK-3000, with the joints filled with grout or sealant in the color of the coating, is much better at fixing polymer-sand tiles to a concrete coating.

+ And finally, plastic in products gives ease of processing(Used angle grinder, so-called “grinder”, cutting wheel for stone), saws smoothly, easily, without “fighting” and cement dust, as when cutting concrete tiles.