Profile-production methods are quite diverse. The method is selected according to the intended use of the finished product. Profile production is similar to pipe production, but there are important differences: profiles have a complex cross-sectional geometry that must be considered in the production cycle.
These products are divided into two broad categories: profiles without internal enclosed cavities and closed profiles.
The first category includes:
The second category includes:
Before starting profile production and selecting the optimum process, the following profile parameters must be determined:
The same type of profile can be produced using different technologies. Much depends on the available equipment and the engineering recommendations developed for the specific process.
For example, a rectangular hollow profile can be produced using a special forming tool or from a cylindrical blank. The profile can be made from a strip extruded through a die slot and then deformed in a calibrator. It can also be produced by welding or by another process. There are therefore many possible solutions, and the specific method is chosen mainly according to the available equipment and the technical requirements for the product. Below we look at common profile types and production methods.
This type of product is calibrated using a set of plates. The plates are installed in a special tank that is evacuated and equipped with the required fixtures. A vacuum pump installed in the tank removes the air.
The technology is similar to pipe production, with one difference: the profile can be formed from a blank shaped as a hollow cylinder.
This is convenient and highly productive: the method can produce profiles with three, four, or more corners.
Hollow and chambered profiles generally require a long calibration unit that uses vacuum. The tool head forming the profile must reproduce the product shape in cross-section.
The extrudate cooling process must be controlled to maintain the required product strength and protect the profile from subsequent deformation. This process uses two cooling stages; at the final stage, the profile is cooled with water or an air stream in a special unit located after the calibrator.
These products are manufactured using approximately the same method as the two types described above. Calibration is also performed in a short vacuum calibration unit.
However, if the profile has thicker walls, a special block consisting of «dry» calibrators is required. A special cooling tank containing calibration plates must also be installed.
This profile-production method creates significantly more friction, so the profile must be pressed more firmly against the tracks.
This technology requires careful selection of the die and calibrator because the process can be unstable. This must be taken into account.
In relatively rare cases, the drawing method can be used for calibration.
Combined profiles usually consist of different compatible materials. They may differ in color, composition, or polymer type. Such profiles can be calibrated using standard process schemes. Profiles that do not require calibration, most often PVC plastic, can be cooled in a water tank or on a belt conveyor using an air shower.
These products contain a special core made of various materials, such as polymer, metal, reinforcing mesh, or steel wire. The core is usually degreased and heated in advance and may be coated with an adhesive to improve bonding. In some cases, the sheath is applied to the core under vacuum.
profitability FROM 90%
payback FROM 1 MONTH
staff: 1–2 PEOPLE
To produce a high-quality composite GFRP profile that meets all GOST requirements, it is essential to use proven, certified technology developed by professionals. Our company has its own laboratory specializing in research and development of composite materials.
The research laboratory at our company is headed by Pavel Vyacheslavovich Nikolaev.
- Doctor of Chemical Sciences and professor at the Department of Chemistry and Technology of High-Molecular Compounds at Ivanovo State University of Chemistry and Technology (ISUCT).
This is how Pavel Vyacheslavovich describes his work:
Since 1973, my research interests have included epoxy oligomers and composite materials based on them. Since 2012, I have headed the laboratory of the Ivanovo Mechanical Plant research and production company. Manufacturing construction materials is a huge responsibility: peoples health and even lives are at stake, so the technology must be approached with due care.
Running the laboratory required applying the knowledge and experience I accumulated over more than 40 years of scientific work. Product quality, high output, and environmentally responsible production are the main priorities in the laboratory technology development.
Learn more about our laboratory on the Our Laboratory page
Our own research laboratory, combined with many years of research experience, guarantees that our partners receive high-quality, certified technology that meets the strictest requirements of technical regulations.
Call us now and we will explain how to manufacture the best GFRP composite profile.
Length, width, height: 25 × 2 × 2 m.
Space is also required for a finished-product warehouse.
Total line power: 380 V/50 Hz, 10 kW (excluding mold-heating power)
Our energy optimization can save up to RUB 20,000 per line per shift, in addition to profit.
0.5–1.2 m per minute per die
Monthly fiberglass output per die: up to 21,000 linear meters.
One or two operators are sufficient to operate the line
Our specialists train operators.
Complete technical documentation is supplied with the line.
Equipment warranty: 3 years.
Warranty and post-warranty service.
The equipment is reliable, with a proven service life of 10 years without major overhaul.
We provide our customers with innovative, certified production technology.
We deliver ordered equipment anywhere in Russia and worldwide.
We have supplied equipment to 135 companies in Russia and 30 companies in the CIS and the European Union.
We deliver, assemble and set up your equipment and produce a trial batch.
We train your employees to operate the equipment and help with online sales.
You can always count on us. We provide complete maintenance for our production lines.
GFRP outperforms metal in every key parameter.
Composite plastic does not rust, is stronger and less expensive than steel, and is four times lighter. Glass-fiber-reinforced plastic is dielectric and has low thermal conductivity.
These and other properties make it an excellent material that is indispensable in construction.
Pultrusion of GFRP profiles makes it possible to produce profiles of any cross-section, type, purpose, size, and color by changing the settings of the same line. This includes all profile types, cross-sections, and linear dimensions used in construction — solid and hollow profiles analogous to metal products: rectangles, squares, round tubes, channels, beams, T-sections, I-beams, U-, T-, F-, W-, and S-shaped profiles, angles, rods, and strips or plates.
GFRP profile production does not require a large factory, heavy melting, casting, rolling, or forging equipment, powerful lifting mechanisms, or heavy-duty transport for delivery.
Compared with steel, and especially with wood, GFRP structures have a very long service life and minimal water absorption. They are resistant to ultraviolet radiation, moisture, and temperature fluctuations. Adding UV-blocking pigments to the binder eliminates the cost of protective painting and other operating expenses.
In many applications, metal used in construction can and should be replaced with durable, lightweight, and affordable GFRP.
Power supply and communications: supports, poles, and masts.
Construction of industrial and residential buildings: supports, piles, posts, floor structures, battens, partitions, and frames.
Replacing light-gauge steel frames with plastic frames in prefabricated residential and industrial buildings increases service life and reduces heating costs by eliminating thermal bridges.
Finishing and facades: starter and guide mounting profiles for composite plastic panels, lining, drywall, polycarbonate, and more.
Fences, stairs, ramps, bridges, children's playgrounds, greenhouses, and anything else that human imagination can create.
I had long dreamed of starting my own fiberglass production business in Iraq. The IMZ team explained every aspect of the production process and showed me videos of the plant and its products. I was impressed. We ordered the equipment and started production a month and a half later. It is profitable. I highly recommend it.
I am very pleased with our cooperation with NPO Zvezda. We have no complaints about delivery or assembly: everything was completed on time and to a high standard. All documents, certificates, technical specifications, the business plan, and test results were provided immediately.
I spent a long time deciding which supplier to work with and chose NPO Zvezda. They had never let us down before. The machine was delivered and installed on time, everything was explained and tested. I am happy with my purchase; now it is up to me.
We have been working with construction materials for more than 12 years. We decided to start manufacturing composite rebar. IMZ was selected as the equipment supplier "IMZ". We first ordered a rebar production line and then expanded with mesh and profile lines. IMZ has proven to be a reliable and responsible partner that guarantees product quality.
I had always wanted to start my own business, but every option required a lot of money. Then I saw an advertisement for a composite rebar production line. No special expertise was required; the technology and suppliers are provided. I chose the SPA-2 line, and it has fully met my expectations. I am considering further expansion.
We would like to thank IMZ for implementing our production modernization project. The aim was to increase output and bring quality in line with GOST standards. This success was achieved thanks to the company highly qualified specialists and prompt resolution of the assigned tasks.
Composite materials have long been recognized in developed countries and are used successfully by builders.
The construction market is vast. High-quality composite GFRP profiles have a wide range of applications and are in high demand.
GFRP and BFRP composite materials are indispensable for constructing and repairing all types of foundations and walls of buildings of any height. GFRP profiles are lighter and less expensive than steel profiles and are often stronger. GFRP profiles are especially suitable and necessary for structures operating in areas with high humidity and chemically aggressive environments.
You can purchase our GFRP composite profile production line anywhere in Russia, including: Moscow, Saint Petersburg, Ivanovo, Novosibirsk and other locations.
Have questions? Call us.
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