The Line of Producing Constructional Monolithic Sandwich Panels Thermopanel.
There are two methods of producing panels: manual fitting on bench line and automatic production line.
Automatic production of Thermopanel panels with constant quality control gives vast production potential to produce modern construction material.
One of the special features of panels production at Thermosteps-MTL is production of all components within one plant. Three high-technology lines are in use:
- line of producing mineral insulation material on the base of water-repellent basalt fiber – Thermo
- line of coloring Zn-steel sheets in rollers – Thermocolor
- line of producing constructional monolithic sandwich panels – Thermopanel
Thermosteps-MTL uses two automatic state-of-the-art lines produced by Robor S.R.L (Italy) with productivity of 4 million sq.m. of Thermopanel panels per year.
Since 1972 Robor S.R.L has been producing machines and equipment for insulation products such as mineral wool panels, polystyrene, and polyurethane. Robor S.R.L is the leading producer of insulation material due to serious approach, reliability, professionalism and major consideration to search and improvement.
Principal Characteristics of the Line of Producing Constructional Sandwich Panels Thermo Panel
| Characteristics | Index |
|---|---|
| Production capacity | 4-8 m/min |
| Density of insulation material: mineral wool equals dense | 100-125 kg/m3 |
| Type of a sheet: colored or zinked | Толщина 0,5 – 0,8 mm |
| Thickness of end item | 50-200 mm |
| Minimum length of end item 10 м/min | 3 000 mm |
| Maximum length of end item | 14 000 mm |
The middle heat-insulation layer of Thermopanel panel consists of mineral wool plated, cut into laminae with vertical fiber orientation. Cutting is done on saw machine with a special frame with instrument kit. Quick-changing cartridge cuts laminae 50-80-100-120-150-200 mm in thickness, so it matches panel thickness. On a belt conveyor vertical orientation of mineral wool fiber takes place to strengthen panels construction. Next, laminae are launched onto the line also in automatic mode. This automatic process applies to both main constructional laminae and trapezoidal laminae to fulfill crimping of roofing panels.
Quality of panel construction depends on safety of lock system. That's why, cap locking is one of the most important phases of panels production.
12 calenders from both sides form complex lock structure. Special bend of metal sheet create air tightness of the assemblage and results in fast and accurate attachment of Thermopanel panelsduring erection. Due to its structure, the lock doesn’t need extra joint airtight packing in normal climatic conditions.
Dual component glue is used to produce Thermopanel panels. It forms safe gluing of metal paneling with heat-insulation material. Glued joint is used in upper and lower metal sheet with two mobile traverses with spray device, due to which, glued joint distributes evenly.
Double lamina transporter (perpetual press) provides high strength of glued joint : length 21 m, width 1,25 m, pressure 2 kg/sm2.
Saw cut of panels is carried out with belt floating saw that can do the cutting in two opposite directions.
The discharger, 14 m in length, is used to remove and supply Thermopanel panels. Maximum pile height is 800 mm. Every movement is coordinated by central control system, which guarantees precise synchronization of each element.
Roofing panel has crimped external surface, that's why it is important to lay one panel straight, and another in reverse, both for joint and packing density. When panel gets into the discharger, special machine unrolls it to 180°. Thus, cripples join at upper side, and the panel gets into the discharger. The next panel doesn’t turn over, but it is put with cripples down to get into the previous panel. This method helps to pack loads of panels with equal packing size.
Packing machine (to pack up with stretch film) guarantees high quality of packing Thermopanel panels. Machine packing program supplies full packing with head crossing.
