Sip Housing Solutions Congo 25.9.12

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  • 1. Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 2. Featured:Factory requirements• Manufacturing process for the production of SIPs panels:• Photographs of the machinery:• Required Production Requirements and suggested volumes to meet volume specified:• Allied machinery requirements for processing SIPs panels:On SiteAffordable/Emergency housing OptionsStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 3. BackgroundThis process has in fact been used for many years within other industrialareas around the Globe, one of its first uses was in the aerospaceindustry during the second world war; using plywood skins with an endgrain balsa wood core for structural elements of the twin engine BritishFighter Bomber the Mosquito. Of course since that time materials andadhesives have improved dramatically, but fundamentally the principal isexactly the sameStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 4. Process By separating two substrates of high strength with a core material bonded between them (EPS, expanded Polystyrene), one in fact creates a Virtual Steel “I” beam with the HFGBS Wall System, but of course with substantial weight savings. Core materials and skin materials of many types can be combined to create a composite panel, however the HFGBS Sips Panel, is made from a Cement Fiber Board, with this system to stay competitive we must therefore, utilize the most competitively priced raw materials so as to compete with other forms of construction, while staying within the parameters of our Product Approvals and Certified Engineering credentials, our system must also demonstrate exceptional high strength so as to ensure the structural integrity of a Family Home, or Commercial Building, the HFGB manufacturing System achieves these goals.Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 5. Production Requirements: The Plant described within this presentation has been designed to produce 9 million Square Feet of SIPs panel per Year or (3000 Homes at 80m/2 aprox), however, this has been based on three shifts per day working a five day week; therefore higher volumes are achievable by either increasing the shift pattern to four per day and or increasing from five days to seven. Production Process: To achieve a balance of semi-automation with manual labor is at times challenging, however, the process described here, does exactly that, additionally this machinery also utilizes systems that are virtually maintenance free. Further automation is also an option with this system, at a later time:Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 6. HFH Factory, Florida, USAStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 7. Panel requirements: 12ft x 4ft panels = 48ft2 per panel at 8 inches thick 20ft x 4ft panels = 80ft2 per panel at 12 inches thick 4,500,000ft/2 of 12ft x 4ft panels = 93,750 panels per year 4,500,000ft of 20ft/2 x 4ft panels = 56,250 panels per year Assume 48 weeks working, 5 days per week, 3 shifts = 1,260 shifts per year Assume a 4ft daylight press divided by 8 inches = 6 panels per press Assume a 4ft daylight press divided by 12 inches = 4 panels per press Assume 1.5 hour press time = 5 press loads per shift Therefore, three presses at 12ft x 4ft will be required and three presses at 20ft x 4ft to produce the volumes requiredStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 8. The skin material be it cement fiber board or our Hi Tec Engineered OSB for roofpanels is lifted via vacuum assisted crane onto the adhesive machine, which isalso a motorized conveyor, the machine carries datum guides so as to ensurewhat will be the bottom skin is in the correct position, this is pre- programmed via adigital control panel, the adhesive is applied to the bottom skin via a beadapplicator head which is driven by a digitally controlled servo motor, but only to thearea to be bonded; that is in this case 50mm in ( 2 inches ) from each side, thecore material, in this case polystyrene (E.P.S.) is placed onto the bottom skinagain using datum guides to ensure exact positioning.Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 9. Adhesive is then applied in exactly the same way to the top of the foam core, finally the top skin, again is lowered into place via datum guides onto the foam core, this whole process for this panel takes around three minutes. (For technical data on the adhesive please go to appendix A)Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 10. Automated Adhesive Line Option The panel is then conveyed by the motorized conveyor contained within the adhesive machine onto a loading table with gravity fixed rollers; this table is in turn attached to tracks so as to move the table side ways so as to load one of two presses.Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 11. The panel is then subsequently loaded into the pneumatic press, once thepanel is in position the press is closed, compressing the composite paneltogether whilst the adhesive cures, in this case around six minutes. Oncethis cycle is completed the press releases the pressure and lowers, allowingthe operators to remove the panel for trimming, to ensure the volumerequirements are met there will be a total of four presses; these will be fed bytwo adhesive bead applicators, by completing a panel for pressing everythree minutes with a press time of six minutes, then the volumes required aslisted above on an annual basis will be met by operating three daily shiftsover a five day week.Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 12. Additional Automated Machinery: • Computer aided saw, capable of cutting cement fiber board and OSB Board sandwiching a Styrofoam core, the maximum panel size to be 24ft x 4ft x 12 inches thick: • Vacuum lift with crane, to lift heavy skin material onto the bead applicator/conveyor • Mobile transfer tables, to move pressed panels to cutting area.Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 13. CNC Computerized Panel Cutting Machine An industrial strength machine, able to cut through deeply layered laminated wood or SIP panels. Dimensioning of material can be almost limitless in width or length, for custom-fitted applications. This is a CNC controlled, patented woodworking centre. It can process wall panels in widths of 3000 to 8000 mm (10 ft to 26 ft) wide, thickness up to 400mm (15 3/4") and, because of its modular structure, unlimited length. What makes this machine unique is a patented tool holder of exchangeable tools with a permanent saw blade of diameter up to 1000 mm (39") and a 5-axis tool changer that can host large-dimension tools for processing just about any material.Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 14. SIP Machining TableSIPs that are ready for machining are transferred onto the SIP machining table.When SIPs are aligned on the machining table with the use of four (4) pneumaticalignment pins, three (3) in the X-axis and one (1) in the Y-axis, the Multi-FunctionBridge (MFB) machines them to size and shape. We are offering two types oftables in this proposal, the standard table with four locating pins for location of one(1) panel, and an optional table that has the flexibility to locate four (4) 4’ x 8’panels.Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 15. Multi-function Bridge CNC Machining Center Automated Conveyor SystemStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 16. Automated Roller Belt Conveyor to transport Panels from Glue Laminatorto PressesStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 17. Vacuum Lift System from Machine to PalletStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 18. Vacuum Panel StackerStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 19. Pod PressStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 20. ESTIMATED FACTORY SIZE: • Panel production area, 429M2 • Cutting and preparation, 200M2 • Assembly area, 350M2 • Storage area for raw materials 150M2 • Office space/meeting rooms 50m2 • Total Factory size 1,129M2 (12,152ft2)Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 21. APPENDIX A - Adhesives Mor-Ad M-650 is an ICC approved (ESR-1023) polyurethane single part moisture cured adhesive, Mor-Ad M-650 series of adhesives that have been developed specifically for laminated sandwich panels; these products have been formulated for good adhesive penetration coupled with excellent bond strengths. They also exhibit a high modulus of elasticity for improved long span performance. This adhesive has been used by Home Front Homes at their plant in Miami Florida and the Company has never experienced any co-adhesive failure, in fact such is the nature of polyurethane adhesive in terms of the bond strength and the very high elongation to break; that it will always out perform both the core material and skin material in any three point bend, rolling drum and lap shear strength test. Therefore this also applies to any polyurethane adhesive manufactured today, however the Company is looking at other alternative adhesive options that comply with their US Product Approvals together with ICC Criteria in order to insure their availability in the required Geographical locations where Factories are being considered.Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 22. Therefore to achieve the production volumes required for Home Front Homes an open time of 3-4 minutes with a 6-8 minute press time will be used, this being combined with the use of two conveyor bead application machines and four presses will result in a continuous production of panels. Automated Glue Laminator (Optional)Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 23. Computerized Monitoring of Plant and Machinery: HFGBS intends to include Computerized Monitoring Systems and Live Web Cam Technology to Monitor its Plants 24/7 this plant and its production volumes can be accessed by management 24/7 from any Computer, anywhere in the World:Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 24. On Site InstallationStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 25. Completed Unit in 5 daysStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 26. Affordable & Emergency Housing Solutions(1 Bed)Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 27. Affordable & Emergency Housing Solutions(2 Bed)Structural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 28. Affordable & Emergency Housing SolutionsStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 29. Affordable & Emergency Housing SolutionsStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 30. Low Cost Modular ApartmentsStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.
  • 31. Modular Residential Solutions • Detailed Design • Project Co-ordination • Manufacture • Delivery and Installation • External Work and Foundations • After Care Package Contact details Miami, USA: 260 West 27th Street Hialeah, FL 33010 Mr John Butler, Mr Gabe Rispoli Office 001.305.888.3902 Email johnbutler@gmail.com Email gaberispolijr@mac.com UK & Ireland Mr Edward McCarthy, Mr Olan Crowley Mobile 0044.7827280304 Mobile 00353.878272686 Email edwardmac@btinternet.com Email olan.crowley@live.ieStructural Insulation Panel (SIP) Housing solutions for DemocraticRepublic of the Congo.