Welcome to the world of advanced composite rebar production technologies from Composite-Tech. We are a global leader in creating machinery for producing composite construction materials, utilizing the most innovative and patented technologies. In this article, we will discuss our unique production process, the key advantages of our products, and why Composite-Tech is your best choice.
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Production Process on Composite-Tech Machines
The production process of composite rebar starts with raw material preparation. The first stage involves heating fiberglass strands to a temperature of 150°C to remove excess moisture and sizing, freeing up space for the resin. This ensures optimal adhesion between the resin and fibers, which is critical for the final quality of the rebar.
Next is the stage of impregnating the strands with epoxy resin. Our impregnation bath uses pneumatic cylinders of Italian manufacture, ensuring optimal resin squeezing and preventing its overuse. This not only reduces costs but also enhances the environmental safety of the production. Our impregnation drum is equipped with unique equipment that allows the resin to be evenly distributed among the fibers, significantly increasing the strength of the finished product.
The next stage is the winding of the ribs. The rib winding angle on our machines is controlled by a computer program, ensuring precise adherence to all quality requirements. The software developed by Composite-Tech allows real-time monitoring of all winding parameters, ensuring process stability and repeatability.
After winding, the raw rebar is directed to the booster polymerization chamber, where special lamps initiate the polymerization process from within the rebar, preventing surface burning at all stages. This patented method is used exclusively by Composite-Tech and significantly improves the rebar’s characteristics, such as tensile strength and chemical resistance.
Then, the rebar enters the 12-meter-long ovens, where polymerization is completed. High-temperature ovens ensure even and complete curing of the resin, guaranteeing the stability of the rebar’s dimensions and shape. The temperature in the ovens reaches 180°C, which allows achieving optimal material structure.
The next important stage is cooling. Composite-Tech is the only company using both air and water cooling, which prevents thermal shock and the formation of microcracks. This significantly improves product quality and extends its service life. The combination of the two cooling types ensures temperature control with an accuracy of 1°C, which is critical for maintaining material structure.
In the final stage, the rebar passes through a pulling device equipped with pneumatic cylinders for precise pressure control. We use wear-resistant rubber capable of withstanding tens of thousands of kilometers, guaranteeing the durability and reliability of the equipment. Pneumatic cylinders allow precise adjustment of the force, ensuring high surface quality of the rebar.
Unique Technologies of Composite–Tech
One of Composite-Tech’s key advantages is the use of unique technologies that we have developed and implemented in our production lines:
- Automated Quality Control Systems: Our machines are equipped with advanced quality control systems that monitor each production stage and guarantee high product quality. Sensors and monitoring systems provide constant control of process parameters such as temperature, pressure, and speed.
- Customizable Settings: We offer the ability to customize the equipment according to the specific requirements of the customer, allowing for the production of rebar with unique characteristics. For example, our clients can choose between different rebar diameters (from 4 to 32 mm) and profile types.
- Energy-Saving Technologies: Our machines are designed with modern energy-saving requirements in mind, reducing production costs and minimizing environmental impact. Energy-saving components and process optimization reduce energy consumption by 20%.
Advantages of Composite-Tech over Competitors
- High Product Quality: Thanks to our unique technologies and stringent quality control, our rebar is characterized by high strength and durability. For example, our rebar has a tensile strength of up to 1800 MPa, significantly exceeding similar indicators of competitors.
- Individual Approach to Each Customer: We offer flexible solutions that meet the needs of even the most demanding customers. Our specialists work with each client to develop the optimal solution for their specific needs.
- Innovation and Development: We continuously work on improving our technologies and equipment, allowing us to remain a market leader. Composite-Tech invests more than 20% of its annual turnover in research and development.
- Experience and Professionalism: Our team consists of highly qualified specialists with many years of experience in the field of composite materials. More than 80% of our employees have higher technical education and undergo regular advanced training.
Specific Indicators
Composite Tech prides itself on its achievements in composite rebar production:
- Productivity: Our machines can produce up to 10,000 meters of rebar per shift (8 hours), allowing us to meet even the largest orders in a short time.
- Energy Consumption: Thanks to the use of energy-efficient technologies, energy consumption per 1 meter of produced rebar is only 0.016 kWh.
- Precision: Our machines ensure rebar diameter precision up to ±0.1 mm, guaranteeing compliance with the most stringent standards.
- Equipment Service Life: Composite Tech machines are designed for 15 years of operation without major repairs, as confirmed by numerous customer reviews.
Conclusion
Composite-Tech continues to set new standards in composite rebar production, offering its clients high-quality products and innovative solutions. We are proud that our unique technologies allow us to surpass competitors and ensure the reliability and durability of our products. By choosing Composite Tech, you choose quality, innovation, and professionalism.
Composite Tech is your reliable partner in producing high-quality composite rebar. Our machines are the key to a successful business and an excellent product. Contact us today to learn more about our capabilities and take the first step towards successful cooperation.