sip housing solutions congo 25.9.12

Structural Insulation Panel (SIP) Housing solutions for Democratic

Republic of the Congo.

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 Site

Affordable/Emergency housing Options

Structural Insulation Panel (SIP) Housing solutions for Democratic Republic of the Congo.

This process has in fact been used for many years within other industrial

areas around the Globe, one of its first uses was in the aerospace

industry during the second world war; using plywood skins with an end

grain balsa wood core for structural elements of the twin engine British

Fighter Bomber the Mosquito. Of course since that time materials and

adhesives have improved dramatically, but fundamentally the principal is

exactly the same

Background





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.

Process

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:


HFH Factory, Florida, USA


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 required



The skin material be it cement fiber board or our Hi Tec Engineered OSB for roof

panels is lifted via vacuum assisted crane onto the adhesive machine, which is

also a motorized conveyor, the machine carries datum guides so as to ensure

what will be the bottom skin is in the correct position, this is pre- programmed via a

digital control panel, the adhesive is applied to the bottom skin via a bead

applicator head which is driven by a digitally controlled servo motor, but only to the

area to be bonded; that is in this case 50mm in ( 2 inches ) from each side, the

core material, in this case polystyrene (E.P.S.) is placed onto the bottom skin

again using datum guides to ensure exact positioning.



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)


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.

Automated Adhesive Line Option



The panel is then subsequently loaded into the pneumatic press, once the

panel is in position the press is closed, compressing the composite panel

together whilst the adhesive cures, in this case around six minutes. Once

this cycle is completed the press releases the pressure and lowers, allowing

the operators to remove the panel for trimming, to ensure the volume

requirements are met there will be a total of four presses; these will be fed by

two adhesive bead applicators, by completing a panel for pressing every

three minutes with a press time of six minutes, then the volumes required as

listed above on an annual basis will be met by operating three daily shifts

over a five day week.


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.


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.

CNC Computerized Panel Cutting Machine


SIP Machining Table

SIPs 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) pneumatic

alignment pins, three (3) in the X-axis and one (1) in the Y-axis, the Multi-Function

Bridge (MFB) machines them to size and shape. We are offering two types of

tables 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.


Multi-function Bridge CNC Machining Center

Automated Conveyor System


Automated Roller Belt Conveyor to transport Panels from Glue Laminator

to Presses


Vacuum Lift System from Machine to Pallet



Vacuum Panel Stacker


Pod Press


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)


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.


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)


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:


On Site Installation



Completed Unit in 5 days


Affordable & Emergency Housing Solutions(1 Bed)


Affordable & Emergency Housing Solutions(2 Bed)


Affordable & Emergency Housing Solutions



Low Cost Modular Apartments

• Detailed Design

• Project Co-ordination

• Manufacture

• Delivery and Installation

• External Work and Foundations

• After Care Package

Modular Residential Solutions

Miami, USA:

260 West 27th Street

Hialeah, FL 33010

Mr John Butler, Mr Gabe Rispoli

Office 001.305.888.3902

Email [email protected]


UK & Ireland

Mr Edward McCarthy, Mr Olan Crowley

Mobile 0044.7827280304

Mobile 00353.878272686



Contact details


sip housing solutions congo 25.9.12

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