Own business: metal tile production

* The calculations use the average data for the World

The metal tile is one of the varieties of roofing materials made on a metal base, on top of which, in turn, a protective and decorative coating of polymers is applied. These are not individual pieces of roof tiles, which are covered by the roof, but large sheets of area, on the surface of which a drawing is imitated that imitates the pattern of evenly laid tiles. Thus, the use of metal can significantly save on labor costs (laying large sheets is much easier and faster than individual small elements) and improve the quality of the coating (a large roofing material means fewer joints). The metal tile has a relatively low weight (for example, compared with clay tiles, which is six times more).

Sheets of metal are made of galvanized steel and aluminum. These materials are least affected by precipitation, so they are optimal for the manufacture of roofs. To give the coating greater strength and an attractive appearance, the metal on both sides is coated with several layers of colored plastic from 27 to 50 microns thick at once. Depending on the type of product and manufacturer, the plastic used for protective purposes may have different characteristics. First of all, it must be resistant to ultraviolet rays, so that the bright colors of the roof covering do not fade under direct sunlight. Due to the special properties of the materials used for the production of metal, this coating can withstand temperatures from -500 to 1200 degrees Celsius. The length of metal tile sheets can be from 40 cm to 8 meters, depending on the needs of customers. The width of the coating is about 1 meter, and the thickness is about 0.5 meters. Separate sheets of metal are mounted on a waterproofing coating. Then they are fixed to the crate with the help of special corrosion-resistant self-tapping screws. In this case, the holes do not need to be drilled in the coating itself. Sheets overlap. It is also possible to mount metal tiles on top of old wood roofs. Thus, the business associated with metal roofing can have two areas - directly the production of material and its laying. The service life of metal is up to fifty years. In total, manufacturers subdivide the entire metal tile into three main classes, which differ in the thickness of the metal and its polymer coating. This indicator can range from 0.37 to 0.75 mm. Western companies (for example, Swedish) for the production of metal tiles use the thinnest sheet metal with a thickness of not more than 0.4 mm. Such a sheet has the smallest mass, but it is difficult to mount. Therefore, many domestic construction companies refuse to work with such material. Domestic manufacturers use thicker sheets as a basis. However, there are some nuances. So, for example, steel with a thickness of 0.55 mm or more can not be molded, for this reason, when working with a material of this thickness, a specialized metal tile production line is used. It should also be borne in mind that sheets of metal tiles on a dense basis are less compatible with each other than a thinner coating. For these reasons, specialists in roofing materials consider the basis of 0.5 mm to be optimal. Such sheets are easily formed and have the required margin of safety. As a result of sequentially applied longitudinal rolling, a strip with a characteristic profile is obtained.

The metal tile has the widest application. It is used to equip the pitched roof of private houses, country houses and cottages. It is also used to cover the roofs of various administrative and commercial buildings.

So, the production of metal can be an excellent option for starting and developing your own business. If you are a beginner in this field, experts advise you to pay attention to products made of galvanized thin sheet (GOST 14918) coated with polymers (GOST 30246-94) with a thickness of 0.45-0.5 mm. It is such a roofing that is one of the most popular metal tiles on the market, due to its low price. It accounts for almost 80% of total sales. High-quality roofing materials are produced on modern equipment by the method of roller rolling and subsequent cold stamping during a continuous process.

This creates the most accurate repetition of the tile pattern. Savings are achieved due to the low metal consumption of roofing sheets, which are cut to individual sizes for each project, depending on the wishes of the customer. This allows customers not to overpay for unnecessary material leftovers.

Some companies that try to attract buyers with the cheapness of their products use galvanized sheets, which, after machining, are painted almost manually with special acrylic paints. The disadvantage of this production method is that the finished product is significantly inferior in quality to good roofing materials. Firstly, when painting in artisanal conditions, it is almost impossible to achieve perfectly even application of acrylic. All this is fraught with the appearance on the roof surface of unpainted areas, a drop, swelling, ugly smudges. But the disadvantages from an aesthetic point of view, the disadvantages of this method of production are not limited. Worst of all, a pre-shaped sheet cannot have a perfectly smooth surface. Due to the presence of a large number of various irregularities, the paint does not adhere well to the substrate. As a result of this, it can peel off over time, and the metal under it can rust. The service life of such a roof can be 2-3 years. After this time, the roof will have to be changed. Therefore, if you value the reputation of your company and take your business seriously, experts recommend spending more money and time searching, acquiring and mastering modern equipment and advanced technologies, thanks to which your products will be of high quality.

As raw materials for the manufacture of metal tiles, a special metal is used, designed for profiling and stamping, of domestic production. At a price it turns out to be more expensive than Chinese metal, with which most Russian companies work, but its quality is much higher. The manufacturing process of a metal tile consists of several main stages. First, a large roll of metal sheet is installed on the unwinder line for the manufacture of metal. Then the expanded sheet is fed into the rolling mill, where it is subjected to longitudinal rolling followed by transverse stamping. After rolling, the steel sheet is hot dip galvanized on both sides. As a result of this procedure, its surface becomes resistant to corrosion. Then the sheet is passivated. The so-called passivation layer protects zinc from oxidation and provides the very same adhesion - reliable adhesion of the soil to the metal base.

After that, a protective primer is applied to the passivated surface of the metal, and then a layer of polymer coating with a thickness of 35 μm. Even such a thin layer of polymer is sufficiently resistant to ultraviolet radiation and temperature extremes. Such a coating has a long service life and is fire resistant. In fact, polymer coatings are applied in several stages according to the following scheme: passivation, primer, polymer coating, protective varnish. In this case, the polymer composition of the tile, as a rule, is covered only on the upper side, and a colorless protective coating is applied on the lower side. As the polymer coating can be used in different materials. For example, polyester, which is applied in a layer up to 25 microns thick. It is highly resistant to temperature changes and wear, is not damaged during molding, which allows you to feed sheets with an already coated coating on the profile stamping. An additional advantage of polyester is its price - it costs less than many other polymers. In addition to polyester, pural is used. It is applied to the sheet with a layer of 50 microns. Pural gives the surface a pleasant silky matte texture. With a thicker polymer layer, the resistance of the roofing material to negative environmental factors increases, but such material can withstand worse molding. Finally, plastisol can be used as a polymer coating. It is applied with a thickness of 200 microns. Its color scheme is the widest. In addition, plastisol is resistant to mechanical and thermal influences. However, the minus of this material is that it quickly heats up in direct sunlight and burns out.

After applying the protective polymer, the metal tile is sent to the molding mechanism, where it acquires the specified profile. After profiling, it is cut into sheets of the desired size.

At the last stage of production, the inspectors check the quality of the products, pack and send the finished metal to the warehouse. Pallets are used for packaging roofing material. The tile is screwed onto a wooden pallet to prevent deformation during transportation using metal tapes. In order to protect the surface of coatings from possible chips and scratches, soap solution is poured between the individual sheets. A plastic film can also be used, with which each layer of tile is laid. On the sides of the metal, laid on pallets, closed with cardboard inserts, and the entire package is wrapped in a dense plastic film. For the shipment of products, special equipment is used - a forklift truck, which avoids losses when packing and moving metal sheets. The production area where roofing materials are manufactured is equipped with automated lines with a roll forming machine. The minimum list of necessary equipment includes a metal tile production line, a beam crane, work tools, and a forklift. The main machine from the entire line is considered to be a bending mill, thanks to which the tile acquires its characteristic texture.

The choice of equipment for the production of various profiles and with different capacities is quite wide. Most entrepreneurs prefer domestic equipment, as it is not inferior to foreign equipment in quality, but at the same time it will be cheaper, taking into account shipping costs. When choosing a line, pay attention to its configuration. The cost depends on how many types of metal tiles can be produced with it. A line of domestic production, which allows you to produce two types of profiles with a capacity of 5 square meters. meters per minute, will cost 3 million rubles. The line is standard with a capacity of 7 square meters. meters per minute costs about 3.5 million rubles. Automated equipment is about 20 meters long, 2.5 meters wide and 2 meters high. Accordingly, its placement will require an area of ​​about 100 square meters. meters. At the same time, one worker per shift is sufficient for servicing on such a line.

The business of manufacturing metal is considered quite profitable and promising, since this roofing material is considered one of the most popular in the world. The same trend applies to our country. According to the researchers, the annual consumption of this material for roofing is over 170 million square meters. meters. Every year the market grows by 15%. Of course, such a profitable segment could not fail to attract the attention of other entrepreneurs. Competition among domestic manufacturers of metal tiles is very high. In total, there are about three hundred companies on the market, not counting Western brands. In order to take its place in this segment, it is recommended to choose one price category (inexpensive products are most in demand) and immediately, even at the planning stage, look for channels for its sale. For example, manufacturers of roofing materials sell them directly to construction companies, and also work with a dealer network - wholesale companies that sell construction materials.

Such a business requires a relatively large investment. Production equipment alone, including delivery, installation and commissioning, will cost 4-4.5 million rubles. Add to this the cost of purchasing raw materials (the first batch of 1 million rubles) and other costs. Total, according to a rough estimate, at least 7 million rubles will be required to organize own production of metal tiles. With production volumes of 200 square meters. metro per hour and when generating about 18 thousand square meters. meters of products per month, the wholesale price of the product is 170-180 rubles. per sq. meter, the payback period of the production enterprise will be two years. According to various estimates, net profit for such indicators is about 250 thousand rubles. per month.

Related article:

Opening a metal tile business

Sysoeva Lilia

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08/18/2019

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