We start producing SIPs after receiving an advanced payment and confirmation that the project complies with the customer’s requirements. Materials for sandwich panels are purchased according to the specification provided by the designer. Certificates for materials purchased are checked for conformity with the characteristics claimed (density of polystyrene boards and OSBs, deviations of geometrical dimensions etc.). Deviations identified are recorded in the Raw Materials Inspection Report. After the inspection the materials are taken to the Bonding Workshop. Then the workshop area and its equipment are prepared for gluing: the operating air and glue temperatures are reached, the air required to operate mechanical moving parts is injected with a compressor, injectors are cleared, continuous adhesive flow is launched. The operator and assistant occupy their workplaces and test automatic equipment. Then OSBs and polystyrene boards are stacked on a conveyor trolley, positioned and run under a moving set of injectors. Adhesive is evenly applied automatically. Activation/deactivation of the flow of adhesive through the injectors is controlled by optical sensors and limit switches. Adhesive is constantly pumped through the system even when the injectors are closed, which prevents its premature thickening, reduces losses and makes it always ready to apply. To activate glue we use fine water atomizers to increase glue adhesion (penetration) level and strength of the surfaces to be bonded. Each coat of glue applied is controlled by the operator. Half-finished glued sandwich panels are stacked (looks like a layer cake) to be put under a press for drying. While glue is drying and soaking the materials, the process continues. The same steps are done to form another stack of half-finished panels. Another stack is put under a press on the opposite side of the line. Ready sandwich panels are recovered from under presses, checked for bulges or protrusions and taken to the storage. The same process works for the next batch. SIPPU line performance is 7-9 panels per hour with sandwich panels passing a multi-stage quality control.
Sandwich panels for kit homes are processed in the Cutting and Foam Removal Workshops. In the Cutting Workshop sandwich panels are sawed according to the cutting ticket and marked according to the design documents.
MITRE CUTTING OF PANELS
The last phase is SIP grooving for beams to be put in.
The ready to apply kit home elements are packaged (at customer’s request), stacked to be shipped to the construction site.