Sheet Applications in the Field of Construction

KraussMaffei BerstorffExtrusion Devision MunichMunich, 2007

Sheets in the Field of ConstructionMaterialsPVC SheetsPolyolefine SheetsMarket

Chapter 1 – Sheets in the Field of Construction

Applications in the Field of Construction as for example for a One-Family House

Coverings

Window- and Door Fillings

Systems for Doors

Trimboards

Container Construction

Advertising Boards

Tent- and Hall Construction ......

Sheets in the Field of ConstructionMaterialsPVC SheetsPolyolefine SheetsMarket

Chapter 2 – Materials

MaterialsUsed Materials

● PVC rigid

● PVC chemical foamed

● HDPE rigid and chemical foamed

● PP rigid und chemical foamed

● ABS

Twin Screw Extruder

for rigid -

and soft PVC

KMD

Single Screw Extruder

with grooved bush in the intake section

KME / B

Single Screw Extruder

with grooved bush in the intake section and degassing

KME / BV

TECHNICAL THERMOPLASTICS

PS, ABS, PMMA….

POLYOLEFINE

PE, PP

Sheet Lines

PVC (rigid, soft)

MaterialsKrauss Maffei Berstorff, Munich Products for Sheet Extrusion

Sheets in the Field of ConstructionMaterialsPVC SheetsPolyolefine SheetsMarket

Chapter 3 – PVC Sheets

● Rigid PVC

(density 1,4g/cm³, thickness range 0,8 – 30 mm)

● Chemical foamed PVC, mono layer,

called „Free Foam Sheet“

(density about 0.55 – 0,7 g/cm³, thickness range 1 – 32 mm)

● Chemical foamed PVC with rigid layers,

coextruded,

called „Coex-Sheet“

(thickness range 2 – 12mm)

PVC SheetsMaterial PVC Sheet Extrusion

Main Extruder

Coextruder

Coextrusion: ABC outside rigid A inside foam B outside rigid C

Extruder

Die

Mono – Freefoam or Rigid Sheet

2 -12 mm

1 - 30 mm

2 -12 mm

PVC SheetsDifferent Kind of Layer Possibilities

Monoextrusion

CoextrusionCoextrusion: ABA outside rigid A inside foam B

2 -12 mm

Coextrusion: AB outside Rigid A inside foam B

Die

Rigid PVC Sheets: High hardness of surface (Shore D) Very good mechanical features, for example stiffness Corrosion-resistant Flame retarding Smooth surface Transparent sheets are possible

Further Advantages of Foamed PVC Sheet: Saving of material Still higher stiffness Workable like wood Less heat conduction Effect of absorbing vibrations

PVC SheetsCharacteristics of PVC Sheets

Advertising Boards of foamed Sheets - printed- laminated

PVC SheetsApplications of PVC Sheets

Tent- and Hall Construction of rigid PVC Sheets - deep-drawn

PVC SheetsApplication of PVC Sheets

Doors of rigid PVC - deep-drawn sheets, thickness about 1,5 mm- glued with foam core of PS or PUR

PVC SheetsApplications of PVC Sheets

Window- and Doorfillings of Sandwich Sheets - rigid PVC Sheets, thickness about 1 - 1,5 mm- glued with XPS-foam

PVC SheetsApplications of PVC Sheets

“Trimboards” - PVC Free Foam Sheets for Coverage of Buildings

PVC SheetsApplications of PVC Sheets

Window frame

Kitchen cabinet

Cabinet

Wall covering

Kitchen Construction - PVC Free Foam and Coex Sheets

PVC SheetsApplications of PVC Sheets

Layout of a PVC Free Foam Sheet Line

Roller Table

Cross CuttingSaw

Saw Dust Extraction

Edge TrimChopper

Longitudinal Saw Four Roll Haul Off

Cooling Roller Conveyor

Heater-, Cooling- Units

Polishing Roll Stack GravimetricDosing Unit for 4 Components

Twin ScrewExtruderKMD 114 -32/PLKMD 133 -32/PLKMD 164 -32/PL

Pre-cooling Rolls

PVC SheetsTechnology for Manufacturing PVC Sheets

Sheet Die

Multi Component Gravimetric Dosing Unit

For Dosing of:

● Dryblend (New material)

● Recycled Material

● Chemical Blowing Agent

● Masterbatch for Colouring

PVC SheetsTechnology for Manufacturing PVC-Sheets

Twin Screw Extruder of 32D Series

● Highest output

● Best melt homogeneity

● Wide Production Range

● Easy to handle due to the

modern C5 Control System

● Excellent price-/performance-ratio

PVC SheetsTechnology for Manufacturing PVC Sheets

Extruder KMD 164–32/PL for Production of PVC Free Foam Sheets Output max. 1700 kg/h

PVC SheetsTechnology for Manufacturing PVC Sheets

Pre-cooling Unit for fast Cooling of the Surface

• 2, 4 or 6 pair of rolls, according to output

• Electrical adjustment of gap with a precision of 0,01mm

• Unit horizontal moveable

PVC SheetsTechnology for Manufacturing PVC Sheets

3 Rolls PVC Polishing Roll Stack Width 2400mm, Diameter of Rolls 400mm - 600mm - 600mm

● Gap adjustment of rolls with

0,01 mm precision

● Electrical gap regulation of rolls

● Precision of temperature of the roll width +/-1°C

PVC SheetsTechnology for Manufacturing PVC Sheets

Sheets in the Field of ConstructionMaterialsPVC SheetsPolyolefine SheetsMarket

Chapter 4 – Polyolefin Sheets

● HDPE

● PP (Homo- and Copolymere)

● Chemical foamed Polyolefine sheets

(density range 0,6 – 0,7 g/cm³)

Polyolefine SheetsMaterial PO in the Sheet Extrusion

Container Construction

Polyolefine SheetsMaterial PO in the Sheet Extrusion

Barrage Construction

Polyolefine SheetsMaterial PO in the Sheet Extrusion

Polyolefine SheetsTechnology for Manufacturing Polyolefine Sheets

Polyolefine Sheet Line

Extrusion Components

• Gravimetric for dosing of new material, regrind material and blowing agent incl. dynamic mixer

• KME 150–36 D/PL

• Screen changer

• Special sheet die for foamed PO sheets (picture: width 2500 mm)

System shown without melt pump!

Polyolefine SheetsTechnology for Manufacturing Polyolefine Sheets

Vertical Polishing Roll Stack

• Roll diameter 400-600-600 mm ( ± 1°C precision of temperature over the total roll width)

• Regulation of the roll gap during production

Polyolefine SheetsTechnology for Manufacturing Polyolefine Sheets

Infrared- Heater

• for optimization of the sufaces

Polyolefine SheetsTechnology for Manufacturing Polyolefine Sheets

Polyolefine SheetsTechnology for Manufacturing Polyolefine Sheets

Pressroll Unitfor optimization of the flatness by

• mechanical flat rolls

• different temperature treat in the upper and lower rolls

Sheets in the Field of ConstructionMaterialsPVC SheetsPolyolefine SheetsMarket

Chapter – Market

PS35%

PVC20%

PP20%

Acrylilcs5%

PE4%

Others8%

PET8%

Raw Material Consumption and Trends in the Sheet Extrusion

Europe 2005

Germany23%

Benelux9%

Spain7%

Scandinavia5%

Other WE8%

Poland4%

Italy20% UK

9%

France10%

Other CE5%

Raw Material Consumption and Trends in the Sheet Extrusion

Consumption European Countries 2005

Raw Material Consumption and Trends in the Sheet Extrusion

Plastic Consumption (Thermoplastic) in Europe

2001

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