Manufacturing SIP panels as a business from scratch. Do-it-yourself house made of vulture panels: all the subtleties of construction

The production of SIP panels is a fairly simple and quick process, which, if desired, can be carried out in your own garage. Producing such material with your own hands will help to significantly reduce its cost for you, and therefore reduce the cost of constructing any building as a whole. This article describes in detail the technology for making a SIP panel with your own hands, and at the end you will find a useful training video on this topic.

Prefabricated houses made from vulture panels are gaining increasing popularity in do-it-yourself construction. Let's look at the main points of building a house according to Canadian technology using sip panels.

Prefabricated houses from sip panels: construction technology

Foundation for a frame vulture house

Houses using Canadian technology are quite light and durable. At the base of the structure, a pile foundation will suffice; the grillage can even be made from timber of the appropriate diameter.
Watch the video about SIP panels on Discovery, interesting experiments!

Construction technology

Sip construction is the assembly of ready-made factory panels using the tongue-and-groove connection principle. The most important point here is the quality of the source material; only with proper execution of the panels themselves will the house be built without gaps at the joints, which will ensure a good and durable structure.

When assembling a sip house, the seams and joints are processed polyurethane foam, which is highly not recommended to cut after hardening. Foam tends to degrade under the influence of ultraviolet radiation; cutting off the edge only speeds up this process.

Construction of a semi-structured house can be carried out in any season, but the most favorable is winter, because... The summer construction rush may delay you at some stages of construction, and in the off-season there is a chance of rain and bad weather.

Finishing

The finishing of the vulture panels (and the external one) can be chosen to suit your taste - any will do. There are no restrictions here, except financial ones, since sip panels perform equally well when finishing wooden materials, and when using tiles or, and in all other options.

Advantages and disadvantages of sip houses

Let's consider the main advantages of houses using Canadian technology and the existing disadvantages of these buildings.

Sip panels advantages - houses

• Interest in sip construction is explained by the low cost of such structures compared to other types of private construction, short terms construction of houses, a simplified system of external and internal finishing.
• A lightweight structure made of sip panels can be erected on a simple screw or pile foundation. Quick assembly of ready-made factory panels at the construction site significantly reduces the time of building a house with your own hands.
• Finishing sip panels is extremely simple. Smooth and even wall panels do not require leveling or additional processing before starting finishing works. Which also has a beneficial effect on the cost of the finished home.

Cons of sip panel houses

• However, despite the fact that sip panels have unconditional advantages, these houses are not environmentally friendly, although companies try to claim the opposite, do not believe it (when using sip panels the level of formaldehyde should be controlled); therefore good finish, defence from sun rays required!
• Despite their good thermal insulation properties, they cannot boast of good sound insulation, and their fire safety rating is quite low.
• You should be extremely careful when installing electrical wiring and heating systems in vulture houses.
• Also, one of the features of vulture houses is that they need constant ventilation, because... The materials used do not allow air to pass through.

Is it worth building a sip house? conclusions

Building a house using Canadian technology with your own hands is quite possible, but you should be careful when choosing materials and manufacturers. The strength, durability, beauty and reliability of a sip house directly depends on the quality of the materials (panels) used.

SIP panel technology is known to everyone who is even slightly involved in construction. The high popularity of frame-panel houses would be even greater if not for their cost. In private construction, this issue is easily resolved, because you can make sip panels with your own hands in a small workshop or garage. Thus, if you have a desire to build a building, you can reduce the cost to a minimum.

Structure of SIP panels

SIP panels are a composite construction material. They have 3 layers:

• insulation (inner layer);
• OSB boards (outer layers on 2 sides).

Insulation

Expanded polystyrene is used as insulation. It's easy durable material, which does not deform for a long time. Its advantages are that it is not hygroscopic and does not get wet. In addition, mice do not like polystyrene foam; they do not build nests in it.

In the absence of hygroscopicity of this insulation, one can also see its disadvantages, because it requires high-quality ventilation of the walls. Here it is enough to follow the technology of construction and insulation of curtain facades.

OSB

The outer layer of the panels on both sides is oriented strand boards. They consist of sawdust, bonded into a durable board with a special resinous composition. At this point, many people see disadvantages, since the composition of the resin is almost always unknown. This is why it is better to buy OSB from famous manufacturers. This increases your chances of purchasing environmentally friendly material many times over.

To assemble SIP panels you will need the following equipment:

• table;
• press;
• glue, for example, Kleyberit;
• expanded polystyrene grades C-25-35;
• OSB boards 12 mm thick;

Manufacturing of SIP panels

OSB is placed on the table and covered with glue. The above-mentioned Kleiberite is used according to the following technology. It is applied to the surface of the OSB with a notched trowel, brush or a special glue roller. It should be taken into account that such an application is due to the fact that it is necessary to create not a continuous layer of glue, but with grooves. The average consumption is 150±50 g/m2.

Next, the composition is kept on the surface for 8±2 minutes, a sheet of polystyrene foam of the appropriate size is placed on it. The next layer of glue is applied to the insulation. Leave for the same amount of time (if Kleiberit is used) and lay OSB on top. Next, the finished structure is placed under a special press.

Drying finished panels without a press

If there is no press, you can do this: each new SIP panel is assembled directly on the previous one. When a stack of 5 pieces is formed, it is covered with tent fabric, which is hermetically sealed with quick-setting glue. For example, you can take the one-component composition Cosmofen.

Next, air is pumped out from under the tent using a vacuum pump to create high pressure. Leave to dry for 1 hour. Then remove the fabric and wait another 1 day. After this, the panels can be used for construction.

You should know that SIP panels are connected to each other using timber. It should be on one vertical side of each panel. In this way, a rigid fastening is created and ensured. The advantages of this connection: strength, absence of cold bridges.

SIP panel sizes

The following dimensions of finished SIP panels (mm) are considered optimal:

• 2800x1250;
• 2500x1250;

Manufacturers adhere to these sizes. You can create slabs of any size with your own hands. However, they must comply with those provided for in the construction project. If the slabs are smaller in size, the following construction disadvantages may appear in winter: a large number of joints will lead to heat transfer to the outside.

Optimal thickness of each layer

They also take into account not only the dimensions, but also the thickness of each layer. OSB is chosen with a thickness of 12 mm, and the insulation depends on the purpose of use:

• for facade walls, polystyrene foam is taken with a thickness of 200 mm;
• for internal partitions, it is enough to take polystyrene foam with a thickness of 100 mm, 140 mm.

For the construction of a residential building, it is better to take OSB-3. In them, the gluing of chips differs in direction in the outer and inner layers: longitudinal and transverse. You should know that this arrangement of chips ensures high strength and long service life of the material.

Panel house: pros and cons

Are there any disadvantages to making SIP panels yourself? If you violate the technology, you will not get the expected result. The house may become too energy-intensive. If the layer materials are selected correctly and the drying rules are followed, you will be able to build a high-quality structure with your own hands. This will reduce the time and financial costs.

The panel house is characterized by quick construction and low weight. It is not necessary to build a heavy foundation for it. It is enough to build a columnar reinforced concrete or screw piles taking into account the characteristics of the soil.

If you want to do it well, do it yourself....

The idea of ​​making SIP panels with my own hands came to me at the moment when I had an understanding of how many panels are needed for a relatively small house in 100 m2. After carrying out simple calculations, I found out that construction would require about 100-120 panels of various sizes. I didn’t want to order a ready-made house kit; my project was already ready. Buy ready-made panels, transport them, store them somewhere, then cut them to size...

In general, the decision was made. I decided to do it myself. The main issue that needed to be resolved was the location for production. Luckily, I have a large two-story garage measuring 6x8m. The area required for materials, equipment and finished panels, according to first estimates, was available. Plus the ability to glue panels of the required sizes and different thicknesses, combining materials. Looking ahead, I will say that in reality such areas are only enough to produce 30 - 40 panels of full-size panels. Then they need to be taken out, freeing up space for the production of the next batch. Additional equipment for the garage included the purchase of a diesel heat gun and a duct fan, which provides exhaust of combustion products and, subsequently, smoke generated when cutting polystyrene foam.

The next issue that needed to be resolved was the type and design of the press. After searching the Internet for information on the topic, I decided that I would make a screw press. For my tasks of leisurely manufacturing SIP panels from time to time, it suited me perfectly. I made 5 panels, pressed them together, turned off the lights, and left them until tomorrow (or until the next weekend).

Since gluing requires a fairly high pressure (recommended for TOP-UR type adhesives - 700 kg/m2), I chose a press design with six M24 studs. The area of ​​the SIP panel is about 3 m2, which means a force of more than 2 tons is required.

I welded the frame from an equal angle angle 50x50x5 mm. Frame dimensions: 2800x1500 mm. That is, initially I made a press to be able to glue panels with dimensions up to 2800x1250 mm. After 500mm I welded cross members from the same corner. True, after that we had to weld another one for panels according to the American-Canadian standard with dimensions of 2440x1220 mm.

The panel manufacturing process is as follows.

Immediately before the process of making panels, I cut sheets of foam to fit the size of the panel. Since I took an OSB board with dimensions of 2440x1220mm, and a sheet of foam plastic has dimensions of 2400x1200mm, I had to cut 60 or 80mm from each edge. Homemade cutters were made to cut foam. The design is clear from the photo. The basis of each is a wooden frame secured with nichrome wire. Power supply for cutters from LATR. I set the voltage to about 30-40 Volts. When cutting foam plastic, I make sure to use a hood, since the smoke released is very corrosive.

Next, I place one sheet of OSB board on the press, which acts as a base. I put it on it bottom sheet OSB of the first panel, and a sheet of foam plastic on top. Next, I apply glue with a homemade hand clarinet. Before each application of glue, I wipe the surface of the foam with a damp cloth to remove dust. The same applies to the surface of the OSB board. I use polyurethane one-component adhesive TOP-UR 90, produced by PU INDUSTRIYA. After applying the glue, I distribute it evenly using a metal spatula with slots, paying attention Special attention edges.

I spray it with water from a pump sprayer and, turning the sheet of foam over, lay it with the glue-applied side on the OSB sheet. I level it on the sides using a meter-long piece of 150x50mm board. I repeat the whole process, always applying glue to the foam sheet.

The entire process of manually manufacturing 5 panels takes about 1.5 hours. Glue consumption is about 300 ml per side, or 0.6 liters per panel.

After forming a pack of SIP panels of 4 or 5 pieces, I place longitudinal pipes on the top panel and press them with transverse channels. I tighten the press with a force of about 10 - 15 kgf on each nut and leave it until the next day. Thus, no more than 5 panels can be produced per day. In principle, it is enough for your own needs.

It is becoming more and more popular every day. The only factor that stops many developers is the price.

However, you can save a lot if you make such panels yourself. This way, building a house will cost the least amount of losses for the family budget. Using sandwich panels, you can build a house in the shortest possible time.

Composition of SIP panels

Let's talk in more detail about how to make SIP panels at home. First you need to understand what the building structure consists of. Sandwich panels include three layers: 1 internal (thermal insulator), 2 external (fencing).

Inner layer

The following can be used as a heat insulator:

• mineral wool (non-flammable, non-caking);
• expanded polystyrene (low fire resistance, lightness, strength, low cost, resistance to deformation);
• polyurethane foam (high moisture resistance, rigidity).

To decide on the brand and thickness of insulation, take into account the purpose of the building and make a thermal calculation.

Outer layer

For the outer layer of sandwich panels use OSB boards. They contain sawdust, which are combined with a resinous composition.

Some believe that this is huge, since it is not known what the resin consists of. To avoid low-quality materials, choose a trusted manufacturer.

For the shell of SIP panels, the following materials are used:

• aluminum
• galvanized steel sheet
• plastic
• tree

What is needed for assembly

To assemble this building structure you will need a table, a press, OSB boards, a heat insulator (expanded polystyrene) and glue. The latter can be one- or two-component.

The one-component adhesive composition hardens in air. It is mainly used for semi-automatic or manual assembly, since a thin layer of glue may not lose its properties for a long time. You can increase the life of the glue if you cool the working area and lower the humidity in it.

In turn, the two-component polymerizes only after a chemical reaction of its components. It does not lose this property throughout the entire service life of the panels (50 years).

In addition to durability, the glue must be safe, heat and moisture resistant. It should not lose its properties both at -40 degrees Celsius and at +50.

Assembling a SIP panel with your own hands requires careful preparation of materials. Check the OSB boards and heat insulator. Clean them if necessary.

Manufacturing process

The production of SIP panels implies strict adherence to all of the following stages:

• Place the OSB board on a hard surface.
• Cover with polyurethane glue. As the latter, it is better to choose Kleiberite.
• To apply the glue correctly, you will need a notched trowel or a special sprayer and a brush. You should end up with a grooved layer. The consumption should be a little more than 150 g/.
• Leave the glue on the surface for about ten minutes.
• Place a layer of polystyrene foam on top.
• Apply another layer of glue to the heat insulator.
• Wait ten minutes
• Lay the second OSB board on top.
• Keep the resulting sandwich panel under pressure until the glue is completely cured.

The entire process of assembling sandwich panels can be viewed in more detail in this video. Critics have not passed the time; they called the main disadvantage of this type of production of sip panels too high labor intensity:

Assembly difficulties

The main difficulty in making panels yourself is working with glue. The glue is very foamy when applied to a surface.

High-quality assembly of sip panels requires the right choice pressure force to obtain the correct density and thickness of the adhesive layer. Therefore, only a press will help here, in which the panel should be kept for about 4 hours.

The glue polymerizes very quickly, and this leaves no time for thinking when assembling. If it hardens, then no solvent will help you; you will have to remove it mechanically. It is better to work with someone in pairs, since it is difficult to cope with such a load alone.

Corrugated panels

In addition to the above option for assembling panels, they can be made from corrugated sheets. The difficulty is that the company uses hot pressing to create them. But it is quite difficult to perform such manipulations at home.

Honeycomb material is also laid between the cladding. For maximum strength, you can add several layers of insulation to the panel.

The use of corrugated sheets gives the panels special rigidity and reliability. In this case, the walls turn out to be three times thinner, and also reduces the load on the building structure. But this in no way affects the quality of construction. Such panels are more resistant to temperature changes and mechanical stress.

To make panels with your own hands you will need: and filler (mineral basalt wool, polyurethane foam or polystyrene foam).

You can make it yourself different kinds designs. To do this, insulation is laid between the metal corrugated sheets.

The corrugated sheets have locking fastenings. This type is convenient to use when constructing wall sandwich panels or roofing panels.

How to make a castle

As is already known, SIP panels are connected to each other using the “lock” principle. In a commercial plant, the joint is formed under pressure. But a hand press cannot perform such a function.

How to make a castle with your own hands? Place a wooden beam between the outer layers of the panel on one side. It should extend slightly beyond the boundaries of the OSB board. At the other end you will have insulation protruding. Feel free to trim off the excess. That's all, actually.

How to dry the panel if there is no press

If you do not have the opportunity to use a press, you can do do-it-yourself press for sip panels. This way you should have a vacuum pump. Here the work process is significantly different:

• Collect each new panel on the old one, you should get a stack of five pieces.
• The panels are covered with awning fabric and the edges are tightly clamped. With the help of awning material, a sealed cover is formed that does not allow air to pass through.
• Using a vacuum pump and hose, the air is pumped out. At this vacuum pressure (1 ton/1 assembled panels are maintained for about an hour.
• Received building construction lay on a flat surface for a day.

With this pressing process you can make about thirty panels in nine hours. Another important advantage self-assembly is saving half the budget.

You can also make abs yourself. The machine can be welded from profile pipe (100*100). This way you will get a fairly rigid structure.

Pressure can be applied using two car jacks (2 tons each), which can be mounted at a distance from both sides.

It will be enough to make a machine to load four panels; you can make it larger or smaller. It all depends on your convenience and desire.

Next, using a regular drill, it is recommended to bring the machine to the required level and tighten everything with a regular adjustable wrench. To adjust the same degree of compression, measure the distance with a tape measure and press it with a jack to the desired point.

The clamping frame can be lifted using a winch. In order for the pressing surface to move freely, hinges can be welded to it. This will also allow you to press down all parts of the panel evenly.

Weld support beams on the sides. This will help you not to set the panels on a tape measure each time, but simply place them, like in a jig.

You can also try building a screw press. It will require six M24 studs. Weld the frame using equal angle angle, you can also make cross beams from it. Once you've laid down a few panels, place some beams along the top. They should be pressed using channels and the press should be tightened with a pressure of 15 kgf for each nut.

Before making a press for sip panels with your own hands, make drawings of the future design:

Dimensions and thickness

The main sizes of produced sandwich panels are 2.8 m * 1.25 m and 2.5 m * 1.25 m. When assembled manually, you yourself regulate the size of your panels. But do not forget that it is necessary to strictly follow the construction project.

The thickness of OSB boards is 1.2 cm. But the dimensions of the heat insulator depend on its purpose. So, for example, for the facade it is better to take thick insulation (20 cm), and for interior walls 10-14 cm is enough.

Conclusion

Certainly self-production Sandwich panels have their drawbacks. At home, it is important to strictly follow the assembly technology, even if it takes a lot of time. Failure to do so could result in higher energy costs for your home in the future.

Select only high-quality materials and properly dry the manufactured panels. Only this will help you build a strong and warm house.