Types, characteristics of technology for the manufacture of terrace coatings. Terrace board production: a profitable business for beginners Terrace board factory
A terrace board is ideal for covering the floor of an open terrace, veranda, balcony, gazebo or loggia. Decking is laid around pools, on moorings, piers. It is used for paving embankments near ponds, garden paths, playgrounds and floors in saunas and baths. The production of a terrace board differs depending on the material from which the coating is made. The technology for manufacturing a terrace board from wood is simpler. It is suitable for self-fulfillment. For wood-polymer composite products, you need to buy special equipment for the production of terrace boards.
WPC decking production
The technology for the production of decking from wood waste is the most complex and requires the use of specialized equipment.
Raw materials for production
The manufacturing technology of polymer decking involves the use of wood flour, shavings or sawdust. Shredded wood waste is mixed with polymers (PVC, polyethylene or polypropylene). To give the product a certain color, dyes are added. The consumption of materials depends on the proportion of the main ingredients. High-quality boards are made from a mixture in which the content of wood components is not lower than 60-80 percent.
It is more profitable to manufacture a terrace board from Russian raw materials. At the same time, the following proportion of ingredients is observed:
- wood powder- within 50-70 percent (as a rule, the powder is made from coniferous wood);
- polymer - 30-50 percent (these are thermoplastic polymers, among which HDPE is most often used - low-pressure polyethylene, less often polypropylene and PVC);
- various additives to improve performance (5% of the total volume comes to the share of modifiers).
Important! WPC products accurately imitate the surface of natural wood. They have a more reasonable cost in comparison with solid wood flooring, and their technical and operational characteristics are much higher.
At the preparation stage, you need to purchase the following equipment for the manufacture of terrace boards:
- crushing machine for crushing woodworking waste. On this equipment, raw materials are crushed to a powder state.
- Special drying for crushed raw materials. This equipment will be needed to pre-dry the wood flour. On sale there are products designed for different volumes of material.
- mixing plant for mixing polymers and wood flour.
- Special Line for the transformation of powdered raw materials into granules. The quality of the manufactured product depends on the efficiency of this machine and the obtained granules.
Directly for the manufacture of terrace decking, you will need the following equipment:
- Grinder needed to process the finished product and give it a characteristic matte wood texture.
- Forming line decking profile. In fact, this is a cutter that cuts the product.
- Front side embossing tools are needed to obtain a characteristic corrugated surface for anti-slip protection.
- You will also need brush machine or a cleaning device that artificially ages the surface, cleans it of debris and forms the characteristic roughness and grooves of wood.
If you need equipment for the production of decking, the price of ready-made lines will be the highest. But when producing on a large scale, it is more profitable to use one of the varieties of the production line:
- One step lines designed for the supply of raw materials in the form of polymers, wood flour and additives. The whole line consists of raw material feeders, cooling devices, sizing and pulling tools, a special mixer for preheating and mixing the mass. It also includes a device for squeezing the prepared mass through the mold.
- Double pitch lines work on granular raw materials. They consist of devices for sizing, feeding and cooling of raw materials, as well as devices for extruding and pulling.
The sequence of manufacturing WPC terrace decking is as follows:
- modifiers, polymers and wood flour are thoroughly mixed in an industrial mixer while heating to a high temperature;
- then the raw material is placed in a granulator to form granules;
- to give the board a shape, the mass is extruded, that is, melted and passed through special dies;
- then a continuous solid canvas is cut into products of given sizes;
- to make the surface wear-resistant and non-slip, the board is polished.
Terrace board made of natural wood
If you are interested in making your own hands, then a terrace board made of natural material is what you need.
Raw materials for production
Resinous coniferous wood is used as a raw material for the production of solid wood decking. Wood of cedar, ordinary larch and well-known pine is suitable, since it is naturally protected from moisture and decay.
Heat-treated wood is also suitable. To do this, the material is placed in special chambers, where it is heated to a temperature of 200 degrees under the influence of water vapor. As a result, the product is more resistant to moisture and rot, it acquires a beautiful shade.
Equipment and manufacturing process
The production of a terrace board from larch and other types of wood with your own hands is as follows:
- Prepare edged boards measuring 0.025x0.1x6 m.
- We process the elements with universal deep penetrating impregnation. So you increase the protection of the product from mold, rot, burning and moisture. Usually the impregnation is applied in several layers, and the previous layer must be completely absorbed.
Attention! Processing with impregnations is carried out only in the open air.
- After the composition has dried we cover the elements with working off, which we apply with a wide brush.
- After absorption and drying of mining, we proceed to the laying of products. We will not describe the installation process itself.
After laying the decking, the surface of the finished flooring is carefully sanded with a grinder. Then the floor is cleaned of debris and opened with varnish for outdoor use.
If it is necessary to cover the floor on a terrace, veranda or balcony, then you can use not only traditional materials, but also terrace board ( or decking). This relatively new material has unique features that make it possible to obtain a wear-resistant coating, the appearance of which will pleasantly surprise even skeptics. The main material for the production of such a board is made from wood powder, polymer and various additives. Scope of application decking- these are buildings and structures that are built in the climatic conditions of the Russian Federation according to I1-I2, II1-II12 according to GOST 16350.
Advantages of a deck board
Among the positive decking properties can be attributed:
- No deformation, so it can be used as a base coat in open areas and even in baths;
- No rotting - due to the fact that the composition contains a polymer, decking not afraid of high humidity and even direct exposure to water;
- It does not require additional processing due to its structure, it is enough to adjust the pattern during installation and the coating is ready for use;
- Under the influence of ultraviolet does not fade;
- Insects do not start in it, and fungus does not appear on the surface, since the polymer component is used.
Features of manufacturing technology
Decking production This is a rather complicated process, with a number of subtleties. If we simply consider the production technology, then it involves mixing woodworking waste with polymer compositions and the additional addition of dyes to obtain wood-polymer composite given structure and color. A quality decking board (such as Bruggan, Legro or Mirradex) uses a mixture with a wood content of 65-80%.
The main ingredients for terrace board production are:
- Wood powder (in most cases from coniferous species or wood flour corresponding to GOST 16361-87) - 60-80%;
- Polymer binder (low pressure polyethylene, polypropylene, polyvinyl chloride according to GOST 16337/16338) - 20-40%;
- Auxiliary additives and dyes to improve operational decking properties- no more than 5%.
It is important to know that the surface DPK is an exact imitation of the surface of natural wood, but at the same time its performance is higher, and the cost relative to solid wood is lower. has one interesting feature - in its production, secondary polymeric materials can be used, which significantly reduces the cost of final products.
How is a deck board made?
For the manufacture of terrace board high quality, the use of special equipment is mandatory. Initially, the raw materials are prepared, and for this you need:
- Crushing equipment, with the help of which woodworking waste is crushed into powder;
- Drying for the resulting powder, which allows you to get rid of excess moisture;
- Mixer for mixing the polymer component and wood powder;
- Line for the production of granular raw materials.
Upon completion of the preparatory work for obtaining DPK the resulting granules are mixed with simultaneous heating to high temperatures, and then the mass is fed into the extruder. As the composite passes through the extruder, it is also constantly heated and then passed through the dies. As a result, a continuous web is obtained, which is cut to the specified dimensions with the help of milling equipment. In order for the surface terrace board was resistant to wear and was not slippery, it is polished with grinders, which also make it possible to give the finished product a matte texture.
After it has been manufactured and passed technical control at production facilities, it can be transported and stored in accordance with the requirements of GOST 12.3.020 in our warehouses before being sold to the consumer.
Not so long ago, houses with open terraces came into fashion. This phenomenon is not too familiar, but for some reason it appealed to many people.
An increasing number of people who wish to live in their own home include open terraces as part of the house design. Perhaps because our summer is short, so you want to spend more time outdoors, for which the terrace is simply irreplaceable.
In connection with the popularity of terraces, the question arose of how to make an eco-friendly wooden deck (decking) so that it looks beautiful and at the same time serves for a long time. And all this on the condition that it is in the cold under the snow, in spring and autumn it will be watered by rain, and in summer the sun will dry out.
The term of operation of a terrace covering completely depends on that material from which it will be made.
Terrace classes
There are only three classes of coatings suitable for
- larch and pine wood subjected to special treatment;
- wood of rare and very expensive wood species with high density and strength;
- wood-polymer composite (WPC).
The wood of such rare tropical species as zebrano, rosewood, kumaru, iroko, massaranduba belongs to the perimum class of terrace coverings, therefore it is hardly accessible to the average consumer. Therefore, most likely, he will have to choose between a deck board made of natural wood or WPC.
When it comes to natural wood, you need to know that pine without special treatment will not last long, and it is also very susceptible to insects and fungus. Therefore, having saved at the initial stage, you can spend serious money on ensuring the normal operation of the site.
In this regard, larch is more reliable and durable, especially if it has been impregnated - wood is impregnated with a protective compound under high pressure. At the same time, the antiseptic penetrates deeply into the thickness of the board, which makes even pine much more resistant to various influences.
A WPC board made from wood flour mixed with polymeric materials looks not much different from, but practically does not rot, does not warp and is not afraid of moisture.
In the country at the moment, along with foreign suppliers of decking, there are quite a lot of domestic manufacturers, whose products are practically in no way inferior to imported ones.
The most famous decking manufacturers
NEWWOOD– has been operating since 2012 and produces polymer deck boards. The company uses Austrian equipment.
Decking of this brand has found wide application where the coating has to be in contact with aggressive media:
- garden paths;
- parking;
- operated roofs;
- ferries;
- sports grounds;
- pool areas.
The intensive period is 10 years or more, while the appearance and quality of the coating retains its original characteristics. Terrace board NEWWOOD has a wide color palette, so it can be used for any design.
ecodeck- a composite product, popular due to its low cost. Produced on the basis of polyethylene and wood flour in a ratio of 3:7. The high content of wood flour in the composition of the composite provides the same tactile sensations as natural wood.
Board size leaves:
- width 165 mm;
- thickness - 24mm;
- length 4000, 6000 mm.
This width - 165 mm boards save a lot on fasteners. Ecodeck decking is painted in milk chocolate color and has a specially treated rough surface that prevents slipping.
The service life of the board is about 20 - 25 years. This is due to the fact that the board is protected from UV radiation with the help of special additives. Maintenance of the terrace is simple: it can be washed with cold water straight from the hose. When stains appear on the surface, they are removed with soapy water.
Terrapol- the decking of this Russian brand can be used in a variety of places: on piers and piers, near swimming pools, on sports grounds. Its dimensions are: 3000 or 4000 mm, decking width - 147 mm, thickness - 24 mm.
The Terrapol board has a high moisture resistance, shows itself well when operating in the temperature range from - 50 to + 70 degrees.
The composite of this brand is distinguished by a beautiful texture, as close as possible to the texture of natural wood.
Ligna Tek is the first Russian enterprise that opened a production facility for the production of boards from wood-fiber composite material.
The board of this brand is distinguished by the following properties:
- mechanical strength;
- high moisture resistance;
- durability;
- slight thermal expansion;
- attractive appearance.
The enterprise currently produces a board with the following characteristics: section - 160 * 33 mm, length - 3000, 4000, 5000, 6000 mm. The color range is quite wide: malachite, chocolate, chestnut, nature, terracotta, anthracite. The material is adapted to the conditions of the Russian winter.
— products have been known on the Russian market since 2007. The board is made on the basis of natural wood and PVC in the ratio 1:1. The content of PVC in the material gives it durability and strength.
contains several shades, the most popular of which have become; almonds, chocolate, graphite and white sand.
MultiDeck- is a product of the Russian company Multiplast, manufactured on Italian equipment.
The board is made from the following materials: polyethylene - 24%, wood flour - 70%, additives - 6%.
The size of the board in diameter is 140 * 22 mm, length - 3000 mm.
The color range contains the following shades: white night, chocolate, quartz, wenge, burgundy, azure, emerald.
Decron- Russian terrace board is made from 60 - 65% wood flour, 25 - 30% binders and 10% additives.
The size of the section of the board is 153 * 28 mm, length - 3000, 4000, 6000 mm. Available shades: natural, black, terracotta, brown, grey.
Eternal tree company produces a terrace board from a composite with a section of 150 * 25 mm and a length of 3000 mm.
Compared to other brands of WPC decking.
Decking color range Eternal wood: malachite, bamboo, coral, anthracite, marble, rosewood.
Among foreign manufacturers of composite decking boards, the following brands can be noted:
- XylTECH is a product of the French company SEDPA;
- Dekeunick "Twinson" - Belgium;
- Dumadeck - Belgium;
- Grinder - Russia - Germany;
- Holzdorf - Germany - Ukraine;
- TREX - USA;
- Porch is a Czech company that produces durable products at an affordable price;
- Werzalit is a German manufacturer that produces a board with a double-sided profile.
As for the terrace board from, it is produced by many enterprises, well-known and not very well-known. The cost of such a product is usually lower than WPC boards, but its service life is also shorter.
Of the foreign companies, Rehau is the most famous, whose products are distinguished by excellent protection against temperature, moisture, as well as chemical and biological factors.
Decking prices
Decking cost is greatly influenced by:
- the material from which it is made;
- manufacturer;
- type of board processing.
For example, a floor made of larch has a cost 1.5 - 3 times lower than that of wood of rare species. There are 4 decking boards:
- Budget - made from larch. The cost, depending on the type of wood, can range from 400 to 2000 rubles / sq.m.
- WPC board. The cost ranges from 1500 to 3500 rubles/sq.m.
- The middle category - the material is exotic wood species. The cost varies in the range of 3000 - 5000 rubles / sq.m.
- The highest price category includes a board, also made from tropical trees. Its cost is from 5,000 to 12,000 rubles / sq.m.
Despite the advantages of WPC, a board made of natural wood is still used more often in private housing construction. It can also serve for a long time, but with proper care.
Thus, any person who dreams of creating a terrace, sports ground, gazebo has a huge number of terrace boards available on the Russian market. To get started, you need to ask yourself the following questions:
- where exactly the terrace will be used;
- in what conditions it will be (open or under a roof);
- which profile of the board - narrow or wide suits you more;
- what color is better combined with the exterior of the house and the site;
- what budget can you allocate for the construction of the terrace.
After solving all these issues, choosing the right material will not be difficult.
Do you want to have a profitable business in the construction market? Open your terrace board production. Do you think it is difficult and it is not known when it will pay off? Weigh the pros and cons.
First you need to understand this matter and familiarize yourself with existing proposals. The terrace board is easy to "find" with the eyes. Among the usual floor coverings (parquet, board, laminate, tile), it is distinguished by its grooves on the outside, reminiscent of velvet fabric (remember ribbed trousers). This was done not just for the external effect, but according to scientific tests, it prevents slipping.
Different types of deck boards. It is distinguished from other building materials by characteristic grooves on the sides.
Types of decking are distinguished according to the material used. They happen:
- from the massif (based on species of moisture-resistant, durable and rare trees);
- composite (they got their name from the mixing of two components: chopped wood and polymers).
The difference, as you can see, is not difficult to determine between them. For a massive board, oak, larch, mahogany or other durable types are taken. A mixed look is obtained artificially by combining different materials using a production line.
Production technology
For the production of decking boards, 3 key components should be used:
- Specialized particles of crushed wood;
- Artificial or organic thermoplastic polymers or their mixtures;
- A set of special modifiers designed to improve the consumer and technological qualities of the original consistency and the finished board.
And most importantly, this board is recyclable. Therefore, composite decking is suitable for processing and forming new products from materials previously applied and used by you.
If the material is planned to be produced from a natural array, you need to know:
- What type of wood is best suited (most often it is or needles);
- How to heat treat so that quality is your business card;
- How to achieve the texture of the board;
- How to cover, so as not to harm the environment and the health of customers.
At the moment, the most popular manufacturers are:
- Holzdorf (Ukraine) - easy to install, no additional processing and special maintenance is required;
- Bruggan (Belgium) - the advantages are high quality, long service life, durability, as well as a variety of board color palettes;
- Mirradex (Malaysia) - this manufacturer has supplemented the composition with new materials that do not require special care, such boards are not afraid of mold and fungus, therefore, they can serve you for many years;
- SunDeck (Turkey) - due to its composition with polypropylene, even from the action of adverse weather conditions, the board will not dry, crack and deform.
Self-manufacturing
If you decide to make this product yourself, then you should consider:
- You can independently start your own production only from solid wood;
- In the absence of carpentry skills, it is worth taking a few lessons;
- Purchase the necessary materials and machines.
Types of terrace boards. There is not so much diversity in Russia, so there is room to grow
Novice and experienced decking manufacturers, when promoting their own business, are guided by the following sequence:
- Choose a certain type of wood (ideally - coniferous);
- Cover the board with a primer (penetrating deeply, it will protect the tree from decay and insects);
- On the inside, make grooves that will help the board retain its original appearance in any vagaries of the weather;
- Apply a "signature pattern" (make shallow relief grooves, thanks to which the feet will not be slippery even in a downpour);
- Steam it (the color will appear and become stronger).
A typical production line consists of the following 7 parts:
- Crusher - grind the material up to the required volume;
- Dispenser - clearly hangs out all the components;
- Dryer - dries the crushed material;
- Mixer - mixes all components;
- extruder;
- Grinding machine - gives the final product a specific degree of smoothness and roughness;
- Embossing machine.
The product is ready for installation, final sanding and, at the request of the client, painting, varnishing or wood oil.
Production of coatings from WPC
The modern market offers to replace the usual wooden board with an alternative one. Scientists, by mixing wood and polymers, have invented a new type of flooring - wood-polymer composite. The production of coatings from WPC is technologically different from independent production. It is more expensive from the financial side, since special machines and raw materials are needed.
Stages of work:
- Using a crusher, grind wood or waste from it;
- Dry thoroughly.
Using an installation resembling a mixer, mix the necessary components:
- dry wood powder;
- plastic;
- chemical components;
- dyes.
At this stage of production, human presence stops. Machines continue the next technical part. Further, the board will be formed, polished and at the output you will receive products ready for sales. Its advantages:
- durable;
- hardy;
- not afraid of the sun, rain, water, frost;
- does not crack;
- harmless;
- easy to clean;
- no need to paint;
- looks great;
- does not change shape and color;
- serves for a long time;
- used as flooring, fencing, exterior wall.
The number of options for using WPC coatings is so great that only designers will help and suggest how and where to apply this material, if it is difficult to decide for yourself.
It can be sold not only in the high season, but also in winter, because the board serves as a decoration for the apartment rooms
You can easily sell this board even in winter, when all external construction work is suspended. Thanks to its clean formula, it is suitable for covered balconies, loggias and even hallways. Also used in children's playgrounds.
The downside is the price. Product quality increases the need to purchase top quality polymers. But we must not forget that at such a price, the payback of WPC coatings will be good. Considering the service life (it is 10 - 40 years, depending on the manufacturer and the quality of raw materials) - the cost justifies itself. In addition, demand is constantly growing.
Board production lines
The popularity of the product increases the demand for equipment for the production of picket fence and decking. If you do not have financial restrictions, then it would be advisable to purchase a line with a full cycle. This will minimize the use of human labor. With such production, you will have machines that:
- They will make practically flour out of wood;
- Measure, weigh and accurately dose all the components involved in the production;
- Dry flour;
- Thoroughly mix everything until smooth;
- Prepare granules;
- Melt, form and pressurize the board;
- Grind, cool, cut;
- Apply "drawing".
Operating line for the production of coatings from WPC
As you already understood, this production is interesting because everything happens in constant motion. Equipment line vendors offer advanced machines. They are computerized, which makes it easy to manage the process and achieve high quality decking.
Production from finished raw materials
If there is no money for a full cycle, you will be offered equipment that will help you start your own production at minimal cost. You can do without machines that grind, dry and mix. You buy ready-made granules (they already include everything you need to form a board). Then it remains to purchase only those machines that will form products and lead to the final result. The advantages of this approach:
- Saves you time and money;
- Helps to develop own business gradually;
- Allows you to vary when buying machines (take the required minimum or used, while making sure that they are in good condition);
- To produce products of average cost, which will pay off faster.
A large selection, ample opportunities will help to produce goods of good quality at low cost. This is thought about everywhere. A Russian-made terrace board is no different from the same one made in Europe. Nobody wants to lose their customer. Modern production of deck boards requires constant improvement of equipment for its production. The quality depends on it. Manufacturers need not to lose quality at minimal cost and not to frighten the buyer with the price of the product.
Decking name | Price |
Terrace board Twinson from WPC (Belgium) | from RUB 2,905.00 |
Terrace board ECO (Russia) | from RUB 1,850.00 |
terrace board Crown Exotic Ipe Tabaco | from RUB 6,486.00 |
Terrace board Terradeck Deckron | from RUB 237.00 |
Terrace board Terradeck Evo | from RUB 285.00 |
Terrace board CM Decking Natur Rowan | from RUB 810.00 |
Terrace board Dumadeck | from RUB 3,990.00 |
Terrace board Dumadeck Solid corrugated | from RUB 2,430.00 |
Terrace board Dumadeck | from RUB 3,990.00 |
The construction market will always be at the peak of popularity. The novelties that he will offer will be of interest. Terrace board production is good for promoting your own business because, thanks to a computerized process, it will be able to provide a quality product for a long time and surprise its consumers. It is worth considering this suggestion. Perhaps this is your life's work.
WPC terrace board or decking is a special flooring that is an excellent alternative to natural wood, tiles, porcelain stoneware. This material is characterized by high resistance to the destructive effects of weather factors: from sudden changes in temperature to decay due to precipitation.
Manufacturers of terrace and facade boards for outdoor areas offer two types of products: smooth - with a pronounced texture and especially spectacular appearance, and corrugated, represented by popular options suitable for solving any problem.
In the production of WPC, polymers (polyethylene, polypropylene or PVC), wood filler - specially prepared wood flour, as well as various additives (including antifungal) are used. All WPC manufacturers strive to improve product quality and create an ideal material with high performance. For this, numerous tests of finished products are carried out in laboratories. The influence of various additives on quality and products is being studied, production formulas are being adapted.
Composition and consumer properties
Modern production of terrace boards is the most complicated technological process, which involves the correct selection and use of various components of raw materials: agents, functional additives, plasticizers and modifiers - in order to give finished products special physical properties. As a result, the finished product is able to undergo the same processing as ordinary wood, it can be drilled, planed, sawn, but surpass natural wood in operation.The material is characterized by environmental friendliness, resistance to moisture and decay processes, good fire protection and resistance to deformation.
Features of WPC production
EKODEK company has been a manufacturer of decking and other decorative and finishing materials based on WPC since 2010.
Despite the relatively recent appearance on the domestic market, composite terrace boards are rapidly gaining popularity among consumers, which leads to an increase in the production of these materials.However, abroad the production of terrace boards has been developing for a long time and has become widely demanded. There is no doubt about the repetition of its success in Russia.
Terrace boards and other profiles from WPC are produced using two main technologies: one-stage (this process involves the direct supply of raw materials to the extruder for its subsequent processing, dosage, mixing and extrusion) and two-stage technology for the production of WPC, where the mixture is prepared at the first stage and preparation of special granules, and on the second of the resulting granulate, a profile is made.
The production of terrace boards in EKODEK complies with current European and Russian standards. We use the best European equipment, high-quality raw materials, and a recipe adapted to our climate to obtain environmentally friendly high-class products.
Following the latest developments in the production of WPC allows us to present to our customers WPC decking boards with high strength and wear resistance, suitable for use in aggressive environmental conditions.
Thanks to modern technologies, as a result of the production of terrace boards, the finished profiles have ideal geometric parameters, and on their surface there are no chips and other defects characteristic of natural wood.
We invite you to cooperate!
Specializing in the production of WPC, the company "EKODEK" offers favorable and convenient terms of cooperation for customers and partners. We sell terrace and facade boards and other finishing materials in a wide range and at reasonable prices.
All products are covered by a quality guarantee.
Making a choice in favor of EKODEK materials, you give preference to solutions with outstanding consumer characteristics and operational properties. A high-quality terrace board from the manufacturer is the best option for finishing the floors of various rooms and all kinds of outdoor surfaces. Such coatings have unique strength and reliability, and therefore they are able to perform their functions in any weather for many years.
To find out the details of our cooperation offer for dealers or to buy wood-polymer composite boards, please contact EKODEK specialists in any way convenient for you.
Main sales office:
OOO TD "EKODEK", OGRN 1185050006096