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Structural Insulation Panel (SIP) Housing solutions for Democratic
Republic of the Congo.

Featured:

Factory requirements

• Manufacturing process for the production of SIPs panels:
• Photographs of the machinery:
• Required Production Requirements and suggested volumes to meet volume
specified:
• Allied machinery requirements for processing SIPs panels:

On Site

Affordable/Emergency housing Options


Background

This process has in fact been used for many years within other industrial
areas around the Globe, one of its first uses was in the aerospace
industry during the second world war; using plywood skins with an end
grain balsa wood core for structural elements of the twin engine British
Fighter Bomber the Mosquito. Of course since that time materials and
adhesives have improved dramatically, but fundamentally the principal is
exactly the same


Process

By separating two substrates of high strength with a core material bonded
between them (EPS, expanded Polystyrene), one in fact creates a Virtual
Steel “I” beam with the HFGBS Wall System, but of course with substantial
weight savings.
Core materials and skin materials of many types can be combined to create
a composite panel, however the HFGBS Sips Panel, is made from a Cement
Fiber Board, with this system to stay competitive we must therefore, utilize
the most competitively priced raw materials so as to compete with other
forms of construction, while staying within the parameters of our Product
Approvals and Certified Engineering credentials, our system must also
demonstrate exceptional high strength so as to ensure the structural
integrity of a Family Home, or Commercial Building, the HFGB
manufacturing System achieves these goals.


Production Requirements:

The Plant described within this presentation has been designed to
produce 9 million Square Feet of SIPs panel per Year or (3000 Homes at
80m/2 aprox), however, this has been based on three shifts per day
working a five day week; therefore higher volumes are achievable by
either increasing the shift pattern to four per day and or increasing from
five days to seven.

Production Process:

To achieve a balance of semi-automation with manual labor is at times
challenging, however, the process described here, does exactly that,
additionally this machinery also utilizes systems that are virtually
maintenance free. Further automation is also an option with this system,
at a later time:


HFH Factory, Florida, USA


Panel requirements:

12ft x 4ft panels = 48ft2 per panel at 8 inches thick
20ft x 4ft panels = 80ft2 per panel at 12 inches thick
4,500,000ft/2 of 12ft x 4ft panels = 93,750 panels per year
4,500,000ft of 20ft/2 x 4ft panels = 56,250 panels per year

Assume 48 weeks working, 5 days per week, 3 shifts = 1,260 shifts per
year
Assume a 4ft daylight press divided by 8 inches = 6 panels per press
Assume a 4ft daylight press divided by 12 inches = 4 panels per press
Assume 1.5 hour press time = 5 press loads per shift

Therefore, three presses at 12ft x 4ft will be required and three presses at
20ft x 4ft to produce the volumes required


The skin material be it cement fiber board or our Hi Tec Engineered OSB for roof
panels is lifted via vacuum assisted crane onto the adhesive machine, which is
also a motorized conveyor, the machine carries datum guides so as to ensure
what will be the bottom skin is in the correct position, this is pre- programmed via a
digital control panel, the adhesive is applied to the bottom skin via a bead
applicator head which is driven by a digitally controlled servo motor, but only to the
area to be bonded; that is in this case 50mm in ( 2 inches ) from each side, the
core material, in this case polystyrene (E.P.S.) is placed onto the bottom skin
again using datum guides to ensure exact positioning.


Adhesive is then applied in exactly the same way to the top of the
foam core, finally the top skin, again is lowered into place via datum
guides onto the foam core, this whole process for this panel takes
around three minutes. (For technical data on the adhesive please go
to appendix A)


Automated Adhesive Line Option

The panel is then conveyed by the motorized conveyor contained within
the adhesive machine onto a loading table with gravity fixed rollers; this
table is in turn attached to tracks so as to move the table side ways so
as to load one of two presses.


The panel is then subsequently loaded into the pneumatic press, once the
panel is in position the press is closed, compressing the composite panel
together whilst the adhesive cures, in this case around six minutes. Once
this cycle is completed the press releases the pressure and lowers, allowing
the operators to remove the panel for trimming, to ensure the volume
requirements are met there will be a total of four presses; these will be fed by
two adhesive bead applicators, by completing a panel for pressing every
three minutes with a press time of six minutes, then the volumes required as
listed above on an annual basis will be met by operating three daily shifts
over a five day week.


Additional Automated Machinery:

• Computer aided saw, capable of cutting cement fiber board and OSB Board
sandwiching a Styrofoam core, the maximum panel size to be 24ft x 4ft x 12
inches thick:

• Vacuum lift with crane, to lift heavy skin material onto the bead
applicator/conveyor

• Mobile transfer tables, to move pressed panels to cutting area.


CNC Computerized Panel Cutting Machine
An industrial strength machine, able to cut through deeply layered laminated
wood or SIP panels. Dimensioning of material can be almost limitless in width or
length, for custom-fitted applications.
This is a CNC controlled, patented woodworking centre. It can process wall
panels in widths of 3000 to 8000 mm (10 ft to 26 ft) wide, thickness up to 400mm
(15 3/4") and, because of its modular structure, unlimited length. What makes
this machine unique is a patented tool holder of exchangeable tools with a
permanent saw blade of diameter up to 1000 mm (39") and a 5-axis tool changer
that can host large-dimension tools for processing just about any material.


SIP Machining Table

SIPs that are ready for machining are transferred onto the SIP machining table.
When SIPs are aligned on the machining table with the use of four (4) pneumatic
alignment pins, three (3) in the X-axis and one (1) in the Y-axis, the Multi-Function
Bridge (MFB) machines them to size and shape. We are offering two types of
tables in this proposal, the standard table with four locating pins for location of one
(1) panel, and an optional table that has the flexibility to locate four (4) 4’ x 8’
panels.


Multi-function Bridge CNC Machining Center

Automated Conveyor System


Automated Roller Belt Conveyor to transport Panels from Glue Laminator
to Presses


Vacuum Lift System from Machine to Pallet


Vacuum Panel Stacker


Pod Press


ESTIMATED FACTORY SIZE:

• Panel production area, 429M2

• Cutting and preparation, 200M2

• Assembly area, 350M2

• Storage area for raw materials 150M2

• Office space/meeting rooms 50m2

• Total Factory size 1,129M2 (12,152ft2)


APPENDIX A - Adhesives

Mor-Ad M-650 is an ICC approved (ESR-1023) polyurethane single part
moisture cured adhesive, Mor-Ad M-650 series of adhesives that have been
developed specifically for laminated sandwich panels; these products have
been formulated for good adhesive penetration coupled with excellent bond
strengths. They also exhibit a high modulus of elasticity for improved long
span performance.

This adhesive has been used by Home Front Homes at their plant in Miami
Florida and the Company has never experienced any co-adhesive failure, in
fact such is the nature of polyurethane adhesive in terms of the bond strength
and the very high elongation to break; that it will always out perform both the
core material and skin material in any three point bend, rolling drum and lap
shear strength test.
Therefore this also applies to any polyurethane adhesive manufactured today,
however the Company is looking at other alternative adhesive options that
comply with their US Product Approvals together with ICC Criteria in order to
insure their availability in the required Geographical locations where Factories
are being considered.


Therefore to achieve the production volumes required for Home Front Homes
an open time of 3-4 minutes with a 6-8 minute press time will be used, this
being combined with the use of two conveyor bead application machines and
four presses will result in a continuous production of panels.

Automated Glue Laminator (Optional)


Computerized Monitoring of Plant and Machinery:

HFGBS intends to include Computerized Monitoring Systems and
Live Web Cam Technology to Monitor its Plants 24/7 this plant and its
production volumes can be accessed by management 24/7 from any
Computer, anywhere in the World:


On Site Installation


Completed Unit in 5 days


Affordable & Emergency Housing Solutions(1 Bed)


Affordable & Emergency Housing Solutions(2 Bed)


Affordable & Emergency Housing Solutions


Low Cost Modular Apartments


Modular Residential Solutions

• Detailed Design
• Project Co-ordination
• Manufacture
• Delivery and Installation
• External Work and Foundations
• After Care Package

Contact details
Miami, USA:
260 West 27th Street
Hialeah, FL 33010
Mr John Butler, Mr Gabe Rispoli
Office 001.305.888.3902
Email johnbutler@gmail.com
Email gaberispolijr@mac.com

UK & Ireland
Mr Edward McCarthy, Mr Olan Crowley
Mobile 0044.7827280304
Mobile 00353.878272686
Email edwardmac@btinternet.com
Email olan.crowley@live.ie


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Sip Housing Solutions Congo 25.9.12

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Sip Housing Solutions Congo 25.9.12