Ceramic tiles are the oldest type roofing with a long history. Despite the huge variety of modern finishing materials, it is confidently leading in its segment. The production technology for this period has not changed, only the equipment for the production of ceramic tiles has been improved. Consider this popular type of roof, how it is made and the benefits.

Production technology

Labor intensity technological process implies that it is used industrial equipment for the production of ceramic tiles, excluding the possibility of handicraft production.

The prepared clay is mixed with water until a plastic homogeneous mass is obtained, compacted and squeezed out in the form of a flat ribbon, which dissolves into fragments of a certain size. During the drying process, it is mandatory to control the temperature and humidity of the air in order to avoid uneven shrinkage, cracking and curvature. finished products. Firing completes the manufacturing process, giving the tiles strength and water resistance.

Heat treatment is an energy-intensive cycle, which is the reason for the high price of clay products. The ceramic tile production line is mostly an automated process that increases productivity and improves product quality.

The natural color of the tile is terracotta, therefore, in order to change it, the tile-shaped surface is coated with special compositions during firing:

• engobe - white-burning or colored clay, providing a stable color;
• glaze - a vitreous coating applied to the product and fixed by firing.

Using the latest equipment for the production of ceramic tiles, failures due to the "human factor" are completely excluded. Control at all stages of the processing lies with automation, largely due to this, a very high quality of the product is achieved.

Protective cover fastening

The installation work includes laying insulation on the rafters, waterproofing and vapor barrier layers, counter-lattices, and on top - lathing beams. One step wooden flooring influences the heavy weight and size of ceramic tiles. It is calculated individually and depends on the model. The marking of the rows is made with a cord.

The roofing is laid from right to left, then from bottom to top. The large weight of ceramic tiles determines their placement on the roof before installation - in stacks of 5 pieces to evenly distribute the load on the crate and rafters.

Fasteners are made with galvanized screws. With a slope of more than fifty degrees, the roofing material is additionally fixed with clamps. Grooved tiles should be laid with a single overlap, and flat tiles, respectively, with a double overlap. The tile located in the top row should overlap the joints of the two bottom ones.

Installation of ceramic tiles is a job that requires high qualifications, so it should only be trusted by professional roofers.

Advantages of ceramic tiles

Only by strictly observing the technology and using specialized equipment for the production of ceramic tiles, you can be sure that the durability of this roofing material will be about a hundred years. The advantages of a unique coating include:

• environmentally friendly raw materials;
• reliable sound and heat insulation;
• ease of repair;
• low water absorption;
• resistance to weathering, temperature extremes;
• minimum waste during installation.

Cons of clay roofing

The disadvantages of natural tiles are a small number:

• high cost, which is covered only by an increased service life;
• impossibility of mechanization installation work, an increase in the cost of arranging truss system by 20%, while the reliability of the coating is highly appreciated;
• the choice of colors is limited to natural shades only.

The appearance of a house covered with ceramic tiles becomes aesthetically attractive, exuding coziness and comfort. This roofing gracefully repeats all the curves of the roof, looks spectacular, standing out with restrained nobility. natural materials. This quality is truly time-tested.

Denis Gudkov, specially for the site
rosproizvodstvo.ru, fromzlatoust.ru, arkom-tula.ru

H tile is one of the most ancient roofing materials that are still in use today. Roofs made of tiles are distinguished by strength, reliability, durability, beauty and sophistication. Modern tiles can be made from various materials, which determines its technical characteristics, the possibility of using it for certain purposes and cost.

Distinguish:

• metal tile(galvanized steel coated with polymeric material),
• soft tiles (bituminous tiles, fiberglass impregnated modified bitumen),
• ceramic tiles(natural, made of clay),
• cement-sand tiles(made from cement and washed sand with the addition of metal oxides),
• composite tiles(steel coated with aluzinc and outside with acrylic primer with granules natural stone),
• polymer-sand roof tiles(sand, polymeric materials).

According to statistics, today in Europe and America, natural tiles in new construction and repair occupy a leading position - 86%, of which 67% are cement-sand, and 19% are ceramic, 3% are metal tiles, and 11% are other roofing materials. In the Russian market, the consumption of natural roofing materials (ceramic and cement-sand tiles) has been increasing every year by 30% since 1998.

Tiled roofs have high soundproofing properties (they absorb the sound of rain, hail), they do not burn, do not accumulate static electricity, do not emit harmful or strong-smelling fumes. In addition, they are distinguished by exceptional durability (up to 100 years). Cement-sand tiles are currently the most popular roofing material, since their production is less expensive, and technical specifications it is not inferior, but even superior to ceramic.

Contemporary production of cement-sand tiles is based on the following technology: preparation of a mixture of cement and filler (sand), molding tiles from the resulting mixture by rolling or using vibropresses on special pallets at specified parameters, followed by curing of the finished product in curing chambers at constant temperature and humidity.

Equipment for the production of cement-sand tiles is offered by various manufacturers both in Russia and abroad. For example, Stroytekhnika Plant LLC(Zlatoust, Russia) produces full set equipment ( line "Rifey"), intended for the production of tiles using vibropresses. The kit includes:

• molding machine for the production of slotted tiles,
• ridge tile forming machine,
• mixing mixer with a volume of 100 liters,
• pumping unit to drive the molding machine,
• lodgment,
• pallets for molding and curing tiles.

The declared productivity of this line is 500 pieces (50 m2) of ordinary tiles per shift and 50 pieces (19 m) of ridge tiles at an installed power of 17.4 kW and a pressure in the hydraulic system of 50 kg/cm2. The size of the resulting products is 420x330 mm, weight - 4.5 kg. The size of the production site required for the operation of the equipment is 8x8.5 m.

Another manufacturer of rolling equipment for the production of cement-sand tiles is LLC "South Ural Industrial Company"(Orsk, Russia). The line includes:

• installation of TsCH-P, intended for the formation of slotted tiles,
• CHR-K for the formation of ridge tiles,
• mixer,
• steam chambers.

The declared capacity of this line is 800 pieces (53 m2) of slotted tiles with an installed power of not more than 5 kW. Service staff - 3-4 people. The resulting products comply with TU-21-0284757-6-91 and have a size of 400x240x12 mm. For the manufacture of 1 m2 of tiles, it is necessary to spend 11.5 kg of cement, 23 kg of sand, 4.5 liters of water, 200-400 g of coloring pigment.

It should be noted that the application rolling forming method products can significantly improve the performance of the equipment. So, the lines developed JSC "VNIISTROM" them. P.P. Budnikova(Kraskovo village, Moscow region), operating on the basis of rolling technology, have a capacity of 3600 - 4000 pieces (240 - 300 m2) per shift with 6 - 8 service personnel and an installed capacity of 20 kW. The resulting products have a size of 400x240x12 mm, withstand a breaking load of up to 80 kg. Frost resistance of products - up to 50 cycles.

Foreign companies, mostly German manufacturers of roofing materials ERLUS AG, CREATON AG, Wienerberger, Dachkeramik Meyer-Holsen, Nelskamp, ​​Braas(ceramic or cement-sand tiles), as a rule, use their own equipment and technological solutions. Without exaggeration, the world leader in the production of tiles can be called Braas(Germany), which owns more than 224 tile factories in the world. Since 1996, a joint Russian-German enterprise LLC BRAAS DSK-1 has been operating in Moscow for the production of Frankfurt cement-sand tiles. Products are manufactured in accordance with TU 5756-001-4154053-98 by conveyor rolling. The resulting products have a size of 420x330x24-31 mm, weight 4.5 kg.

Currently, polymer-sand tiles are gaining popularity, for the production of which secondary polymer raw materials can be used in the proportion of 40-50% polyethylene and 50-60% polypropylene, polystyrene, etc. Approximately in this ratio, waste is in landfills. The consumption of materials for the production of 1 m2 of such products is as follows: 5.2 kg of plastic, 15.8 kg of sand, 100 - 150 g of dye. According to the declared technical characteristics, this material even surpasses traditional ones:

• water absorption ~ 0.3% (for cement-sand ~ 6%),
• application temperature range - from -65 to +1000С,
• combustibility - group G2,
• mechanical loads up to 350 kg/cm2 (axial compression) and up to 135 kg/cm2 (bending).

The weight of such a product is 2 times less than cement-sand analogues, and the service life can reach 50 years. Equipment for the production of polymer-sand tiles is produced Detail-project company(Tver), Polymer-Technology LLC(Orsk). Package Included:

• polymer crusher PT 2003.00.000(plastic shredding, capacity 900 kg/h),
• extrusion machine PT 2004.00.000(polymer regeneration, capacity 85 kg/h),
• APT-FRI 2002.00.000(mass preparation for molding, productivity 250 kg/h), molding unit PT 2001.00.000(forming products from a polymer-sand mixture).

The polymer-sand mixture ready for molding has a temperature of 150 - 1800C, it is the responsibility of the operator of this line to separate the required amount for further molding into the finished product. The productivity of the entire line reaches 35 m2 per shift, the staff is 2-5 people.

Nevertheless, despite the many advantages of polymer-sand materials over traditional ones, it is obvious that their quality and individual characteristics will directly depend on the composition of the secondary polymer raw materials used for production. In this regard, the use of such materials requires more stringent quality control.

Minimum output for tiles 3000 pcs/day

This information is presented in order to study in more detail the basic features of the manufacturing technology of various building materials clay and then fired.

I. The general composition of the line and the main nodal elements
1. Preparatory unit. Knot - 1 (1 set)

(1) Air drying of raw materials until moisture reaches 13% (for loader) →
(2) Belt feeder with hoppers, model TL-WLJ-PD6 (for transportation) →
(3) Conveyor type TL-SSJ-PD11 (for transporting raw materials) + 2 magnetic traps, type TL-RCBD-6.5 (to protect equipment from metal objects) →
(4) High-speed mixer crusher, type TL-XSJ-DG800 (for preliminary crushing and mixing of raw materials, obtaining a fraction of not more than 5 mm) →
(5) Conveyor, type TL-SSJ-PDPD12 (for transporting processed raw materials) →
water supply system (for mixing raw materials and achieving a moisture content of 18%-22%) →
(7) Conveyor type TL-SSJ-PD13 (for transporting recycled wet material) →
(8) High-speed mixer-crusher, type TL-XSJ-DG800 (for preliminary crushing and mixing of raw materials, obtaining a fraction of not more than 1.5-2 mm) →
(9) Conveyor, type TL-SSJ-PD14 (for transporting prepared material) →
(10) Mixer-granulator, type TL-ZLJ-YPA (for the subsequent processing of raw materials by granulating them, which significantly improves the quality of the final product before the subsequent aging of the clay for 3-6 days. This is especially true for raw materials containing an increased amount of sand .) →
(11) Conveyor, type TL-SSJ-PD15 (for transporting semi-finished products) →
(12) Warehouse for storage (aging) of clay (laying out of clay for 3-6 days after its granulation, to ensure higher quality end products) → Node-2
(13) Automatic system control (for preparation before further use of the material)

2. Automatic extrusion & semi-dry molding. Knot - 2 (1 set)


Description of the basic principles of the technological process:
(all subsequent processes up to item 20 are carried out automatically)
14) Conveyor, type TL-SSJ-PD21 (for transporting the prepared semi-finished product to ...) →
15) Belt feeder with hoppers, model TL-WLJ-LB6 (for feeding and dosing material) →
16) Conveyor, type TL-SSJ-PD22 (for transporting prepared quality material to the extruder) →
17) Vacuum extruder, type TL-CXJ-B40-30 + tile forming nozzle, type TL-JCM-RT-ST, or other nozzle (for primary tile forming) →
18) Automatic tile molding machine, type TL-AUTOYWJ-1W + tile mold, type TL-SYM-RT-ST or other mold (to form a clear shape and correct geometric dimensions of the tile) →
19) Conveyor-type manipulator for capturing and transferring products, type TL-JXSSSJ-JZ (for moving freshly molded products from the molding zone to the post-processing site) →
20) Loading transport pallets into drying plants (carried out by workers) *** 0 → Node-3
21) Automatic control system (for preparation before further use of products)

Description of the basic principles of the technological process:
(not for tiles)
20) Transport pallets (for loading by workers or automatic system***2 to) →
22) Multi-Tracks Dryer (for drying products & after hot air treatment from ovens, the presence of humidity should be less than 3-5%. After drying, the products are transported to the unloading area and unloaded by workers or automatically ***3) →
23) Transport system (for transporting products in the oven) →
24) Tunnel kilns (for firing products at a temperature of about 1150℃ until the final product is ready) → Sorting and packaging of the finished product (performed by auxiliary workers or automatically***4) +
25) Automatic control system (for drying and firing)

***0, 1, 2, 3, 4---We need to know what type of fuel you prefer to use, its calorific value and characteristics in order to make the best stove offer for you. This is very important to maintain the correct temperature during firing. And also we need to know your investment budget in order to give you the best offer, and in particular, in order to know for which mode to prepare an offer for "Node - 3" - automatic control or not.

II. Description of the main equipment in the line.

1. twin shaft mixer, type TL-JBJ-300 II

Main Technical Parameters of High Speed ​​Double Mill Type TL -XSJ -DG 800
Dimensions LxWxH(mm)	Productivity (tons / hr)	Particle size inlet / outlet (mm)	Motor power (kw)	Weight (kg)
3.150 x 1.580 x 1.550	15~25	≤100 / ≤2 ~ 5	67	≈ 6000
Features of this type
1.Special design for fine grinding and screening process. 2.Some modifications may have their own characteristics; type CG double geared rollers, type DG double hammers, type CX - impact screen grinding method, and type GS4 - rotary screen, to perform all options grinding.

4. Belt feeder with hoppers, type TL -WLJ -PD 6

5. Vacuum extruder, type TL -CXJ -B 40-30

Main Technical Parameters of Vacuum Extruder Type TL -CXJ -B 40-30
Dimensions LxWxH (mm)	Capacity (VFD adjustable) (tons/hr)	Max shaft diameter (mm)	Nominal screw diameter (mm)
4.600 x 1.800 x 1.300	5 ~ 8	￠162	￠400 / ￠300
Vacuum pressure (mpa)	Mixing / Motor power (kw)	Extruding pressure (mpa)	Weight (kg)
≤ - 0.095	45	3.0	≈ 6000
Designed specifically for the production ceramic tiles, bricks, other high quality cubic elements. The all-metal body, special hard-alloy screws and a reliable gearbox ensure the stability of the equipment and the quality of the products.

6. Modular tunnel ovens.

1. One set consists of 148 meters of tunnel ovens
The proposed tunnel ovens are a prefabricated structure of individual modules that can be assembled in a short time at almost any job site. The preliminary proposal contains recommendations for the use of natural gas as a fuel. Each set of tunnel ovens consists of 41 modules (each 3600 mm long).
All modules are made of special steel reinforced with hot-rolled steel profiles and coated with fire-resistant paint. The joints between the modules have special lock slopes that provide a smooth transition between them with a reliable hermetic connection.
Tunnel kiln length: 1,480,000mm, Inner/outer tunnel width: 2650mm / 3600mm
Size of mobile racks: 3600 x 2600 mm, Height of transport pallets: 620 mm

2. One set of double hot air ducts - 73 meters
The hot air ducts are equipped with exhaust fans and temperature detectors that regulate the humidity and temperature inside.
Each channel can accommodate up to 19 mobile pallets, for a total of 38. The ceiling of the dryer is made of reinforced concrete slab. The dryer itself is equipped with an easy-to-mount sliding gate. The dryer and air preparation system are designed, among other things, to accommodate standard bricks in it.
Dryer length: 73,000mm, Dryer inner/outer width: 5250mm / 5750 mm Mobile rack dimensions: 3600 x 2600 x 620 mm

7. Brief final conditions.

1 Appropriate arrangements for sending company specialists abroad (to Russia, Kazakhstan, Georgia ...): if necessary, the equipment supplier can send technical specialists to the buyer to carry out equipment installation, configuration and commissioning. In this case, the buyer pays the costs associated with travel, accommodation and meals for specialists, as well as pays for their work at the rate of USD 30 for each working day per person.

2 Power consumption system: three-phase, voltage 380V／50Hz (or other system according to customer requirement).

3 Terms of delivery and installation of equipment:
Manufacturing and delivery of equipment are carried out within 90 days after the signing of the contract and receipt of prepayment; installation of equipment is carried out within 60 days.

4 Ensuring the quality of equipment and services provided:
a) The warranty period of the equipment is one year, provided that it is operated in accordance with its functional purpose;
b) Sending qualified personnel to adjust and adjust the supplied equipment; c) During the warranty period, the buyer is fully serviced on all issues related to the management of equipment by telephone (fax), postal and other form of communication;
d) To ensure the normal operation of the equipment, the enterprise ensures that problems are corrected and necessary repairs, provided that such problems arose during the occurrence of a warranty case;
e) Installation and test run: During the installation and testing of the equipment by the manufacturer's technicians, in compliance with the norms and standards established by the Chinese quality system, it is desirable that during this period, the buyer's technical personnel work together to improve their skills and training. This The best way Familiarization with the equipment and its possible malfunctions.

5 Conditions of the offer fulfilled by the customer:
a) The Buyer independently ensures the supply to the location of the equipment: gas, water, electricity;
b) The Buyer independently ensures the organization of production areas and premises necessary for the placement of equipment;
c) The buyer independently ensures the availability of the line at the location necessary tools, fuels and lubricants, special equipment, etc.;
d) The Buyer is solely responsible for other necessary elements not mentioned in this offer.

6 Packing of equipment is carried out on transport pallets, taking into account all the requirements necessary for sea transportation.

7 Payment terms: Payment is made in US dollars on the terms of T/T:
a) Thirty percent (30%) of the basic price, in the form of an advance payment, is paid within 7 days after the signing of the contract;
b) Sixty-five per cent (65%) of the total contract price must be paid upon notification of the buyer that the equipment is ready;
c) Five percent (5%) is paid within 7 days after receiving the equipment and checking its quality and completeness.

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Long since under construction private bath on the site, the material for the roofing of its roof was made by hand. Moreover, only environmentally friendly and cost-effective materials, such as clay, were used. That is why today, in the man-made age, where even in the process of building houses almost nothing natural is used anymore, ceramic tiles as a roofing material have become again in demand and popular. Moreover, clay tiles for the roof of your bath can be made without the help of specialists - as in the old fashioned way.

Ceramic tile has gained its popularity due to the naturalness of its material.

I stage. Clay selection

The quality of the clay directly affects how durable and aesthetic ceramic tiles will be. It is best to take the clay that is usually used to make pots: not greasy, but not too sandy. Because natural tiles from too oily clay will warp and crack when dried, and from lean clay they will intensively absorb moisture and do not tolerate frost well. Clay should be viscous, soft and clean. Here's how you can determine its quality:

1. Method 1. Crush the lump of clay and throw it with force on the floor. It should flatten out like dough, into a cake - without cracks and without crumbling pieces.
2. Method 2. Rub the clay between your fingers - sand should not be felt.
3. Method 3. Knead the clay and try to mold it into shapes. It must be plastic.

And for even greater reliability, one ceramic tile is made from the selected clay - for testing. If the clay was suitable, then:

• the color will be even, red;
• the surface will have an even glassy coating, without any distortions or cracks;
• high-quality ceramic tiles lowered into the water should not increase much in weight;
• when hitting the tiles, a clear metallic ringing will be heard;
• the finished ceramic tile laid on two bars should easily withstand an adult standing on it;
• the total volume of one tile during firing did not decrease by more than 5%;
• at the break, a good ceramic tile will be the same color without bubbles.

II stage. Clay preparation

Clay for tiles should be constantly mixed, as well as filled with water.

Once a good clay is selected, it can begin to be prepared for processing. Usually clay is harvested for tiles at any time of the year, but it still has to overwinter.

So, the clay taken out of the ground must be folded on the surface of the soil in the form of ridges 2 m wide and 70 cm high. Such ridges are usually called stacks. This is how the clay will have to lie until warm - in the fall it will get wet from the rains, freeze in the winter, and thaw in the spring. After all this, it will be much easier to process it. And in order for the clay to freeze better, it is advisable to periodically mix the stacks and even fill them with water. After all, the longer it freezes, the better. Even if the clay lies like this for several years, it will only benefit it.

III stage. Clay preparation for processing

Before processing, the frozen clay must be soaked, and after two or three days it will be possible to start kneading. For this, there is a pug grinder, which you can make yourself from wooden barrel or thick boards in the form of a box. It is necessary to insert a wooden or iron axle inside the pug mill, and iron knives are screwed onto it in a helical way. The mechanism is similar to twisting meat in a meat grinder. And for better mixing, you can put additional knives on the sides of the pug mill. It is better to mix the clay itself at least twice.

IV stage. Shaping the shingles

The easiest way to make a flat ceramic tile for roofing. To do this, you need a wooden or iron molding frame with a handle with dimensions of 33x21 cm, and a little more than 2.5 cm thick. A plank will be attached to the frame as a movable bottom, which will pass exactly through the frame and be 1.25 cm thick, and also at the top to have a cutout for the spike.

So, a frame is placed on the desktop, and a plate with a cutout is placed in it. All this is sprinkled with ash or dry sand. A large lump of already crumpled clay is placed on the table nearby and it is shaped into a cube. Next, several layers with a thickness of 2 cm are cut with a stretched thin steel wire.

Now one layer of clay is taken, placed in a frame and strongly compressed where the tile should have a spike. Then a lump of clay is added and a rolling pin soaked in water (so that it does not stick) is cleaned off the excess clay from the frame itself. After all this, the frame must be carefully removed, and the ceramic tile itself is covered with a drying board. Next, you need to turn it over and remove the board. And that's all - the tiles can be taken to the drying shelves. The main thing is that when forming the tile, the layer should be cut off so that the frame is completely filled, because after firing the added clay will lag behind.

Forming Roman or Dutch tiles is a little more difficult, but this technology can be mastered without any experience. There is even a statistic that only one worker is able to make such 500 blanks per day.

But installation of natural tiles has its own characteristics. So, for the ridges of the roof, a special ceramic tile, called ridge, is being prepared.

V stage. Drying clay tiles

The formed ceramic tiles should dry well - slowly and evenly over the entire surface, otherwise cracks cannot be avoided. And the drying time depends on how cool the clay was mixed - the damper it was, the faster the water will come out.

Clay for tiles should dry thoroughly and evenly.

Drying tiles can only be indoors, or at least under a canopy. To do this, you need to make temporary shelves or bricks as coasters in advance. And it will take 10 days to dry.

VI stage. Treatment

Burnt natural tiles do not always turn out to be perfectly even in color, and therefore they are often pre-treated with additional processing. Basically it is glazing. The tile is covered with a special vitreous layer, which makes it more beautiful. But that's enough expensive pleasure, and therefore, more often, irrigation is applied to the tiles, which is made from red pure oily clay. It is first dried and ground, and then diluted with water like thick milk. Before the firing itself, the clay is dipped into such a solution and again placed on the drying rack. After firing, the tile turns out to be even red in color, with improved qualities and an extended service life.

VII stage. Burning

Firing is the most crucial moment in the production of tiles. Tiles need to be fired in special ovens, which are called batch ovens. These can be seen in the old Dutch villages, and it is quite possible to design something similar according to a similar scheme on your site, however, of a smaller size.

So, a tile kiln consists of four sections - a furnace, an ash pan, a firing chamber and a pipe. A wall with holes is installed behind the firebox, which separates it from the firing chamber. Once the chamber is fully loaded with shingles, a temporary perforated wall will be laid out at the back of the chamber. Also, in such a furnace, a special valve is installed to reduce or increase traction, and the furnace itself is covered with a vault.

By the way, behind such a furnace there is always a larger opening for unloading and loading tiles. And at the time of firing, it is laid with bricks or covered with sand - to reduce heat loss. But they always leave a small door - to monitor the firing process and take samples.

The tile itself can be laid for firing in different ways: vertically if it is a Dutch or Tatar tile, and sideways on an edge if it is flat. But any tile should stand upright, at a small distance from each other and without any slope. So that it does not bend over, you can jam it with pieces of broken and already burned.

It is necessary to fire the tile to such an extent until it becomes slightly vitrified on its surface. In general, vitrification is a sign of burnt tiles, but it is better to overexpose it in the fire than underbake it. Usually, the longer the tile lasts in the stove, the stronger it is. AND installation of ceramic tiles with burnout - a guarantee of special strength and durability of the roof. But without fanaticism - it is quite possible to completely burn the clay.

VIII stage. Sorting

The steeper the slope of the roof, the better for the tiles.

After the tile has cooled, it is unloaded from the oven and sorted. So, for the roof, all of it should be straight, sonorous, without cracks and evenly colored. And the rest of the tiles can be safely used to cover the canopies. Shingles should be stored under a canopy, with good protection from snow and rain. And the bottom rows should not lie on the ground, but on the boards.

All tiled roofs are durable, easy to maintain and very beautiful. Yes and installation of ceramic tiles is not difficult even for a novice builder - everything is extremely simple. The steeper the slope, the better for the tile itself - the snow will linger on it less. But in hot areas, tiles can also be used to cover sloping roofs.

It is best to select a production room with the expectation of possible direct sales, since tiles are most often used in private construction of houses, therefore, especially at the beginning of a business, it is too early to talk about wholesale sales.

The tile is made in wide assortment at the modern factories equipped with the automated equipment. Ceramic tiles are used as roofing material mainly in individual housing construction. Compared to other types of roofing materials, it has a number of significant advantages: tiles are fire resistant, durable and maintenance costs are negligible.

The main expense item in the process of organizing a tile manufacturing business is the purchase of equipment. It will take at least 150 thousand rubles to purchase it. This fact scares away many potential organizers of this promising type of business. Not everyone is capable from the very beginning production process incur such significant costs, especially considering the fact that the cost of equipment is only about 40 thousand rubles. However, there is a worthy way out of this situation. To reduce the costs associated with the purchase of equipment, it is necessary for the production of tiles to just make the production process less mechanized. And this path is not at all as complicated as it might seem at first glance.

The technology for the production of tiles with the help of manual labor is quite simple. The mixed cement mass must be placed in a machine for the manual production of tiles, which can either be purchased or made independently with your own hands. And for self-creation the machine will need only a board measuring seven hundred by twenty to make a box along the length of the tile, in which the punch will subsequently be placed under the press.

So, the main cost item in the process of organizing a tile manufacturing business is the purchase of equipment. It will take at least 150 thousand rubles to purchase it. This fact scares away many potential organizers of this promising type of business. Not everyone is able to bear such significant costs from the very beginning of the production process, especially considering the fact that the cost of equipment is only about 40 thousand rubles. However, there is a worthy way out of this situation. To reduce the costs associated with the purchase of equipment, it is necessary for the production of tiles to just make the production process less mechanized. And this path is not at all as complicated as it might seem at first glance.

In fact, the whole point is that it is beneficial for companies supplying equipment to spread the word that the production of tiles is impossible through manual labor, and, therefore, requires large investments, most of which end up in the pockets of equipment suppliers. In practice, the situation is quite different: manual production of tiles is not only possible, but also must be present in order to reduce the cost of finished products.

The cost of tiles is on average from 70 to 100 rubles, and one square meter finished products - about 280 rubles.

Business plan for the production of cement tiles.

Ceramic tiles are one of the strongest and most durable roofing materials. But, even it has one significant drawback - a very high price. Therefore, an interesting alternative has appeared on the market - cement-based tiles. Its cost has been reduced by almost half, but in terms of its quality characteristics, the material is practically not inferior.

Cement-sand tiles are durable, high strength, wear resistance, fire safety resistance to external factors.

The obvious advantages of cement-based tiles make the buyer pay attention to this particular material. Therefore, it makes sense to base your business on the production of cement tiles. Moreover, this material has been actively used in European countries for a long time. Since it pleases with its efficiency with the possibility of operation in a temperate climate.
Yes, and the base itself refers to an environmentally friendly material, which also becomes its indisputable advantage. But in order to create a successful business, it is important to start by doing some information gathering to determine the level of customer demand and competition.

The choice of production premises.

To create a successful business, you need to start with paperwork and finding a suitable premises. For work, a room with a size of 100-120 square meters is suitable. m. This area is quite enough to organize the space and allocate zones for workshops, warehouses, as well as a room for workers. It is important that all communications are in the room.

It is worth paying special attention to the well-established water supply system. It is important that ventilation works and lighting is well thought out. Ceiling height must be at least 4 meters. It should be noted that the premises should be located away from the city limits, namely the residential area.

H and the rent of the premises is allocated at least $1.2 thousand.

Equipment.

1. Installing the CPC-K - from $ 1.5 thousand;
2. Installation of TsCH-P - from 2 thousand $;
3. Shelves for drying - from $ 800;
4. Pallets - from $400;
5. Dryer - about $ 1 thousand.

On average, it takes about $5-6 thousand to purchase all the units.

Staff.

In the production of tiles, you just need to mix all the ingredients, put them in a mold and bake. Additional Assembly need not. It is enough just to follow all the steps according to the technology. Therefore, for the production of this type of tile, 3-4 people are needed. These are specially trained personnel who will be able to work with raw materials and equipment using technology. It is better to opt for men, middle-aged with no respiratory diseases. You will also need a security guard, an accountant and a customer service manager.

For payments wages workers are allocated almost $2,000.

Raw material.

For production of a tile cement of the M-400 brand is used. The wholesale price of one bag (50 kg) is approximately $2.50. For the production of 1 sq. m of tiles allocated approximately 11 kg of cement cost of $ 0.6. Sand is also required, it should be purchased immediately in a large batch of 10 tons. The cost of 1 kg of sand is $0.05. Pigment is also needed. If you take high-quality foreign pigment, then you should pay about $ 2.6 per 1 kg. And approximately 400 grams of pigment is needed to make 1 square. m. tiles at a cost of $ 1.1.
You also need paint, which will give the future tiles different colors. 1 kg of such paint will cost about $ 2. For 1 sq.m. the finished material takes almost 200 grams in the amount of $ 0.2. Thus, to make 1 sq. a meter of cement-sand tiles needs to be prepared for about $ 4.55.

Therefore, at least $4,000 is allocated for the first batch of raw materials.

To advertise your own production, you need to create a website, it is advisable to start promoting it. It is also worthwhile to create catalogs and other printed materials for the presentation of goods to customers. Worth renting outdoor advertising in a busy part of the city. It is also important to regularly take part in exhibitions and external events in the construction industry.

Basic costs.

When creating a production facility aimed at manufacturing tiles from cement, it is worth paying attention to the following categories of waste:

1. Rent of premises - 1.2 thousand $;
2. Equipment - 5-6 thousand $;
3. Staff - $2,000;
4. Raw materials - 4 thousand $;
5. Advertising - $800.

In total, about $13,000 is needed to start a business.

Profit and payback.

The cost of 1 square. m. cement tiles is about $ 5. The same amount of material will go on sale at a price of $15. The profit from the sale will be about $10. But in order to reach a high level of profitability, production must create about 1900 sq. m. tiles. Then the profit for the enterprise will be $19,000.

But, taking into account the monthly costs, the net profit will be about $8,000.

With successful sales and starting a business during the season, it is possible to recoup the initial income in the business in 3-4 months.

Clients and options for development.

The main customers are enterprises operating in the construction industry, as well as buyers with an average income level. As development, attention should be paid to production and increasing its capacity.

	You can make a table, or a door, or tombstone. A frame is made of iron of the appropriate shape. Well, let's say for a table meter by meter you made a frame with an internal size of meter by meter.