Description

Advantage when using special equipment obviously. The equipment is easy to use and maintain; setting up the machine allows you to avoid wasteful use of components and produce a product of a given thickness and quality. Using the machine allows you to reduce the number of service personnel (on average, a team of specialists of up to 3-5 people is required: 2 on the machine and 1-3 auxiliary workers preparing the mixture). At the same time, labor productivity is several times higher than that of a non-mechanized team, at least 1000 m2/day. During participation production company in an open competition (tender), technical equipment plays an important role when the organizers determine the winner. Characteristics: 1. Filling width: 2500 mm 2. Movement speed: 0.8-6 m/min. 3. Filling capacity: 100-500 m/hour 4. Power: 8 kW 5. Weight: 850 kg. 6. Dimensions: (l*w*h) 3000*1800*720 mm. Description of the machine: 1. Working area: has steel flat surface With anti-corrosion coating, can work in harsh conditions. 2. Front scraper: Steel structure, the distance to the ground can be manually adjusted via a screw, allowing you to set the thickness of the coating. The width can be adjusted using the upper limiter. 3. Control and working device: based on chain transmission. It has a speed controller, it can move forward, backward and along a curve. 4. Device for movement: if necessary, move the machine, on wheels. The hydraulic cylinder lifts work surface from tracks for manual movement. Pressure plate: has 4 functions: height setting, angle setting, temperature setting and vibration. The mixture is leveled by a plate after vibration, pressing and smoothing. Vibratory laying is necessary for proper compaction of the material, and heating up to 80 C ensures faster setting and hardening of the surface and improved coating quality. Areas of use and resulting products: The products of this equipment are seamless coatings made of crumb rubber, which are laid as a solid carpet on a hard or prepared surface. Basically, the coating is laid on playgrounds and sports grounds. The coating can be: . Colored; . Two-layer (thin colored top layer and thick black). In this case, the black layer is laid first, and after it dries, the colored layer is laid (with a stacker or using a PTJ-120 sprayer). To make a colored layer, either black chips interspersed with EPDM or only colored granules from synthetic rubber EPDM; . Black. As additional equipment The PTJ-120 crumb and glue sprayer can be used. When spraying onto a seamless black layer, you can get 2 types of surface - water-permeable and waterproof, depending on the ratio of crumbs and glue, and the fraction of crumbs. When laying the top colored layer using a paver, you get a water-permeable surface with a drainage effect, on which puddles do not form even in rain. On any type of surface described above, in the cold season you can pour a skating rink, and in the warm season it will again be a sports or playground. Any possible color options: uniform any color, coating with inclusions. On sports and playgrounds it is possible to apply various variations of markings and patterns. Products can be from 4 to 20 mm thick (set during installation). general description technologies 1. Materials (crumbs, binder) and equipment (paver, mixer) are brought to the installation site. 2. Prepare the surface. If this concrete screed, dirt and dust are removed. 3. Primed thin layer glue, which is used for cold styling. Glue consumption is from 100 to 300 g/m2 depending on the surface topography. This promotes improved adhesion of the material. 4. Equipment and materials are placed in place. 5. Mix the crumbs and binder (glue) using a mixer. To do this, the crumb and glue warehouse should be located next to the mixer. A scale is needed to accurately dose the binder material. Depending on the crumb fraction, type of mixer, air humidity and brand of binder, the ratio of glue to crumbs should be 15-20% by weight of the crumbs. After completing the cycle of mixing the components, the resulting mixture is moved onto a cart and transported to the laying site and poured onto the working surface of the paver. For mixing and transportation, 1-3 people are required, depending on the required productivity. 6. The scattered mass is leveled by the paver, the joints with the previously laid layer of material are leveled manually by the paver operator using special trowels. All possible surface irregularities are filled and leveled with material. 7. Drying time 8-24 hours (depending on temperature, humidity, brand of binder material). After this, you can lay or spray the top color layer. The second layer is laid without prior priming. 8. If necessary, markings or drawings are applied. The glue is mixed with the required color of dye, and the resulting mixture is applied with a brush to the pre-drawn markings. Another option is possible: the required pattern, logo, inscription is cut out of a roll of rubber material according to a template and laid with glue on the first black layer. Next it is covered and sealed protective coating and a second color coating layer is applied on top. After drying, the protective material is removed, and we get a coating with a pattern, inscription or logo. -The surface on which the material is applied must be dry and clean. -It is not allowed to work when negative temperatures air and precipitation. -The crumbs used must be dry. The size of the crumb fractions is from 1 to 4 mm. -Weight of 1 m2 of coating, 10 mm thick: 7-8 kg. -The service life of the coating is at least 10 years.

The latest technological advances have given us seamless rubber coatings.

An environmentally friendly, injury-preventing material has found its application in the field of physical education, sports, and active recreation.

The production of rubber coating can be carried out both using improvised means and through partial mechanization of the process.

Let's take a closer look at the technologies for laying seamless rubber coating.

Regardless of the rubber coating manufacturing technology you choose, you will need:

• rubber crumb;
• adhesive composition;
• coloring pigments.

Rubber crumb

Grinding degree rubber tires determines the further scope of their use.

• chit less than 2 mm in size– formation of two-layer floor coverings for sports grounds and stadiums, running tracks, swimming pools, industrial workshops, car washes, livestock buildings;
• granules 2-5 mm in size– filling of sports equipment, arrangement of foundations for children's, sports and playgrounds.

When purchasing crumb rubber, pay attention to the following conditions:

• quality of product cleaning;
• sorting by size;
• crumb shape.

For 1 m 2 of coating, an average of 8 kg of rubber will be required.

Crumbs produced by machining tires, has smooth edges, so much less connecting elements are required than when using a grated analogue.

The cost of finished crumb rubber starts from 10-12 rubles. per 1 kg of product and depends on the volume of purchase and seasonal demand for products.

Adhesive composition

For making seamless flooring made of rubber are used predominantly one-component formulations, less often - two-component.

One-component

As a binding element in glue mixture bitumen or polyurethane is used. The choice of adhesive is determined by the performance properties of the future coating and the work conditions.

Adhesive for rubber coatings on a polyurethane basis has the following properties:

1. Water permeability. Water does not linger on the surface of a coating made with polyurethane, but passes through it. The finished coating can be used both indoors with high humidity levels and outdoors. outdoors.
2. High abrasion resistance. Suitable for making floors subject to high mechanical loads.
3. Elasticity. Allows you to create an injury-proof covering for sports.
4. Environmental friendliness. The absence of harmful fumes makes it possible to use rubber floors in play areas for very young children.
5. Long service life, due to resistance to ultraviolet radiation and sudden temperature changes.

Another feature of the polyurethane binder is that it hardens when sufficiently high level humidity – 60-70% and temperature environment 20-25 o.

Compositions with bitumen are less suitable for making a seamless rubber surface.

Bituminous components do not mix well with paint and have lower performance properties.

Cost 1 kg. one-component glue – from 185 rub.

Two-component

Two-component adhesive is sold in separate containers containing epoxy-polyurethane binder and chemical hardener.

Both components are mixed directly at the time of work.

When choosing a two-component adhesive for crumb rubber, you should take into account that the finished composition should be used in the first 30-40 minutes after its preparation.

This feature of the glue requires careful calculation of the need for it to carry out work in this period of time. The advantage of the two-component composition is high chemical inertness.

The cost of 1 kg of glue is from 165 rubles.

Requirements for work

The formation of a high-quality seamless rubber coating is possible only with strict adherence to the proportions recommended by the adhesive manufacturer.

For 1 kg of crumb rubber, about 250 g of polyurethane glue is required; the consumption of the binder depends on the size of the granules used.

Another condition for uniform polymerization of the working composition is maintaining the required level of humidity and temperature at the work site.

Pigment compositions

The coloring of the future rubber coating is given by coloring pigments added to the working composition.

What should you pay attention to when choosing paint?

• production from inorganic components;
• presence of iron oxides.

This component composition of the dye makes it resistant to precipitation and ultraviolet radiation, extending the aesthetic life of the coating.

The dosage of the dye depends on the desired color intensity of the surface being formed and averages 62 g per 1 kg of crumb rubber.

The uniform consistency of the working composition is achieved by strictly following the manufacturer's recipe.

The cost of 1 kg of dye is from 110 rubles.

Primer material

A polyurethane-based primer is another component without which it is impossible high-quality styling seamless rubber coating.

The material, which has good penetrating ability, ensures high adhesion of the components of the laid mixture with the treated coating.

The price of a primer ranges from 10 rubles. for 1 kg. and depends on the volumes purchased.

Coating production equipment

The quality and durability of the future product largely depend on the equipment used in production.

The use of special mechanisms is especially important when it is necessary to produce a two-layer coating or production of large volumes of work.

It is not necessary to buy equipment - can be rented the equipment you need.

Mixer

High-quality mixing of crumb rubber, glue and dye is ensured by using an industrial mixer.

Unmixed lumps in the working mixture are a manufacturing defect and can ruin all your attempts to create a high-quality seamless rubber coating.

Distinctive features of the mixing device - simple design and operational reliability.

Let's look at some types of mixers for crumb rubber:

• device with top feed of raw materials and side unloading window;
• designs with removable containers and top position engine;
• screw mixer.

The MSRK-90 crumb rubber mixer has good reviews from the online community. The device has a top loading of working components and convenient window for removing the finished mixture.

The capacity of the mixer and the power of its motor allow mix the mixture well from 90 kg of rubber.

Autostacker

Mechanized laying of rubber coating has the following dignity:

• high labor productivity, allowing, depending on the brand of equipment used, to lay a surface area of ​​up to 1000 m2;
• staff reduction for the execution of work;
• possibility of customization equipment for obtaining coverage of strictly specified parameters;
• convenience and basic maintenance.

The paver is an equipment equipped with an adjustable scraper at the front of the working platform, a pressure plate and heating elements at the rear of the device.

The stacker is controlled by regulating the speed and direction of its movement; there are also devices for manually moving the mechanism.

In the process of work, laid out on rough surface the rubber mixture is distributed and leveled by the paver over the entire width working area devices. Heating elements heat the rubber mixture, thereby accelerating the polymerization process of the glue.

Stitch roller

Hand rollers for compacting the rubber-adhesive mixture must be quite heavy. Light fixtures are not able to effectively compact the working composition, which will lead to rapid destruction of the rubber coating.

There are three types of rollers used to form rubber coatings:

• large roller for compacting the main surface area;
• roller for rolling out joints and joints;
• roller for forming surface corners.

Composition sprayer

Spray device provides technology uniform application working composition onto the surface being treated.

The advantage of the sprayer is the ability to hide minor “flaws” during coating production by applying a thin finishing layer of raw materials.

The operation of the equipment is carried out as follows: the composition, ready for application to the working plane, is placed in the receiving hopper.

Using a pump, the mixture is high pressure fed to the spray gun and applied to the surface with a layer of the required thickness, Raw material spray radius is adjustable.

The equipment works well with crumbs up to 1 mm in size. A larger fraction clogs the spray nozzle and disables it.

Weighing equipment

Exact adherence to the proportions of the ingredients of the working composition is a condition for obtaining a high-quality seamless rubber surface.

The use of measuring containers is prohibited to determine the volume of a particular component of the mixture - a deviation from the norm of 5-10% significantly reduces performance characteristics finished coating.

Rubber coating manufacturing technologies

Laying seamless rubber coating is accessible even to amateur craftsmen. The main requirement for the production of work is strict adherence to instructions when preparing the working composition, as well as careful stirring and applying the mixture.

Single layer surfaces

Installation of the rubber coating is carried out in the following sequence.

Preparing the base

The service life of the future coating largely depends on the quality and type of base.

The most popular types of bases are:

Crushed stone. Used for installation of rubber coating on playgrounds, sports facilities intended for running and race walking.

Cost-effectiveness and moisture permeability are the main features of a crushed stone base.

The coating laid on crushed stone must have a thickness of more than 15 mm. and used exclusively for light loads.

Excavation is being carried out at the work site.

The size of the recess depends on the level of occurrence groundwater, as well as the type of soil and its drainage capacity.

The distance from stormwater wells also matters.

The next step is soil compaction and drainage laying. Then layers of sand and crushed stone of various fractions are laid with mandatory compaction. Upper layer formed from small screenings.

A high-quality crushed stone base has a slight slope to remove moisture, does not contain depressions or bulges, and does not press down when walking.

Asphalt. Base from asphalt concrete mixture allows you to lay rubber crumbs in a layer of 1 cm. This type of base is used in the construction of professional sports facilities. Its advantage is its high strength, which can withstand the weight of special equipment.

Another condition is the absence of stains from petroleum products.

The asphalt base can be formed in either one or two layers, with the obligatory arrangement of underlying layers of sand and crushed stone.

Compliance with the technology of manufacturing asphalt pavement allows you to obtain a base that can withstand significant mechanical loads.

Concrete. The concrete base is the strongest and most durable and has a universal scope of use.

Like asphalt pavement can withstand heavy loads and can even be used to form floors in car parks.

Qualitative concrete covering requires effective waterproofing and polishing.

What else should you pay attention to when installing a concrete foundation?

1. The thickness of the concrete layer must be more than 1.2 cm, exact amount concrete per 1 m 2 of working area is calculated based on the type of soil and the planned loads on the foundation.
2. Concrete reinforcement should not be neglected. Fine mesh wire mesh significantly improves the quality of the future foundation.
3. Forming the base plane at a slope and careful waterproofing prevents delamination of the concrete layer and the accumulation of puddles on its surface.
4. It is necessary to sandblast the concrete to achieve complete adhesion to the layer of rubber and glue.
5. The base is considered ready when its moisture level is less than 4%.

Rubber layer on concrete base– from 1 cm.

Primer

To increase the “adhesive” properties of the glue to the subfloor or base, it is necessary to prime the surface.

For these purposes, you can use store-bought primer mixtures or prepare them yourself.

For the simplest primer, you will need turpentine and polyurethane-based glue. The components are mixed in equal proportions and applied with a roller to the surface to be treated.

The primer “hardening” time depends on the level of humidity, temperature of the work site and is from half an hour to several hours. The mixture consumption per 1 m2 of surface is 300 g.

Calculation of components and mixing of the working mixture

Depending on the volume of the mixer tank and the power of its engine, you can immediately prepare a composition for laying on 5-10 m2 of base.

So, when gradually forming a rubber coating 1 cm thick in “steps” of 5 m2, you will need:

1. Crumb rubber – 40 kg.
2. Glue – 8.5 kg (see instructions for use for exact proportions).
3. Dye – 2.5 kg.

The finished components are fed into the mixer tank in the following order: crumbs, after 2 minutes pigment dye. After the rubber particles are uniformly colored, glue is added to the mixer. Mixing of the composition is carried out until homogeneous mixture and usually takes 10-15 minutes.

Application

For ease of work, you can mark the working surface into segments with an area of ​​1 m2. A mixture weighing 10.2 kg is poured into each square. The rubber-adhesive mass is leveled over the surface special devices in the form of spatulas and pressed down with rollers.

At mechanized way work, the available equipment is replaced by an automatic stacker.

Only minor defects in the finished surface, which periodically arise when using equipment over large areas, are corrected manually.

Complete sintering of the composition depends on weather conditions and averages 8-12 hours.

Double layer technology

The rubber coating can be laid in one or two layers. With a two-layer technology, you can save on painting the lower layers of rubber.

To make the coating more elastic, it is advisable to use fine crumbs (up to 2.5 m) to form the first rubber layer.

After the first layer of rubber has completely hardened, it is necessary to reinforce the surface with fiberglass mesh. This technique increases the strength of the coating, increases its service life.

The top layer of rubber coating can be formed with the addition of ready-made colored rubber granules or consist entirely of them. In this case, pigment dyes are not used.

The thickness of the top layer, depending on the purpose of using the future coating, is from 1 cm.

"Dry" floors

The technologies we have considered fall into the category of do-it-yourself installation of rubber floors using binding components. There is another method, the so-called “dry” production of rubber flooring.

The laying technology is a simple spreading of rubber crumb in a layer of more than 8 cm on the base.

This way of doing work good for quick formation temporary floor covering, and this is where all its advantages are limited.

Production price

Making and laying rubber coating yourself is the most a budget option production of work. The cost of third party services varies greatly and depends on the following factors:

• purpose of the product;
• coating thickness;
• number of layers of the product.

Let us present the results of a study of the market for services for the production of seamless rubber surfaces(consumption and prices per 1 m2) in the following table:

It is very cost-effective to set up a tire laying business if you make your own tires. Of course, to open such a business you need equipment, which you can familiarize yourself with.

Video on the topic

This video clearly demonstrates how to apply the mixture for a seamless coating of crumb rubber, distribute it and roll it using a roller:

Conclusion

Production of seamless rubber surfaces – great way use of waste products.

Economical products with high consumer properties can be used for personal needs or become the subject of commercial use.

In contact with

450,000 rub.

Machine for applying the top spray layer on sports surfaces made of crumb rubber. It features high performance and fine tuning. Suitable for arranging treadmills.

90,000 rub.

Electric mixer for the production of rubber coatings. Mixes crumb rubber, polyurethane binder and pigments into a homogeneous mass in 5 minutes. The maximum permissible single load is 90 kg.

24 rub.

Fine rubber crumb is intended for creating the top sprayable layer of sports surfaces and for backfilling artificial turf. The granules are packaged in big bags. The mass of crumb rubber in one bag is 1000 kg.

Protect glue from heat

How to protect glue from high temperatures in summer?

IMPORTANT! How to store glue in winter

All isocyanate-containing products, when temperatures drop below +5 degrees, begin to crystallize and can be in the form of grains and cloudy lumps. The product must be warm when working! It must be heated in volume, but not higher than +50.

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Materials for 1 sq.m. coatings

Super advantageous offer!

A set of materials and consumables for covering 1 sq.m.

In the spring, you discovered that you slightly damaged the coating with a shovel in winter when removing snow and now you want to repair it? You received a call from a client for whom you were building a sports or playground with a request to complete minor repairs? Do you need to cover the steps or entrance group?

Promotion! Discounted tiles!

Discount on puzzle tiles in the amount of 200 rubles per piece!

We present to your attention puzzle tiles measuring 950*950*15mm at a special price.

Easy to assemble and disassemble like a puzzle. Thanks to the smooth surface and large size tiles look like a single surface. Has high wear resistance. Ideal for use on sports fields and garages on solid ground.

Promotion! Sale of spray coating materials

A snowstorm is blowing outside, but we, like most likely you, are actively preparing for the new season. Today we are holding a promotion for spray coating materials. We are all used to seeing Treadmills with red spray coating. But, of course, this is not the only color for professional athletics surfaces. And today we offer you a super promotion:

A set of materials for the production of blue spray coating for an area of ​​up to 1800 m2 - for only 811 RUR/m2!

2019-08-05T09:05:29+03:00

In our country in Lately Rubber crumb coating is becoming increasingly popular. produced in sports facilities, children's playgrounds, both outdoors and indoors. This is primarily due to its shock-absorbing properties. Plus, the safety of rubber coatings, high anti-slip properties, elasticity, and resistance to abrasive wear. And the most important advantage of this coating is its seamlessness.

The final result, that is, the durability and quality of the coating, will subsequently depend on such a simple operation. If for some reason the granules are poorly coated with glue, and there is no connection between the rubber crumbs and the glue, this often leads to the appearance of holes, brittleness, cracks and bald spots in the coating. By the way, the lifespan of a poorly mixed coating is not long at all - a maximum of 2 years. And if all recommendations are followed, the coating will last more than 10 years. The quality of the coating is greatly influenced by the quality of the components included in the composition.

If in rubber crumb a large number of metal cord and textiles, this may affect appearance and the coating in this case will become very dangerous for use. The presence of dust will also worsen the adhesion of the granules to the glue and often causes the destruction of the coating. If the quality of the glue is very low and does not provide the required viscosity of the mixture, then the laid coating will become brittle, brittle and lack shock-absorbing properties.

Methods for laying crumb rubber

It is best to entrust the installation of the coating to professionals, so as not to change it several times a year in the future. Although the necessary components for such work are low cost. As you know, today there are four methods of laying crumb rubber coatings:

• sprayer;
• manual method;
• combined method;
• method using an automated stacker.

It is better to entrust the laying of crumb rubber to professionals, then the coating will be of high quality and durable

Types of equipment used

It is recommended to use special equipment for laying rubber coating. This allows you to reduce service staff and increase labor productivity. One of specialized tools is an automated stacker rubber tiles. It is a steel track-mounted structure consisting of a pressure plate and a front scraper, which is manually adjustable to allow required thickness coverings. The width can be adjusted using the upper limiter, and the plate has 4 functions.

The top layer of crumb rubber is sprayed under high pressure

Rubber crumb is a seamless, elastic coating that is resistant to temperature changes and precipitation. It is used for the construction of children's playgrounds, jogging and cycling paths, areas along swimming pools and skating rinks.

PU glue

(In the picture: construction mixer)

• First mix the crumb rubber for 10 minutes
• Add glue to them - 20-25% of the mass of crumb rubber. Stir the mixture for five minutes
• To work with rubber crumbs outdoors, the air temperature must be +20 ºC and without precipitation

Equipment for laying crumb rubber

Depending on the area that needs to be covered with crumb rubber, different equipment is used.

If we're talking about If a large site, for example, a sports arena, is subject to damage, then you cannot do without an automatic crumb rubber stacker. It allows you to control the thickness and width of the coating, work at high speed (at least 800 square meters per day), and also distribute the material evenly over the surface, pressing it down so that it does not peel off.

(Pictured: auto stacker)

Usage: pour the prepared polymer mixture onto the surface in even parts, then level it using an auto-layer.

The budget and easiest-to-use equipment for laying rubber crumbs is a roller and a grater. Large roller and a float is used to compact the coating, a forming roller is used for corners and joints. Before starting, the tools are soaked in turpentine so that the rubber crumbs do not stick to the surface.

(In the picture: roller)

(In the picture: grater)

Usage: pour the prepared polymer mixture onto the surface in even parts, then level it with a roller and press down with a grater.

The sprayer consists of air compressor and pumps. It is used for spraying a second layer of crumb rubber to cover vertical surfaces layer of crumbs up to 1 millimeter. It allows you to apply the components evenly and hide the unevenness of the first layer.

(In the picture: sprayer)

Usage: the polyurethane mixture is poured into the receiving hopper, from there it is fed to the spray gun using a pump and applied to the surface under pressure.

After laying the crumb rubber, you need to wait until it dries for 24 hours. Complete hardening of the coating occurs after five days.

Clean the equipment with organic solvents: acetone or xylene.