CG-1 Manufacturing line for the production of fiber-reinforced polymer rebar

Composite Group Chelyabinsk LLC is a research and production association that has been working in the industry of composite building materials for 15 years.

The company develops production technologies and supplies end products to 20 countries.

If you're considering CG-1 for your operation, we’re ready to talk specifics. We’ll help with calculations, technical details, and selecting the right configuration for your needs.

Key Achievements

Certification

ISO 9001:2015 TÜV AUSTRIA

Global Partnerships

Joint venture in Brazil
3 agreements on JV creation in China

Production

3 generations of equipment
6 types of machine lines
Delivered to 9 countries

Patent Portfolio

20 PCT patents for inventions
6 patents in India
4 patents in China
National-level registration in progress in 14 countries

Innovation Award

Winner of the Bortnik Fund competition (2022) for innovative developments in composite technologies. Received a grant for R&D of an automated production line with minimal human participation.

Exporter of the Year

6× recipient of the award. In 2022, the CEO received the All-Russian Exporter of the Year Award at the Kremlin from Andrey Belousov, First Deputy Chairman of the Russian Government.

The company foresees its future in the years and decades ahead and, therefore, has global goals: to alleviate the environmental burden on Earth's ecosystem through offering solutions for environmental problems and to reduce the price per square meter of housing and commercial real estate for the end consumer.

The company contributes to the development of markets worldwide (Russia, India, Brazil and KSA) and participates in the adoption of national standards for FRP.

Gallery

Requirements

Electricity consumption:

12 kW/h – average
24 kW/h – peak
380 V, 50 ±1 Hz – power supply

Water consumption:

1 m³ per production cycle (closed-loop system recommended)

Minimal staffing:

Only 2 operators per shift required — full cycle automation reduces labor costs

Budget to Start:

Only $100,000 to run the plant

Plant space:

500 m² required for installation and operation

Dimensions:

Length: 42 m
Width: 6 m
Height: 2 m

Only
$100,000
and 500 sq.m.  to run the plant

Results

Quantity of stream produced simultaneously:

20 – 32 mm – in 1 stream
16 – 42 mm – in 1 stream (optional)

Daily Output:

Equivalent to 13.2 tons of steel rebar – high-volume composite production per 24 hours

Production speed:

4,030 m of 20 mm rebar/day (at a recommended speed)

Yearly Capacity:

Up to 1000 tons (steel equivalent) – consistent high-volume performance

Capacity equivalent
5,000
tons of steel p.y.

Key notes

Payback:

Less than 0.83% of the production cost over a 10-year cycle

Warranty:

Standard warranty — 12 months,  optional extension available

Material Cost:

1$/kg

Cost Advantage:

2 times cheaper than steel for own consumption

Eco-friendly:

Permitted within 500 m of residential buildings – meets local environmental standards
The enterprise has an eco-passport

Recycled Glass:

Can be used as raw material – supports sustainable production

Cost 2 times cheaper than steel

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Contact Information

Office Address

36/1, 2nd Paveletskaya Street, Office 303, Chelyabinsk, Chelyabinsk Region, 454047 Russia

Business Hours

Monday–Friday: 09:00—18:00 (GMT+5)

Messanger

Recommended speed

Roving:

is coated with a silane-based sizing compatiblewith unsaturated polyester, vinyl ester, and epoxy resins. It is designed for filament winding, pultrusion, and weaving applications.
should be stored in a cool and dry place. The temperature should not exceed 35 ° C, and the relative humidity should be maintained below 75%.
must remain packed immediately before use. It is necessary to avoid damage to the packaging during storage. If moisture gets into it, it becomes unsuitable for further use.

MSDS for Roving

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Epoxy resin storage:

save in cool, dry and well ventilated place.
save applicable laws and regulations.
avoid direct sunlight.
no open fire.
prevent static electricity and keep away from combustible materials or heat sources.
collected them in sealed containers.
store away from water and sewer.

MSDS for Epoxy Resin

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MTHPA:

significantly improves the technical characteristics of the finished product that is obtained as a result of solidification of the epoxy binder.
characterized by high moisture resistance, chemical resistance, and electrical insulation properties of cured materials
is capable of absorbing waterfrom the air
dissolves perfectly in water and is converted into the appropriate acid. It is soluble in organic solvents (toluene, acetone, benzene), easily mixes with epoxy compounds.

MSDS for Hardener

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Basic delivery set

CG-1 Manufacturing line for the production of fiber-reinforced polymer rebar

Roving rack

included: 4 units

Holds and feeds fiber rovings into the production line in a stable and controlled manner.

Impregnation and wringing unit

included: 3 units

Impregnates fiberglass with a polymer mixture.

Control panel

included: 1 unit

Allows to customize the reinforcement diameter, and production speed.

Polymerization chamber

included: 6 units

Has automatic temperature control and a protective box.

Water cooling unit

included: 1 unit

Сools the FRP stream with a water jet until it harden.

Track pulling unit

included: 1 unit

Moves the FRP stream further along the line.

Cutting unit

included: 1 unit

Platform for convenient cutting of finished products. Features rebar fixation and dust extraction

Supply tray

included: 4 units

Organizes finished rebar and folds them for further packaging or use.

Spinning frame

included: 1 unit

Twists the roving and winds it onto spools. Later, the twisted roving is unwound from the spools and applied onto the rebar body to form the deformed surface (rib profile).

Manufactoring method

Composite fiber-reinforced rebar is manufactured by the needletrusion method. With this method of production, the rod, consisting of fibrous threads impregnated with a polymer binder, is first separated into separate parts, passed through separate channels, and then reconnected with a simultaneous spiral braid and tension of a weaving harness embedded in a bundle of fibers.

This is the main difference between needletrusion and pulltrusion, in which reinforcing fibers (glass, carbon, basalt) impregnated with a polymer resin (polyester, vinyl, epoxy resins) is stretched through the die heated to the polymerization temperature. Rebar made by needletrusion has high anchoring properties in concrete media, reliable fastening of the spiral rib (a periodic profile) on the main rod, as well as high physical and mechanical properties.

Production speed:

4,000 m
per 24-hours shift (for D 20mm)
End product diameter range:

4-42 mm

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Additional tools and equipment you will need for the production of FRP rebar

Bottom heater

need: 1 pc

2kW, with thermostat

Dissolver

need: 2 pcs

supplied with 120 mm milling cutter

Drill

need: 1 pc

750W

Nozzle head-mixer for drill

need: 1 pc

Cordless drill screwdriver

need: 1 pc

Angle grinder

need: 1 pc

125 mm diameter

TURBO diamond cutting disk

need: 20 pcs

Cutting disk for metal

need: 10 pcs

Vernier caliper

need: 1 pc

range 0–150 mm

High-precision scales

need: 1 pc

accuracy of 0.5 g

Coil weighing scales

need: 1 pc

for coils up to 20 kg

Barrel lever pump

need: 6 pcs

for oils, 300 ml/stroke, GROZ GR44100 – LBP/04

Hand cart for barrels

need: 2 pcs

for 200L barrels

Working gloves

need: 30 pcs

reinforced nitrile coating on the cuffs

Power strip on coil

need: 1 pc

IP-44, thermo connecting wire, PVC insulation 3x2.5, 4 sockets, 25 m

Scales with high stand and label printing

need: 1 pc

accuracy of 5 g, weighing limit up to 30 kg

Current pliers

need: 1 pc

with CEM DT-3341 temperature sensor

Vacuum cleaner

need: 1 pc

for collecting chips and dust

Bits for cordless drill-screwdriver

need: 2 pcs