3D MANUFACTURING PROCESS
Our proprietary processes; chemistry; manufacturing and engineering
are closely kept industrial secrets.
The buildings are manufactured mostly by robots
on long automated production lines very similar to the car industry
using 14 layers of 12m x 3m panels.
50% of lines for manufacturing building panels, painting, cutting out windows and doors;
50% of lines for manufacturing windows and doors
RFID & BARCODE
At the each part of the process there are quality control inspections - some automated, some manual inspections.
Rather than operate a “zero faults forward” approach which is more appropriate to high value and engineering critical items e.g. aircraft components
- a quick determination is made whether re-finishing is suitable,
or the component should be manufactured again from scratch.
Because all parts are bar coded and scanned by the robots
and inventory tracking system, it makes stock easy to manage
and enables simple match up of windows and doors to panels.
In the overall scheme of things this is more cost effective and efficient
rather than holding up the lines for faults.
There is minimal wastage as faulty panels are ground up
and re-used as raw ingredients.
There are two large areas at the end of the lines:
- flat packed - Panels are plastic wrapped by job order by the equivalent of large palleting robots before preparing for dispatch.
- Assembly - of partial and complete modules with floor finishes, plumbing, bathrooms, kitchens and electrics with further Quality Control Inspections.
STRUCTURAL INSULATED PANELS (SIPS)
SIPS is the term given to modern building panels that are constructed in a factory. They resemble a sandwich, in that there are several layers comprising the panel, each layer specified for specific strengths and properties.
They should include the following properties:
- Thermal insulation - often a foam core
- Strength for building structures - outer sheets (Wood / MDF / Cement / Steel)
- Sound Insulation (to some degree)
- Accurate dimensions and consistent quality control
- Rapid to build with compared to brick / concrete etc
- Easy / fast to finish e.g. paint / wallpaper etc
- A degree of fire resistance is vastly preferable
They are normally made of a wood / or an engineered wood derivative e.g. Cross Laminated Timber / MDF etc.
Now trickle down technology from aerospace and automotive industries which was far too expensive to consider implementing before is starting to appear.
Our composite technology is at the cutting edge and one of the first worldwide.
BENEFITS OF OUR SIPS
- Massive Strength and Load Bearing
- Super Light Weight - Lighter and stronger than wood and CLT
- Very high quality & very smooth finish
- No Plastering or wet trades
- Water Proof - Resistant to damp, mould and fungi
- Far stronger than steel and concrete by weight
- Excellent sound insulation and resistance to footfall noise
- Heat insulation as good as polyurethane foam and the best SIPS panels
- Reduced Costs and Carbon Foot Print
- Earthquake and Seismic Activity resistant compared to wood and CLT
- Increased Fire Resistance compared to wood, CLT and similar SIPS panels
3D PRINTING & MANUFACTURING PROCESS
Here is a step by step description of the process of 3D manufacturing high tech composite panels:
- FIRE RESISTANCE - Polyisocyanurate [PIR] (higher in strength and fire resistance than Polyurethane) is first manufactured using very high pressure machinery to inject pentane into the mixture before spraying it into moulds
- ECO - The resultant super stiff foam is around 90% air by volume.
- FIRE RESISTANCE - Robots place the outer OSB / MgO / cement board on the large vacuum moulds.
- STRENGTH - The first layer of super strong polymer resin is sprayed by robots.
- The fibre mix is then sprayed directly on top, a second layer of resin is sprayed on top.
- SERVICES - Placement robots lay the fire resistant thermoset plastic conduit / pipework for electrical and plumbing services inside the panels.
- INSULATION - The foam sections are then placed on top of the bed of resin / fibre / resin, with gaps between them added for strength.
- STRENGTH - Another layer of resin is sprayed, followed by fiber mix and another layer of resin. These are applied both into the gaps and on top of the foam.
- FIRE RESISTANCE - The outer magnesium oxide / cement board is placed on top and the mould closed.
- QUALITY - The sandwich panel is then vacuum baked under pressure - this takes out all air gaps and ensures a tight seal between layers. The tight seal formed by the resin between layers adds to the torsional rigidity and load bearing strength of the panel.
- high fire resistance, strength and insulation - Closed cell Polyisocyanurate [PIR] is injected under pressure into a large vacuum oven, instead of cheaper (& highly flammable) conventional Polyurethane [PUR] and Polystyrene.
- After closed baking, laser cutting robots cut the panels, windows, sockets and door frames to exact size - accurate to 1mm.
- Next spray cells accurately paint the panels.
WINDOWS AND DOORS
The double glazed windows and doors are precision manufactured using German extrusion machinery in aluminium, uPVC
- and where cold bridges are to be avoided in composite.
- The glass is UK manufactured and comes from Wilkinson as very large 6m x 12m sheets.
- It is cut on CNC beds - accurate to 1mm. Then bonded to a thin aluminium frame approx 10-20mm thick with argon gas filling the air gap.
- The thickness of the air gap - according to the level of heat insulation required.
- This is very cost effective and more profitable and logistically efficient than buying in the windows and doors...
- The double glazed windows and doors are installed and bonded with polymer resins, producing a super strong air tight seal.
MECHANICAL, ELECTRICAL & PLUMBING (MEP) SERVICES
- Electrical cables for power and lighting and the plumbing pipes are fed into the conduits - ready for first fix.
- Clients have the option of flat pack or modules delivery.
- In the case of modules, clients can specify the lights, electric and light sockets wired and fitted at the factory by registered electricians and ship complete with electrical safety certificates.
- For modules the bathrooms and kitchens are fully fitted in the factory.
- For flat pack, the cables and pipes are connected on site to sockets and the relevant kitchen and sanitaryware.
Nearly all new build and modular housing are electric only - there is no gas. Keeping costs low and reducing risk dramatically.
Effectiveness, Speed of Manufacture and Build Quality,
- Unprecedented within our industry.
RDA is one of the forerunners in the field of mass production and automation for modular solutions.
ECO HOUSE / PASSIVHAUS
These proprietory modular houses are damp resistant and very heat efficient.
To heat a 3 bed house only costs from £200 per year.
With very small waste in production, materials, energy and water used, they qualify as eco houses to “Passivhaus” standards.
Institutional Clients are keen to realise these cost savings on a large scale.