Faygo, Wanplas 공장 with 22 years of dedicated experience in plastic pipe and profile extrusion, builds the continuous production lines that turn rigid and flexible PVC compounds into the sealing sections engineers embed in construction joints to keep water out of tunnels, subway stations, and deep underground utility structures. In tunnel and underground engineering, a single leaking joint can compromise an entire segment, so the profile that fills that joint has to be dimensionally stable, chemically durable, and tightly bonded to the surrounding concrete. Co-extrusion makes that possible by forming a rigid carrier body and a soft sealing layer in one pass, eliminating the adhesive line that single-layer strips rely on and that eventually fails under hydrostatic pressure.
Why Continuous PVC Profiles Are the Backbone of Underground Waterproofing
지하 구조물은 서비스의 대부분 기간 동안 수위대가 구조물 위쪽에 위치하는 지속적으로 젖은 환경을 마주합니다. 콘크리트만은 다공성이며, 건조 및 정착 과정에서 미세 균열이 발생하므로 실제 물 방벽은 구조물 주변에 배치된 조인트, 밀봉, 멤브레인 시스템에 의존합니다. 물 정지 스트립은 콘크리트 두 번째 포밍 전에 구조물 조인트의 중앙에 미리 형성된 프로필이며, 콘크리트 표면이 그 리브와 볼을 감싸고 굳어질 때 스트립은 조인트의 두 부분에 기계적으로 잠깁니다. 그리고 이 스트립은 자체적으로 균일하거나 코-압출되어 있으며, 시트 기반 장벽의 가장 약한 지점인 이음새를 제거합니다. 긴 터널 운전 및 지하철 컷 앤 커버 박스에서 수천 킬로미터의 이 프로필이 설치되므로, 이를 만드는 압출 라인은 일관된 단면, 안정적인 색상 및 충전재 분포, 그리고 수천 미터의 연속 생산 동안 예측 가능한 해안 경도 변화가 없는 것을 제공해야 합니다.
The choice of PVC as the base polymer is not accidental. Rigid PVC offers high compressive strength and low creep, so the carrier body holds its shape under the pressures of fresh concrete placement and the later load of surrounding soil. Plasticized PVC, or a co-extruded thermoplastic elastomer layer, supplies the flexibility that lets the soft fins deform and recover as the joint opens and closes with thermal movement and settlement. By co-extruding these two materials through a single die head, the line produces a monolithic strip in which the hard and soft phases share a welded interface rather than a bonded one, which is the difference between a seal that lasts the design life of the tunnel and one that delaminates within a few seasons of saturated service.
코-압출이 스트립 아키텍처를 어떻게 변화시킵니다.
A single-layer extruded water stop is limited to one material and therefore one set of properties across the whole cross-section. Co-extrusion breaks that limitation by feeding two or more extruders into a common co-extrusion die, where separate melt streams are brought together at the land of the die so they fuse under heat and pressure into a single unified profile. In a typical water stop strip, a conical twin-screw extruder plasticizes the rigid PVC carrier compound while a single-screw extruder handles the softer sealing compound, and the two melts meet in the die to form a strip with a rigid spine and flexible edge ribs in one continuous piece. Multi-layer co-extrusion can add a third stream, for example a hydrophilic or color-contrast layer that makes inspection easier after installation. The technical advantage is that each layer can be optimized for its function without compromise, so the carrier can be highly filled and stiff while the seal stays soft and resilient.
생산 측면에서 코-엑스트루젼은 부실품을 줄이고 하위 라인을 단순화합니다. 별도의 적층 단계가 없으며 접착제 건조 오븐과 두 번째 교정 작업이 필요하지 않기 때문에 결함 모드가 적어지고 공장 마당 면적이 줄어듭니다. 제어 시스템은 도ver층 비율을 유지하기 위해 양 제조기 간 온도, 압력, 탈출 속도를 일관적으로 관리할 뿐입니다. 또한 최신 서보 드라이브 방식의 라인은 전체 생산 과정 동안 도ver층 비율을 엄격하게 제한된 범위 내에 유지시켜 줍니다. 여러 배치에서 일치하는 스트립을 필요로 하는 터널 시공업자는 이러한 배치 간 일관성을 통해 설치된 씰을 개별적으로 검증된 부품의 시리즈가 아닌 하나의 엔지니어링 시스템으로 취급할 수 있습니다.
레진에서 완성된 스트립까지의 생산 라인 아키텍처
The complete water stop co-extrusion line follows the same downstream logic as any profile extrusion system, beginning with material preparation and ending with automatic cutting and stacking. Rigid and flexible compounds are first conditioned in drying hoppers if needed, then metered by loss-in-weight feeders into their respective extruders so the layer ratio stays exact. Each extruder uses a barrel divided into feed zone, compression zone, and metering zone, with the screw geometry and L/D ratio selected to give the compound full plasticizing without thermal degradation of the heat-sensitive PVC. The melts are filtered and, where required, passed through a melt pump for steady pressure before entering the co-extrusion die head, where the profile shape is defined.
도구에서 뜨거운 프로필은 냉각된 금형 표면에 맞춰져 정확한 최종 치수를 갖도록 하는 진공 교정 슬리브에 들어갑니다. 이는 수중 정지 스트립이 조인트에 올바르게 맞도록 하기 위해 폭과 두께에 대한 엄격한 허용 오차를 충족해야 하기 때문입니다. 다 벨트 하우오프는 일정한 속도로 압출 출력을 따라 스트립을 끌어당기고, 행성식 또는 플라이 나이프 커터는 프로젝트 길이에 따라 스트립을 절단합니다. 라인 전체에서 레시피 관리 기능을 갖춘 터치스크린 제어는 스트립 유형별 매개 변수 세트를 저장하므로 20밀리미터 폭의 중심 볼 스트립에서 30밀리미터 폭의 리브 스트립으로 전환하는 것은 레시피 변경이 아니라 구성 변경입니다. Faygo, Wanplas 공장은 턴키 시스템으로 이 완전한 프로필 압출 패키지를 제공하므로 구매자는 맞춤형 압출기, 도구, 교정, 하우오프, 커터를 별도로 구매하지 않고 하나의 시스템으로 제공받습니다.
Faygo FAYGOPLAST 코-압출 프로파일 라인
For water stop and similar functional profiles, Faygo offers the FAYGOPLAST profile co-extrusion line built on the same engineering platform that serves its PVC window profile and WPC composite profile lines. The line pairs a conical twin-screw extruder for the rigid carrier with a single-screw extruder for the soft layer, both mounted on a common base and governed by one PLC with HMI recipe control. Output is scaled to the strip cross-section, and because the Wanplas factory designs the screw arrangement, barrel structure, and calibration together, the line holds dimensional tolerance across long runs. The table below summarizes the headline parameters a project engineer would use for first screening.
| Line | Output | Screw Ø | Power |
|---|---|---|---|
| FAYGOPLAST 코-압출 프로파일 라인 | 80 to 320 kg/h | 51 to 80 mm (twin) | 55 to 132 kW |
| Rigid carrier extruder | 60 to 240 kg/h | 51 to 65 mm conical | 37 to 90 kW |
| Soft layer extruder | 20 to 80 kg/h | 45 to 60 mm single | 18 to 45 kW |
| Calibration and haul-off set | matched to line | vacuum sleeve | 7.5 to 15 kW |
The line is delivered after a 72시간 연속 작동 test at the factory, which is the Wanplas factory standard for every extrusion system it ships, and all electrical components are drawn from internationally recognized brands to keep spare sourcing simple for overseas users. Because the die and calibration are engineered as a set, the same base line can produce center-bulb strips, ribbed strips, and dumbbell sections by exchanging tooling rather than re-plumbing the extruders, which keeps capital cost down for contractors who supply several strip types.
Faygo PVC 프로파일 압출 Equipment Range
Beyond the dedicated co-extrusion configuration, Faygo’s broader profile extrusion range covers the single-layer and structured profiles that underground and construction projects consume in volume, from PVC window profiles to WPC composite profiles and custom extrusions. The core extrusion capability spans 12 to 575 millimeter diameter equivalents with wall thickness up to 6.5 millimeters, covering both pipe and profile geometries, and the same control philosophy, intelligent parameter setting with real-time adjustment, carries across the range. For a water stop producer who also supplies conduit, cable protection pipe, and drainage accessories from one plant, standardizing on Faygo equipment means one control language, one spare-parts pool, and one service channel through Wanplas.
| Line | Size range | 재료 | Application |
|---|---|---|---|
| PVC window profile line | custom profiles | rigid PVC | window and door frames |
| WPC composite profile line | custom profiles | PVC plus wood fiber | decorative and outdoor |
| Custom profile extrusion | per drawing | PVC, PE, PP | seals, trims, liners |
| PVC pipe production line | 12 to 575 mm | UPVC, PE, PP | water, drainage, cable |
Each of these lines shares the Wanplas factory commitment to CE and ISO certification, so a buyer building a full underground-materials plant can document a consistent compliance posture across equipment. The 13 national patents held by the Faygo operation, including 8 invention patents, sit behind the calibration and haul-off mechanics that determine whether a profile seats correctly in the field, which is the part of the machine that most directly affects installation quality.
PVC Compound Requirements for Sealing Strips
The performance of the finished strip is decided as much by the compound as by the machine, so the extrusion line must be matched to the material behavior. Rigid carrier compound is typically a calcium-carbonate-filled rigid PVC with enough impact modifier to survive handling and placement without fracture, while the soft layer uses plasticized PVC or a thermoplastic elastomer with a low durometer for recovery. The table below lists the properties the line must accommodate and the typical targets a compounding spec would state.
| 재질 | 일반적인 값 | Note |
|---|---|---|
| Carrier hardness | 75 to 90 Shore D | rigid PVC base |
| Seal hardness | 55 to 75 Shore A | soft PVC or TPE |
| Thermal stability | good to 200 deg C | avoid degradation |
| Filler loading | up to 40 phr CaCO3 | cost and stiffness |
| 밀도 | 1.35 to 1.55 g/cm3 | varies by fill |
Because PVC is heat sensitive, the extruder screw and barrel must plasticize efficiently at moderate temperature rather than through high shear, which is why conical twin-screw geometry is favored for the rigid layer; it conveys and melts the filled compound gently while maintaining output. The line control holds melt temperature and back pressure in a window that prevents decomposition, since degraded PVC not only weakens the strip but also releases corrosive gas that shortens screw and barrel life. Proper drying of reclaim and strict colorant dispersion round out the material discipline that the equipment is designed to support.
Key Process Parameters and How They Interact
동시 압출된 워터 스톱을 허용 범위 내에 유지하는 것은 작은 수의 프로세스 변수를 균형 맞추는 일입니다. 따라서 운영자는 두 제어 패널을 다루지 않고 한 화면에서 이러한 변수를 확인할 수 있습니다. 용융 온도는 다이에서 층 두께를 설정하며, 스크류 회전 속도는 처리량을 설정하고, 호프오프 속도는 당김 및 최종 치수를 설정하며, 진공 교정은 표면 및 단면 정확도를 설정합니다. 한 변수가 움직일 때 다른 변수도 따라야 하므로 레시피 관리가 기존의 용량보다 더 중요합니다.
| 매개변수 | 일반적인 범위 | 기능 |
|---|---|---|
| Barrel temperature | 160 to 195 deg C | plasticize PVC |
| 스크류 속도 | 15 to 45 rpm | set output |
| 하우 오프 속도 | matched to output | fix dimension |
| Vacuum level | 0.04 to 0.08 MPa | calibrate shape |
In practice the Wanplas factory configures the line so that a recipe stores the full set for each strip type, and the operator selects the recipe rather than dialing values by hand. This removes most of the human error that causes out-of-spec batches and makes it realistic for a plant to run several strip geometries on one line across a single shift without a quality drift between the first and last piece.
Water Stop Strip Cross-Section Types
The co-extrusion line can be tooled for the common strip geometries specified in tunnel and underground waterproofing, and the right geometry is chosen by the joint design rather than by machine limitation. A center-bulb strip seats in the middle of a pour joint and resists water passing through the concrete plane, while ribbed strips increase the mechanical lock and the path length water must travel. Dumbbell and tongue-and-groove forms suit movement joints where some opening is expected. The table lists representative sizes the line supports and the typical hardness split.
| 섹션 유형 | Width | Carrier hardness |
|---|---|---|
| Center-bulb strip | 20 to 30 mm | 80 Shore D |
| Ribbed strip | 25 to 40 mm | 82 Shore D |
| Dumbbell strip | 30 to 50 mm | 85 Shore D |
| Soft-fin variant | 20 to 35 mm | 70 Shore A fins |
Because the die defines the shape, switching between these is a tooling exchange rather than a new machine, and the same co-extrusion platform that makes a rigid carrier can add the soft fin by activating the second extruder. For a supplier serving multiple tunnel contracts, that flexibility protects margins because one capital line covers a catalog of strip types.
터널 및 지하 공사 분야에서의 응용
이 라인에서 생산되는 물 정지 프로필은 터널과 지하 구조물을 통해 물이 담긴 토양을 뚫는 철도 및 도로 터널, 커브트 앤 커버로 건설된 지하철역, 지하 유틸리티 및 통신 배관 터널, 폐수 처리 탱크, 지하 주차장 구조물, 댐 갤러리 조인트 등 전 범위의 지하 건설 분야에서 사용됩니다. 지하수 압력이 가장 높은 벽-기반 및 벽-덱 조인트에는 같은 스트립 패밀리가 사용됩니다. 교통 이외의 분야로는 장비 수명을 단축시키는 침투를 막기 위해 통신 및 전력 인프라가 있습니다.
The application reach extends to the associated plastic products a modern underground project consumes, where Faygo and Wanplas cover adjacent needs from one source. PVC cable protection pipe, drainage pipe, and WPC composite profiles for accessways can be produced on related Faygo lines, so a contractor or a material supplier can standardize procurement and service on a single Wanplas factory relationship. That breadth matters on large infrastructure programs where delayed sealing material can hold up an entire placement sequence, and where having one accountable equipment and process partner simplifies qualification and documentation.
The service life expectation for these strips is measured in decades rather than years, because once the concrete is poured the seal cannot be economically replaced, so the extrusion quality that goes in at the factory is the quality that performs for the structure’s whole life. PVC’s resistance to the alkaline environment of cured concrete and to the biological and chemical load of groundwater means a properly co-extruded strip retains its seal long after a bonded or glued alternative would have failed at the interface. For asset owners who model whole-life cost rather than first cost, that durability is the real economic argument for co-extrusion, and it is the reason the line’s calibration discipline receives so much engineering attention at the Wanplas factory.
프로젝트 규모에 맞는 라인 선택
요구 사항에 맞게 라인 용량을 조정하면 유휴 자본과 납기 기간을 놓치는 것을 방지할 수 있습니다. Wanplas 공장은 용량과 스트립 복잡성에 맞춰 라인을 선택하며, 여러 터널 계약에 서비스를 제공하는 지역 공급업체는 더 높은 용량과 유연한 출력을 필요로 하며, 단일 프로젝트를 공급하는 공장은 더 단순하고 단일 계층 또는 코-압출 구성에 표준화할 수 있습니다. 아래 표는 일반적인 시나리오를 Faygo 라인과 매치합니다.
| Project scale | 출력 요구 사항 | Recommended line |
|---|---|---|
| Single tunnel contract | under 120 kg/h | single-layer profile line |
| Regional supplier | PVC 물 정지 스트립은 무엇에 사용됩니까? | FAYGOPLAST 코-압출 라인 |
| Multi-project plant | 240 to 320 kg/h | dual co-extrusion line |
| Full materials plant | pipe plus profile | co-extrusion plus pipe line |
선택 시도구 교환 및 자동화도 고려해야 합니다. 수요 변동에 가장 빠르게 대응하는 라인은 과로 시간 없이 수요 변동을 흡수하는 라인입니다. Faygo 엔지니어는 견적 단계에서 구매자의 스트립 도면을 검토하고 연간 용량을 고려하여 스크류, 다이, 교정 관련 세부 사항을 제안합니다. 일반적인 기계가 아닌, 실제 생산 계획에 맞게 구성된 라인을 제안합니다.
Quality Control and Calibration Discipline
A water stop strip is a passive component that is buried in concrete and expected to work for decades, so it cannot be field-tested after installation; quality has to be built in on the line. Dimensional checks at calibration confirm width, thickness, and rib geometry against the joint specification, while routine samples verify hardness split and visual uniformity of the co-extruded interface. The vacuum calibration sleeve and chilled mold surface are the decisive elements, because any drift there becomes a permanent dimension error in every meter that follows. Faygo’s 72-hour pre-delivery run is the factory’s proof that the line holds these parameters under sustained load before it ever ships.
압력 캐스케이드는 두 번째 기둥입니다. 분류 구역은 버퍼 구역보다 위이고, 버퍼 구역은 일반 공장보다 높에 위치하며, 각 단계 간 격차가 5에서 10 pa 수준입니다. 이 종로는 공기가 항상 청결에서 덜 깨끗한 곳으로 흐르도록 보장합니다. 압력 차이는 지속적으로 모니터링되고 경보가 발동되면 알람이 울리며, 자문식 열리는 도중, 필터가 막힌 경우, 공급 시스템 풍선이 고장 났을 경우 캐스케이드는 몇 초 이내에 붕괴됩니다. 작업자 및 물자 진입 지점에는 에어록이 장착됩니다. 이 문은 동시에 열리지 않도록 인터록이 장착되어 있습니다.
Installation and Joint Sealing Practice
The value of a precisely extruded strip is only realized if it is placed correctly, and the extrusion supplier’s job extends to making that placement predictable. Strips are delivered in cut lengths with clean ends that can be joined by welding or mechanical splice so the run stays continuous around corners and through changes in joint plane. At placement, the strip is centered in the formwork, fixed so it cannot float during the pour, and protected from displacement by the fresh concrete head. The rigid carrier resists the placement force while the soft fins recover against the hardened concrete to close the capillary path.
동시 압출된 스트립은 이를 간소화합니다. 소프트 레이어가 이미 캐리어에 접착되어 있으므로 현장에서 위치 및 접착제를 적용할 필요가 없으며, 두 가지 일반적인 설치 실패 요소가 제거됩니다. 프로젝트가 이동 가능성을 요구하는 경우, 동일한 라인의 소프트 핀 변형은 조인트에 필요한 복구를 제공하며 다른 제품군을 사용하지 않아도 됩니다. 취급, 고정 및 접합에 대한 교육이 Wanplas 공장 지원 패키지의 일부이므로 계약업체 직원이 라인이 생산하도록 설계된 방식으로 스트립을 설치합니다.
서비스 및 지원 From Faygo and Wanplas
Buying an extrusion line is the start of a long operating relationship, and the Wanplas factory structures its support to keep the line running through its full service life. Every Faygo system ships after the 72-hour factory test and is covered by a warranty with free replacement of damaged parts inside the warranty window. Beyond that, the Wanplas shared policy provides USD 500 free spare parts every year, which keeps a standing pool of wear items such as screws, barrels, seals, and cutter blades without a separate annual negotiation. Remote monitoring lets factory engineers read PLC data and flag abnormal trends before they become stoppages, and on-site installation, commissioning, and operator training are included so the line reaches rated output quickly.
The Wanplas open factory policy welcomes buyers to visit the Zhangjiagang plants, review the 26,650 square meter FAYGOPLAST facility, and verify the 13 patents and CE and ISO certifications firsthand. For a water stop producer, that transparency supports the documentation infrastructure projects require, and the single-channel accountability of dealing with one Wanplas factory for pipe, profile, and co-extrusion lines reduces the coordination cost of running a multi-product plant. Spare parts, process optimization advice, and capacity expansion planning are all reachable through the same service desk.
자주 묻는 질문
What is a PVC water stop strip used for?
터널 및 지하 구조 조인트에서 물이 통과하는 것을 막기 위해 기계적 잠금과 소프트 씰링으로 구현되는 사전 형성된 프로필입니다.
Why choose co-extrusion over a single layer?
Co-extrusion welds a rigid carrier and a soft seal into one monolithic strip, removing the adhesive line that single-layer bonded strips rely on and that eventually fails.
동시 압출 다이에는 어떤 압출기가 공급합니까?
A conical twin-screw extruder plasticizes the rigid PVC carrier while a single-screw extruder handles the soft layer, both meeting in the co-extrusion die head.
이 동시 압출 라인은 어떤 스트립 폭을 생산할 수 있습니까?
The FAYGOPLAST line is tooled for 20 to 50 millimeter widths across center-bulb, ribbed, dumbbell, and soft-fin cross-sections by exchanging die and calibration tooling.
How does Faygo verify line quality before shipping?
Every line runs a 72시간 연속 작동 test at the factory and carries CE and ISO certification, with recipe-managed process records for traceability.
What after-sales support comes with the line?
Support includes installation, commissioning, training, remote monitoring, warranty replacement, and the Wanplas policy of USD 500 free spare parts per year.
Can one line make several strip types?
Yes, by changing die and calibration tooling and selecting a stored recipe, the same co-extrusion platform produces multiple strip geometries in one shift.
Work With Faygo for Your Sealing Profile Line
If you are specifying or supplying water stop profiles for tunnel, metro, or underground engineering, the fastest path is to share your strip drawing, target output, and material specification with the Faygo team, a Wanplas factory, so the line can be configured to your exact joint design rather than a generic preset. The Wanplas factory welcomes a plant visit to review the FAYGOPLAST profile extrusion line in operation, run a sample on your compound, and confirm calibration accuracy on your cross-section before you commit. Reach out with your project requirements and let the engineering team propose a turnkey co-extrusion system with installation, commissioning, training, and lifetime support built in.
