Key Production Facilities at Gold Roof



Gold Roof (Pvt) Ltd. has all the required production facilities for manufacture of Pre-fabricated solutions at its factory in Hattar Industrial Area. This facility is equipped with state of the art machinery to manufacture all the components and requisites of any type of Pre-Fabricated construction project, including production of EPS block, manufacture of PVC/UPVC windows, bending and fabrication of steel structures for frames and trusses, production of trapezoidal GI Sheets and EPS Panels. Some key production capabilities of Gold Roof in detail are:


EPS Block Manufacturing

EPS is manufactured from styrene monomer, derivative of ethylene and benzene, using a polymerization process which produces translucent spherical beads of polystyrene, about the size of sugar granules. During this process a low boiling point hydrocarbon, usually pentane gas, is added to the material to assist expansion during subsequent processing.

EPS is produced in a three stage process. In the first stage, polystyrene beads are expanded to between 40 and 50 times their original volume by heating to about 100ēC with steam in an enclosed vessel called a pre expander. During this process the beads are stirred continuously. In this process the final density of EPS is determined. This is typically between 14 kg per cubic meter and 30 kg per cubic meter. After pre expansion, the expanded beads are cooled and dried in a fluidized bed drier, before being pneumatically conveyed to storage silos for maturing.

During maturing, the second stage of processing, the expanded beads containing up to 90% air are stabilized typically over a period of 24 hours. Following pre-expansion, the beads have a partial vacuum which must be equalized before final processing by allowing air to diffuse into the beads until equilibrium is reached.

Expended polystyrene Manufacturing machine at Gold Roof Factory Hatter Industrial Area

In the third stage of processing, known as the molding stage, beads are conveyed into a mould, and once in the mould are heated again by the introduction of steam. Under the influence of steam, the beads soften and start to expand again. However, as they are contained in a mould they cannot expand freely, and therefore create an internal pressure within the mould. Under this pressure the softened beads fuse together when the correct temperature is reached within the mould. Following fusion the mould is cooled, usually under the influence of a vacuum to remove moisture. The molded product is ejected from the mould at the completion of the cycle. During processing, the pentane gas is expended, so that the finished products contain no residual gas.

There are generally two molding processes for EPS. One is called Block Molding and produces large blocks of EPS up to 5 meters in length. These are subsequently cut into shapes or sheets for use predominantly in packaging and in construction.


Manufacturing Process

The second molding process is known as Shape Molding, and produces shaped parts ready to use in a wide range of applications. Electronic product packaging in particular is where shape molded EPS is used extensively. Computers, office machines, televisions and stereo equipment are everyday examples.



EPS Sandwich Panels Manufacturing

Sandwich panels are typically single piece, modular factory engineered units comprising two metal faces and a fully insulating core. The metal facings are fully bonded to the core so that the panel acts compositely when under load, in most cases, providing free standing panels. Facings used for insulated panels are predominantly of steel. The insulating core is typically bonded to the facings using a conventional adhesive bond. If other than EP, the core material is usually a material that provides good thermal insulation properties. The panels are typically manufactured on a continuous production line, as shown below.

The following generic core material types are often used in Sandwich Panel:
•    Expanded Polystyrene (EPS)
•    Polyurethane (PUR)
•    Polyisocyanurate (PIR)
•    Mineral Wool / Stone Wool
•    Phenolic foams
•    Phenolic/EPS Composites

This is designed to produce fabricated panels for factories, warehouses and house. The line applies E. P. S, Glass & Mineral Wool, Polyurethane and cuts to required length. It is the best material for wall and roof of electronic, medicine, precise machinery and general factories and warehouses.

This is to produce panels for constructing factories, warehouses and houses. After forming 0.4~0.5 mm pre-painted steel sheets, the line attaches them to EPS (Expanded Polystyrene) and cuts into required size. Roof and wall panels can be produced by the same machine.


Feature of EPS Panel Line

•    Thickness of products, 50 mm, 75 mm, 100 mm, etc, can be easily adjusted.
•    Prompt Post Management with the standardization of all parts
•    By data input, it is easy to choose the length and quantity of products
•    Line speed can be regulated at will

Features of EPS Panels

Metal insulate against heat compound board production line pigeonhole , compound in thicker interior core two sides of material color with steel roll with strong binding agent behind the shaping, have formed high , light , insulates against heat new construction material of keeping warm , sturdy and durable appearance with esthetic shape of a kind of intensity. Apply to light steel construction and wall extensively, the products have the characteristics that bright in color , it is ornamental not to need two times, our company has already developed and produced serial dedicated devices .


Production of Trapezoidal GI Sheets

Apart from conventional EPS Panels Gold Roof can also produce a variety of Trapezoidal GI Sheets locally at its production facility. The list of all the types of sheets, Gold Roof can provide to its clients, is given later on:


Production of u-PVC Windows

Gold Roof u-PVC and PVC Windows opens a new age in the u- PVC Windows. It is a response to the expectations of those customers who do not make compromises with their needs. Our windows perfectly combines all features of esthetic, economic, reliable, durable, secure and modern solutions. We at Gold Roof provide with the latest u - PVC Windows systems which is successfully being used in various Projects.

Our winds have been manufactured to work in Pakistani climatic conditions helping in saving energy by effectively segregating the temperatures of inside and outside, thereby saving on electricity bills. In fact, it actually pays back its cost in approx in its lifetime.

Every u - PVC Windows is engineered in accordance with our specification using Imported Automated Fusion Welding Equipment. This ensures that every window is supplied to the highest quality and performance standards & consistency.


Frame and Structural Elements Production

Another key facility at Gold Roof Factory is production of U and C Channel on automated rolling production lines. This production technique ensures a consistent and measured quality of finished product. Additionally we have hydraulic presses and sheering machines to produce any kind of structural element. This combined with our truss and frame production area enables us to produce any type and scale of frame and steel structure.