Innovative Building Materials - Lecture 5

FRP
MANUFACTURING
Prof. A. Prota
October 7, 2012

FABRICATION PROCESSES
Some of the manufacturing methods for construction
related products:
- Pultrusion
- Weaving
- Filament winding
- Manual lay-up
- Compression Molding
- Resin Transfer Molding

Pultrusion
Process for
manufacturing
continuous lengths of
constant or nearly
constant profiles.
Fibers (mats or rovings)
are pulled through a
bath of thermoset resin,
through forming guides,
and through a heated
die (tapered to achieve
both compaction and
cure)
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Pultruded GFRP Shape

Surfacing Veil

Continuous Roving

Continuous Mat
4

Pultrusion
Pultrusion
Process
Process
Cont.
Cont.

Pultrusion
Pultrusion
Process
Process Cont.
Cont.

Pultrusion
Pultrusion
Process
Process Cont.
Cont.

Bent
Shapes

Pultrusion Machine

Roving Creels

Resin Impregnator

10

Surfacing Veil & Preformer

11

Forming & Curing Die

12

Pull Blocks

13

Cut-Off Saw

14

Weaving
Weaving is a textile preforming manufacturing technique.
Weaving is the basis for textile preforming. In weaving
continuous longitudinal strands of fiber are interwoven
with crossing strands to form a grid or more complex
pattern. Typically, the fibers are interwoven at 90 , but it
is possible to make more complex geometries depending
on the requirements of the system. When fibers are
woven at 90 to each other, they are called biaxial. Triaxial weaves are also easy to produce and occur when
the fibers are woven at 90+/-60.

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Weaving Cont.
Weaving is
accomplished using a
loom. A roll of
individual fiber strands
is positioned at one end
of the loom.
The majority of 2D
weaves which are
created are one of three
main types; 1) plain
weave, 2) twill weave,
and 3) satin weave.

Simple two harness weaving loom

(a) plain weave; (b) twill weave; (c) satin weave

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Filament Winding
Refers to the procedure of
wrapping a narrow band of
resin-impregnated tow around
a convex, rotating mandrel,
resulting in a shallow structure
that can be subsequently
cured

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Manual Lay-up
It is the simplest technique, probably to make a modern
composite structure. In this method, the fabric or mat is
saturated with liquid resin and the lay-up is made by building
layer upon layer to obtain the desired thickness. The
impregnation of the layers is done in process that is at the
time the material is layed into the mold. This method is used
most extensively with polyester and fiberglass, although some
epoxy fiber composite parts are also layed up-wet.

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Compression molding
It is technology based on
pressing a charge (pre
manufactured material) in order
to shape and then cure it during
the molding process. The first
applications of this production
method were in automotive
industry (i.e. vehicle tailgate,
vehicle hood, truck cab etc). In
general, this process provides
semi structural components
since either continuous or cut
length or chopped fibers are
used for the charge

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Resin Transfer
Molding
Resin Transfer molding (RTM) is a
closed mold low-pressure process
that allows the fabrication of
complex and simple, low
performance to high-performance,
and small to very large size
composites.
The dry reinforcement and the
resin are combined within the mold
to form the composite component.
The fiber reinforcement is placed
into a tool cavity, which is then
closed. A tube connects the closed
tool cavity with liquid resin, which
is pumped into the tool to
impregnate the reinforcement,
which is subsequently cured.

Several similar composite

fabrication processes fall into the
resin transfer-molding category
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PRODUCTS / TECHNOLOGIES
GLASS FRP RODS

1
2

1. C-BAR
(MARSHALL
INDUSTRIES
COMPOSITES
INC)
2. TBD
3. TBD

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GLASS FIBER REINFORCEMENT

POLYMER REBAR
1. 5/8 COATED

1
2

2. ASLAN - GFRP
PULTRUTED WRAPED
AND SAND COATED
REBAR (HUGHES
BROTHERS)
3. COATED

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CARBON FIBER REINFORCEMENT

POLYMER REBAR
1

1. INDENTED SPIRAL
SAND COATED

2. INDENTED SPIRAL
SAND COATED 5/8
3. ROUND

2
5
3

4. INDENTED SPIRAL 3/8

5. INDENTED SPIRAL
STIRRUP (CFRP ROD
LEADLINE TM
MITSUBISHI
COORPORATION)

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CARBON FIBER REINFORCEMENT

POLYMER REBAR
1
2

1. INDENTED SPIRAL
SAND COATED
2. INDENTED SPIRAL
SAND COATED 5/8
3. SMOOTH ROUND

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CARBON FIBER
REINFORCEMENT POLYMER

1. 19-WIRE NACC STRAND

(25 (as tendon or
reinforcing material) SUZUKI
METAL INDUSTRY, CO.,
LTD. NIPPON STEEL
CORPORATION
2. BRAIDED RC 15

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CARBON FIBER
REINFORCEMENT POLYMER

1. 7-WIRE (NACC STRAND 15.0 )

2. CFCC (CFRP BRAILED SEVEN
TWISTED WIRE )

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ARAMID FIBER
REINFORCEMENT POLYMER
1

1. FIBRA - AFRP BRAIDED

2. ARAPRE - AFRP PULTRUDED

3. TECHNORA ROD - AFRP

PULTRUDED AND WRAFFED

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CFRP GRIDS SYSTEMS

2
1. CFRP C 10 NEFMAC NEFCOM CO., Ltd.
2. CFRP 864 T1251A CLARK SCHWEBEL
TECH-FAB CO.

3. CFRP NEFMAC

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STRUCTURAL GRIDS: FIBER GLASS

REINFORCEMENT EPOXY

1. T 1011
2. 2. T - 1012

warp

Non Woven
Reinforcement in both warp
and weft direction are
uniformly tensioned
Laminates are cured

weft
CLARK SCHWEBEL
TECH-FAB CO.
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FABRICS
COLLINS CRAFT
COMPOSITES
1. A1112

2. UNIWRAP / FABRIC

3. A1110PC

1
TORAY
4. UT70-20

4
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REFERENCES
http://www.tifac.org.in/news/civil.htm, Biswas, Soumitra;
Mittal, Atul; Nangia, Sangeets; Srikanth, Gudavalli
http://www.mdacomposites.org/Manufacturing.htm, Market
Development Alliance of the FRP Composites Industry,
Copyright 2000-2001 Market Development Alliance of the
FRP Composites Industry
Karian, Harutan G., Handbook of Polypropylene and
Polypropylene Composites, Marcel Dekker, Inc., 1999,
New York, NY
Firzer, E., Manocha, L.M., Carbon Reinforcements and
Carbon/Carbon Composites, Springer-Verlag Berlin
Heidelber, 1998, Germany
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Ko, Frank K., Du, George W., Handbook of CompositesTextile Preforming, Chapman and Hall, 1998, London,
England
Bader, Michael G.; Smith, Wilburn; Isham, Allan B.;
Rolston, J. Albert; Metzner, Arthur B.; Delaware
Composites Design Encyclopedia-Volume 3, Technomic
Publishing Company, Inc., Lancaster, Pennsylvania, 1990
Mallick, P.K., Composites Engineering Handbook, Marcel
Dekker, Inc., 1997, New York
Grayson, Martin; Encyclopedia of Composite Materials
and Components, John Wiley & Sons, Inc., New York,
1983
Kelly, Anthony, Concise Encyclopedia of Composite
Materials, BPC Wheatons Ltd, 1994, Exetor, England

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Jones, I.A; Owen, M.J.; Middleton, V; Integrated Design

and Manufacture Using Fibre-Reinforced Polymeric
Composite, CRC Press LLC, Cambridge, England, 2000
http://ccm.udel.edu/mission/technologies/DEACIRTM/DEA-CIRTM6.html, 201 Composites
Manufacturing Science Lab, University of Delaware
Engineering Materials Handbook, Volume 1, Composites
International Encyclopedia Of Composites, Volume 3
Composite Engineering Handbook

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