FIBREGLASS REINFORCED PLASTIC (FRP)

Introduction to FRP
Fibre Reinforced Plastics (FRP) is the generic term fora uniquely versatile
family of composites used in everything from chemical plant to luxury power
boats. An FRP structure typically consists of an unsaturated polyester (UP) resin
applied to a mould in combination with reinforcement, most commonly glass
fibre, to form a part that is rigid, highly durable and low in weight. The
composite have a combination of highly superior mechanical, chemical,
electrical and thermal properties.
Raw material for FRP
A-Glass(alkali): high alkali (25% soda lime ),very good resistance chemical,
lower electrical properties.
C-glass(chemical): extremely high chemical resistance. Mainly used as surface
tissue in the outer layer of in chemical/water pipe and tanks.
E-glass(electrical): low alkali, good electrical resistance, strong resistance
water (> 50% in reinforcement is E-glass.
S-glass(strength): 40%-70% higher tensile strength than E-glass.
D-glass(dielectric): low dielectric constant with superior electric, mechanical
properties not good as E-glass.

PAN(polyachrylonitrile): Produced by carbonization of PAN precursor,

having high tensile strength and high elastic modulus specified designed for
structural composites.

Pitch type: produced for carbonization for oil/coal pitch precursor, having high,
heat conductivity, electric conductivity, high tensile strength and high elastic
modulus.

Aramid fibre

Organic polymer by spinning a solid fibre from liquid chemical blend.

High organic strength and low density.
Good resistance to impact.

FIBRE
REINFORMWNT
Coir
structure
FORMS

grid fibre

Woven fabric

Hybrid fabric (carbon/aramind)

Continuous Fibre

Fibr

glass roving
Multi axial nonwoven fabric

MANUFACTURING OF FRP COMPOSITES

Vacuum assisted resin transfer moulding (VARTM) is likely the most common acronym of all
used in the discussion of low pressure closed mould reinforced composite moulding. The often used
VARTM acronym is most accurately applied to the process of vacuum infusion, that is where the
composite is moulded using a rigid mould to provide part geometry and a thin flexible membrane over the
fibre, with outer atmospheric pressure compressing the fibre tight against the rigid mould surface. It should
be noted however that VARTM simply means to add vacuum at the exit vent of the moulding tool, thus any
form of resin transfer moulding in which vacuum is applied to the vent would qualify for the VARTM
association. Often, the aerospace industry will have very high fibre volume composites mould within a
rigid matched mould set in which the fixed cavity mould is clamped closed using a press and the resin
injection pressures typically range less than 100 psi, yet could be as high as 600psi as used to fill the mould
encapsulating the dry fibre within.

Materials Options:
Resins: Generally epoxy, polyester and vinylester.
Fibres: Any conventional fabrics. Stitched materials work well in this process
since the gaps allow rapid resin transport.
Cores: Any except honeycombs.
Main Advantages:
1. As RTM above, except only one side of the component has a moulded
finish.
2. Much lower tooling cost due to one half of the tool being a vacuum bag,
and less strength being required in the main tool.
3. Large components can be fabricated.
4. Standard wet lay-up tools may be able to be modified for this process.
5. Cored structures can be produced in one operation.
Main Disadvantages:
1. Relatively complex process to perform well.
2. Resins must be very low in viscosity, thus comprising mechanical
properties.
3. Unimpregnated areas can occur resulting in very expensive scrap parts.
4. Some elements of this process are covered by patents (SCRIMP).
Typical Applications: Semi-production small yachts, train and truck body
panels.
PULTRUTION
Fibres are pulled from a creel through a resin bath and then on through
a heated die. The die completes the impregnation of the fibre, controls the resin
content and cures the material into its final shape as it passes through the die.
This cured profile is then automatically cut to length. Fabrics may also be
introduced into the die to provide fibre direction other than at 0 degrees.
Although pultrusion is a continuous process, producing a profile of constant

cross-section, a variant known as pulforming allows for some variation to be

introduced into the cross-section. The process pulls the materials through the die
for impregnation, and then clamps them in a mould for curing. This makes the
process non-continuous, but accommodating of small changes in cross-section.

Materials Options:
Resins: Generally epoxy, polyester, vinylester and phenolic.
Cores: Not generally used.
Main Advantages:
1. This can be a very fast, and therefore economic, way of impregnating and
curing materials.
2. Resin content can be accurately controlled.
3. Fibre cost is minimised since the majority is taken from a creel.
4. Structural properties of laminates can be very good since the profiles
have very straight fibres and high fibre volume fractions can be obtained.
5. Resin impregnation area can be enclosed thus limiting volatile emissions.
Main Disadvantages:
1. Limited to constant or near constant cross-section components
2. Heated die costs can be high.
Typical Applications:
Beams and girders used in roof structures, bridges, ladders, frameworks.
FILAMENT WINDING

This process is primarily used for hollow, generally circular or oval

sectioned components, such as pipes and tanks. Fibre tows are passed through a
resin bath before being wound onto a mandrel in a variety of orientations,
controlled by the fibre feeding mechanism, and rate of rotation of the mandrel.

Materials Options:
Resins: Any, e.g. epoxy, polyester, vinylester, phenolic.
Fibres: Any. The fibres are used straight from a creel and not woven or stitched
into a fabric form.
Cores: Any, although components are usually single skin.
Main Advantages:
1. This can be a very fast and therefore economic method of laying material
down.
2. Resin content can be controlled by metering the resin onto each fibre tow
through nips or dies.
3. Fibre cost is minimised since there is no secondary process to convert
fibre into fabric prior to use.
4. Structural properties of laminates can be very good since straight fibres
can be laid in a complex pattern to match the applied loads.

Main Disadvantages:
1. The process is limited to convex shaped components.
2. Fibre cannot easily be laid exactly along the length of a component.
3. Mandrel costs for large components can be high.
4. The external surface of the component is unmoulded, and therefore
cosmetically unattractive.
5. Low viscosity resins usually need to be used with their attendant lower
mechanical and health and safety properties.
Typical Applications:
Chemical storage tanks and pipelines, gas cylinders, fire-fighters breathing
tanks.