FIBRE REINFORCED PLASTICS

(FRP)

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 9.1 INTRODUCTION

➲ Reinforced plastics-Generally similar to laminates in a

number of applications.

➲ FRP- Polymeric resin and reinforcement usually in fibre form

along with other additives such as filler, catalyst, initiator,
lubricants etc.

➲ Both thermoplastics and thermosets are used in FRP but

thermosets are most widely used.

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 9.1.1 COMPOSITE

➲ Reinforced materials are simply referred to as composite

or filled plastics.

➲ The term composite is generally applied to fibre

reinforced engineering structural materials, in which the fibre
are continuous or long enough that they can be oriented to
produce enhanced strength properties in one direction.

For E.g. Polyester resin reinforced by continuous glass fibre.

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 Fig.1 Composite car.

➲ A reinforced plastic consists of two main components:

a matrix, which may be either thermosetting or
thermoplastics and reinforcing filler, which usually takes
the form of fibres.

➲ Other materials such as fillers, pigments, catalyst may

also be present.

➲ In general the matrix has TRAINING

CORPORATE a lowAND
strength in comparison
to the reinforcement, which is also much stiffer, but brittle.
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 Fig. 2(a) Windsurf (b) Water jet gun

Fig.3(a) Storage box cooker (b)

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AND
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Fig.4(a) Series of ceramic fibre products (b) Nose cone

Fig.5(a) Flexible smoke carriers [Link] lab equipments

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 9.1.2 WHY USE FRP?

Reinforced plastics comprise a large portion

of the industry, because
1. High strength/weight ratio.
2. Rigidity
3. Virtually unlimited moulding size.
4. Ease of fabrication.
5. Wide range of manufacturing techniques.
6. Low capital out lay.
7. Design versatility.
8. Excellent water resistance.
9. Chemical resistance.
[Link] resistance.
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 9.1.3 MATERIAL SYSTEM
➲ Both Thermoplastic and thermosets can be used. But
thermosets are most dominating resin used in FRP.

➲ The primary ones include polyester, Epoxy, Phenolic,

Silicone, amino plastics and polyurethane.

The most important group of fibre composites are based on

unsaturated polyester, because they are

➲ low cost, readily molded at moderate to low temperature,

fire retardant, good mechanical, physical and chemical
properties, versatility in formulation etc.
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 9.1.4 PROCESS DEVELOPMENT

➲ Unsaturated polyester resins were first used for the

manufacturing of glass-reinforced plastics by hand lay-up
techniques.

Today different fabrication process are used to improve

➲ laminate consistency, reduce labor content, reduce
mixing errors, increase production rate, and for various
other reasons.

➲ In recent years more automated techniques are

developed to achieve above parameters.

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 9.2 MATERIALS

9.2.1 RESIN SYSTEM

The resins are commercially available in a variety of forms,
as
➲ powders, flakes, water solutions, water emulsions and
latex solutions in organic solvents and in liquid form covering
a wide range of viscosity.

➲ Resins that can be used at low pressures are most often

preferred for FRP.

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➲ The most used of all laminating resins are the
unsaturated polyester resins.

➲ These resin can be cross linked or cured through the

unsaturated links to give hard, infusible, thermoset solids.

➲ Glass Reinforced polyester (GRP) is the materials

commonly referred to as ‘fiberglass’ and is used for boat
hulls, furniture, tanks, pipes, building panels, roofing lights
and so on

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Fig.6 (a) Fan and other parts for hair dryer (b) Large diameter filament wound
made of FRP. GRP pipe.

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➲ The next most important class of resins used is the epoxy
resins.

➲ The resins itself may be a low molecular weight liquid or a

low melting solid.

➲ This is reacted with a curing agents or hardener to form a

cross-linked structure.

➲ The resin and curing agent reacts together by a chemical

reaction.

➲ One advantage that epoxy resins have over polyester

resins is reduced shrinkage (1-2 %) during cure.
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➲ The primary disadvantage of the epoxy resins is that they
require long curing times and poor mould release
characteristics.

➲ Epoxy is superior to polyester resin in four areas.

1. They have excellent resistant to chemical attack.

2. They have very low water absorption characteristics.
3. They have low shrinkage.
4. More durable and tougher.

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➲ The third class of resin is the vinyl ester resins.

➲ These combine part of the chemical backbone of epoxy

resin with a curing mechanism of a polyester resin.

They possess
➲ good resistance to wide range of different chemicals at
room and elevated temperatures.

➲ Vinyl esters were specifically developed for the

reinforced plastic components for use in corrosive
environment.

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➲ Furan resin is another class of resin matrix comprise of
furfural alcohol polymer blended with furfural as reactive
diluents and cross linked by using acid catalyst.

The mains advantage that a cured furan resin offers over

other laminating systems are

➲ exceptional chemical resistance. Another major advantage

of furan resin laminates is very low smoke emission under fire
conditions.

➲ Silicon resin or polyorganosiloxanes is an inorganic

polymer.

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➲ Cross-linking is done by in the presence of a catalyst
such as cobalt naphthenate, zinc octoate,
triethanolamine.

➲ Fully cured silicone/glass cloth laminate have outstanding

thermal stability compared to other laminates, silicone
based laminate have relatively poor mechanical strength.

➲ Due to this and relatively high cost, silicone laminates not

found widely in commercial purpose.

➲ Resol type phenol formaldehyde is used for composite

applications. They can be cross-linked by heating alone.

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➲ Phenolic composite offer good thermal stability, electrical
property, excellent water and chemical resistance.

➲ Melamine Formaldehyde can be used to produce translucent

laminates. They are used in tabletops and other decorative
applications.
They have excellent resistance to hot water and therefore
used for tableware items such as cups and plates.

➲ Urea formaldehyde resins offer light colour, good electrical

properties at low frequencies and good tracking resistance
when cured, better arc resistance and find application in light
fitting and diffuser, outer skin of decorative laminates where
Kraft paper is used as the reinforcing
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 9.2.2 REINFORCEMENT

➲ The reinforcement type and form depend on performance

requirements and the method of processing.

They are used

➲ to improve the mechanical properties of the cured resin

and to provide usable products.

Surface tissue:
➲ consists of a thin randomly distributed fibrous mat. They
are available in different thickness ranging from 0.08 to
0.34 mm manufactured from C- glass or synthetic fibre
such as PAN or PET.

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Advantages of surfacing tissue are

➲ They provide a resin rich finish with improved chemical

and weathering resistance.

➲ Ensure adequate bond between the resin- rich surface

layer and the bulk laminate.

➲ Help to mask the pattern of the underlying glass

reinforcement.

➲ Provide a degree of elasticity to the surface layer to

improve impact and abrasion resistance.

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 Fig.7 Surfacing tissue.

➲ Industrially the most important fibre used with polyester and

epoxy resins is glass fibre, which is relatively inexpensive.

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➲ High strength and rigid carbon fibres reinforced resin
system, coupled with their low density is ideal for
applications where strength to weight ratio is primary
importance.

➲ Typical application include aerospace and reciprocating

machine parts.

➲ Aramide fibres provide upto 30% weight saving over

glass and upto 50% over aluminum alloys.

➲ Asbestos fibre provide composite with greater stiffness

than glass reinforcement alone.

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 Fig.8 Prime pneumatic air conveyor valve containing 15% glass reinforcement

➲ Different types of glass are ‘A’ or alkali glass which is the

basic material for glass fibre production,
E or electrical grade glass,
C or chemical resistance glass and
High strength glasses such as R & S glass used mostly for
aerospace application.
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➲ Aramide fibre have excellent strength and stiffness/weight
ratio, excellent impact resistance, good fatigue resistance,
high resistance to solvents, fuels, lubricants, acid and alkali,
good vibration damping properties, superior dielectric
property.

➲ They are normally used as reinforcement in epoxy resin

matrices.

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Fig.9(a) Chopped strand mat. (b) Continuous strand roving.

(c) Chopped fiberglass strand. (d) Woven roving fabric.

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 OTHER MATERIALS

➲ Other materials are frequently added to produce

decorative effects, aid handling, improve moulding
characteristics and cured properties.

➲ Catalyst
sometimes called as initiator or hardener is
thoroughly dispersed in the resin to ensure uniform cure.

➲ Accelerators or promoters
are used in conjugation with a catalyst to increase the rate of
reaction.

➲ Inhibitors
are added to the resinCORPORATE
to ensure adequate
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➲ Curing agents
produce a cross linked thermosetting polymer from
an initially linear or branched polymer

➲ Fillers
are used to reduce cost of the system.

Other effects are,

➲ Opaque surface, increase rigidity, impact resistance,
decrease flammability and water absorption, raise
HDT,Increase abrasion resistance.

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Pigments and dyes
FRP are coloured with transparent dyes or pigments. They should
be compatible with the resin system

Lubricants
Prevents use of release agents. E.g. Zinc stearate

Light stabilizer
FRP laminates can be protected from UV light by mixing the
resin with light stabilizer such as phenyl salicylate.

Release agent and Sealing Compounds

Used to ensure complete demoulding of the laminates from the
mould. For E.g. Wax, PVA, Cellophane etc.

Other ingredients which are used in FRP are Coupling agents, flame
retardants, thixotropic additives, skin former etc.
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 Moulding Materials
➲ With hot press moulding, injection and transfer moulding,
the most convenient procedure is to use a pre-formed
moulding compound to which all necessary ingredients have
been added.

➲ DMC consists of a dough like mixture of a resin ,fibre

reinforcement and fillers to which pigments and other
ingredients may added.

➲ Polyester and glass fibre is most commonly used

combination in DMC along with other additive.

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➲ DMC usually made in a high shear Z-blade mixer,
after which the compound is often extruded into rope
form.

➲ To achieve a dry moulding compound high filler

loading is used.

➲ Usually polyester DMC contains glass fibre strand,

with fibre lengths ranging from 3 to 12 mm and a fibre
content of between 15 and 20 %.

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 A typical formulation for DMC is given below.

INGREDIENTS PARTS BY WEIGHT

Polyester resin 100
Benzoyl peroxide (Catalyst) 1-2
Filler 200
Pigment dispersion 10-15
Glass reinforcement 45-70
Aluminium Stearate (Release 3-4
agent)

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➲ Another important compound is Sheet Mouldings
Compounds (SMC) which contain

➲ glass fibre, fillers, pigments, catalyst, release agent, flame

retardant additives and so on and prepared in the form of a sheet.
A typical formulation for SMC is given below.
INGREDIENTS PARTS BY WEIGHT
Polyester resin 100
t-Butyl peroxybenzoate (95%) 2-3
Filler 140-180
Pigment dispersion 5-8
Chopped roving 50-100
Zinc Stearate (Release agent) 3-4
Magnesium Oxide (Thickening agent) 2-3
Thermoplastic additives 5-20
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➲ In a typical SMC manufacturing process a first layer of
continuous polyethylene or Cellophane film is coated with a
formulated polyester resin system into which a layer of either
chopped strand mat or chopped rovings is placed.

➲ A second layer of polyethylene film, similarly coated with

resin system, is placed over the first resin coated and
reinforcement deposited polyethylene layer.

➲ The sandwich thus formed is passed through with a series of

roller to press the glass fibre into the resin and ensure thorough
wetting of the reinforcement by the resin.

➲ The sandwich is then wound into a roll and allowed to stand

while the resin thickens. In use the SMC is cut to the shape and
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the both layers of polyethylene film are removed.
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➲ SMC is usually stronger than DMC because fibre length
(high fibre content 20-35 %, and longer fibre, 21-55 mm)
orientation and volume fraction are easier to control.
➲ Mouldings made from SMC therefore have somewhat
higher mechanical properties. However, SMC does not
flow as easily as DMC during moulding.

Fig.10 SMC Manufacture.

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 Thick Moulding Compound (TMC)

➲ Thick Moulding Compound (TMC) is also a pre-formulated

reinforced thermosets which is similar to SMC but has a
thickness of upto 2 in. with random fibre distribution, against ¼ in
for [Link] is claimed to yield moulding with more uniform
properties.

Fig.11 Thick Moulding

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➲ Prepregs is one of the high profile moulding compound which is
a unidirectional continuous fibers pre-coated with controlled quantity
of an uncured catalyzed resins formulation.

➲ The resin matrices are Epoxy, Polyimide. bismaleimide and

phenolic resins.

➲ Principle fibre used are Aramide, carbon and glass fibre as

reinforcement.

➲ Prepregs differ from SMC in that fillers, pigments and other

additives are rarely, if ever, present.

➲ One of the major outlet for epoxy prepregs is in the production

of printed circuit board for electronic applications.
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Fig .12 A typical printed circuit board made from woven
glass cloth – Epoxy prepregs.
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➲ In a typical manufacturing the fibre reinforcement (woven
cloth , rovings etc.) is passed through a solution of the resin
system contained in a bath and then through a doctor blade
or metering roller assembly to control resin pick up.

➲ The impregnated reinforcement is then pass through a

vertical heating zone to evaporate the solvent and partially
advance the cure of the resin system .

➲ After this the prepreg is cooled and either wound into a

roll or cut into sheet.

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Fig. 13 Typical vertical treater for making prepregs
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 Core Materials

➲ Core materials are used to provide stiffness, thermal insulation

and lightweight to composite structure especially in boat
construction.
➲ These materials include
Balsa wood, plastic foams and honeycombs of paper.
➲ Laminates can be readily built on a balsa core to produce a
sandwich construction, which exhibit a high rigidity/weight ratio.
➲ A variety of honeycombs can be used as core materials for
sandwich construction where low weight and high stiffness is
required.
➲ Such a honeycombs cored laminates find application as flooring,
decking, partitions and furniture, where weight saving and rigidity
are of prime importance, for example in aircraft, marine structure
and vehicle.

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 9.3 DESIGNING IN FRP
➲ Fibre reinforced plastics offer almost unlimited possibilities for
shape, size and colour and can be produced with a variety of
surface finishes.

➲ Sandwich construction can be used to produce rigid lightweight

mouldings.

➲ Factors which influence design are resin selection,

reinforcement selection and moulding process.

➲ The choice of moulding process will be affected by the number

of mouldings to be produced, production rate, moulding complexity
and size of moulding.

➲ In many cases the final design will be a compromise between

the requirements of the designer and the molder.

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 9.3.1 Material And Process Selection
➲ This includes resin and reinforcement selection. The following
factors need to be consider while selecting the materials.

 Mechanical properties
Strength/weight ratio
Specific gravity
Stiffness and impact strength
Fatigue life

 Thermal properties
Heat Distortion Temperature
Operating temperature
Coefficient of expansion
Humidity conditions
Fire resistance
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 Chemical resistance
Resistance to liquid, gases or solvent solutions.
Whether exposed to continuous / intermittent
operating temperature.

 Biological
Is food contact involved?
Problems due to bacteria, microbes and termites.

 Electrical Properties
Dielectric strength and Dielectric constant
Surface and volume resistivity

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Outdoor weathering
UV exposure
Whether the moulding be subjected to tropical,
marine or arctic climate.

 Clarity and colour

Transparent, translucent or opaque
Colour
Surface finishes
Resistance to yellowing
 Performance testing

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 ➲ The use of fibre composite in the case of main and tailor
rotor blade for helicopters and trial flights (See [Link].14)
has given the designer greater freedom in fabrication and
permitted optimization of the mechanical and dynamic
characteristics of the rotor blade.

➲ The level of enhancement of the properties of

thermoplastics as a result of fibre reinforcement is not the
same for all plastics.

➲ In general the crystalline plastic responds better to

reinforcement than the amorphous plastics. (See Table
No.3)

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Fig. 14 Use of composites in air frame application

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 Table No. 3 Improvements in properties of plastics as a
result of 30 % glass fibre reinforcement

Property  Heat Distortion Tensile strength (MPa) at

Temperature
23 0 C
(0C) at 18.6 kg/cm2
Materials Actual Enhanceme Actual Enhanceme
nt nt

Crystalline
Nylon 66 248 +153 180 +100
PEEK 300 +145 175 +75
PBT 210 +145 135 +75
Nylon 6 212 +137 160 +100
Polypropylene 148 +83 86 +51
Acetal 164 +54 140 +75
Amorphous
PES 216 +15 145 +55
Modified PPO 145 +15 125 +59
Polycarbonate 140 +10 120 +56
ABS 100 +10 90 +40

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 Process Selection
➲Processing factors

♠ Moulding size -whether small, medium or large.

♠ Unit cost- includes material and production cost.
♠ Number of moulding and production rate
♠ Nature of surface.
♠ Section thickness variation.
♠ Overall shape.
♠ Use of undercuts (For this a split mould is
needed).
♠ Sharp edges or small radii.
♠ Is sandwich construction required?
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 9.3.2 Flanges, corners and Inserts

➲ Flanges
provide adequate stiffness on small moulding.

➲ Inserts
Can be incorporated with little difficulty, particularly
with hand or spray- up technique.

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 9.4 MOULDS

➲ Before any moulding process can be undertaken a suitable

mould must be [Link] can be made from many materials
however the most commonly used material is glass fibre
reinforced polyester (GRP).

➲ GRP moulds
Made from glass reinforced polyester resin by hand or
spray-up techniques. FRP mould can give excellent
service.
➲ When not in use, mould should be stored flat to prevent
distortion and protected from dust and moisture.

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➲ For long run
 Matched metal mould used
➲ For few moulding to be produced

 Wooden or plaster mould used

➲ For intermediate quantity of moulding

 GRP and Epoxy mould Used

➲ Plaster moulds (See fig. 15)

 Porous , surface must be sealed with solution of shellac,

Cellulose acetate, nitrocellulose or Poly vinyl alcohol before
polishing

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Fig.15 Construction of a Plaster Pattern.
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➲ Epoxy resin moulds have

 long service life with many thousands of molding

produced from one mould.

 Unlike steel, Epoxy moulds will not corrode and

therefore do not require protecting with grease during
storage.

 If damaged, they can frequently be repaired.

 Exhibits negligible shrinkage during cure
 Remain dimensionally stable, once cured
 Can be cast in thick cross-section with low exothermic

➲ Epoxy mould is made by either laminating or by casting.

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➲ Steel mould required for

Hot press, centrifugal casting, transfer and injection

moulding and pultrusion techniques.

➲ Best materials in designing the mould

Tool steel with flame hardened and hard chrome plated.

➲ Adequate taper
Incorporated to permit easy removal of the moulding

➲ Mould release agent

Essential with all metal moulds, silicone being the most
popular.

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➲ Aluminum alloy moulds
Light weight, high rigidity, good quality finish, easier
to machining but they are not as hard as steel moulds
and can therefore be more easily damaged.

➲ Mould from wax, water soluble hot melt thermoplastic and

inflatable balloons
For making cylinders and sphere by filament
winding. These mould render easy removal once the
winding has been completed and the resin is cured.

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 9.5 MOULDING PROCESS

➲ The wide range of thermosetting resins and reinforcements

available and their ability to be used under a variety of
processing conditions, has resulted in the development of an
extensive range of processing techniques.

Main problems associated with moulding reinforced plastics

♠ The possibility of air bubbles being trapped in the mould.

♠ Design of the mould so that the component can be

extracted from it.

♠ Thermosetting resins can reduce in volume by upto 8%

during the setting and curing process.
Rapid and uneven shrinkage generates internal stresses
in the cured part and CORPORATE
can cause TRAINING AND
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➲ Five distinct operations of FRP conversion process

1. Mixing resin and activator

2. Dispensing resin into the mould
3. Curing (for gel coat)
4. Positioning reinforcement
5. Resin application and final Curing

➲ All fibre reinforced polymer composites manufacturing process

contain these five elements.

➲ Processing may involve equipment that is simple to operate, or it

may require intensive specialized equipments.

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➲ Most common FRP process

 Contact moulding process

1. Hand lay-up/open moulding process
2. Spray up/open moulding process
3. Vacuum bag
4. Pressure bag
5. Autoclave

 Matched moulding process

1. Cold press
2. Compression moulding or hot press.
3. Transfer moulding
4. Resin transfer moulding
5. InjectionCORPORATE
mouldingTRAINING AND
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 Continuous process
1. Continuous laminating
2. Pultrusion

 Other processes
1. Filament Winding
2. Centrifugal Casting
3. Sandwich construction

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9.5.1 CONTACT MOULDING

➲ Most common method for making both small and large

reinforced polyester products such as boat hulls, vehicle bodies,
building panels, cladding, ducts and tanks.

1. Hand Lay –up Process

➲ Although labour intensive and difficult to control the hand

laminating process is still widely used because of its inherent
flexibility and the low capital outlay in moulds and equipments.

The various stages of this technique is shown in figure No.16

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Fig.16 Various stages of Hand Lay Up Process
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 Fig.17 Hand lay up laminating using chopped strand mat

➲ The mould surface must be coated with a good quality

silicone free wax and thoroughly polished to give a smooth
glassy finish. A mould release agent such as PVA is then
generally applied using spray or sponge.
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➲ When the release agent is completely dry, the gelcoat is
applied by brush or spray.

➲ When the gelcoat has been given time to partially cure,

the main reinforcement is partially applied.

➲ The advantage of this technique is that the strength and

stiffness of the composite can be controlled by building up the
thickness with additional layers of mat and resin as desired.

➲ Alternative layers of resin and reinforcement applied to

the mould and a rubber metal roller (See Fig. 18 ) used to
consolidate the laminate (See Fig.17).

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➲ A topcoat of pigment resin is often
applied to the partially cured laminate.

➲ Demoulding by hand facilitated by

 use of compressed air
 Filling the gap between the moulding and
the mould with water to dissolve the PVA
release agent.

➲ Post cure is usually carried out after

demoulding and the moulding should be
adequately supported to prevent distortion.

➲ Finished mouldings contain between 30

and 35% by weight of glass reinforcement. Fig.18 Different – types of
laminating rollers.

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 Data sheet for hand laminating process
Other Name Process parameter
Processing pressure : Ambient
Contact molding Processing temp : Ambient
Hand lay-up (HLU) Production rate : 1-4/day/mold

Materials Cost factors

Reinforcement : most types are used Production cost : High
Resin : Polyester, epoxy, vinyl, phenolic Material cost : Moderate
Filler : up to 10% by volume Tooling & Equipment: Low
Tolerance Design details
Ribs : Yes,
Overall dimensions : 1-5 mm Bosses : Yes
Thickness : 1-3 mm Holes : can be moulded- in
Advantages Disadvantages

Low capital outlay, Operator dependent, labor

No size limit, intensive, low production rate,
Flexibility poor weight and thickness control,
only one molded face
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 Spray –up Process

➲ Both resin and fibre are sprayed into the mould

simultaneously. (See fig.19 and 20)

 Air-driver chopper unit is mounted on a resin spray

gun.

 Chapped fibre reinforcement and resins are dispensed

and positioned simultaneously in the mould.

 Consolidation
By hand rolling as in hand laminating,

But is easier as the reinforcement contains no binder

and the fibre content is more inform.
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Fig. 19 Spray – up Process

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Fig.20 A typical spray gun and chopped unit in use
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➲ A stronger laminate can be produced if alternate layers are
sprayed at 90° to each other.

➲ As in hand lay up the first layer of a gelcoat may be applied

over the mould, followed by successive passes of the sprayed -
on composite before a final gelcoat is applied.

➲ Spray-up - highly productive process but thickness is entirely

in the hands of the operator.

➲ This makes the process unsuitable for critical applications.

➲ But it is popular for high volume, non – critical products.

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 Data sheet for spray up process

Other Name Process parameter

Processing pressure :Ambient
Spray lay-up Processing temp :Ambient
Production rate : 1-4/day/mold

Materials Cost factors

Reinforcement :Chopped roving only Production cost : low
Resin : Polyester, vinyl ester Material cost : low
Filler : not recommended Tooling & Equipment: Low

Tolerance Design details

Overall dimensions : 1-3 mm Ribs : yes Bosses: no
Thickness : 2-3 mm Holes :can be moulded in

Advantages Disadvantages
Low material cost,comparatively high Very Operator dependent, very
production rate, large parts. poor thickness control, only one
molded face
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 9.5.2 VACUUM AND PRESSURE BAG
MOULDING.

1. Vacuum bag

➲ Simplest form of the closed mold process

➲ Reinforcement and resin are applied by hand laminating to

a simple open mould.

➲ A release film is then laid over the laminate followed by a

rubber bag which is clamped to the edge of the mould.

➲ The space between the bag and the mould is evacuated so

that atmospheric pressure is applied over the surface of the
laminate .(See fig.21)
CORPORATE TRAINING AND
PLANNING
Fig. 21 Vacuum bag

CORPORATE TRAINING AND

PLANNING
➲ Prepreg system based on polyester sheet moulding compounds,
epoxy resin impregnated cloths used.

➲ Automated tape laying machine accurately placing the glass or

carbon fibre prepreg onto moulds.

➲ This machine provides fast and accuracy.

➲ One advantage that accurate fibre alignment can be achieved.
This can be essential for aerospace application where
strength to weight ratio is of prime importance.

➲ Vacuum bagging produces a fairer finish than hand laminating

➲ Very effective method for bonding sandwich laminate together
and for making thin section.
CORPORATE TRAINING AND
PLANNING
 Data sheet for vacuum bag moulding process

Other Name Process parameter

None Processing pressure :1 bar

Processing temp : Ambient
Production rate :3/shift/mold
Materials Cost factors
Reinforcement :Mats or cloth Production cost : High
Resin : Polyester, vinyl ester Material cost : Moderate
Filler : can be used Tooling & Equipment : low

Tolerance Design details

Overall dimensions : 1-3 mm Ribs : yes, Bosses: difficult
Thickness : 0.5-1 mm Holes :can be moulded in

Advantages Disadvantages

Low capital outlay, low cost Low production volume

tooling, large components, well
suited to making sandwich panels Labor intensive process
CORPORATE TRAINING AND
PLANNING
 9.5.3 Pressure Bag Moulding.

➲ Similar to vacuum bag but Use higher pressure (upto 3.5

bar) than atmospheric.

➲ An inflatable elastic pressure bag is positioned within the

preform and the assembly is put into a closed mould. (See
fig.22)

➲ Resin is injected into the preform, and the pressure bag is

inflated to the required pressure, heat (by air or steam) is
applied and the part is cured within the mould.

➲ When curing is complete, the bag is deflated and pulled

through an opening at the end of the mould before the part is
removed.
CORPORATE TRAINING AND
PLANNING
Fig.22 Pressure Bag
CORPORATE TRAINING AND
PLANNING
 9.5.3 AUTOCLAVE
➲ Combination of vacuum and pressure bag moulding

➲ The process uses a vacuum bag assembly inside a heated and

pressurized vessel.

➲ Layers of prepreg materials are laid on the mould to make up the

full thickness.

➲ Bleed cloth, release film and vacuum bag are placed over the
prepreg.
➲ Laminate subjected to vacuum pressure and heat simultaneously.
➲ This ensures that all air is extracted from the laminate and full
consolidation and cure is achieved.
➲ Advantage-Moulds are not subjected to large force and can
therefore be of reasonably light construction.

CORPORATE TRAINING AND

PLANNING
Fig. 23 Autoclave
CORPORATE TRAINING AND
PLANNING
 Data sheet for Autoclave moulding
process
Other Name Process parameter

None Processing pressure : upto10 bar

Processing temperature : 1400C
Production rate : 1/shift/mold
Materials Cost factors
Reinforcement : Prepregs Production cost: : high
Resin : Epoxy Material cost: :high
Filler : no Tooling & Equipment cost : high
Tolerance Design details

Overall dimensions : 0.5-1 mm Ribs : no,

Thickness : 0.1-0.5 mm Bosses: no
Holes :can be drilled
Advantages Disadvantages

[Link] quality, controlled cure, high High capital investment, labor

fiber content. intensive and slow process.
CORPORATE TRAINING AND
PLANNING
 9.5.4 RESIN INJECTION OR
RESIN TRANSFER MOULDING (RTM)

➲ Closed mould, low pressure process in which a dry

reinforcement preform is preplaced and impregnated with a
liquid resin in an injection or transfer process, through an
opening in the centre of a mould.

➲ Suitable for use with Polyurethane polyester and epoxy

resin.

CORPORATE TRAINING AND

PLANNING
Fig.24 Resin injection
CORPORATE TRAINING AND
PLANNING
 Data sheet for resin injection/ resin
transfer moulding process

Other Name Process parameter

Reaction injection Moulding-RIM Processing pressure :Upto 2 bar

Processing temp : 20-500C
Production rate : 1-4 /Hr/mold
Materials Cost factors

Reinforcement.:Cont. strand mat,preform Production cost : Moderate

Resin : Epoxy, PU, Polyester Material cost : Moderate
Filler : no Tooling & Equipment : Moderate

Tolerance Design details

Overall dimensions : 1-2 mm Ribs : no
Thickness : 0.25-0.5 mm Bosses: no
Holes : can be drilled
Advantages Disadvantages
Good surface on both side, accurate
dimension., wide range of part geometry, Massive tooling, low fibre content
reasonable production rate
CORPORATE TRAINING AND
PLANNING
 9.5.5 COLD PRESS MOULDING
➲ Uses low-pressure room temperature curing resin, and
inexpensive moulds.(20-50 Psi)

➲ Release agent and gelcoat are applied to the mould surface and
a glass mat is laid into the lower part of the open mould.

➲ The activated resin is then poured on top of the mat and when
the mould is closed the resin spreads throughout the reinforcement.
(See fig.25)

➲ Advantage over hand lay-up-Two smooth surfaces are produced

on the moulding, since it is formed between matched metal mould
surfaces.

➲ Produces accurate components at a reasonable rate with

modest tooling costs.
CORPORATE TRAINING AND
PLANNING
Fig. 25 Cold press Moulding
CORPORATE TRAINING AND
PLANNING
 Data sheet for cold press moulding process

Other Name Process parameter

None Processing pressure : 2-5 bar

Processing temp : 20-500C
Production rate :10-30/shift /mould
Materials Cost factors
Reinforcement :[Link] mat or Production cost : low
woven cloth Material cost : Moderate
Resin : Polyester Tooling & Equipment : Moderate
Filler : up to 20% by volume
Tolerance Design details
Ribs : no,
Thickness: 0. 25 -0.5 mm Bosses : no,
Holes : can be cut or drilled
Advantages Disadvantages
Good surface finish on both side, Limited by press size and low fibre
accurate dimension and good content
production rate.
CORPORATE TRAINING AND
PLANNING
 9.5.6 HOT PRESS/MATCHED METAL MOULDING

➲ Rate of production can be increased dramatically by

applying heat to the mould surface to accelerate the cure
process.

➲ To achieve the highest output the moulds needs to be at

140°C and this necessitates the use of metal moulds.

➲ Heated matched metal moulds are mounted in a hydraulic

press fitted with automatic opening and closing and accurate
speed control.

➲ Press temperatures in the range 100-170°C.

CORPORATE TRAINING AND

PLANNING
➲ Uses Continuous fibre prepregs or SMC and DMC

➲ Uses Silicone release agents

➲ High volume , high pressure process suitable for

moulding simple or complex parts

➲ Glass content -20-35%

CORPORATE TRAINING AND

PLANNING
Fig .26 An inverted mould for hot press moulding
CORPORATE TRAINING AND
PLANNING
 Data sheet for hot press Moulding
Other Name Process parameter

Compression Molding Processing pressure : 50-155 bar

Processing temp : 130-1500C
Production rate : 30 parts /Hr
Materials Cost factors

Reinforcement :Prepreg, SMC/DMC Production cost : very low

Resin :Epoxy, Vinyl ester, Material cost: :low
Polyester Tooling & Equipment : Very high
Filler :up to 40%
Tolerance Design details

Thickness: 0.2-0.5 mm Ribs : yes

Bosses: yes,
Holes : can be drilled
Advantages Disadvantages

Fine details, close tolerance, low Modest mechanical properties, high

cost and long tool life tooling cost
CORPORATE TRAINING AND
PLANNING
 9.5.7 INJECTION AND TRANSFER
MOULDING

[Link] Moulding

➲ More automated and far higher productions over both

compression and transfer moulding.

➲ Although mould cost is higher than for compression

moulding, overall finished components cost are generally
lower.

CORPORATE TRAINING AND

PLANNING
➲ Mixed and reinforced resin dough (DMC) loaded into the
hopper of the moulding machine.

➲ Process similar to unreinforced materials

➲ Only short, random fibre used

➲ Properties of parts tends to be variable.

➲ Typical temperature for polyester DMC

Feed Zone = Ambient temperature

Metering Zone= 50-600C
Nozzle = 80-900C
Mould = 135-1850C

CORPORATE TRAINING AND

PLANNING
Fig.27 Simple Schematic of plunger – type injection moulding

CORPORATE TRAINING AND

PLANNING
 [Link] Moulding

➲ Used for the manufacture of small components and is

particularly suitable with multi-Cavity moulds and where small
inserts are to be molded in.

➲ Tooling costs are higher than for compression moulding.

➲ Pre-weighed quantity of DMC is placed in a heated transfer

pot by hand.

➲ Ram compresses the material and causes it to flow into the

heated mould cavity where it cures.

CORPORATE TRAINING AND

PLANNING
➲ Mould mounted between the platens of a press.

➲ To reduce transfer time and increase overall efficiency

the moulding compound may be preheated in an oven or
high frequency pre-heater such as microwave oven.

➲ Mould temperature=155 to 170° C both for polyester

and epoxy resin compounds .

➲ Moulding pressure =5 to 100 MPa depending on the

type of compound to be processed, mould design,
temperature.

CORPORATE TRAINING AND

PLANNING
 9.5.8 Centrifugal Casting

➲ Cylindrical/ hallow objects with uniform wall thickness made.

➲ Mainly large pipes, upto 5m in diameter, from either polyester

or vinyl ester resin system are produced.
➲ Tank, poles for street light, flags etc.

➲ Resin and reinforcement are placed inside a cylindrical

mould, which is rotated at high speed.

➲Centrifugal acceleration forces distributes and compacts the

resin and fibres against the mould surface, expelling air and
consolidating the laminate.
➲ Reinforcement being more dense, tends to move to the outer
surface, while the inner surface becomes resin rich.
CORPORATE TRAINING AND
PLANNING
Fig.28 Construction of a typical rigid centrifugally cast pipe

CORPORATE TRAINING AND

PLANNING
➲ Moulds-Bored and polished to a mirror finish and of
sufficient strength to withstand, without distortion.

➲ A steam Jacket or other means of heating may be blown

through the mould.

➲ Traversing spray – up gun for random reinforcement and

resin application.

➲ Reinforcement pack wrapped around a mandrel and loaded

into the mould.

➲ Mandrel is then removed and the mould is rotated to force

the layers out into their proper position.

➲ Resin is then deposited by a traversing gun while the mould

is rotating.
CORPORATE TRAINING AND
PLANNING
Fig. 29 Centrifugal Casting
CORPORATE TRAINING AND
PLANNING
 Data sheet for Centrifugal Casting

Other Name Process parameter

None Processing pressure :Ambient
Processing temp : 40-600C
Production rate : 4-8/shift/mold
Materials Cost factors
Reinforcement: Mats or cloth Production cost : low
Resin : Polyester, vinyl ester Material cost : Moderate
Filler : can be used Tooling and Equipment : high

Tolerance Design details

Overall dimensions : 1-3 mm Ribs: no, Bosses: no
Thickness : 0.5-1 mm Holes: can be drilled
Advantages Disadvantages
High production rate, good
thickness control, very good Limited parallel or tapered cylinder,
consolidation, good fibre content Non-moulded inner surface.
control, resin rich inner surface.
CORPORATE TRAINING AND
PLANNING
 9.5.9 Filament winding

➲ Simple hallow shapes, rocket motors, gas bottles, pipes,

tubes, cylinders and sphere shape and is frequently used for
the construction of large tank and pipe work for the chemical
industry.
➲ particularly suitable for pressure vessels

➲ Highest strength to weight ratios and can have glass

contents of upto 80% by weight.

CORPORATE TRAINING AND

PLANNING
Fig.30 Filament winding (a) Sectional elevation (b) Plan view
CORPORATE TRAINING AND
PLANNING
 Fig.32 Selected winding
methods and design

Fig.31 Filament wind pattern

CORPORATE TRAINING AND
PLANNING
➲ Roving or simple strands passed through a resin bath,
which is mounted, on the lathe- traversing head.

➲ Fibre emerges from the bath via nip rollers (to remove
excess resin) pass through a vertical comb before being
wrapped around the rotating former (mandrel).

➲ Mandrel mounted on a shaft, fitted to a lathe so that it can

rotate.

➲ Fibre orientation and thickness can be varied to give

optimum performance. This ensure very high strength to be
achieved and is particularly suited to pressure vessels.

➲Used to provide a protective laminate on the outside of steel

pressure pipes where external corrosion can takes place.

➲ Limitation-Used for products which have some degree of

symmetry about a central axis.
CORPORATE TRAINING AND
PLANNING
 Data sheet for Filament winding process

Other Name Process parameter

Hoop winding, spiral winding Processing temperature: Ambient

(FM) Processing pressure : Ambient

Production rate : 1-5/day/mold

Materials Cost factors
Reinforcement :Cont. roving only Production cost : low
Resin : Polyester, epoxy, vinyl ester Material cost : low
Filler : can be used Tooling & Equipment: Moderate

Tolerance Design details

Overall dimensions : 1-2 mm Ribs : hoop only
Thickness : 0.5-1 mm Bosses: no
Holes : can be drilled
Advantages Disadvantages
Excellent Mechanical property, high Limited range of shapes, Limited
production rate, good thickness no. Of practical winding pattern.
control, good internal finish, good
fibre content control
CORPORATE TRAINING AND
PLANNING
 9.5.10 Pultrusion Technique

➲ Reinforcement is impregnated with resin and pulled through

a heated die, which gives the product shape.

➲ Product emerges from the die at speed upto 1.5m/min and

then passes through a tunnel oven to accelerate the curing of
the resin.

➲ The pultruded composite is eventually cut to length for

storage.
➲ Continuous production method similar in concept with
extrusion
➲ Profiles, structural I-beams, L-channels, Tubes, angles, rod
etc. CORPORATE TRAINING AND
PLANNING
➲ Machine- Reinforcement handling system (creel as used in
textile weaving), a resin impregnation station and material
forming area.

 Designed to heat, continuously pull, and cut the profile

to the desired length

➲ Continuous yarn, woven cloth and mat reinforcement used

➲ Open and closed profile with close tolerance and

multicellular profiles are possible

CORPORATE TRAINING AND

PLANNING
Fig. 33 Pultrusion

CORPORATE TRAINING AND

PLANNING
 Data sheet for Pultrusion process

Other Name Process parameter

None Processing pressure : varies

Processing temp : 130-1500C
Production rate :10-30 mtrs/Hr

Materials Cost factors

Reinforcement :All types cont. fibre Production cost : low

Resin : Polyester, Epoxy, Vinyl ester Material cost : Moderate
Filler : up to 25% by weight Tooling: high Equipment : high

Tolerance Design details

Ribs : yes,
Thickness: 0.1-0.2 mm Bosses : no,
Holes : drill or cut

Advantages Disadvantages
High production rate, close tolerance Shape limitation and limited
and high mechanical properties transverse
CORPORATE TRAINING AND properties
PLANNING
 9.5.11 CONTINUOUS LAMINATING OR SHEET
MANUFACTURE

➲ Flat sheet , corrugated roof sheet, translucent and decorative

sheeting.

➲ Resin and glass reinforcement are sandwiched between two

sheets of release film such as Mylar or cellophane which
transport the laminate on a conveyor and passed through rollers
to consolidate the laminate before curing in an oven.

➲ Resin applied to the release film by spraying.

➲ Glass reinforcement is laid in the resin and a second layer of

release film applied.

➲ This sandwich is passed through a series of rollers to expel

all air bubbles and consolidate the laminates to the correct
CORPORATE TRAINING AND
thickness. PLANNING
Fig. 34 Continuous Sheet laminating

CORPORATE TRAINING AND

PLANNING
 Data sheet for continuous laminating process

Other Name Process parameter

None Processing pressure : Low

Processing temp :100-1500C
Production rate : Upto100 mtr/Hr

Materials Cost factors

Production cost : very low
Reinforcement : random/woven Material cost : low
Resin : Polyester Tooling : Low
Filler : up to 20% by Equipment : high
weight
Tolerance Design details
Ribs : no
Thickness: 0.5-1.00 mm Bosses: no
Holes : drill or cut

Advantages Disadvantages
Very high production rate, low
cost, consistency and good Shape limitation
mechanical properties CORPORATE TRAINING AND
PLANNING
 9.5.12 SANDWICH CONSTRUCTION

➲ Core material such as balsa wood, plastic foam such as

expended PVC or EPS or phenolic or polyurethane foam and
honeycombs of paper and glass fibre is coated on both sides with
a laminate.
➲ Produce composite material with increased stiffness, increased
thermal insulation and in many cases increased buoyancy.

➲ Aircraft floor panels, building panels, boats and surfboards.

➲ Both polyester and Epoxy resin.

➲ Reinforcement -Glass, carbon and aramid fibres

➲ Form-chopped strand, woven fabrics or unidirectional fibres,

depending on strength and rigidity requirements.
CORPORATE TRAINING AND
PLANNING
 9.5.13 TRIMMING AND FINISHING
➲ Sharp knife held at right angles to the laminate, cutting
towards the mould rather than away from it.

➲ Range of carborundum and diamond tipped cutting tool

available from several different suppliers.

➲ To prevent delaminations during trimming or drilling operation,

the moulding should be supported and clamped as close to the
cutting line as possible.

➲ All surfaces exposed by machining or drilling should be sealed

with suitable lacquers to prevent ingress of water or chemicals.

➲ Normal wax release agent and polishes require washing off

with white sprit.
➲ Final rinse should be with clean, fresh water.
➲ Once the surface thoroughly dry it can be painted.
CORPORATE TRAINING AND
PLANNING
 COMMON FAULT IN GRP MOULDING

GENERAL FAULT WITH POLYESTER MOULDING

Fault Causes Remedies

Wrinkle Insufficient cure of gelcoat Give sufficient cure time to
Finish gelcoat.
Insufficient gelcoat thickness Increase the Thickness.
Inadequate resin formulation Check that the resin formulation is
correct.
Insufficient polishing of the mould. Adequate polishing of mould.
Flaking Use of soft mould wax which Use proper wax.
gelcoat penetrate the gel coat.
Poor laminate consolidation. Ensure adequate consolidation.
Fish eye Check release agent Use preferably PVA
and
craters
Crazing Gelcoat too thick Keep within 0.3 – 0.5 mm.
or Faulty dosage of catalyst Choose proper dosage of catalyst
cracking
CORPORATE TRAINING AND
PLANNING
 Fig.36 Close-up of wrinkle finish Fig.37 Pinholing

Fig.38 An internal dry CORPORATE

patch. Fig.39 Fish
TRAINING ANDeyes and craters.
PLANNING
Fig.40 Blister and bubbles Fig. 41 Crazing and cracking

Fig.42 Star cracking Fig.43AND

CORPORATE TRAINING Pull – away of gel coat
PLANNING
 General Fault With Spray Moulding

Fault Causes Remedies

Undercure Variable output from the Service the equipment
spray gun regularly
Blocking or dirty hoses or Check and clean the hoses
dirty nozzle and nozzles.
Use correct level of catalyst
and accelerator.
Varying Uneven application Check that the hopper unit is
glass running smoothly.
content Ensure that the resin and
glass is evenly applied.
Reduction in The glass strand cut are Use the average fibre length
mechanical too short between 50 and 60 mm.
strength
Insufficient glass is present Use correct resin to glass
ratio.
CORPORATE TRAINING AND
PLANNING
 Vacuum Moulding Faults

Fault Causes Remedies

Trapped air Insufficient evacuation Increase evacuating time

Insufficient Mould not sealed properly Check mould seals

impregnating Resin viscosity too high
Use a low viscosity resin
Bubble Vacuum too high causing Reduce vacuum
formation styrene to boil

CORPORATE TRAINING AND

PLANNING
 Faults With Translucent Sheets

Fault Causes Remedies

Fibre pattern Poor consolidations of the Sufficient rolling should

laminate be given

Speckling Wrong type of chopped strand Use suitable chopped

mat are used so that the strand mat
binder dissolved too slowly in
the resin system

Flecking Wrong resin system was Select suitable resin

selected system

CORPORATE TRAINING AND

PLANNING
Fig.45 Speckling due to undissolved blinder Fig.46 Flecking

Fig.47 A Poorly consolidated laminate (left) compared with a correctly prepared

laminate (light). CORPORATE TRAINING AND
PLANNING
 Resin Injection Faults Process

Fault Causes Remedies

Trapped air Injection pressure too high Reduce pressure
Wrong vent design Provide adequate vent
design
Resin Leakage. Provide tight mould seal.

Insufficient Resin viscosity is too high Use a low viscosity resin

impregnating Flow path is too long. Modify mould, equipment
and increase the number of
feed points.
Variation in wall Deformation of the mould Increase the mould wall
thickness during resin injection. thickness, decrease
injection pressure.

CORPORATE TRAINING AND

PLANNING
 Press Moulding Faults

Fault Causes Remedies

Surface Trapped air Ensure sufficient venting
Blister Moulding too cooled Provide uniform heating

Matt Insufficient mold Provide sufficient mold surface

Surface polishing polishing

Moulding Mould temperature Ensure uniform temperature

Distorts uneven Reduce cure temperature
Excessive exotherm Reduce moulding Thickness

Moulding Too soft or damp Dry and pre- heat the compounds
stick to compounds Increase taper
mould Insufficient taper Provide split mold
Under cuts
CORPORATE TRAINING AND
PLANNING
 APPLICATION
TRANSPORTATION : [Link]

➲ Automotive components
Automotive trunk lids and hoods
Flat sheet for vehicle bodies
External body panel
Head lamp housing
Bumper beams
Glove box doors
Instrument panels
Battery trays
Seat back
Sun roof frame
Heat shields,
Radiator support
Roofing
CORPORATE TRAINING AND
PLANNING
 Engineering parts
Leaf for trucks
Bumper fascia
Front grill
Acoustic shields.

 Under bonnet components

Oil pump and rocker cover
Air channel.

 Special applications
Lightweight armour for police protection
Special vehicle body
Tanks for oil
Gasoline
 Railway
Housing and covers
Aerodynamic front ends of the High-speed trains.

CORPORATE TRAINING AND

PLANNING
Fig. 50(a) Electric bus (b) Car speaker

CORPORATE TRAINING AND

PLANNING
 Fig. 48(a) Pedal car (b) FRP body

Fig.49(a) Pocket Bike (b) Side panel

CORPORATE TRAINING AND
PLANNING
2. Sea
Boats
Boat hull
 Marine uses
Powerboats sailboats
Canoes
Marine muffler
Engine covers
Storage boxes and spars
Super structure and fitting of large ships.
CORPORATE TRAINING AND
PLANNING
Fig.52 The first all GRP off shore lifeboat
CORPORATE TRAINING AND
PLANNING
 Fig.51 Boats

CORPORATE TRAINING AND

PLANNING
3. Air
 Aircraft parts
Main landing gear doors (body)
Landing gear doors
Cowl components
Seal plates
Elevators
Rudder
Spoilers
Radoms
Nose cones
Aircraft pulley wheels
Rocket motors
Tail rotor blade for helicopters
Ceiling panel and tail and other interior parts
CORPORATE TRAINING AND
PLANNING
Front fuselage

Wings

Fin

Control devices

Doors

Engine covers

Helicopter interior

Helicopter freshwater or wastewater holding tank

overhead storage pin etc.
CORPORATE TRAINING AND
PLANNING
Fig.54 Fighters are composed of many composite
CORPORATE TRAINING AND
PLANNING
Fig.53 Helicoptor remote hornet

CORPORATE TRAINING AND

PLANNING
ELECTRICAL AND ELECTRONICS

➲ Roofing lights
Electrical insulator
Encapsulating electronic components
Switchgear sky lighting
Printed circuit Board
Switch gears
Tie bar
Brush holder
Motor housing
Bushing
Circuit breakers
Bobbins
Compressor bases
Power tool housing
CORPORATE TRAINING AND
PLANNING
Stand off rods
Electrical Junction boxes
Cherry picker buckets
Electrical trucking conduit
Electrical housing etc.
Frames
Bases
Fan in the manufacture of computers
Vacuum cleaners
Air conditioner
Refrigerators

CORPORATE TRAINING AND

PLANNING
➲ GRP insulators are used for overhead lines
particularly for very high transmission voltages from 420
KV upwards

Distribution power poles

 Protection boxes

 Shock proof tiles etc.

CORPORATE TRAINING AND

PLANNING
 Fig.55 Wire Connector Fig.56 Solar heater

Fig.57 Lighting Dome Fig.58 Fuse Isolators

CORPORATE TRAINING AND
PLANNING
BUILDING AND CONSTRUCTION

➲ Pipes for building

Highways
Bridges & decks
Building panels
Cladding panel
Sheet for roofing
Building insulation
Pipe for ice machine
Pumps
Signal
Turbine pump
Swimming pools
Cooling towers

CORPORATE TRAINING AND

PLANNING
Showers
Sky lights
Food processing wall panel
Roof fitting
Structural frame
Doors & windows
Interior decorations
Washbasin
Sinks
Toilets
Flooring
Septic tank
Letter boxer

CORPORATE TRAINING AND

PLANNING
Meter housing

Corrugated sheeting

Composite bridge

Fire doors

Moulded telephone booth

Roof rear wall

Door component

Side panel trim

Industrial building etc.

CORPORATE TRAINING AND
PLANNING
Fig.59 GRP panel for car park

CORPORATE TRAINING AND

PLANNING
 Fig.61 Nine foot diameter pipe from fibre glass
Fig.60 Filament wound epoxy pipe.

Fig.62 Floating roof crude oil storage tank Fig.63 Post office building panel moulded from GRP

CORPORATE TRAINING AND

PLANNING
Fig.64 Ceiling Fig.65 Glass Wash basin

Fig.66 Pipe Clamp Fig.67 Reaction tanker

CORPORATE TRAINING AND
PLANNING
 Fig.68 Tent Fig.69 Wash basin

Fig.70 Gazemo CORPORATE TRAINING AND Fig.71Translucent panel

PLANNING
Fig.72 Fibre playground

CORPORATE TRAINING AND

PLANNING
LAMINATE AND FURNITURE
➲ Building panels

Beams
Outdoor structural panel
Roofing
Corrugated panels
Office furniture
Chairs
Tables and other modern furniture design

CORPORATE TRAINING AND

PLANNING
➲ Electrical laminate
Slot wedges in electric motors
Terminal boards
Printed circuit board
Transformer.

 Aircraft and automobile components

 Laboratory bench tops

 Floorings

 Road surfaces
 Radiator supporter

CORPORATE TRAINING AND

PLANNING
Fig.73(a) Shampoo Chair (b) Bubble Chair

(c) Seat (d) Glass

CORPORATE fibre
TRAINING racing
AND car seat
PLANNING
MISCELLANEOUS

➲ FRP lining are applied to prevent

corrosion of vessel to prevent leakage and predicts
contamination in tanks, ductwork, pumps etc by
spraying resin onto the surface with the glass-
reinforcing media laid down by hand

➲ One of the most important industrial

applications is FRP pipes, tank and pressure vessel.

CORPORATE TRAINING AND

PLANNING
➲ Machine covers and guards, for coal, oil slurries

 Railway tank cars

 Off shore oil platform
 Heater & boiler tubes
 Heating panel designed to operate at upto
200 & 400°C
 Compressor blades
 Wheel
 Fastener nail
 Propeller
 High-tech bicycle wheel etc.

CORPORATE TRAINING AND

PLANNING
➲ Appliance and sports
Trays
Containers
Housing
Boxes
Luggage
Seating
Kitchenware
Dishwasher inner door
Refrigerator base support

CORPORATE TRAINING AND

PLANNING
 Tops of washer and driers

 Air conditioner parts

 Fishing rods

 Golf club shafts

 Golf crates

 Snow skis and water skis

 Computer terminal housing

 Washing machine gear housing etc.

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 Fig.75 GRP gas main for
sulphuric acid plant

Fig.76 Various polyester resin buttons

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PLANNING
 Fig.77 Artificial wildlife trophy- Fig.78 Body slim wet steam sauna
Leopard head capsule

Fig.79 Carbide grinding wheel Fig. 80 Fibre glass planter

Fig. 85 Decorative
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Fig.81 Fibre glass self adhesive mesh tape Fig.82 Fire Suit

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Fig.83 Home Theatre PLANNING Fig.84 Plastic doll
 Handling And Safety Precautions

General Precautions

➲ Synthetic resins, catalyst, curing agents and solvents

➲ Mixing and application procedure should be devised which

minimize skin contact and vapor exposure.

➲ Use protective barriers creams

➲ Wear protective gloves to minimize Skin contact.

➲ Wear goggles, face shields or glasses.

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➲ Materials which give off fumes or vapor should be handle
in areas with suitable exhaust ventilation.
➲ Ovens and heated presses - exhaust ventilation.
➲ Personal hygiene at a high level- avoid possible skin
irritations
➲ Before taking a break for smoking, eating, drinking or
toilet purposes, all operators should wash their hands with
appropriate cleansing agent or soap or water.
➲ Hazards can invariably be reduced by careful design of
workshop layout and mixing areas.

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 Remedial Measures

➲ First aid in case of accidental contamination of eyes-

immediate and continued washing for at least 10-15 min. with
clean water.

➲ Other is recommended treatment for contamination with

specific chemicals -clearly indicated in the workshop and first
aid areas.

➲ Accidental or unavoidable skin contact areas -washed by

soap and water or washing with fresh clean solvent such as
acetone, methyl ethyl ketones.

➲ Solvent -never be used around open wounds.

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➲ Skin irritation, burns or other damage- advice of a doctor
should be sought without delay.

➲Materials give of harmful fumes e.g. certain isocyanates -

appropriate remedial measure must be taken.

➲ If large amount of resin are ingested- mouth should be

washed out with water and a large quantity of water drunk.

➲Worn Protective clothing - when dealing with spillages

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 RESIN
➲ Unmodified epoxy resin - mild to moderate skin irritants
➲ Fully cured Epoxy - practically non toxic, non – irritant and non –
sensitizing to the skin.

➲ Dust from machining of epoxy resin and composites -health

hazards

➲ follow dust extraction procedure

➲ Follow normal handling precaution -Furan resins and pronged

skin contact may cause irritation.

➲ Wear Gloves and safety goggles

➲ Use well-ventilated areas.

➲ Polyester resin - moderate to severe skin irritants.
➲ Eye contact - acute eye irritation - goggle should be worn.
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 Curing Agents And Catalyst

➲ Wear Protective clothing

➲ Well ventilated areas.

➲ Aliphatic amines such as diethylene triamine is volatile and

strong irritants and potent sensitizers.

➲ Avoid all contact

➲ advice of doctor should be sought immediately on skin

damage .

➲ Aromatic amines - less irritating and less sensitizing than

aliphatic amines.

➲ Cycloaliphatic amines - extremely irritating to the eyes.

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➲ Anhydride curing agents - irritating to the skin, eyes, mucous
membranes and respiratory track and may cause burn

➲ Peroxide catalyst - should always be handled with caution.

➲ Handled in well-ventilated area and inhalation of fumes avoided.

➲ If peroxide is swallowed, large quantity of water must be drunk

and vomiting induced immediate medical attention must be
obtained.

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 PIGMENT

➲ Some of pigment and fillers- give to health

problems when inhaled

➲ Appropriate precautions may need to be taken with

their handling and use, particularly with silica containing
materials.

➲ Silica and blue asbestos are very dangerous when they

are heated.

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Reference

1. Text book of Polymer Science-Bill [Link].

2. FRP manufacturing Process – Philip Ball
3. Composite polymeric materials – Sheldon
4. FRP technology – Weatherhead
5. Design data for reinforced plastics – Hancox & mayer
6. Advanced polymer composites – Bor Z Jang.
7. Polymer engineering composite – M.O.W Richardson
8. Carbon fibre composite – Enid Keil Sichel

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9. Fibre composite hybrid materials – Macmillan
10. Composite manufacturing technology – Bratukhin /
Bogolyuboy
11. An introduction to composite products – Kevin potter
12. Polyester moulding compounds and moulding technology
13. Advanced composite mould making - Meyer
14. Corrosion resistant plastic composites in chemical plant
design – Mallinson
15. CIPET bulletin
16. Plastic news journal
17. Popular Plastics & Packing journal
18. Modern plastics international journal

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