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FRP Pultruded Profiles E-mail

The project on 'Development of FRP Pultruded Profiles' was launched under the Advanced Composites Mission of TIFAC in August 1998 in partnership with M/s. Sucro Filters Ltd., Pune with technology support from National Chemical Laboratory, Pune. Sucro Filters has been working on pultrusion process, pultruded profiles and development of pultrusion dies with the NCL since January, 1998.

Pultruted FRP Profiles
Pultruted FRP Profiles

NCL support towards pultrusion die design, optimization of process parameters, resin formulation, selection of catalyst combinations in the resin etc. helped achieve a high pultrusion speed of 1.0-1.5 m/min with improved curing. Flame retardancy characteristics as per UL94V0 was achieved using halogenated resin & ATH (aluminium trihydrate) combination in pultruded FRP profiles.

The pultruded profiles like I-beams, channels, angles, flat strips, notch bars for industrial gratings, cable-trays & ladders and solid rods for electrical insulation, etc. developed under the project were tested for mechanical & physical properties. The properties compared very favourably with the internationally available products.

Mechanical Properties of Pultruded Profiles Vs. Other Structural Materials

Mechanical Properties

Pultruded
FRP

Rigid
PVC

Mild
Steel

Stainless
Steel

Wood

Tensile Strength
(N/mm2)

382

44

340

340

80

Flexural Strength
(N/mm2)

468.3

70

380

380

12

Flexural Modulus
(N/mm2)

22489

2400

196000

196000

700

Izod Impact
(Kg.m/cm)

2.15

0.09

1.5

0.53

-

Physical & Chemical Properties of Pultruded Profiles Vs. Other Structural Materials

Physical & Chemical Properties

Pultruded
FRP

Rigid
PVC

Mild
Steel

Stainless
Steel

Wood

Specific Gravity

1.8

1.38

7.8

7.92

0.52

Thermal Conductivity
(Kcal/hr/m2/ C)

24.4

6.4

1220

732.00

0.4

Coeff. of Linear Expansion
(cm/cm C) x 10-6

5.2

37

8

10

1.7

Safe Working Temp.
(C)

130

55

600

600

160

Flame Resistance

Good*

Poor

Excellent

Excellent

Poor

Corrosion Resistance  
a. Acidic

Excellent

Good

Poor

Excellent

Poor

b. Alkaline

Good

Fair

Good

Excellent

Poor

c. Solvents

Fair

Poor

Good

Excellent

Fair

d. Coastal
Environment

Excellent

Good

Poor

Excellent

Fair

e. Outdoor Exposure

Excellent

Poor

Fair

Excellent

Fair

f. Effluent Water

Excellent

Good

Poor

Excellent

Fair

g. Steam

Good

Poor

Fair

Excellent

Fair

* Excellent with special additives
(Source : Product Information Brochure; DK Fibre Forms, Pune, India)

Pultrusion is the most cost-effective method for the production of fibre-reinforced composite structural profiles. It brings high performance composites down to commercial products such as light-weight corrosion free structures, electrical non-conductive systems, off-shore platforms and many other innovative new products.

Advantages of Pultruded FRP Profiles :

Features

Description

Benefits

Applications

Strong Unit strength in tension & compression is approx. 20 x that of steel when these properties are combined on the basis of unit density Optional strength as desired. Exceptionally high impact strength reduces damage potential Structural process equipment support. Tank supports. Cooling tower ancillaries. Flooring supports. Trusses & joints.
Light Weight Density of pultruded components is about 20% of steel and 60% of aluminium Higher performance at less weight. Lower shipping, handling & installation costs. Less operational energy demand. Automotive leaf springs & bumpers. Prefabricated walkways & platforms. Bus components.
Corrosion Resistant Unaffected by exposure to a great variety of corrosive environment & chemicals. Minimum maintenance costs. Long term safety. Longer life. Chemical plant hand railings, gratings, walkways & bridges. Cable trays. Pipe supports.
Electrical Insulation Provides strength & rigidity with dielectric properties. Lesser no. of components. Non-magnetic & safe. Predictable insulation values for wide range of frequencies. Ladders, Cable trays. Switch gear components. Mounting braces and backboards.
Thermal Insulation Pultruded components have a low thermal conductivity, 1/250 of aluminium & 1/60 of steel. Reduces installation thickness. Eliminates condensation problems. Reduces energy operation requirements. Bulk head frames. Walk in refrigerator door jams. Window frames. Insulated roll up panel doors.
Consolidation Many individual components can be combined into a large profile. Reduced assembly cost. Reduced inventory. Fewer parts improve reliability. Window latch supports. Roll up door
Dimensional Stability Pultruded components are highly resistant to warping stretch/swelling over a wide range of temperature & stresses. No permanent deformation under high stress. Close tolerances. Spring bumpers. Crossing gate arms. Scrubber components.
Safety The pultruded components are very strong & safe to work with. They are microbes and insect proof. Many gratings suffer from the problem of microbes etc. due to wet or unhygienic working conditions. This property makes them ideal choice for pharmaceutical & food industries.

(Source : Product Information Brochure; DK Fibre Forms, Pune, India)

Based on the success of initial pultrusion trials at NCL, an associate Company, M/s. D K Fibre Forms Ltd. (DKFFL), Pune was promoted by Sucro Filters towards diversifying into the business of pultruded products. D K Fibre Forms has already set up quite a sophisticated pultrusion equipment & stabilized the process. A tool room equipped with radial drilling machine, plano milling machine & surface grinding machine and allied testing facilities for fabrication of pultrusion dies has been created at Sucro Filters with the assistance from TIFAC.

Industrial Gratings
Industrial Gratings

Towards the market seeding for commercialisation of the pultruded product, the Company targeted three major segments viz. new projects, replacement market in industrial & non-industrial applications. The orders for gratings for Alfa Laval, High Explosives Factory, Thermax Ltd., Pudamjee Pulp & Paper Mills etc. and also for railway coach interiors for the Integral Coach Factory, Chennai have been executed. Various applications & usage of the product have been actively pursued and the product has been recognized by acclaimed consulting agencies such as Humphrey & Glasgow, Uhde, Tata, EIL, Bechtel etc. DKFFL has recently bagged an order for supplying cable trays, fittings & other accessories to M/s Dabhol Power Project (DPP) as per the specifications of M/s Bechtel International Inc., the prime consultant for DPP.

The amount of energy required for fabricating FRP composite materials for structural applications with respect to conventional materials such as steel & aluminium is lower and would work for its economic advantage in the end.





CONTACT:
M/s. D K Fibre Forms Ltd.

Mr. Rajeev Kulkarni, Managing Director
Gat No. 1073/6, Mutha - Urawade Road
Village - Pirangut, Tal - Munshi
Dist. Pune- 412 108, INDIA
E-mail: This e-mail address is being protected from spambots. You need JavaScript enabled to view it , This e-mail address is being protected from spambots. You need JavaScript enabled to view it
Phone: +91 - (0)2139 - 22604, 22826, 22827
Fax: +91 - (0)2139 - 22828