Manufacturing Process
Pultrusion Process
Pultrusion is a continuous moulding process fabricating products of uniform cross section such as I Beams, Channels, Flat Bars, Rods, Hollow Section, etc, utilising glass fibre, resin, filler, peroxide and a release agent.
The glass reinforcement is drawn into a resin impregnation zone where the glass substrate is thoroughly impregnated with the resin mixture. The wet fibrous material will be pulled through a preformer into a heated die.
The shape of the end product is determined by the configuration of the die and the resin is then polymerised. This continuous and uniform method ensures consistency throughout the entire product length, therefore eliminating the possibility of weak spots.
Roving Mat
Unidirectional glass roving fibres give longtudinal reinforcement of the profile while mats give transverse strength.
Resin
Bonds with the reinforcement and provide resistance to chemicals.
Heated Die
Where polymerisation or curing takes place and product forms into the shape of the profile.
Pullers
Assures continuous drawing of the profile.
Automatic Cutter
Cuts product to the pre-set length.
BENEFITS OF PULTRUDED FRP PRODUCTS:
Comparison of Intech Pultruded FRP Products vs others Products
| Property | INTECH Pultruded FRP PRODUCTS | Other FRP PRODUCTS | Mild Steel | Stainless Steel | ALUMINUM PRODUCTS |
|---|---|---|---|---|---|
|
Cost Effective |
Extremely long life compare to
other materials. Maintenance free. |
Long life compare to other
materials. Maintenance free. |
Maintenance required. |
Depend on application and
grade. |
Depend on application. |
|
Flatness & Thickness Consistency |
Pultusion is pultruded from heated die, therefore flatness is consistence even cut into smaller sizes.
Thickness is even and consistent. |
Production of FRP hand-lay
products is based on the
workmanship and has a high
probability of uneven surfaces due to the production process. |
Flatness and thickness is even
and consistent. |
Flatness and thickness is even
and consistent. |
Flatness and thickness is even
and consistent. |
|
Impact Resistance |
Continuous strand glass mat in FRP
Products distributes the impact load
to prevent surface damage even
under sub-zero temperature and will
not permanently deform and stay flat
for the life of the product under
closed mold pultrusion processing.
High in mechanical strength. |
Chopped strand mat used in FRP hand-lay products will probably deform or crack under impact
without going under the closed
mold processing and pultrusion system. Low in mechanical
strength. |
Will permanently deform under impact and take a permanent
set (dishing in trench application due to overloading).High in mechanical strength. |
Will permanently deform under impact and take a permanent
set (dishing in trench application due to overloading).High in mechanical strength. |
Will permanently deform
under impact and take a
permanent set (dishing in
trench application due to
overloading). Low in
mechanical strength. |
|
Corrosion Resistant |
Corrosion resistant under the most aggressive conditions |
Corrosion resistant. |
Non-corrosion resistant |
Depends on grade. SS304 not recommended in off-shore. SS316 better corrosive
resistant. |
Corrosion resistant. |
|
Safety |
Electrically non-conductive and non-magnetic. Low in thermal conductivity. No sharp edges after cutting. |
Electrically non-conductive. Low in thermal conductivity. No sharp edges after cutting. |
Conductive. Grounding potential around electrical
equipment. High in thermal
conductivity. Sharp edges after cutting. |
Conductive. Grounding potential around electrical
equipment. High in thermal
conductivity. Sharp edges after cutting. |
Conductive. Grounding potential around electrical
equipment. High in thermal
conductivity. Sharp edges after cutting. |
|
Fabrication |
Produced in light weight and it can be shipped to the site or fabricated and installed on site with simple carpenter tools. |
Produced in light weight and it can be shipped to the site or fabricated and installed on site with simple carpenter tools. |
Require special blade torch, and harder to cut it. Sometimes requires more manpower to move and place. |
Require special blade torch, and harder to cut it. Sometimes requires more manpower to move and place. |
Require special blade torch, and harder to cut it. Sometimes requires more manpower to move and place. |
|
Vandalism |
Totally no recycle value, and this will not encourage any theft or vandalism. |
Totally no recycle value, and this will not encourage any theft or vandalism. |
Mild steel products carry good
recycle value. |
Stainless steel products carry
good recycle value. |
Aluminum Products carry
good recycle value. |