WHAT IS FRP ?

General Composition :

Fiber [Carbon,Glass]
+
Resin [Polymers]
 TYPES OF FRP
 Common Fibre Types:
 Aramid(AFRP):
- Extremely Sensitive to environment conditions
Glass(GFRP):
- Subject to creep under high sustained loading
- Subject to degradation in Acidic or Alkaline environment
- Most Widely used
Carbon(CFRP):
- Premium Cost
Basalt:
- The future of FRP fibres?
 What is fibre ?
Fiber is the basic filament from which yarn is spun which is further woven
into fabric, knit fabric, lace, felt, non-woven etc by means of an
appropriate interlacing method is called as textile fiber.
Fibers can be natural like cotton, flax, hemp, wool or silk or
A fiber that can be spun into yarn or processed into textile such as a
woven fabric.
 FORMS OF FRP
Used in many differerent forms:

Short fibers Chopped fibers

Long fibers Woven fibers

 FRP Material

Short fibers Chopped fibers

Long fibers Woven fibers

 What is Resins ?
In polymer chemistry and materials science, resin is a solid or highly
viscous substance of plant or synthetic origin that is typically convertible into
polymers.
Resins are usually mixtures of organic compounds.
Plants secrete resins for their protective benefits in response to injury.
There are two basic types of resin
- Plant resin
- Synthetic resin
 Factors for Resin selection?
 Physical properties:
- Resin base type , Solvent type , Colour , Supply Form, Curing Behaviour
Etc.
 Chemical properties:
- Density @ 20 °C ,Viscosity @ 23 °C , Solubility in water , Flash point (Abel
close cup °C), PH value,Boiling range (°C),Vapour pressure(N/M2),Solubility
in organic solvents.
 Mechanical properties Cured clear cast resin:
- Barcole hardness , Heat deflection temperature , Tensile strength , Tensile
modulus , Elongation at break(%),Flexural strength, Flexural modulus ,
Volume shrinkage(%) , Water Absorption at 25 °C after 24 hours etc.
 Economical factor:
- Cost of resin (Rs. /Kgs)
 Application type & Required operating Conditions:
 FRP type or MOC :
 Fabrication Method :
 Types of Resins
 Two categories:
 Thermoset Resins(Most commonly for structural uses):
- Liquid state at room temperature prior to curing
- Impregnated into reinforced fibres prior to heating
- Chemical reaction occurs during heating/curing
- Solid after heating/curing ; Can’t be reversed/reformed
 Thermoplastic Resins:
- Solid at room temperature(recycled plastic pellets)
- Heated to liquid state and pressurised to impregnate reinforcing
fibres.
- Cooled under pressure; Can be reversed/reformed
 What are Thermoset resins?
 Common Thermoset Resin Types:
 Polyester resin
 Vinyl ester Resin
 Polyurethane Resin
 Epoxy Resin
 Phenolic
Modified acrylic
 Polyester resin
 Advantages:
- Easy to use in wide range of temperature
- Most reliable cure due to low mix ration sensitivity
- Easy to available at lowest cost than other resins
- No heating of cartridge are required
Disadvantages:
- Sensitive to UV degradation
- Only Moderate Mechanical properties
- Low corrosion resistance
 Vinyl esters resin
 Advantages:
- Higher strength & flexibility than Polyesters
- Greater Corrosion resistance than Polyster
- Superior Elongation, toughness an impact resistance than Polyesters
- Better heat resistance
Disadvantages:
- More costlier than Polyesters but lower than Epoxy
 Polyurethane resin

 Advantages:
- Higher strength & flexibility than Vinyl esters
- Very high Chemical/Environmental resistance
- Higher Mechanical Properties than Vinyl esters
Disadvantages:
- Higher costlier than Vinyl esters
Examples
-
 Epoxy resin

 Advantages:
- High Mechanical and thermal properties
- High Moisture resistance
- Long Working time available
- High temperature Resistance
 Disadvantages:
- More expensive than Polyurethanes resins
- Critical Mixing/Consistancy
- Corrosive handling
 Examples:
-
 What are Thermoplastic resins?
 Common Thermoplastic Resin Types:
 Polycarbonate
 Acental Copolymer Polyoximethylene
 Acental Homopolymer Polyoximethylene
Polyethylene
Polypropylene(PP)
Polystyrene
Polyvinyl Chloride(PVC)
Polyvinyledene fluride
Chlorinated PVC
Teflon
Acrylic
 FRP Manufacturing Processes

 Manufacturing processes:
 Predominant processes:
- Pultrusion
- Vacuum Infusion
Other processes:
- Hand layup
- Wet layup
- Filament winding
- Bladder Moulding
- Compression Moulding
 What is UN1866 ?
UN 1866 is the one of the UN No from 1801 to 1900 as assign by the
United National committee of expert on transportation for dangerous
goods.
UN 1866 code made for Flammable class liquid solution resins for
transportation.
UN 1866 meets the requirements of 49 CFR 172.500 for domestic and
international shipments of hazardous materials by highway, rail and water.
Your compliance is our top priority. In the code “49 CFR 172.500 “ 49 –
define the transportation No , and CFR means Code of federal regulation,
and 172.500 defines Hazardous Materials Table, Special Provisions,
Hazardous Materials Communications, Emergency Response Information,
And Training Requirements.
 FRP Pultrusion Process
 Pultrusion processing:
 Linear,continuous process
Reinforcing(Roving & Mats) Saturated with resin
Pulled through Heated die
Chemical reaction occurs as it cures(Polymerisation)
The resine saturated reinforcements exit the die the die in solid state & in
the form of cross section of die.
Types of products produced:
- Structure shape w/ constant cross section
- GFRP/CFRP Reinforcing bars & CFRP Pre-stressing bars.
 FRP Pultrusion Process
 Pultrusion processing:
 FRP Pultrusion Process
 Pultrusion processing:
Contineous Strad Mats : Reinforcement in any direction; consistent along
length of memebers.
 FRP wet layup Process
Hand layup process:
Advanytages:
- Low cost
- Room temperature curing resin used
- Used for producing large parts with less complexity in shapes.
Disadvantage:
- Low concentration of reinforcing phase( upto 30%)& Low
densification of the composites(entrape air bubbles)
- More time consuming
- Labour consuming
 FRP wet layup Process
Wet layup process types:
 Manual hand resin wet layup
 Spray gun resin wet layup
 FRP Hand wet layup Process
Hand layup process:
Advantages:
- Low cost
- Room temperature curing resin used
- Used for producing large parts with less complexity in shapes.
Disadvantage:
- Low concentration of reinforcing phase( upto 30%)& Low
densification of the composites(entrape air bubbles)
- More time consuming
- Labour consuming
 FRP Hand wet layup Process
Hand layup process:
A pigment gel is firstly spayed on mould for high quality surface
After curing of gel coat reinforced chopped strand mat & woven
rovings are placed on mould
The catalysed resin is poured on mat surface
 Manual Rolling then remove entrap air and thoroughly wet the
reinforcement surface With resin
Additional mat and woven rovings and resins then added for thickness
A catalyst or accelerator initiate curing into resign system which
harden the composite without any external heat.
 FRP Hand wet layup Process
Hand layup process:
 FRP Spray wet layup Process
Spray wet layup process:
Advanytages:
- Low cost
- Faster production than hand resin layup
- Used for producing large parts with more complexity in shapes.
Disadvantage:
- Labour consuming
 FRP Spray wet layup Process
Spray wet layup process:
A pigment gel is firstly spayed on mould for high quality surface
After curing of gel coat reinforced chopped strand mat & woven
rovings are placed on mould
The catalysed resin is sprayed through resin spray gun on mat surface
 Manual Rolling then remove entrap air and thoroughly wet the
reinforcement surface With resin
Additional mat and woven rovings and resins then added for thickness
A catalyst or accelerator initiate curing into resin system which harden
the composite without any external heat.
 FRP Spray wet layup Process
Spray wet layup process:
FRP Filament winding Process
Filament winding process:
Advantages:
- High strength Pipe are possible to manufacture due to winding
design in various direction like hoop/helical
- High Production rate due to high Winding speed of 100m/min
- High quality can be achieved
- Layers of different material can be use.

Disadvantages:
- high Production cost than hand layup process
- high skilled person required to handle CNC machine
- Limited only for manufacturing of round or cylindrical products
FRP Filament winding Process
 Filament winding process:
 Firstly round or circular Mould or pattern is made as per dimensional requirement.
 Placing of mould on predefined Mandrel.
 A pigment gel or tape of resin is then Placed on mould for high quality surface
 After curing of gel coat reinforced chopped strand mat are wraped on mould
 The catalysed resin is sprayed or placed through resin spray gun or by hand manualy on
mat surface
 Manual Rolling then remove entrap air and thoroughly wet the reinforcement surface
With resin
 Woven rovings or filaments with resin is wrapped around circumferentially with helical
or hoop pattern as per requirements
 Additional woven rovings and resins then added for thickness.
 A catalyst or accelerator initiate curing into resin system which harden the composite
without any external heat.
FRP Pipe by Filament winding
Process: