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FIBERGLASS PRODUCTS

FRP FABRICATION METHODS

HAND LAY-UP

The hand lay-up process is the oldest, simplest, and most labor intense fabrication method. The hand lay up process uses a room temperature curing system where catalyzed resin is applied to the surface of a mold or piece of existing equipment and fiberglass, whether it is veil, chopped mat or roving, is placed on top of the resin. Then the fiberglass is saturated with the resin by rolling the surface with a steel roller. The rolling action of the steel roller assists in removing air bubbles that could prove detrimental to the laminate performance. After the surface is rolled and all, if any, air bubbles are removed, more resin and fiberglass is applied to build up the corrosion barrier and the structural laminate. Consecutive layers are applied to the surface or existing piece of equipment in the same manner until the desired thickness is achieved.

SPRAY UP

The spray up fabrication process is a much faster and less labor intense method for fabricating FRP products. The spray up fabrication method can be used for the corrosion barrier and structural portion of any FRP product. The spray up process is a room temperature cure process where continuous strand roving combined with catalyzed resin, is fed thru a chopper gun and sprayed on a mold or piece of existing equipment. The surface is rolled to remove all, if any, air bubbles and additional layers of resin and glass are applied and rolled to achieve the desired thickness.

FILAMENT WINDING

The filament winding method of fabrication is less labor intensive than both the hand lay-up and spray-up methods. It produces very uniform structures as far as thickness, resin to glass ratio, ect. This method is recommended only for the structural portion of FRP equipment. The corrosion barrier will be fabricated using one the method mentioned above. Filament winding uses a room temperature cure system with very long gel times. A resin rich corrosion barrier is applied to a mandrel and allowed to cure. Continuous strand glass or roving is then pulled through guides, impregnated with resin and guided onto a rotating mandrel in a helical pattern. This action produces the structural portion of the FRP equipment has is typically 60% glass. Chopped mat and/or roving may also be applied to accelerate the build-up of the structural portion. Filament winding is an excellent process method for fabricating round equipment such as tanks, pipes, duct, ect.

FRP RE-INFORCEMENTS

SURFACING VEIL

Surfacing veil or sometimes referred to as surfacing mat is used to provide reinforcement for the resin rich inner liner of the corrosion barrier which prevents cracking and crazing. There are three types of surfacing veil used in our FRP fabrications:

• "C"-glass veil

• NEXUS^® synthetic surfacing veil

• Carbon veil

For most corrosion environments "C"-glass veil is most commonly used. Environments that contain fluoride compounds synthetic veil is preferred. For abrasive environments carbon veil is most often used. It is also used as a conductive liner for static electricity control.

CHOPPED STRAND MAT 

"E" and "ECR" are the two primary types of chopped strand mat used in the corrosion industry. Each is available in a variety of thickness. The most common thicknesses used in corrosion applications are 0.75 oz., 1.5 oz., and 2.0 oz.

WOVEN ROVING

Available in a variety of weights and thicknesses, woven roving consists of continuous glass fiber rovings that are woven together to form a heavy mat. The structural portion of hand lay-up laminates are produced by alternating layers of woven roving and chopped strand mat.

CONTINUOUS STRAND ROVING

Primarily used in filament winding, continuous strand roving can be chopped into fibers for spray-up applications to replace chopped strand mat.

SPECIAL FRP FABRICATIONS

ABRASION RESISTANT FRP

Fine particles of silicon carbide, combined with polyester or vinyl ester resin, can be integrated into the corrosion barrier of FRP products to handle abrasive slurries. This procedure can be incorporated into new fabrications, as well as existing products. With the proven corrosion resistance of polyester and vinyl ester resin, along with the addition of silicon carbide, we can more effectively handle any abrasion problem.

ELECTRICALLY CONDUCTIVE FRP

There are some cases where the flow of an explosive gas can create a static charge in FRP duct or piping systems. This charge must be bled off to ground. With the development of carbon veil by glass manufacturers, this can now be achieved. The combination of carbon veil, the excellent corrosion resistance of polyester and vinyl ester resins, and conductive connection devices will allow the electric current to flow between pipe sections and lead it to ground. This can be especially useful in the pharmaceutical industry.

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