Section 1 - Metric
The Basics
SECTION 1
THE BASICS
Look for this blue line in the left margin of the
Design Manual documents. This line shows
you where the latest update has been made.
Copyright © 2019 Strongwell Corporation
All Rights Reserved
1-1 Rev.0419
Section 1 - Metric
The Basics
The Basics
WHAT IS FIBERGLASS REINFORCED POLYMER?
Fiberglass reinforced polymer (FRP) is most often referred to simply as “fiberglass” in practice (as in fiberglass
tanks, fiberglass grating, fiberglass structural shapes, fiberglass boats, etc.). Used in this context, “fiberglass” is a
composite consisting of a polymer resin matrix reinforced by embedded glass fibers. The strength of a fiberglass
part is determined primarily by the type, orientation, quantity, and location of the glass fibers within the part.
The resin binds the reinforcing glass together and this resin/glass bond aids in developing stiffness in the part.
The type of resin used determines corrosion resistance, flame retardance, and maximum operating temperature,
as well as contributing significantly to certain strength characteristics including resistance to impact and fatigue.
WHAT IS PULTRUSION?
Pultrusion is a manufacturing process for producing continuous lengths of FRP structural shapes. Raw materials
include a liquid resin mixture (containing resin, fillers and specialized additives) and reinforcing fibers. The
process involves pulling these raw materials (rather than pushing as is the case in extrusion) through a heated
steel forming die using a continuous pulling device. The reinforcement materials are in continuous forms such
as rolls of fiberglass mat or doffs of fiberglass roving. As the reinforcements are saturated with the resin mixture
(“wet-out”) in the resin impregnator and pulled through the die, the gelation (or hardening) of the resin is initiated
by the heat from the die and a rigid, cured profile is formed that corresponds to the shape of the die.
While pultrusion machine design varies with part geometry, the basic pultrusion process concept is described in
the following schematic.
SURFACING
MAT CREELS MATERIAL
PULL BLOCKS CUT-OFF
GUIDE SAW
PREFORMER
FORMING AND CATERPILLAR-
RESIN CURING DIE TYPE PULL
IMPREGNATOR
SURFACING
ROVING CREELS MATERIAL
CONTINUOUS PULTRUSION
The creels position the reinforcements for subsequent feeding into the guides. The reinforcement must be located
properly within the composite and controlled by the reinforcement guides.
The resin impregnator saturates (wets out) the reinforcement with a solution containing the resin, fillers, pigment,
and catalyst, plus any other additives required. The interior of the resin impregnator is carefully designed to
optimize the “wet-out” (complete saturation) of the reinforcements.
Upon exiting the resin impregnator, the reinforcements are organized and positioned for the eventual placement
within the cross section form by the preformer. The preformer is an array of tooling which squeezes away excess
resin as the product is moving forward and gently shapes the materials prior to entering the die. In the die the
thermosetting reaction is heat activated (energy is primarily supplied electrically) and the composite is cured
(hardened).
Copyright © 2019 Strongwell Corporation
All Rights Reserved
1-2 Rev.0419
Section 1 - Metric
The Basics
Upon exiting the die, the cured profile is pulled to the saw for cutting to length. It is necessary to cool the hot part
before it is gripped by the pull block (made of durable urethane foam) to prevent cracking and/or deformation by
the pull blocks. Strongwell uses two distinct pulling systems, one that is a caterpillar counter-rotating type and
the other a hand-over-hand reciprocating type.
In certain applications an radio frequency wave generator (RF) unit is used to preheat the composite before
entering the die. When in use, the RF heater is positioned between the resin impregnator and the preformer.
Copyright © 2019 Strongwell Corporation
All Rights Reserved
1-3 Rev.0419