Composite Materials for Industrial Construction and Process Equipment

Composite Materials for Industrial Construction.

A composite can be defined as a combination of two or more materials that retain their macro-structure resulting in a material that can be designed to have improved properties than the constituents alone. Fiber-reinforced polymer (FRP) composites are made by combining a polymer resin with strong, reinforcing fibers.

Typically, a composite material is made of reinforcement and a matrix. The reinforcement material provides the mechanical strength and transfers loads in the composite. The matrix binds and maintains the alignment or spacing of the reinforcement material and protects the reinforcement from abrasion or the environment. The combination of a matrix material with a strong reinforcement material enables lighter weight products relative to monolithic materials (like metals) with similar or better performance properties. Resin and fibers can be combined in a multitude of ways and further processed through a series of forming and consolidation steps. The specific manufacturing technique is dependent on the resin material, the shape and size of the component, and the structural properties required by the end use application.

The landscape of manufacturing segments and systems that benefit benefit from the lower cost, high strength and stiffness, corrosion resistant, and lightweight composite materials is growing. Successful industrial implementations for composites include material handling systems, compressed gas storage systems, heat exchangers, pipelines, geothermal energy equipment, turbine blades, structural materials for buildings, power generation flywheels, support structures for solar systems, and shipping containers, just to name a few.

For more information on applying composite materials for industrial construction or process equipment, contact Process Systems & Design at (410) 861-6437 or visit https://www.processsystemsdesign.com.

Pultruded FRP Composites as an Alternate to Steel

Pultruded FRP suspendible roof structure.

Pultrusion is a term that describes a manufacturing process for producing continuous lengths of FRP (fiberglass reinforced plastic) where reinforcing fibers are saturated with resin and pulled through a heated die to form a part. The result is a straight, constant cross-section profiles similar to standard steel shapes.

Pultruded composite sections can be used to design and install lightweight, corrosion-resistant and electrically non-conductive alternatives to steel structures, particularly where speed and ease of construction are important. Pultruded FRP has performance characteristics similar to other construction metals, but unlike steel, it is EM/RF transparent and doesn’t disrupt equipment signals.

Benefits:

• Pound-for-pound stronger than steel.
• Comparable structural performance to other metals such as aluminum, but without the conductivity, corrosion or impact limitations. 
• Can be painted, coated or pigmented during manufacture for little-to-no maintenance in highly aggressive environments
• Designed for UV performance
• Enables rapid cleaning with aggressive solvents at high pressures
• Meets industry requirements for durability, smoothness, absorbency, color, corrosion resistance and washability

Typical Uses:

• Structural profiles and plates
• Decking and planking
• Platforms, stairs, ladders and cages
• Handrails, guarding and kickplates
• Grating and gridmesh
• Bridge components
• Structural building panels
• Sheet piling and round pile
• Containment systems
• Ballistic and storm panels
• Connection hardware

Pultruded FRP composites are ideal for structural elements where a strong, lightweight material is needed; corrosion is a concern for steel or other metals; RF permeability is needed; and low thermal or electrical conductivity is important.

To discuss using pultruded FRP composites on your next project, contact Process Systems Design by calling (410) 861-6437 or visit https://www.processsystemsdesign.com.