Fiberglass Reinforced Polymer (FRP) ─ usually referred to as fiberglass ─ is a composite comprising a polymer resin matrix reinforced by embedded glass fibers.
The strength of a fiberglass profile is determined primarily by the quantity, type, orientation, and location of the glass fibers within the composite.
Fiberglass, also known as glass-reinforced plastic (GRP is used to produce molded products. Fiberglass is combined with resin to form a durable composite with high tensile strength.
Fiberglass can be flattened into a sheet called a strand mat or woven into a fabric. Fiberglass is strong, lightweight, and costs less than carbon fiber composites, and is resistant to corrosion and ultraviolet (UV) damage.
Today, fiberglass profiles are used in a wide range of industry sectors, including:
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Building and Infrastructure: including house building and roofing
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Home construction: including cold water storage tanks (one-piece tanks & sectional cold water storage tanks), bathroom utilities like shower trays and baths
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Telecommunication: towers, poles
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Utilities: cross arms, rods, bars, support beams
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Automotive: vehicle body, parts, and panels
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Aviation: commonly used for internal structures like luggage racks
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Marine: boats and surfboard repairs
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Electronic: circuit boards, mobiles, and audio/visual equipment
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Leisure: bicycles, athletic shoes, sports, and recreation equipment
How is fiberglass made? Fiberglass is made in a process called pultrusion. So, what exactly is pultrusion? Pultrusion is a manufacturing method for producing continuous lengths of reinforced polymer structural shapes with a constant cross-section. Raw materials, a liquid resin mixture, and reinforcing glass fibers are pulled through a heated steel forming die using a continuous pulling device and completely saturating the reinforcements.
In this way, FRP structural shapes can be continuously produced in an automated, energy-efficient process. The resin hardens from the heated steel pultrusion mold. The final product is a strong, lightweight piece that follows the mold's shape.
During the manufacturing process, if desired, the resin systems and glass content can be adjusted to alter the composite matrix and produce pultruded fiberglass tubes. The resulting pultruded profile can have various features and attributes, such as high strength, tolerance for wide temperature ranges, and flame-retardant, track-resistant, and corrosion-resistant properties.
In addition, pultruded profiles can be customized and branded by adding pigments during pultrusion. A UV-resistant treatment can be added to increase the product’s durability for external applications.
Performance Matters
A pultruded profile is extremely strong. For example, when comparing pultruded fiberglass and steel, a range of performance characteristics must be considered. Specifically, two key aspects to consider include:
- how the product performs under stress
- how the product performs in corrosive and extreme environments
In thermal load-bearing projects, fiberglass is superior to steel in many ways. Fiberglass rebars are as strong as steel at the buckling point and are less likely to corrode in exposed environments.
Take the FRP rebar, for example. A study on FRP rebar used in construction for the reduction of thermal bridges found load-bearing fiberglass rebar to have a higher longitudinal tensile strength and lower modulus of elasticity and density when compared with steel (1000 MPa and 50GPa for fiberglass rebar compared to 550 MPa and 200GPa for steel).
Furthermore, pultruded fiberglass rebars maintain their mechanical properties and micro-structural integrity for over 15 years. This reduces the need for replacement and maintenance and enhances its durability. Compared to materials like wood and steel, fiberglass is far more durable in external and extreme environments. It can withstand wide ranges of hot and cold temperatures without warping and is extremely resistant to rust and corrosion.
By and large, FRP products have much lower maintenance costs and replacement rates. Over the medium and long term, they provide a cost-effective option to steel.
Also, FRP rebars are corrosion-resistant, electromagnetically neutral, and do not conduct thermal or electrical currents. They can be used as an alternative material for steel in industries where these properties are required.
When building in waterfront environments or in areas with corrosive elements, fiberglass is also the preferred material, as it will not corrode. Because of this, their use in waterfront boardwalks, over-water bridges, and other ocean-front applications is far more effective than with wood, steel, or other metals. Fiberglass will not rot and resists insect damage. FRP composites can be appropriate for indoor and outdoor applications, including hotels, restaurants, and corrosive environments such as chemical plants, water, and wastewater treatment plants.
Pultruded products can weigh up to 75% less than steel and can reduce the overall weight of end-products.
This makes transportation, handling, and installation of materials much easier, faster, and cheaper than wood or metals. Additionally, vehicles made with composites instead of steel will have a lower weight and, consequently, lower fuel consumption – helping consumers of these end-products cost-wise and having a reduced impact on the environment.
Additionally, fiberglass products can be manufactured to fit a range of safety measures. During pultrusion, glass fibers can be reinforced with fire-retardant additives.
By doing this, the final product will fulfill fire-safety requirements, making it ideal for use in applications such as home/commercial construction where strict fire regulations are in place.
Fiberglass profiles are transparent to radio waves, microwaves, and other electromagnetic frequencies and are regularly preferred in telecommunications applications.
Fiberglass profiles can be manufactured with non-skid surfaces to provide a safe work environment for employees.
The exceptional physical and mechanical properties are driving the popularity of glass fiber composites (fiberglass composites) in the industry. By 2024, the global composites market is projected to reach $131.6 billion, up from $90.6 billion in 2019. Fiberglass will take up a large share of the pie.
Currently, the fiberglass market is pegged at $17.1 billion and projected to grow at a compound annual growth rate (CAGR) of 7% to $23.9 billion by 2024.
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