Ask a person what makes a good design, and you will likely get a number of different answers. According to Dieter Rams ─ a well-known German Industrial designer:
- Good design is innovative
- Good design makes a product useful
- Good design is aesthetic
- Good design makes a product understandable
- Good design is unobtrusive
- Good design is honest
- Good design is long-lasting
- Good design is thorough down to the last detail
- Good design is environmentally-friendly
- Good design is as little design as possible
Source: www.lifeofanarchitect.com
In general, people purchase products to meet certain needs. In engineering, structural performance and sustainability are high on the list.
Today, old-school materials such as wood and steel are used extensively across a broad range of industries. However, fiber-reinforced polymer (FRP) composite products are innovative and can enhance flexibility, durability, and strength in design.
Pultruded composites are made up of two or more components ─ fiber and matrix. When combined, they result in a new material with a low coefficient of thermal expansion (CTE) and good vibrational damping. The pultruded profile ─ which is fatigue-resistant ─ offers design flexibility and significantly reduces the number of parts required for specific applications.
Composite profiles exhibit unique properties, including resistance to acids, chemicals, and moisture. They are also non-conductive, high-strength, lightweight, and impact-resistant. The best thing is that these can be customized to meet the needs of various applications and produced in any shape or size if so desired.
During the pultrusion process, the composite matrices can be used to create profiles that meet specific needs. Resin systems and glass content can be varied to meet specific requirements, such as high strength, tolerance to different temperature ranges, or flame-retardant, track-resistant, and corrosion-resistant properties.
Raw materials used in formulations include:
- Vinyl ester (fire retardant, high temperature)
- Polyester (fire retardant)
- Epoxy
- Polyurethane
- Bonding resins
The materials are then pultruded using Tencom’s proprietary process.
Such unique characteristics provide project managers, architects and designers with compelling reasons to use FRP profiles, such as angles, beams and channels, in projects. The finished product requires less raw material and fewer joints and fasteners. They are also easier to handle and require less time to set up and install.
They have the potential to withstand natural forces and pressure. For example, pultruded profiles are commonly used to build items that are left outdoors for extended periods, such as electrical lines, bridges, and roads. A UV-resistant additive can be added to provide the necessary durability.
And, for branding and identification purposes, colors can be added to the mix.
The following are a few of the frequently asked questions about FRPs.
1. How are pultruded profiles produced?
Fiber rovings are fed into the pultrusion machine. Tensioners may be used to maintain consistent strength throughout the product. The rovings then go through the “wet-out” stage, in which they are saturated with a liquid resin chosen for the required performance.
As the rovings soak, they will become impregnated with resin, which will further improve the product's composition. After this, the product will be formed and cured, leaving it resistant to impact, ultraviolet rays, corrosion, and/or heat.
2. Who uses FRP composites?
FRP products are used by architects, builders, and developers for a variety of applications, including energy-efficient windows, thermal breaks, oil and gas tubes, beams, bars, and crossbars. Other applications include sucker rods, as they are lightweight, with lower installation and energy costs.
They can also be used in spar cap structures for wind turbine blades because of their lightweight and weather-resistant nature.
FRPs have been tested and proven to withstand harsh environmental conditions without degrading. The analyst firm Markets and Markets issued a report supporting the assertion that FRPs maintain their quality, color, and structural integrity for an average of 60 years.
The benefits of using such a durable material speak for themselves, but are most evident in replacement rates and overall running costs compared to traditional materials.
Materials with a longer life cycle provide greater structural support to the building structure over a longer period of time — compared with steel, wood and concrete — which lowers the long-term costs associated with the maintenance of the product.
3. Example of FRPs in use
Originally, FRPs were first used to build parts of buildings such as roof panels and wall cladding. Now, they are increasingly used in all facets of building and architecture. These are used to improve the aesthetics of buildings ─ from floating roofs to incredible facades. Composite architecture and designs can be found both in the United States as well in different parts of the world.
Take a look at 1000 Museum in Miami, Florida, a 62-story, 706-foot skyscraper featuring 83 residential units, a sky lounge, a two-story aquatic center, and the only private helipad (at that time) on a residential tower on the East Coast.
The one-of-a-kind tower design features a curved structural exoskeleton that supports the building. This in itself presented a series of design and engineering challenges. Built with about 5,000 glass fiber-reinforced concrete (GFRC) panels, the use of composites helped minimize costs and construction time, and the exoskeleton allowed the core wall thickness to be cut in half.
The composite panels ─ used in both the formwork and the permanent façade of the exoskeleton ─ were moved to the site, fitted together, set with rebar, and filled with concrete. This marks the first instance where GFRC is used as permanent formwork.
4. What are the key factors driving FRP popularity?
One of the key factors spurring growth in the market for FRP composites is their lightweight nature compared to traditional materials. They are highly maneuverable and desirable in new and retrofit building construction.
FRP composites are lighter than aluminum and wood and can weigh up to 75% less than steel and are about 20% that of stone and concrete cladding.
Architects, designers, builders, and developers have more flexibility when working with FRPs. Additionally, using FRP composites in building construction can significantly reduce dead load, resulting in a smaller foundation, reduced crane requirements, and a more manageable seismic design.
5. Is it safe to use FRPs?
In addition to the benefits inherent in working with a material as lightweight as FRP composites, specialty composites can be made to specific safety needs and building regulations.
FRPs can be made using fire-retardant resin systems that maintain the material's strength whilst also being fire-retardant and heat-resistant, meaning they’re not only practical for construction but also have high safety ratings and can comply with building codes.
Flexibility in Design
With FRPs, architects and designers have more creative freedom, allowing greater design flexibility. In contrast, traditional materials don’t usually allow for forms out of the ordinary.
Designers don’t need to compromise on desired appearances when using these products. FRP composites can be painted to resemble materials such as wood and marble.
The Takeaway
Sustainability and flexibility make FRP composites an invaluable addition to your project and the material of choice to the architect’s toolkit.
If you’d like to learn more about the FRP manufacturing process, download our guide here, where we’ll explain why pultruded fiberglass is important and how it can be used in your project. Talk to us today.
